Prosedur Start Up Boiler.pdf

7/23/2019 Prosedur Start Up Boiler.pdf

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PLTU 1 Jatim-Pacitan (2315MW) Project

Procedure of Start-up Boiler

B Revised as comments 13/11/2010 Liu Gang Long Sheng Zeng Bin Zhang Yaping

A For approval 8/2/2009 Liu Gang Long Sheng Zeng Bin Zhang Yaping

Rev. Description Date Prepared Checked Reviewed Approved

PT.PLN(PERSERRO)Owners DWG

No.0702-00-M-01-QH-001

PT REKADAYAELEKTRIKA

PT.PLN(PERSERRO)JAVA MANAJEMEN KONSTRUKSI


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PLTU 1 Jatim-Pacitan2315MW Project

Procedure of Start-up Boiler REV BCommissioning

ProcedureSCCTI-TS-GL-CS-006-2009A Page 2 of 44

Table of Contents

1. Purpose ............................................................................................................. 3

2. Scope .................................................................................................................. 33. Preparation Basis ................................................................................................ 3

4. Brief Description of System and Equipment......................................................3

5. Tools and Instrument for Commissioning .......................................................... 4

6. Prerequisite for Commissioning......................................................................... 4

7. Measures for Commissioning Organization....................................................... 7

8. Commissioning Procedure..................................................................................9

9. Safety Measures................................................................................................ 34

9.1 Safety rules for commissioning........................................................................ 34

9.2 Personal Risk and Preventative Measures........................................................34

9.3 Equipment Risk and Preventative Measures.................................................... 35

10. Appendix ..........................................................................................................36

10.1 Appendix 1 Commissioning Condition Checklist............................................ 36

10.2 Appendix 2 Format for Trial Run Record ........................................................40

10.3 Appendix 3 Pressure boosting curve-boiling out ............................................. 40

10.4 Appendix 4 Pipeline Blowing System Diagram...............................................41

10.5 Appendix 5 Check list of dampers ................................................................... 43


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1. Purpose

1.1 Provide a guideline and set specifications for the commissioning work of system and

equipment so as to guarantee that the system and equipment will be able to put into operation

normally and safely.

1.2 Check the reliability of electric and I&C interlock protection and signal device.

1.3 Check the operation conditions of equipment. Examine performance of system so as to find

out and eliminate possible defects.

2. Scope

The procedure is applicable to commissioning of startup boiler, including check and

confirmation of adjustment condition, valve baffle test, interlock protection test, drying,boiling, pipe blowing and steam tightness test of startup boiler, safety valve calibration,normal operation and shutdown of the boiler.

3. Preparation Basis

3.1 Operation Manual for Startup Boiler

4. Brief Description of System and Equipment

4.1 Brief introduction of the System

One 40t/h oil-fired start-up boiler, produced by Jiangsu Shuangliang Boiler Co., Ltd., isequipped in PLTU 1 Jatim-Pacitan (2315MW) Project. Model: SZS40-1.25/350-YC water

tube oil-fired package boiler.

4.2 Main Technical Specifications of System Device

4.2.1 Main Technical Specifications of Boiler:

No. Name Unit Values

1 Boiler Parameter

(1) Boiler Maximum Continuous Rating T/h 40


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No. Name Unit Values

(2) Gross Power of Supporting Auxiliaries kW 165

(3) Load Change Scope %BMCR 30100

(4) Steam Temperature Deviation Range 345370

(5) Boiler Blowdown Rating % 2

(6) Type and Arrangement of Burner /Split type atomizerburner, single and frontwall arrangement

4.2.2 Type of Steam Boiler Auxiliaries

(1) Burner : supplied by boiler manufacturer, RPD90L-R

(2) Forced draft fan: supplied by boiler manufacturer, GMB-32, 43000m3/h, 6000pa,

110KW, 380v

(3) Water feed pump: supplied by boiler manufacturer, DG46-308, 46m3/h, 2.0Mpa,

55KW, 380v

(4) Water box: supplied by boiler manufacturer, QR4025m3

(5) Blowdown flash tank: supplied by boiler manufacturer, 1500, 3.5 m3, 127

5. Tools and Instrument for Commissioning

5.1 Walkie talkie;

5.2 Handheld vibration meter;

5.3 Digital multimeter;

5.4 Handheld thermodetector

6. Prerequisite for Commissioning

Before formally beginning system commissioning, commissioning persons should conduct

comprehensive checks on conditions that should be available for commissioning of this


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(2) Boiler proper and flue gas duct have been assembled and insulated.

(3) Individual commissioning and subsystem commissioning of forced draft fan have been

completed.

(4) All dampers of flue gas and air systems have been inspected, adjusted and accepted.

6.1.2 Fuel Oil System

(1) System has been assembled and individual commissioning has been completed.

(2) System hydraulic pressure test and water flushing has been completed successfully.

(3) Compressed air pipeline and valves for blowing should be assembled and tested.

(4) All motorized valves and pneumatic valves for systems have been tested and accepted.

(5) The burner has been assembled and tested.

(6) All interlock protection simulation test for systems have been successfully completed

(7) The ON/OFF tests for all oil guns and high-energy igniters have been successfully

completed.

(8) Static commissioning for all flame detectors has been completed.

(9) Please see oil gun test table of the boiler (on section No.8.2).

6.1.3 Boiler Proper

(1) Boiler proper have been installed, insulated and accepted;

(2) Individual commissioning and interlock protection test for water feed pump have been

completed.

(3) Hydrostatic tests of the boilers have been successfully completed;

(4) The drain, vent, blowdown and nitrogen charging systems of the boilers have been

installed and insulated. All motorized valves have been tested and accepted.

(5) After hydrostatic tests, hydraulic valve spools have been removed from all safety valvesof the drums and superheaters, the safety valves have been restored to original state or

states. Blind plates have been removed from steam and water systems.

(6) Spring supports and hangers of steam and water pipeline are complete and in good order


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(12) Feed water system, desuperheating water systems have been installed and insulated. Allmotorized valves and pneumatic valves have been tested.

(13) All manholes and access doors on the boiler proper are complete and closed;

(14)Please see running parameter table of the water pump (on section No.8.2).

6.1.4 Compressed Air System

(1) Instrument& service air compressors have passed commissioning individually or as a

subsystem and are ready for use.

6.1.5 Fire Protection System

(1) All fire fighting facilities are complete, fire water tests have been successfully

completed and the systems are at standby state.

(2) Fire fighting equipments have been equipped at boiler house, control room and placewith fuel oil systems.

6.1.6 Industrial Water System

(1) Industrial water systems have been installed and hydrostatic tests have been successfullycompleted.

(2) Commissioning of industrial water pumps and industrial water subsystems have beencompleted and pumps and systems are ready for operation.

6.1.7 Chemical Water System

(1) The chemical system is able to supply water continuously.

(2) Commissioning of make-up water systems has been completed.

6.2 Conditions that must be available with electrical and I&C

Please see running parameter table of the FSSS, sequence control of boiler start and

stop ) and interlock (on section No.8.2).(1) Cold commissioning of the boiler FSSS (fuel oil systems and the burner) has been

completed

1) Furnace blowing conditions have been checked and tested;

2) Fuel oil FSSS tests and interlock test (performed after the FSSS test) have been


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(4) For flue gas and air systems, measuring points of air temperature and pressure, furnacenegative pressure, pressure switch, flue gas temperature and pressure of heating surfaceof different grade have been installed and are ready for operation.

(5) For steam and water systems, measuring points of drum pressure, superheater pressure,

steam temperature, feed water pressure, temperature and flow, steam flow and waterlevel meter with electric contacts have been installed and tested and are ready for

operation.(6) For fuel oil system, measuring points of fuel oil pressure and temperature, flow meters,

compressed air pressure have been installed, tested and are ready for operation.

(7) Measuring points of auxiliary current, bearing temperature and vibration have been

installed, tested and are ready for operation.

(8) Commissioning of various protections, alarms and visual and audio signals has beencompleted and they are able to generate alarms properly.

6.3 Conditions Required for Environment

(1) The field is leveling; road is clear; cover on trenches are complete; wastes have be

cleared.

(2) Platforms, ladders, railings protecting sheets are complete; construction scaffold have be

removed.

(3) Site is sufficiently illuminated. Temporary illumination can be arranged if necessary.

(4) Communication device is complete. Reliable communication equipment should beequipped.

6.4 Other Conditions Required

(1) The construction contractor, builder, Owner, Supervisor, Manufacturer and testing

agency inspect the entire units thoroughly to confirm that the unit is ready for ignition.

Problem found must be solved immediately, if any.

(2) Preparation for trial operation has been completed and operators have been assigned,trained sufficiently and examined. Operation procedures and system drawings have been

reviewed and approved and operating tools and log are available.

(3) Chemical products and material required for commissioning have been prepared.Sufficient amount of chemical water, fuel oil and coal have been prepared according to

the design requirements.


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7.1 Responsibilities of Commissioning Contractor

Preparation and revision of commissioning procedures;

Preparation of commissioning plan;

Preparation of instruments and equipment required for commissioning;

Hold technical disclosure meeting for commissioning;Organize the commissioning work to be carried out by various parties;

Give instructions to operators in the operation;

Prepare commissioning report.

7.2 Responsibilities of Installation Contractor

Be responsible for individual commissioning of equipment and provide relevant record and

certificate of commissioning;

Be responsible for inspection, maintenance and defect elimination of equipment under

commissioning;

Prepare maintenance tools and materials necessary for commissioning;

Assist the commissioning contractor in the commissioning of subsystems;

Be responsible for temporary coordination of local I&C components and connection

terminals.

7.3 Responsibilities of Equipment Manufacturers

Representative of manufacturer, if present on the site offering service, shall provide technicalassistance during equipment commissioning.

7.4 Responsibilities of Plant Operator

Prepare tools to be involved in operation;

Prepare operation log and forms;

Operate the system and equipment according to the operating procedures and the instructionsof the commissioning personnel;

Be responsible for patrol inspection, check, and normal maintenance of system andequipment;


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Supervise the execution of commissioning procedures;

Witness the commissioning work;

Accept the results of commissioning

8. Commissioning Procedure

8.1 Test of Valves

(1) Test and accept motorized (solenoid) on off valve, and record data.

(2) Test and accept pneumatic on off valve and record data.

(3) Test and accept pneumatic adjustable valve and record data. See Appendix 5 and 6.

8.2 Interlock protection and alarm check (note: interlock protection test is subject to the results oflogic discussion)

(1) Put the power supply of fans and water feed pump at testing position

(2) Check the flowing items:

(3) Start the fans or water feed pump on computer and the feedback on computer is right.

(4) Stop the fans or water feed pump on computer and the feedback on computer is right.

(5) Operation of the emergency button is reliable.

(6) Interlock protection of start-up boiler system is as the following:

Record table of water feed pump start and trial operation

Waterfeed pump Trial operation

Name unitFirst start Second start

no load no load Normal running

Start current A

Normal running current A

Bearing TEM.

Non Drived side


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Date

Record table of FDF start and trial operation

FDF Trial operation

Name unitFirst start Second start

no load no load Normal running

Start current A

Normal running current A

Bearing TEM.Non Drived

side

Motor bearing TEM.

Drived side

VibrationDrived side

mm/s

Vibrationfan side mm/s

Completed BySEPCTI DEC PLN JASER

Signature

Date

Boiler interlock checklist of FSSS

N T i Fi d l R l R k


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3Drum and superheater pressure high(1 of 2)(drum 1.33

MPa and superheater 1.29 MPa)

1.33MPa

1.29MPa

4 Oil gun has put into service and furnace oil flame detectorno flame (loss flame, delay 8s)

5 Feed Air pressure low 10mbar

2. Boiler Fault reset(or)

1 Reset button on DCS

2 Reset button on PLC control cabinet

3. Furnace purge(conditions meet ,time 2 min.) (and)

1 The FDF has been running and inlet air damper is openedto more than 70%

2 no flame of the flame detector

3 No FSSS protection action

4 All oil feed and return valves closed(4 valves)

5 The lamp of boiler startup is ready for startup

6 Drum water level is normal

4. Results of FSSS protection action

1 Oil gun tripped and closed all oil feed and return valves(4valves)

2 Ignitor solenoid valve close and forbid ignitor to fire

5. Open condition of Oil gun feed valves(and,2valves)

1 Open instruction of oil gun feed valves give out

2 No FSSS protection condition


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3 Small gas gun has been running

8. Trip condition of Oil gun return valves(or,2valves)

1 Boiler shut-off instruction give out

2 Any one of FSSS protections action exists

9. Boiler sequence control

1 Boiler sequence start:

Boiler startup instruction give out , start FDF motor,

automatically open air damper to more than 70%,

automatically start purging furnace for 1 min.; then

automatically close damper to 20% position, then

program automatically give out light instruction.(details:

first, high power ignitor automatically light, then

automatically light up small gas gun ;after about 3s,

automatically light big oil gun and automatically open oil

4 feed/return valves. after 5s, automatically stop small gas

gun. The flame detector detect flame and exist, mean the

startup process is success. If not, after 5s, the flame

detector is no flame, the startup process is failure.

2 Boiler sequence stop:

Press shut-off button, automatically close all oil valves,

inlet air damper of FDF automatically open to 70%

position and automatically start purging process for 2

min.. after completed purging, This air damper

automatically close and stop FDF motor.


Signature


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2. Start condition:(and)

1 Feed water control valve put into less than 10% position

2 Startup instruction give out

3 Power control cabinet is ready

3. Stop condition:(and)

1 Power control cabinet is ready

4. Interlock open of Desuperheater control valve

1 Superheater outlet steam TEM. more than fixed value

5. Interlock close of Desuperheater control valve

1 Superheater outlet steam TEM. less than fixed value

6. Interlock open of Feed water control valve

1 Drum water level low (less than 230mm)230mm

7. Interlock close of Feed water control valve

1 Drum water level high (more than 260mm)260mm

8Open of main steam valves (all conditions are met)

1 Send command to open valve

2 Power supply of main steam valves is not broken

3 State of program control

9.Close of main steam valves (all conditions are met)

1 Send command to close valves


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Date

Interlock checklist of FDF and system

No. Test item Fixedvalue

result remarks

1. Trip condition :(or)

1 Send command to stop FDF

2 MOTOR fault trip

2. Start condition:(and)

1 Feed air damper place in less than 10% position

2 Power supply cabinet is ready

3. Stop condition and

1 Power supply cabinet is ready


Signature

Date

B il i l l h kli


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6 Superheater outlet STEAM TEM. High, only alarm360

7 Feed water pump overload, boiler shut down and alarm

8 FDF overload, boiler shut down and alarm

9 Main pipe inlet oil pressure low, boiler shut down and alarm 2.0mpa

10 Return oil pressure low, boiler shut down and alarm1.0mpa

11 flue gas Temp. high, only alarm 150

12 Inlet Feed Air pressure low, boiler shut down and alarm 10mbar

13 Abnormal flame loss, boiler shut down and alarm

14 Startup failure ,boiler shut down and alarm

15 Furnace pressure high, only alarm 5kpa

Completed By

SEPCTI DEC PLN JASER

Signature

Date

Test record format for oil valve leakage check

Result (local confirmation)No.

Tight not leakage Slight leakage Serious leakage

1 feed solenoid valve


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Date

Test Record Format for Oil Gun Atomization Output

Atomization inspection Output determinationAtomization piece

Specification

(t/h)

FO. press.

1.5-3.5MPa)Atomization angle Atomization effect

Local

output(t/h)

DCS counted output

(t/h)

A1 1.5 MPa

A1 2.5 MPa

A1 3.5 MPa


Signature

Date

8.3 Drying

8.3.1 Purpose

There is moisture in newly-built furnace wall. If putting it into operation directly without slow

drying treatment to increase its strength, the moisture in furnace wall will generate some stressbecause of volume expansion caused by sudden evaporation, which may lead to crack,deformation and damage to furnace wall, even collapse if serious. So, drying under low burning

according to requirements is a must before putting the boiler formally into operation.

According to the special type of water wall, the long period time of boiler installation and

local weather, the boiler maker need not to do the boiler drying work. This information will


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(5) Relevant water releasing system have been installed. Water feed pump can feed water toboiler at any time.

(6) Remote operation of I&C, sound, light and audio signal, and installed and checkedprotection device can be put into operation.

(7) Feed demineralized water to the drum water level -30mm, and flush the water levelmeter clearly.

(8) Cooling water system has been installed and pass the water test.

(9) Water discharge system has been completed. And discharge is smooth.

(10) Daily oil tank has been installed. Oil tank has been cleared, and oil pipeline has been

blown clearly.

(11) Fuel oil system between oil tank and start-up boiler has been installed, insulated, blown

throughly by compressed air, are with normal hydraulic pressure and ready for oil

supply.

(12) All auxiliary device, valves and dampers of boiler have been tagged.

(13) Each rotatory machine has passed commissioning as a subsystem.

(14) On and off of steam and water valves, flue gas and air dampers of boiler have beenchecked. Their movement is flexible, on-off direction and marks are correct.

(15) Safety protection system of boiler has been tested.

(16) Necessary illumination should be arranged for access road and equipments in

commissioning field. Road is clear; cover on trenches and holes are complete.

Communication is ready for clear liaison.

(17) Steam trap on superheater is on to maintain normal pressure in drying.

(18) Started oil guns of burner on boiler is well atomizedl, burn normally and pass servicetest.

(19) The uniform commissioning organization of sufficient number of operators,maintenance personnel and security personnel shall be built. The operators shall be

trained suitably and be familiar with the associated equipments and systems andoperating methods and aware of commissioning measures, their own responsibilities and

works to prevent incorrect operation.

8 3 3 Methods and Steps


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(5) Ignite with firewood. Control the combustion intensity by outlet flue gas temperature offurnace. Control the flue gas temperature strictly. On the first day, the rise does not

exceed 50. Later, the rise does not exceed 80 every day. At last stage, highest

temperature of flue gas does not exceed 160. Highest temperature does not last for

over 24 h. During the drying, the water level of boiler should be maintained normal.

Drying period should be controlled according to the degree of natural drying. During thedrying, do not use hard fire, open exhaust steam valve to release air to keep no pressure

in boiler, and heat slowly to avoid blow hot and cold to prevent the insulating layer offire proof material from cracking and damage. Keep no pressure rising in drum, steam

pressure for drying is not higher than 0.1MPa.

Note: Installation contractor should make temporary racks inside boiler to keep wood.

8.3.4 Safety Notice for Drying

During the drying, fully open steam trap on superheater and exhaust steam valve at outlet ofsuperheater.

(1) Flame should be controlled from light to strong and burn in the center uniformly to

ensure uniform exotherm. Check furnace wall and expansion state of each partfrequently, report the abnormal situation timely, if found.

(2) During drying, strictly control the water level in drum, maintain it in normal scope, andfeed water timely.

(3) Before drying, reserve discharge holes for moisture at proper position.

(4) After drying, prepare temperature rise curve and relevant records.

Boiler drying record table

Date/time Drum water levelMM Outlet TEM. of furnaceRemark


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Eliminate high temperature oxidation peel-roll, corrosion products, welding slag, silt, oil stainand other debris produced in rolling, processing, storage and installation. Generate protectionlayer in the inner wall to prevent corrosion, maintain the heating surface of boiler clean,

increase the steam and water quality to prevent encrustment and corrosion, save fuel, extend

life span and ensure safe and economic operation of boiler unit.

8.4.2 Scope and process of alkaline boil-out

(1) Scope: water screen system, lower drum, upper drum (the part under the flushingcenterline of upper drum )

(2) Washing: three steps are conducted for washing:

Flush with lots of water before washing;

Boil out the boiler with chemicals;

Flush the boiler with hot water after washing.

8.4.3 Conditions required before boiling out

(1) Hydraulic test has been completed and tested.

(2) Commissioning of water feed pumps, induced draft fans and forced draft fans has been

completed.

(3) Chemicals for boiling out and containers for disolution have been prepared.Commissioning of chemical feed pump has been completed successfully.

(4) Chemical water system can continuously supply enough demineralized water with

sound quality. Flushing and recovery of dosing system have been completed and the

system is ready for operation at any time.

(5) Operator of power generator should be on duty and report state of water quality at any

time.

(6) Temporary indicator lights to indicate high, low and normal water level are equipped at

control room the platform of drum, which have been prepared and accepted.

(7) Operator and installation and maintenance people can operate and prepare necessary

tools. Inspection and preparation for igntion should be done in advance according toOperation Specification before boil-out so as to make startup and ignition upon

commands.

(8) Systems have been tagged Correct and clear marks is with various equipments valves


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Fuel oil circulating is qualified;

Fire control device relevant to fuel oil have been tested and accepted.

(3) Water Feed System

8-hour individual commissioning of water pump has been completed successfully;

Flushing of water feed pipeline has been completed successfully;

Relevant interlock test has been completed successfully.

(4) Dosing system is ready for operation

(5) Industrial water system is ready for operation

(6) Ignition system of boiler

Atomization and service tests have been completed.

Ignition device has been tested normally.

(7) All instruments of boiler have been assembled tested and are ready for operation.

(8) Relevant valves of boiler have been assembled tested and accepted.

(9) Water drainage systems are ready for use.

(10) Water feeding system are ready for use.

(11) Blowdown system of boiler are ready for use.

(12) All other systems that impact ignition of boiler

8.4.5 Method and Procedures

(1) Boiler working and hydraulic pressure test

1) Check that the system meets the requirements for hydraulic pressure test

2) Send water to boiler with water feed pump. In hydraulic test, ambient temperatureshould be over 5 above zero. Frost protection measures should be taken when

temperature is under 5. Temperature of water used for hydraulic test should be over

the ambient dewpoint temperature so as to prevent dew formation on the surface of

boiler. The temperature should not be very high in order to prevent evaporation and high

temperature difference. The temperature is usually within 20-70.


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No residual deformation after the test.

No leakage at connection to economizer.

Boiler Record format Of Hydraulic test

item result remarks

No water drops and spray on metal wall or welding Yes No

No residual deformation after the test Yes No

No leakage at connection to economizer Yes No


Signature

8) After passing hydraulic test, release pressure and water. During the pressure reduction,clean I&C tubes, chemical sample tubes and water drainage pipes.

9) Flush boiler with water.

(2) Preparation of chemicals and dosing

1) After the hydraulic test, feed water to 1/3, Stop and check system and isolate the water

feed and drainage and blowdown system. Add chemicals slowly into the container whileagitating. After the chemicals dissolve, feed the solution to the upper drum. Start thewater feed pump of boiler to send water to the low level in drum.

2) Dosing amount: sodium hydroxide (NaOH) 4 kg per m3 water; trisodium phosphate

(Na3PO4) 4 kg per m3 water (calculated according to 100% purity quotient). Water

volume is 25m3 (normal operating water volume in manufacturer's specification)

3) Dosing Requirements:

B f l i f d N OH N PO 12H2O l l t th t i t l


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0.80MPa within 5 to 6 hours. Maintain pressure at 0.8-1.0MPa for boiling out.

7) Record expansion of each part under the following situation:

Before and after feeding water, 0.4Mpa, 0.8MPa, 1.0MPa. Any part found to impact theexpansion should be reported timely to stop increasing pressure. Continue boosting

pressure after eliminate defect.

8) Start timing when the pressure raises to 0.8MPa. Maintain pressure within 0.8-1.0MPafor 24 hours in boiling out. Steam drainage volume is 10%-15% of the rated

evaporation.

9) After 240hour boiling out, maintain pressure of boiler, and each blowdown pointdischarge waste and change water. This moment, strictly supervise water level in drum

and prohibit full and lack of water.

10) After feeding chemicals, take furnace water sample by chemical method to testalkalinity once every two hours. In the later stage of boiling out, test can be done once

every one hour.

11) Normally shut down boiler after boiling out. Decrease pressure and drain water.

12) After the temperature decreases, open the manholes on upper and lower drum and lowerheader of water wall to clear away internal foreign matters.

8.4.6 Boiling precautions

(1) Agitate homogeneously when adding chemicals. Must not lift alkaline chemicals on

shoulder or with hands. Operators should ware rubber overshoes, gloves and protectionmasks. Cold water resource and relevant chemicals should be arranged in place where

prepare and add chemicals.

(2) No water comes into superheater in boiling out. Strictly supervise the water level in

drums and arrange experienced operators as far as possible to adjust feed water timely.

(3) Closely watch the state of each rotary machine and expansion of boiler proper. Solveproblems timely, if found.

(4) In boiling out, one local level meter is set in drum, and one regulated pressure gauge is

used. Assign people to watch the water level and inform water feeder timely.

(5) Pipeline irrelevant to boiling out should be isolated completely. Prevent washing liquidin key system from getting into other systems to avoid accident.

(6) I b ili t bl k d bl d i li d l h ld b l d ti l if


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2 to 3 threads, use a wooden stick to unclench door of manhole (No people face the doordirectly). After the inside negative pressure disappears, open the door of manhole andassemble reticular close board on it.

(10) If no measures are mentioned for some conditions, execute the "Boiler Operation

Specification". If accident occurs, deal with it according to Specification for AccidentHandling.

Boiler record format of boiling-out

Date/time Drum pressureMPA OH- PO43-

Remarks


Signature

Date

8.5 Steam Purging

8.5.1 Purpose

To ensure the safety and economy operation of the units, the inevitable welding slag, metal

rust and other sundries in the boiler superheater and pipeline of steam system of newlyassembled units shall be purged to the cleanest extent before the formal steam supply.

8.5.2 Scope

Boiler superheater system

Steam pipeline connecting start-up boiler to auxiliary steam header

8 5 3 Purging plan


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According to the new "Technical Code for Erection and Acceptance of Electric PowerConstruction(1996 Edition)", while ensuring the purging factor larger than one, the purgingwork is qualified as the matter, maximum particle diameter on the target board no more than

0.5mm and number of macroscopic spot no more than 5, happens for twice continuously.

8.5.6 Temporary devices

(1) The temporary pipeline shall be connected in proper place before plant-service steam

header and be led to safe place for steam exhausting with outlet directed to open space.Target board shall be installed in the suitable place near regular pipeline. In condition

that the quality of purging is guaranteed, minimize the length of the pipe, elbows andjoints to reduce the resistance for the system.

(2) Temporary purging pipeline shall be equipped with solid and reliable supports andhangers and consider the thermal expansion of the pipeline and steam counterforce by

purging.

(3) Same-diameter short pipe shall be connected instead of main steam flow orifice plateuntil the purging work is finished.

8.5.7 Precondition for ignition

(1) Systems return to normal after boiling and cleanup of upper and lower drum and

sub-header of water wall.

(2) Main boiler and auxiliary equipments have been installed and insulated. Platform,handrail and boarding are complete.

(3) All facilities which affect the expansion have been removed.

(4) Sufficient illumination is around the boiler proper and auxiliary units.

(5) Installation of water level meter in drum shall meet the requirements. The local water

level meters are accurate and remote water level meters are regulated and can be put intouse for purging.

(6) Sundries shall be cleared up inside the furnace and funnel.

(7) Water charging and supply system shall meet the requirement and be ready to use.

(8) Purging control valve have been adjusted and temporary pipeline have been completed

according to requirement.

(9) In boiler house, discharge systems of washing water and overflow have been installed as

d i i t


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(15) A sound commissioning management organization has been established, theresponsibilities and liaison system have been clearly defined. Personnel for adjustment,maintenance and operation are on board. Commissioning measures have been approved

and technical clarification has been performed.

(16) Chemicals materials, chemical water and fuel oil for commissioning are ready.

(17) Fire-fighting equipments and facilities in field shall meet the requirements.

(18) The Installation Contractor, Operation Contractor, Owner, Supervisor, Contractor andCommissioning Contractor inspect the entire units thoroughly to confirm that the unit is

ready for ignition. Problem found must be solved immediately, if any.

8.5.8 Tests before ignition

(1) The system valves and dampers for purging shall be inspected completely by operators

to meet the following requirements: flexible operation; on-off direction accords with theindication; and remote panel conforms with local one.

(2) Test for interlock protection

8.5.9 Preparation before ignition

(1) Start up water feed pump until the water level reaches about -30mm in the drum.

(2) Preparation before ignition should been made as per specifications when receiving

ignition signal.

Notify the electric control room to feed the rotary machine, electric dampers andelectrically operated steam and water valves to be used.

Heating control room feeds the panels and instruments to be used.

Put cooling water system into use.

Ignition is implemented as per specifications.

8.5.10 Purging process

(1) Ignite and increase the pressure once receiving ignition signal. When the pressurereaches to 0.2MPa, steam pipeline should be warmed up. After that, trial purging is

started and check if the system expansion and stress state are normal when the pressureis up to 0.3MPa. If normal, boost pressure continuously to 0.4MPa~0.5MPa for next

purging until the target board is basically qualified. Then shut down and cool the boilerfor 12hr and ignite the boiler and boost the pressure again to purge until the target board


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declines greatly even it is invisible when the control valve is closed, increase the watersupply to maintain a visible level when closing the valve. When the water level starts torise again, reduce the water supply promptly to avoid rising too high.

To prevent steam from bearing lots of water, the drum water level shall be maintained

around -50mm before opening the control valve in purging.

(3) No flammable and explosive materials near purging pipeline. No people in area 20m

around steam outlet. Set guard line and assign persons to be on duty.

(4) Make sure that everyone has left before opening the control valve, especially whenchanging the target board. Person unrelated shall keep away from purging pipeline.

(5) Pipeline shall be warmed up completely before purging. Trial purging, under the

pressure 50%~75% of the regular pressure shall be conducted once or twice to inspect

the conditions of support, expansion and leakage of the temporary system and learn thecontrol method of water feed flow gradually. Steam trap on main steam pipeline shall be

partially opened while the other is closed during normal purging work..(6) A target board shall be put in the pipeline to check the dirtiness of pipeline and the

reliability of board in the first purging.

(7) All rotary machines shall be monitored by relevant personnel.

(8) Operation should be conducted in a manner of unity of command. Shut down purging incase of emergency, and handle accident according to Accident Management Procedure.

(9) The parts unable to be purged by steam shall be cleaned mechanically and manually.

Safety measures shall be considered to prevent the dirt from recovered welding joint.

(10) 20 pieces of target board, made of aluminum and polished, should be prepared.

Target boar size: no less than 8% of the inner diameter of discharging pipeline in width;

and equal to the inner diameter in length.

Steam purging record format

Open valve Close valveDate/timeDrum

PRESS.(MPA

Superheater

outlet TEM.

Drum

PRESS.(MPA

Superheater

outlet PRESS.

Superheater

outlet TEM.

MPA

Target

Yes/No


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Date

8.6 Steam Tightness Test

8.6.1 Purpose:

To guarantee the safety operation of the units in future, the steam tightness test, under the

operating pressure at hot state, is to completely inspect the boiler's heating surface, the steam& water pipeline, steam header, flanges. welded junction, expansion system and load-carryingcapability, displacement and the extension of fixing apparatus or spring supports and hangers.

8.6.2 Test Content:

(1) Close the main motorized steam valve at the boiler outlet; the pressure boosting rate can

be controlled by the adjustment of fuel oil pressure or the exhaust steam valve. Whenpressure rises to 1.29MPa and is at steady state, people specially assigned shall check

the tightness of the boiler proper, auxiliary device and the steam and water pipelinesinvolved.

(2) Inspection the tightness of welded joints and flanges of the boiler.

(3) Inspection tightness of all the steam and water valves of the boiler proper system.

(4) For steam and water pipeline of the boiler, check its expansion condition, check whetherthe load-carrying capability, the displacement and the extension of its supports, hangers

and spring hangers are normal, and check whether any barriers impact the expansion.

Steam tightness test checklist

contents Check result remarks

Inspection the tightness of welded joints and flanges of the boiler. Yes No

Inspection tightness of all the steam and water valves of the boiler

proper system.Yes No

For steam and water pipeline of the boiler, check its expansion

condition, check whether the load-carrying capability, the

displacement and the extension of its supports, hangers and spring

hangers are normal, and check whether any barriers impact the

expansion.

Yes No


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(2) Areas inside and outside boiler is cleaned. Road is clear.

(3) All inspection holes and manholes have been closed.

(4) Tests and inspections before ignition have been completed.

8.6.4 Test Procedure

(1) Timely adjust combustion intensity and open rate of steam trap. Control temperature and

pressure rise rate according to Operation Specification.

(2) Record expansion value at the following conditions: before and after water feed,0.30.4Mpa, 1.0MPa, 1.25MPa.

(3) Start steam tightness test when pressure of main steam rise to 1.25MPa.

8.6.5 Safety Precautions:

(1) Strictly control increasing rate of temperature and pressure to ensure sufficient

expansion of each heating part of boiler proper.

(2) Check the expansion state of each heated part in pressure boosting process. Report

problems if found. Stop increasing temperature and pressure, if necessary, to takemeasures to eliminate a hidden danger. Then continue the process.

(3) Operation should be conducted in a manner of unity of command. Strictly follow ordersand prevent personal injury and damage to equipment. All operating personnel

participating commissioning shall strictly follow Safety Regulations and related safety

provisions at site, thus to ensure safe and reliable commissioning.

(4) If equipment damage or personal injury may occur, stop works immediately and shutdown the unit if necessary, and then analyze causes and take corrective measures;

(5) During entire commissioning, personnel of various discplines shall be in place, thus toensure equipment operation safety.

8.7 Safety valve setting

8.7.1 Purpose:

Being the primary safety devices for the boiler, safety valves of drum and superheater shall be

adjusted to act accurately and reliably before commissioning to ensure the safe operation ofthe boiler unit.

8.7.2 Setting parameter: Refer to attached table.


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discharge and action of safety valves. If no problems found, continue boosting pressureto the setting pressure needed for setting. The setting of safety valves is conductedbefore the setting of safety valve of superheater.

(2) Decrease pressure after the setting of safety valves. Start the setting of safety valves on

the superheater.

(3) If the trial actuation of the safety valve is not qualified for the first time, decrease

pressure and adjust it again. Then increase pressure to test the trial actuation until it isqualified.

8.7.5 Safety Precautions:

(1) During the adjustment of safety valve, operators and safety valve adjustors should act

according to the unified command of commissioning personnel so as to ensure personal

and equipment safety. .

(2) Participants should keep their post according to work division and take records of

operation, adjustment and check.

(3) During the adjustment, enough platform and railings should be set around safety valves;

illumination is sufficient.

(4) Before setting, release the drum water level protection, in case the false level caused by

take-off of safety valve starts the protective action of boiler.

(5) During pressure boosting, assign people to check the tightness and expansion of boiler.

Report and solve problems found to impact the increasing of pressure and temperaturetimely.

(6) During the adjustment, operator is responsible to maintain the stable working state ofunit, especially the stable pressure. At the moment the safety valves discharge steam,

drum water level changes greatly. So, when adjusting the safety valves, drum waterlevel should be lower than the normal level. Adjust the water supply to control the drum

water level properly.

(7) Decrease the pressure to 75% of the actuation pressure before adjusting the safety valves.

Experienced operator with protection masks and heating-insulated gloves adjust thesafety valves, and others should be kept away from the field.

(8) During the adjustment, adjust the weight of safety valves on drums. Remove top coverof safety valves on superheater, unscrew or wind up spring to reach the set actuation

pressure. Then tighten fastening screw, assemble the top cover and tighten the hexagon


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A48Y-25

Super heaterSafety valve

SA48Y-25

1.30 1.21-1.25 4-7%

Completed By SEPCTI DEC PLN JASER

Signature

Date

Remarks: Actuation value of safety valve is from the Manufacturer's Information.

8.8 Load commissioning

8.8.1 Test purpose:

Load commissioning is main process of unit commissioning. Concerning to the safety, qualityand project period of unit commissioning, load commissioning is a comprehensiveperformance evaluation of the unit and complete check and inspection of the sub-system

commissioning at the early stage.

8.8.2 Conditions required before load commissioning

(1) Drying and boiling out, steam purging, tightness test, safety valve setting of start-up

boiler have been completed.

(2) All temporary system used in sub system have been removed.

(3) All defects found in the subsystem commissioning have been eliminated.

(4) Chemical water system is complete to supply qualified demineralized water at any time.

(5) Plant-service power system is complete to cut and supply power according tocommissioning requirements at any time.

(6) Illumination and communication system is complete to communicate at any time. Fire

control equipments are equipped.


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Fuel oil system;

Industry water system;

Chemical sampling system;

Drainage system;

Water supply, drainage and fire control system;

Main steam system and its desuperheating water

(10) All on-site instruments and instruments on operation platform and panels have been

installed and calibrated, and can be put into use.

(11) All interlock protection loop has been installed. After static test, all interlock, protection

and alarm value have been set according to requirements. Visual and audio system hasbeen adjusted.

(12) Boiler expansion indicator has been installed according to design requirements.Expansion barriers have been eliminated and expansion indicator has been regulated to

zero.

(13) Observation holes, manhole door and inspection holes have been closed. Explosion door

is complete.

(14) Prepare sufficient fuel oil for commissioning.

(15) Prepare sufficient chemical water and chemicals.

(16) Production preparation has been made. Operators passing training are on duty.

(17) Organization is complete and job division is clear.

(18) Constructor organizes maintenance team and prepare materials and tools formaintenance.

(19) Operation measures should be approved and clarified under the direction ofcommissioning command party. Commissioning, operation, maintenance personnel is on

duty.

(20) Marks of equipment and main pipeline are complete and meet requirements. Tags on

system equipment and valves are complete.

(21) Auxiliary header on the steam supply side has been installed and insulated and are ready

f t


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(1) Non-load procedure

1) Water feed

Water feed time: winter2 hrs; summer1 hrs. Feed water temperature


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burning.

Open the valve of superheat steam outlet to put water feed system into operation,

adjust combustion, open desuperheating water, and supply steam formally.Continuous bolwdown should be carried out during steam supply.

5) Formal steam supply

When steam pressure reaches working pressure 1.25MPa, supply steam. Before

supplying steam, maintain low drum water level, sufficient pipeline warm-up andsteady combustion in furnace,

Desuperheating water is used to adjust the temperature of superheat steam. When

the temperature of superheater steam is higher than the required value, increase the

desuperheat water to decrease the temperature of superheat steam by motorizedcontrol valve of desuperheating system. When the temperature of superheater

steam is lower than the required value, decrease the desuperheat water to increasethe temperature of superheat steam. Adjust the temperature of superheat steam

within 3455.

(2) Load period

1) Adjust the burning capacity according to steam consumption of users and fuel oilpressure. Maintain steady pressure, combustion, water level of boiler. Keep steam

temperature within regulated scope. The oil temperance and pressure meet the

requirements.

2) Start thermal adjustment of automatic control system at proper time, according to loadof boiler.

Automatic adjustment of drum level

Automatic adjustment of combustion(steam pressure)

Automatic adjustment of desuperheating water(superheater outlet temperature)

(3) Normal operation and maintenance

When boiler is in operation, continue feeding water to keep water level withinnormal scope. Water level meter should be flushed at least once each shift.

Note the combustion state frequently. Maintain reasonable air distribution for good

combustion. Keep the furnace pressure between10005000Pa

PLTU 1 J ti P it 2 315MW P j t


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Reduce fuel and corresponding air volume gradually to weaken the boiler capacity.

With the decreasing of the load, reduce water to maintain normal level in drum

When the steam supply is cut off, close the boiler outlet motorized valve. If the

pressure continues boosting, steam release and water fed should be strengthened.

After pressing the shut down button, the burner will turn off oil-gas solenoid valveautomatically. After five minutes, blow the furnace, and the boiler will shut down

automatically. After flameout, check and close flue baffle and manual valves offuel oil system. Stop the oil pump. Stop water feed pump when water is stopped.

Before the drum pressure decreases to the atmosphere, temperature of flue gas andair system and auxiliary device must be supervised continuously.

(5) Occasions for Emergency Shut Down

Pressure over the specified value

Low low water level in drum, and level can't be observed

Water supply device malfunction, fail to feed normally

All level meters malfunction

All safety valve malfunction

Cracks on boiler, blurts of water wall tube, overheat steam pipe and economizerpipe burst and damage of boiler wall threats the safe operation of boiler severely

8.8.5 Complete trial operation record

For main parameter in trial operation, see the Appendix 2.

9. Safety Measures

9.1 Safety rules for commissioning

9.1.1 The parties participating in commissioning shall be familiar with and abide by the relevant

safety rules, wear reasonable clothing and appropriate personal protective equipments.

9.1.2 In case of any accident that damages the equipment or hurts person happened or possiblyhappen during commissioning, suspend commissioning immediately and put the equipment to

the lowest energy state. Then investigate the cause and take corrective measures.

9 1 3 The parties participating in the commissioning shall obey the command of commissioning

PLTU 1 Jatim Pacitan 2315MW Project


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In adjustment or test, injury or death may be caused by object strike. Once in field, wearhelmet and safety belts. Check and eliminate the dangerous thing which may fall fromupper and surrounding area of operation.

Burned by damage of temporary purging pipeline.

All temporary pipeline should be insulated. Before purging, pipeline should be warmedsufficiently to avoid water hammer accident. Perform trial purging several times under

pressure 40%50% and 70%80% of the purging pressure.

Steam burn and noise pollution at purging steam outlet

Assign people to arrange safety isolation measures strictly at purging steam outlet.

Injured by high temperature flue gas of observation hole and manhole door

Close all observation hole and manhole door. Increase pressure properly before fire

observation on site. In fire observation, stand on the side of the hole, and make metal

preparation for evacuation at any time.9.3 Equipment Risk and Preventative Measures

Abnormal operation

If it is found that an operating equipment emits abnormal sound or has other abnormalcondition, and such problem may not be eliminated, stop such equipment and report to

the control rooms immediately

Fuel oil system fire

Strict fire-fighting measures should be set during commissioning. No combustibles andexplosives materials are laid around fuel oil system. Sufficient fire control equipment is

equipped on site.

Bad combustion results in flameout; accumulative oil make explosive flame

Fire failure protection must be arranged. Strengthen combustion adjustment to ensuregood combustion. If atomization of oil gun is poor, must clean it manually. After

flameout in furnace, 5-minute purging must be conducted before re-ignition.

Equipment damages and people injuries result from over temperature or pressure

Feed fuel slowly and steadily. Strengthen the monitoring of flue temperature in differentpoints. In case that burning rate is out of control, shut down boiler immediately. Assume

the pressure releasing accident in advance Strictly control the superheater outlet

PLTU 1 Jatim-Pacitan 2315MW Project


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10. Appendix

10.1 Appendix 1 Commissioning Condition Checklist

No. Items Requirements ResultVerified

by

Rema

rks

1 Conditions for trial commissioning

Boiler air pressure test has been successfullycompleted. Each air leakage has been treated.

Yes No

Boiler proper and flue gas duct have been assembled

and insulated.Yes No

Individual commissioning and subsystemcommissioning of forced draft fans have been

completed.

Yes No

1

Flue gas &airsystems

All damper flue gas and air systems have beeninspected, adjusted and accepted.

Yes No

System has been assembled and individualcommissioning has been completed.

Yes No

System hydraulic pressure test and water flushing has

been completed successfully.Yes No

Compressed air pipeline and valves for blowing should

be assembled and tested.

Yes No

All motorized valves and pneumatic valves for systems

have been tested and accepted.Yes No

The burner has been assembled and tested. Yes No

All interlock protection simulation test have been

successfully completedYes No

The ON/OFF tests for all oil guns and high-energyigniters have been successfully completed.

Yes No

2 Fuel Oil System

Cold commissioning for all flame detectors have been

completed.Yes No

Boiler proper have been installed, insulated andaccepted;

Yes No

Individual commissioning and interlock protection test

3 Boiler Proper

PLTU 1 Jatim-Pacitan 2315MW Project


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PLTU 1 Jatim Pacitan2315MW Project



pipeline are complete and in good order and pins have

been removed.

All motorized valves and pneumatic valves on allsteam and water pipeline have been tested and

accepted.

Yes No

The parties check jointly the boiler proper expansionsystems to confirm that boiler expansion is not

restrained .

Yes No

Ladders, platforms and railing on boiler proper arecomplete and illuminated sufficiently and the boiler

proper has been cleaned thoroughly.

Yes No

Drum level gauges have been installed, the level is

indicated correctly.Yes No

Boiler water samplers and dosing systems have beeninstalled, inspected and accepted correctly.

Yes No

Feed water system, desuperheating water systems havebeen installed and insulated. All motorized valves andpneumatic valves have been tested.

Yes No

All manholes and access doors on the boiler proper are

complete and closed;Yes No

4Compressed Air

System

Instrument& service air compressors have passedcommissioning individually or as a subsystem and are

ready for use.

Yes No

All fire fighting facilities are complete, fire water testshave been successfully completed and the systems are

at standby state.

Yes No

5Fire ControlSystem Fire fighting equipments have been equipped at Boiler

House, Control Room and place with Fuel Oil

Systems.

Yes No

Industrial water systems have been installed andhydrostatic tests have been successfully completed.

Yes No

6

Industrial WaterSystem

Commissioning of industrial water pumps and

industrial water subsystems have been completed andpumps and systems are ready for operation.

Yes No

The chemical system is able to supply watercontinuously.

Yes No

7Chemical Water

System Commissioning of make-up water systems has beenY N



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J j



each auxiliary

deviceStarting conditions, tripping conditions,

program-controlled startup and program-controlled

shutdown of water feed pumpYes No

For flue gas and air systems, measuring points of air

temperature and pressure, furnace negative pressure,pressure switch, flue gas temperature and pressure ofheating surface of different grade have been installed

and are ready for operation.

Yes No

For steam and water systems, measuring points ofdrum pressure, superheater pressure, steam

temperature, feed water pressure, temperature andflow, steam flow and water level meter with electriccontacts have been installed and tested and are ready

for operation.

Yes No

For fuel oil system, measuring points of fuel oil

pressure and temperature, flow meters, compressed airpressure have been installed, tested and are ready foroperation.

Yes No

3 Electric and I&C

Measuring points of auxiliary current, bearingtemperature and vibration have been installed, testedand are ready for operation.

Yes No

4

Various

protections,

alarms and

visual and audiosignals

It has been tested and they are able to alarm properly.

Yes No

3 Conditions for Environment

1Field, road andcover

wastes have be cleared.Yes No

2

Constructionscaffold

complete

have be removed. Yes No

3Temporaryillumination

can be arranged if necessaryYes No

4Communication

equipments

complete

ReliableYes No



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chemical water

and fuel oil

Overhaul toolsand materials

readyYes No

4

A soundcommissioningmanagement

organization

established and the responsibilities have been clearlydefined.

Yes No

5

Commissioningmaterial, tools,

instrument andrecord lists

ready

Yes No

6

Instrumentcontrol, electricand engineering

personnel

on site

Yes No

7


Signature

Date



40/44



10.2 Appendix 2 Format for Trial Run Record

Content Unit Data Content Unit Data

Boiler load T/h Main steam temperature

Main steam pressure MPa Supply oil pressure MPa

Main steam flow T/h Open rate of #1 oil return valve %

Drum pressure MPa Current consumption by forced draft fan A

Water level in drum mm Open rate of damper of forced draft fan %

Feed water flow T/h Outlet pressure of forced draft fan KPa

Feed water pressure MPa Furnace pressure PA

Temp. of feed water Temperature of flue gas at outlet ofsuperheater

Desuperheatering water flow T/h Feed water pump current A

Water level in feed water box mm Open rate of Feed water control valve %

Temperature of flue gas at outlet

convection bank Open rate of desuperheator control valve %

Bearing TEM.OF FDF Bearing TEM.OF Feed water pump

Motor Bearing TEM.OF FDF Motor Bearing TEM.OF Feed water pump

Bearing vibrationOF FDF mm/s Bearing vibrationOF Feed water pump mm/s

Completed By

SEPCTI DEC PLN JASER

Signature

Date



41/44



5

6

52

48

44

40

36

32

28

24

20

1

6

12

8

time

h

MPa

Hot

flush

ing

man

tainepressure

0.8

~1

.0MPa

Pressurecurve

boili

ngout



42/44



Upper drum

superheater

main steam pipe

Mcontrol valve

PipelineBlowingSystemD

iagram

Target board

To atmosphere



43/44

Procedure of Start-up Boiler REV ACommissioning Procedure

SCCTI-TS-GL-CS-006-2009A Page 43 of 44

10.5 Appendix 5 Check list of dampers

Dampers commissioning record

Remote Operating time

Name Local positionindication Direction FeedbackOn

(Open)Off

(Close)

Date Result Signature Remarks

Main steam valve#1 oil inlet valve

#2 oil inlet valve

#1oil return valve

#2 oil return valve

#1 ignition valve

#2 ignition valve


Signature

Date



44/44

Procedure of Start-up Boiler REV ACommissioning Procedure

SCCTI-TS-GL-CS-006-2009A Page 44 of 44

10.6 Appendix 6 Check list of control dampers

Commissioning record of control dampers

Feedback of ascending and descending instruction valuesName

0% 25% 50% 75% 100% 75% 50% 25% 0%Date Result Signature Remarks

Control damper of forceddraft fan

Water feed adjustable valve

Waterbox feed adjustable valve

Desuperheatering wateradjustable valve

1#oil return adjustable valve

2#oil return adjustable valve


Signature

Date

Documents

Prosedur Start Up Boiler.pdf