DUYEN HAI 3 THERMAL POWER PROJECT

COMMISSIONING PROCEDURE

For
0 2016.4.29
Construction Xiong Pei Zeng Bin Pu Xiaoqin Guo Baodong

D For approval 2016.4.7 Xiong Pei Zeng Bin Pu Xiaoqin

C For approval 2016.2.17 Xiong Pei Zeng Bin Pu Xiaoqin

B For approval 2016.1.19 Xiong Pei Zeng Bin Pu Xiaoqin
A For approval 2015．11.17 Xiong Pei Zeng Bin Pu Xiaoqin
REV DESCRIPTION DATE PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

OWNER
VIETNAM ELECTRICITY
THERMAL POWER PROJECT MANAGEMENT BOARD 3

CONSULTANT
POWER ENGINEERING CONSULTING JOINT STOCK COMPANY 3

CONTRACTOR
THE CONSORTIUM OF CHENGDA-DEC-SWEPDI-ZEPC

SUBCONTRACTOR
THE COMMISSIONING & TEST INSTITUTE OF SICHUAN ELECTRIC
SECTI POWER INDUSTRY

CONTRACT No.
PROJECT DUYEN HAI 3 THERMAL POWER PROJECT
DH3-05082011
Commissioning Procedure of coal pulverizing system
FILE NAME

FILE CONTROL No. DH3-31HFC-T-SCT-0010

FILE No. SECTI-TS-GL-CS-010-2014D REV: 0

 CHENGDA-DEC-SWEPDI-ZEPC

Contents
1. Objective of Commissioning ..................................................................................................... 3
2. Content of Commissioning ........................................................................................................ 3
3. Compilation Basis ..................................................................................................................... 3
4. Tools and Instruments................................................................................................................ 4
5. Conditions to be met prior to commissioning ........................................................................... 4
6. Commissioning Procedure......................................................................................................... 4
7. Safety measures ......................................................................................................................... 9
 CHENGDA-DEC-SWEPDI-ZEPC

1. Objective of Commissioning

Through commissioning of coal pulverized system, ensure normal operation of coal

pulverized system.

2. Content of Commissioning

(1) Interlock protection test of coal pulverizing system;

(2) Trail run of coal pulverizing mill and coal feeder
(3) Startup of coal pulverizing system;
(4) Stop of coal pulverizing system;

3. Compilation Basis

3.1 Operation instruction and technical specifications of Burner Equipment

3.2 Operation instruction and technical specifications of Boiler Operation
3.3 Operation instruction and technical specifications of Boiler Products
3.4 Design drawing
(1) DH3-31(32)HNC-M-SWE-1001boiler flue and air system
(2) （Letter No. DH3-CC-A3-I-15-0022）DH3-31(32)HFE-I-SWE-1001- PAF body & oil
station
Letter No. DH3-CS-A3-M-15-0445）
(3) DH3-31(32)HF-M-SWE-1001- coal pulverized system
(Letter No. DH3-CS-A3-M-15-0445）
(4) DH3-31(32)HFC-M-SWE-1001- mill body system
（Letter No. DH3-CS-A3-M-15-0445）
(5) DH3-31(32)HFC-M-SWE-1002- mill oil station
（Letter No. DH3-CS-A3-M-15-0445）
(6) DH3-31(32)HY-E-SWE-9102- SWD of Boiler 6.6KVmotors control in DCS
（Letter No. DH3-CS-A3-E-15-0165）
(7) DH3-31(32)HY-E-SWE-9103- SWD of Boiler 6.6KVmotors control in DCS
（Letter No. DH3-CS-A3-E-15-0165）
(8) DH3-31(32)HY-E-SWE-9104- SWD of Boiler 400Vmotors control in DCS
（Letter No. DH3-CS-A3-E-15-0165）
(9) DH3-31(32)HY-E-SWE-9105- SWD of Boiler 400Vmotors control in DCS
（Letter No. DH3-CS-A3-E-15-0165）

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4. Tools and Instruments

(1) Vibration meter

(2) Infrared thermometer
(3) Process calibrator
(4) Stopwatch
All tools and instrument/equipment shall be calibrated and the calibration certificate
shall be separately submitted to O/E for information.

5. Conditions to be met prior to commissioning

5.1 The installation work is over and the commissioning team agreed to accept the system to
start commissioning.
5.2 A punch list covers all defects or unfinished works is confirmed by the construction sub-
contractor and commissioning team that the defects or unfinished works do not affects
commissioning and system normal running.
5.3 Work permit system is in working.
5.4 Safety isolation measures are implemented.
5.5 Loop check and DCS interface verification have been executed.
5.6 The sundries inside coal mill system have been cleared away.
5.7 The individual commissioning of coal mills completed.
5.8 The individual commissioning of coal feeders completed.
5.9 The individual cold adjustment of burners is completed;
5.10 The individual commissioning for the oil station is completed, the favorable operation
condition, normal parameters and the correct display of DCS state are correct.
5.11 The individual commissioning of the valve is completed, the on/off actions are normal and
the display of the DCS state are correct.
5.12 Motors have passed through electric test successfully, and are in good condition and rotate
in correct direction in two running hours without load.

6. Commissioning Procedure

6.1 Check of Interlock Protection.

(1) Place power supply of coal pulverizer（coal feeder） at test position;
(2) Check the following items:
Start coal pulverizer（coal feeder） from DCS, and check if the feedback is correct.
Stop coal pulverizer（coal feeder） from DCS, and check if the feedback is correct.
(3) Emergency button shall work reliably;
6.2 For pulverizing system interlock protection test, see detailed test items in ITP.
(1) Check general conditions required by coal ignition.
(2) Conditions required by starting mill set (following conditions shall be satisfied

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completely, and Mill A, B, C, D ,E and F are same).

(3) Lubricating oil pumps interlock test of coal mill (A, B, C, D ,E and F are same.)
(4) Conditions at which mill set trips (mill set will trip if any of following conditions is
satisfied. Mill A, B, C, D ,E and F are same.)
(5) Start-up procedure of coal mill: (Mill A, B, C, D ,E and F are same)
(6) Shutdown procedure of coal mill (Mill A, B, C, D ,E and F are same ).
(7) Conditions at which start-up of coal feeder is permitted (feeder A, B, C, D ,E and F are
same).
(8) Interlock trip condition of feeder (feeder A, B, C, D ,E and F are same)
(9) Interlock test of dampers of pulverizing system (Mill A, B, C, D ,E and F are same.)
6.3 Trial Run of Coal Feeder
(1) Confirm the power supply of the motor is in open position, and the insulation of the
motor is qualified;
(2) Conform that coal feeder is permitted to start. Switch on the power supply and operating
power supply of feeder;
(3) During rotation, pay attention to any abnormal noise and record following datum:
voltage and startup current;
(4) During stop, check and make sure that the coal feeder rotates in the right direction, the
belt doesn't slip out, no abnormal sound comes from rotation, and dynamic and static
parts are free of friction;
(5) After normal condition is proved by inspection, restart the coal feeder and keep trial
operation for 4 hours while taking care to note down such information as running
current, bearing vibration and bearing temperature.

Refer to parameters listed in ITP .

6.4 Trial Run of Coal Mill
(1) Completion of motors trial operation are over.

(2) Check and ensure restore of the coupling of motor and coal mill reducer are over. and
operate it by hand, to be normal；
(3) Clearance between roller and bowl shall be adjusted larger temporarily. Clearance shall
be adjusted to meet security requirement adequately.
(4) Result of lubrication oil system test of coal mill is passed;
(5) Start coal mill and shut down it after 5 seconds. Check:

1) if the rotation direction of coal mill meets design requirement;

2) if there is abnormal noise;
3) If there is evident leakage and other abnormal condition in system.
(6) If there is no abnormal condition, restart coal mill after 30 minutes. After mill is started,
keep watch on current to prevent running with current higher than the rated. Write down
parameters:

1) Starting current;

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2) Coal mill current;

3) Temperature of coal mill motor coil;
4) Temperature of coal mill motor bearing;
5) Vibration of coal mill.
Refer to parameters listed in ITP .

(7) Execute 4 hours of trial run on coal mill.

6.5 Check before initial startup of coal pulverizing system
6.5.1 Pulverizing system being put into operation in hot state (first start of mill)
(1) Equipments in system are powered.
(2) Confirm that fire prevention steam is in standby mode.
(3) Start lubrication oil station of coal mill. Regulate oil pressure and temperature to normal
value. Confirm that oil flow is normal. Start lubrication oil station of mill 2 hours in
advance. According to function module of station, when oil temperature in reservoir is
lower than 35℃, electric heater starts to work; when oil temperature in reservoir is
higher than 40℃, electric heater is put out of use. (In winter, it is permitted that oil
cooler is not put into service until half hour before mill is started.)
(4) Confirm that following requirements of lubrication oil of coal mill are satisfied: pressure
at lubrication oil pump outlet of mill is not low; there is no Off signal at control power
supply of lubrication oil station; flow at lubrication oil pump is not low; differential
pressure between inlet and outlet of lubrication oil pump is not high.
(5) Confirm that hot air damper at mill inlet is closed; Cold blast valve of coal mill is closed;
Seal air baffle plate of coal feeder is open; Raw coal hopper gate is open; Thin oil station
of coal mill works properly; Thermal protection system is normal。
(6) If there is coal deposit in coal mill, put blast- and fire-prevention steam into service for
6~10 min before primary air is put into use so as to prevent pulverized coal from
blasting.
(7) Start primary air fan. After primary air fan runs properly, open plug plate at inlet and
outlet of mill to regulate primary air pressure to 8KPa--10Kpa (tentative).
(8) Start seal air fan and build up seal air pressure. Open seal air dampers of coal mill.
(9) Adjust and confirm differential pressure between mill seal air and primary air greater
than 2kPa. Open seal air dampers in coal feeder and at inlet and outlet of coal mill. Put
primary air pressure into auto mode.
(10)Jog coal feeder locally to spread coal. Stop coal feeder after coal is spread on
conveyor belt fully.
(11)Build up primary air flow. Increase primary air flow to maximum value within 3 min,
then purge system. Decrease primary air flow to minimum value 90t/h (70%ECR) after
purging is over.
(12)Control temperature rise of coal mill to 5℃/min or less. ensure inlet temperature of coal
mill to excess 150℃and outlet temperature to 65～82℃. Put hot/ cold air damper
baffles at mill inlet into auto mode. Warm coal mill up for 15 min.

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(13)Inform persons involving in installation and operation. Assign person specially to

supervise equipments such as coal mill and primary air fan to make preparation for start
of mill. If there is abnormal circumstance during starting procedure, report it to person in
charge immediately, and press locally emergency button if necessary.
(14)Inform persons involving in thermal control to make preparation to send out flame
scanning signal of coal compulsively at once after coal mill is started. Obverse flame
through flame TV or by local person. Report abnormal circumstance in time. Stop coal
mill if necessary.
(15)Desuperheating water is in standby mode. Put desuperheating water into service in time
according to change of steam temperature.
(16)Confirm that requirements of start of coal mill are satisfied and check running
conditions locally. Start coal mill. Observe and record starting time and current. Confirm
that requirements of corresponding coal layer putting into service are satisfied. Start coal
feeder to feed coal at minimum capacity 16~20 t/h. If coal mill vibrates at low load,
increase coal feed rate properly. In general, vibration will disappear when coal bed forms
between bowl and rollers.
(17)Increase coal feed gradually according to load. Regulate mill capacity according to
boiler load. In certain range, there is a linear relation between mill capacity and primary
air flow (Air-Coal Curve). Regulate Air-Coal Curve according to coal kind.
(18)After coal mill runs stably, thermal control operator shall regulate fire scanners
dynamically one by one according to notice from commissioning person or shift chief in
commissioning. Put one scanner into service after regulate it, and observe it for some
time until it works stably and reliably.
(19)After coal mill runs stably, thermal control operator shall regulate and put mill into
relative auto mode one by one according to notice from commissioning person or shift
chief in commissioning.
(20)Pulverized air flow and outlet temperature of mill shall be maintained in automatic
control. Coal feed shall be put into auto control mode. If evident disturbance or unstable
running occurs during the above-mentioned is put into automatics, operator shall switch
them from auto mode to manual mode and regulate them to stable situation.
(21)When the load of running mill(s) reaches 60--70%, the next mill shall be put into
operation.
6.5.2 Attentions in start-up of pulverizing system
(1) In the first start-up of mill, send out flame scanning signal compulsively at once after
mill is started, otherwise mill will trip because flame scanning signal can not be detected.
However, flame scanning signal is compulsive, so flame shall be observed through flame
TV or local person assigned specially. Mill shall be stopped immediately if pulverized
coal is found unburned. Remedy the trouble and restart the mill after furnace
temperature rises.
(2) Brief vibration may occur in the first start-up of mill, which is normal. Increase coal feed
rate to eliminate vibration, then adjust coal feed rate gradually to required rate. If mill
vibrates violently or for longer time, shut down the mill immediately and remedy the
trouble, then start it again.
(3) Prepare desuperheating water before start coal mill. Adjust water level in steam drum
lower slightly than the normal. Control the temperature and pressure of steam properly
to lower limit.

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(4) When coal mill starts or stops, steam temperature, steam pressure and water level will
fluctuate violently. Adjust feed water and desuperheating water in time. Contact steam
turbine to increase or decrease load in good time.
(5) After mill is put into operation, analyze fineness of pulverized coal in time and maintain
it to the design size. Regulate burning and improve air distribution to ensure good
combustion.
(6) Keep watch on running parameters which shall be within normal range during mill
operation.
(7) Inform coal handling system to remove foreign matters in raw coal as much as possible
in trial run to prevent foreign matters from entering mill to cause vibration.
(8) After the flame is stable, and load of boiler is stable the flame detector should be
adjusted, in two steps:1-to the mills, one by one, 2-second time, when the fire is done
only by coal mills, the flame detectors should be checked and re-adjusted if it is
necessary.
6.5.3 Dynamic monitor and maintenance of system
When pulverizing system is put into operation, intensify inspection and monitor for
rotating equipments; enhance supervision of running parameters. If any deviation is
found, regulate it in time to ensure that system is in optimum running condition.
(1) Supervision and maintenance of temperature at mill outlet;
(2) Supervision and maintenance of air flow at mill inlet;
(3) Current change of coal mill and feeder; maintenance of coal feed rate;
(4) Change of lubrication oil temperature of coal mill; adjust cooling water rate if necessary;
(5) Supervision of temperature of rolls and motor winding of coal mill;
(6) Current change of primary air fans on both sides; deviation and adjustment of primary
air pressure on both sides;
(7) Supervision of bearing temperature of primary air fan; supervision of temperature of
motor winding of primary air fan;
(8) Supervision of seal air pressure and current of coal mill;
(9) Observation, supervision and adjustment of combustion in furnace;
(10)Supervision and regulation of steam temperature, steam pressure, water level and flue-
gas temperatures of boiler;
(11)Check pebble coal contained in raw coal every two hours in the initial period of mill
running. Eliminate pebble coal in time to calculate its content in raw coal. If pebble coal
content exceeds normal limit, find out the cause and remedy it.
6.5.4 Normal shutdown of pulverizing system
(1) The corresponding oil layer shall be capable of being put quickly into service before
each pulverizing system stops.
(2) Switch control of coal feeder from auto mode to manual mode. Decrease feeder speed
gradually to minimum coal feed rate and decrease air flow to 70% rated air flow of mill.
Strictly control normal temperature at mill outlet during the above-mentioned procedure.

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(3) After load of coal mill is reduced to the minimum, close correspondingly hot air damper
of mill and open correspondingly cold air damper. Switch control of air flow and
temperature to manual mode.
(4) Shut down coal feeder and close the baffles at inlet and outlet of coal feeder when
temperature at mill outlet drops to about 50℃. Keep coal mill running for another 5-10
min at least to eliminate coal deposit in bowl.
(5) Shut down coal mill after coal deposit in mill is eliminated. Close the baffles at inlet and
outlet of mill.
(6) Maintain seal air pressure for 5-10 minutes after mill stops. Stop seal air.
(7) Shut down lubrication oil station 15 min. after mill stops.
(8) Shut down primary air fan and close damper at outlet of primary air fan after all mills
stop.
(9) Shut down seal air fan.
6.5.5 Hot regulation of pulverizing system
When pulverizing system is putting into operation, intensify supervision of equipments
in system. If any deviation is found, regulate it in time to ensure that the system is in
optimum running condition and combustion is stable in boiler.
(1) Regulation of fineness and uniformity of pulverized coal
(2) After pulverizing system is put into operation normally, measure the fineness and
uniformity of pulverized coal in primary air. Regulate air flow and opening of deflector
baffle in pulverizing system.
(3) Regulation of air-coal ratio of pulverizing system
Control temperature at mill outlet within normal range. Regulate opening of cold/ hot air
dampers at mill inlet to change air flow of mill and to guarantee optimum air-coal ratio
of pulverizing system under certain load.
(4) Optimization of pulverizing system
Regulate combustion mode and distribute combustion load reasonably according to
boiler load requirement, steam temperature change of main heater and reheater to
guarantee boiler parameters and economical efficiency in operation.
6.5.6 Running in trial start-up of entire system
(1) The entire system shall be subject to no-load running, on-load running, full-load running,
30-day reliability-demonstrating test to test reliability of system.
(2) Dynamic regulation of system: During the system is putting into operation, especially in
the regulation of fineness of pulverized coal and air flow, intensify the supervision of
equipments to guarantee that the system is in optimum running condition.
6.5.7 Complete trial operation record: Refer to ITP for main parameters in trial.

7. Safety measures

7.1 Safety measures

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(1) All operating personnel participating commissioning shall strictly follow safety
regulations at site, thus to ensure safe and reliable commissioning.
(2) In case that equipment damage, personnel injury, etc. during commissioning are possible
or have occurred, stop commissioning immediately and analyze the cause;
commissioning shall not be continued untill solution is provided.
(3) “Heating up” of mill is carried out at shutdown conditions. “Heating up” of mill is
normally started when hot air temperature at the outlet of preheater reaches to 180°C
and boiler operation reaches about 25% rated load.
(4) The temperature rise rate at the outlet of mill shall be controlled within 5°C/min in order
to guarantee that no excessive temperature difference thermal stress will occur with the
components of mill and at the pulverized coal pipe bends.
(5) The mill must be subject to comprehensive check after it starts operation. For example
the operating conditions of oil station of the mill, if the pipe and sealing points are tight
without leak and if the temperature of shaft bush and the sound of operation of mill are
normal, etc.
(6) The air/pulverized coal ratio must be guaranteed within proper range to avoid excessive
variation of air/pulverized coal ratio affecting combustion effect or even leading to
flame out.
(7) Due to the resistance influence inside the mill proper and the primary air pipe, the
air/pulverized coal flow speed will be excessively low. This will not only make the
operating conditions of mill unstable, but also lead to over-firing of burner. In order that
the ignition is stable, the mill shall be operated at >50% rated output condition.
(8) Starting two mills simultaneously to supply pulverized coal to boiler is strictly not
allowed to prevent excessive pulverized coal from entering the hearth to cause excessive
positive pressure or explosion of incomplete combustion.
(9) Current, pressure difference, outlet temperature, coal feeding capacity, primary air
volume of mill must be monitored during operation. Decisive and correct handling must
be made in case abnormality is observed.
(10) The oil station of mill proper must be frequently checked so that any abnormality if
observed can be solved timely.
(11) In case the mill still cannot restore operation after 1 hour of emergency shutdown, the
mill must be operated with no load to continue running to discharge empty the mass
accumulated coal in the abrasive wheel.
(12) In the shutdown period, pay special attention to the temperature of the shell of the
grinding system so as to find out any abnormal phenomenon or ignition hazard.

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7.2 HAZID/HAZOP

Potential
Num Activity Potential Hazard Factor Prevention Measure
Hazard Result
Wear proper work clothes and keep the safe distance

High temperature object with high temperature object. If need to contact with
1 Site work Personnel scald
surface high temperature object, wear heat insulated gloves or

protective equipment.

Check the protective device of rotating parts is in

position, and keep safe distance with the rotating

Mechanical
2 Site work Contact rotating device equipment, if need to work in the vicinity of the
injury
rotating equipment, to avoid clothes or hair to be

involved

Understand the voltage level of the work area and

equipment before work, check the isolation measures

correctly and reliably, wear suitable working clothes

Insufficient distance with Electric shock
3 Site work and shoes, keep the safe distance with the energized
energized object casualties
object. Reliable measure for de-energizing is required

for the work on the energized object and the detection

and confirmation is needed.

Within special area, provide alert symbols, warning

Injury due to
4 Site work Falling objects from high board and fencing; operation personnel must wear
falling objects
safety protection appliances as required.

Prepare strict fire control measures; sufficient fire

apparatus must be provided at site; smoking while

5 Site work Fire Fire hazard
moving around is prohibited; Work out measures

properly.

Equipment Strictly follow operation procedures, adhere to

6 Site work Mal-operation damaged and operation approval system and never carry out work

Personnel scald not approved.

Slip, fall leading Remove oil or rubbishes from the ground.

7 Site work Ground oil dirt to fall or hit Equipment and instrument for operation shall be
injury placed neatly and orderly.

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