Air Leakage Test

Hydro Test

Commissioning Checkpoints

Equipments Trial Run

Refractory Dry Out

Chemical Cleaning

Boiler Safety Protection Checking

ACTIVITIES OF COMMISSIONING

Grid Air pressure Drop Study

Control Instrumentation Checking

Boiler Light up & Coal Firing

Steam Blowing

Safety Valves Floating

Steam Dumping

Synchronization

ACTIVITIES OF COMMISSIONING

Auto loop commissioning

Reliable Test run

Performance test run

ACTIVITIES OF COMMISSIONING

Air Leakage Test

Pressure parts

The aim of air leak test is to ensure that erection

of the pressure parts is completed and no major

leaks are there.

Air leak test is conducted by introducing air into

the boiler pressure parts at a pressure of

approximately 7 - 8ksc

Air Leakage Test

Non Pressure parts

The purpose of air leak test of air, gas ducting & ESP

is to ensure leakage proof in ducts, welding joints,

flange joints to ensure efficient operation of fans,

boiler

Hydro Test

All the pressure parts of the boiler, which are

subjected to high operating pressure during

operation, should be checked to ensure that they

withstand the high pressure so hydraulic test is

conducted

Commissioning Checkpoints

Checklist have to be prepared for all equipments and

all activities.

After completion of equipments erection, check

points to be made and the trial run of equipments

shall commence

Equipments Trial Run

No-load trial & load trials of following equipments are

completed after fulfilling the commissioning checkpoints

ID fan

SA fan

Loop seal blower

PA fan

Feed pumps

Fuel feeders

Refractory Dry Out

In a boiler furnace, during the phase of erection

refractory is laid in many areas like furnace, second

pass areas, cyclones, bed ash cooler etc,

Refractory drying is to be carried out by utilizing

either light oil or gas

Chemical Cleaning

During the process of erection, there might be

entrainment of unwanted material like rust, dirt, mill

scale etc.

The internal surfaces of a boiler where demineralized

water of high purity is to be evaporated, should be

maintained free of all material which come in the way

of efficient heat transfer and thus effect generation.

The cleaning procedures aim to removal of rust, dirt,

sand and also any foreign material entrained in the

contour.

The cleaning can be achieved by an alkali boil out or

alkali flushing and acid cleaning.

Chemical Cleaning

Boiler Safety Protection Checking

Check the following equipments are having

interlocks

ID fan-I & I vs. loop seal blower

loop seal blower delivery damper open vs. loop

seal blower

IID Fan vs. SA Fan

ID Fan vs. PA Fan

Boiler Safety Protection Checking

Check the following equipments are having

interlocks

PA Fan vs. Fuel Feeders

Drum Level very LOW vs. MFT

Deaerator Level Low vs. Feed pump

Drum level Very High vs. Turbine

Furnace pressure Very high vs. MFT

Boiler Safety Protection Checking

Check the following equipments are having

interlocks

Furnace pressure Very low vs. MFT

Grid Air pressure Drop Study

Grid air pressure drop study is nothing but finding

out the pressure drop across grid nozzle at different

air flows

The pressure drop values measured in grid pressure

drop study are used to find out the bed height when

the boiler is in running condition. i.e. at a particular

air flow

Control Instrumentation Checking

Before boiler light-up, all control instruments have to

be checked i.e. to ensure whether the remote

operation of all equipments is in proper condition

Boiler Light up & Coal Firing

Start –up sequence

Steam Blowing

The objective of steam blowing is to remove dirts, loose

material, cutting bars etc, that might have been

entrapped in Super Heaters, Steam piping, re-heaters

during manufacture, storage, erection at site.

Failure to remove the debris may result in damage to

turbine blades, valves etc

Safety Valves Floating

The objective of the Testing Schedule is to test the

safety valves by actually floating and ensuring

that safety valves lift at recommended values.

Steam Dumping

Steam dumping is nothing but allowing steam from

re-heater through MSL and by by-passing the HP

turbine the steam is send to re-heater via HRH line

and from re-heater it is send to condenser via CRH

line by by-passing IP turbine and LP turbine.

During initial commissioning steam dumping is

done to achieve steam purity.

Steam Dumping

Till achieving purity, the steam can be allowed to

drain from CEP O/L to open drain. After achieving

purity it can be taken to close circuit.

Synchronization

After completion of all activities synchronization of

the unit shall commence

Synchronization is nothing but matching the

generator frequency with grid frequency using

syncro-scope

Reliable test Run

Reliability run is Seven (7) days of Continuous

Power Plant operation at various loads in which 72

hrs at full load and 2 hrs at 110% MCR capacity to be

demonstrated.

During this period two tripping of the plant is

allowed and after tripping plant to be

synchronization within 4 hrs to be demonstrated,

Performance test Run

Boiler performance test run is conducted

For understanding the current level of performance

of the boiler,

For any trouble shooting of the boiler for

performance deviations

For proving the performance guarantees