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Energy from Waste with Combined Heat and Power Facility, Oxwellmains

RPS Planning & Development – Brighton Office JAS4061O:\B_Jobs\4061s\Schedule 4\Appendices.docFebruary 2010Rev1

Appendix D

Typical EfW Plant Commissioning Plan


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Energy from Waste with Combined Heat and Power Facility, Oxwellmains

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Typical for RDF Power Plant

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TEST PLAN

1. PROGRAMME ...................................................... ........................................................... .............................. 2

2. COLD COMMISSIONING....................................................... ........................................................... .......... 3

3. HOT COMMISSIONING................................................................... ............................................................ 4

4. RELIABILITY TEST ...................................................... ........................................................... .................... 5

5. PERFORMANCE TEST ........................................................... ........................................................... .......... 6

COMMENT: This document is for typical use only. Project specific periods, durations

and conditions of commissioning/testing, as stated in POYRI Schedules 9 and 11

and agreed upon between TPSCo and Keppel Seghers prevail.


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1. PROGRAMME

One month before the scheduled start of COLD COMMISSIONING, the

CONTRACTOR will provide a detailed programme for the COLD COMMISSIONING,

HOT COMMISSIONING, RELIABILITY TEST, and PERFORMANCE TEST.


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2. COLD COMMISSIONING

COLD COMMISSIONING is defined as the period when individual items of the

INSTALLATION, electrical systems, control and instrumentation systems are checked

and tested.

During this period, activities such as boiler cleaning, refractory drying, cleaning of

pipe work and tank internals are carried out.

Test Sheets shall be developed by the CONTRACTOR to show what tests, checks

and recordings have been carried out. Such Test Sheets shall be submitted to the

EMPLOYER within two weeks after completion of any test.

During the COLD COMMISSIONING, the EMPLOYER will provide a full team of

operators to the CONTRACTOR for training on-site.

Starting Criteria Mechanical Completion

Ending Criteria Completion of COLD COMMISSIONING Tests

Result of Completion Start HOT COMMISSIONING

Note

Depending on the delivery schedule of the turbine, the cold commissioning of the

turbine may take place later than the cold commissioning of the incineration line. If

this occurs, the start of the hot commissioning of the incineration line shall not be

delayed by the turbine.

The cold commissioning and hot commissioning of the incineration line can takeplace with steam being sent over the by-pass, i.e. RDF is being incinerated, but

electricity production has not yet started.


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3. HOT COMMISSIONING

HOT COMMISSIONING is started after completion of COLD COMMISSIONING.

During HOT COMMISSIONING the plant will be operated with waste within the

boundaries of the combustion diagram.

The HOT COMMISSIONING tests shall be carried out by the CONTRACTOR and

shall cover in general the following topics :

- test of equipment under normal conditions

- test of control, regulation, protection and alarm systems.

The CONTRACTOR shall present a report of the HOT COMMISSIONING.

During the HOT COMMISSIONING, the EMPLOYER will provide a full team of

operators to the CONTRACTOR, during shift work, for training on-site.

Starting Criteria Completion of COLD COMMISSIONING Tests

Ending Criteria Completion of HOT COMMISSIONING Tests

Result of Completion Start RELIABILITY TEST


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4. RELIABILITY TEST

The purpose of the Reliability Test is to demonstrate that the plant is capable of safe

and reliable operation while complying with the emission limits. During this period,

operations and control functions shall be demonstrated to the EMPLOYER.

During the Reliability Test period of two weeks, the trial runs shall include the

following tests :

- start-up and shutdown of the equipment in an economical and well-controlled

manner;

- shut-down of the equipment under emergency conditions;

- stable run at various loads with the design range, under automatic control;

- a 72h run within the boundaries of the combustion diagram.

The CONTRACTOR shall provide all necessary supervision for these procedures.

Commissioning supervisors will be present on site on a 24h basis during the

scheduled period for the Reliability Test. It is the EMPLOYER’s responsibility to

provide a full staff of skilled operators in shift operation.

Minor defects, such as instrument faults or equipment faults which require the

standby operation of auxiliary equipment, shall not constitute a failure of the

Reliability Test, provided that the INSTALLATION continues to operate satisfactorily.

Note: During the first months of operation, too much heat may be extracted from the furnace

due to insufficient fouling and incomplete drying of the refractory lining. The fact that it takes

time to reach the normal fouling degree of furnace and boiler may have consequence for every

point of the combustion diagram. Practice has shown that auxiliary fuel can be necessary

during this period within the complete combustion diagram (and thus also at 100% load) in

order to meet the flue gas residence time requirement (850°C/2s).

Starting Criteria Completion of HOT COMMISSIONING Tests

Duration 2 weeks

Ending Criteria Successful demonstration of tests

Result of Completion Provisional Acceptance and Start Performance Test

Result of Failure Repetition of Reliability Test.


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5. PERFORMANCE TEST

Starting Criteria Not later than 3 months after Provisional Acceptance

Duration see table

Success Criteria The CONTRACTOR shall demonstrate that the plant is

capable of achieving the Performance Guarantees.

Result of Success Final Acceptance

Result of Failure Repetition of tests or

Liquidated Damages for failure to achieve guaranteed

performance

1. Performance test shall be carried out in accordance with the hereafter

described principle. The details to be mutually agreed between the

CONTRACTOR and the EMPLOYER KS to be reflected in a detailed protocol,

established at least 14 days prior to the start of the actual tests.

The protocol shall be in keeping with the current specifications and shall

describe, among other, the type, number and duration of the tests, themethodology (e.g. measurement technique, number of sample points, expected

accuracy, sampling duration & analysis). It shall also clearly identify the

responsibility of all involved parties with respect to the tests.

2. The performance test shall show that all the performance guarantees as

specified are fulfilled.

3. The CONTRACTOR shall provide all necessary supervision for these

procedures. KS supervisors and specialist engineers will be present on site on a

24h basis during the scheduled performance tests period.

4. It is the EMPLOYER’s responsibility to provide a full staff of skilled and trained

operators.

5. Each Party shall carry its own costs for the Performance tests.

6. The Site Representatives and technical personnel of the CONTRACTOR and

the EMPLOYER shall co-operate closely to ensure the smooth execution of the

Performance Tests


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7. Records of the test shall be made by the people nominated by the

CONTRACTOR’s Site Representatives and countersigned by theRepresentatives of the EMPLOYER every day.

8. If the Performance Test fails as a whole or in part, parties shall analyse the

reason together and define the responsible party/parties as soon as possible.

The responsible party/parties shall take immediate action to remedy the

cause(s) and will announce their readiness to recommence or continue the

tests as soon as possible.

Depending on the nature and characteristics of the failure of the tests, the

Performance Tests will be redone completely and for the full duration or in part

and for a shorter duration. This matter is to be addressed in general in the

aforementioned protocol but the actual decision is to be reached by agreement

with all parties immediately after the occurrence of the failure.

All parties shall grant their full co-operation to the repetition / extension of the

Performance Tests.

9. The plant has to be operated in accordance with the combustion diagram and in

accordance with the CONTRACTOR’s operation and maintenance manuals.

10. The RDF should be according to the design specifications as specified in the

AGREEMENT. The time during which no RDF in accordance with the design

specifications is available will be counted with respect to the duration of the

tests, but no guarantees or requirements shall hold. The same holds for

unavailability of RDF (for whatever reason) or unavailability of parts of the plant

that are not in the CONTRACTOR’s scope.

Variations in the composition, heating value and mechanical properties of the

RDF shall be kept to a level that is representative for modern RDF incineration

facilities. A maximum allowable variation will be agreed upon and included in

the aforementioned protocol. The EMPLOYER will inform the CONTRACTOR

about the RDF supply logistics. The preparation of a stable RDF mixture should

be obtained. The supply of different types of RDF will be spread over the whole

day, and concentrations of specific RDF streams over a long period will be

avoided.

11. During the performance tests, the trained operators (and maintenance

personnel), will be at the CONTRACTOR’s disposal to operate the plant.

12. The CONTRACTOR’s representative(s) will be responsible for the instruction of

the plant operation during the performance tests

13. Before a test is carried out, the plant operating conditions shall have been

stable for at least 2 hours (uninterrupted). The stability of the operation will beverified by means of representative operational parameters (e.g. steam


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production, RDF throughput, oxygen contents exit boiler). The limits on the

allowable variation will be included in the aforementioned protocol. TheCONTRACTOR must have the opportunity during at least 4 days to verify the

tuning parameters of the process before the Performance tests start.

14. All parameters shall be continuously recorded during the performance test with

a frequency of at least once a minute.

15. If the contract or the aforementioned protocol is unclear or fails to specify

certain aspects regarding the tests, the industry standard as reflected by the

CONTRACTOR’s reference plants will be applicable and deemed acceptable.

16. There should be no stoppage during a performance test: the relevant line(s)shall be in continuous operation from the beginning to the end of the relevant

performance test.

Plant

Performance Test

Test Duration Remarks

Capacity 24 hours Hourly average should be above 90% of

design capacity (or thermal equivalent to 90%

of design capacity).

Average over test duration should be equal to

or higher than design capacity (or thermal

equivalent to design capacity) as long as the

calorific value of the RDF is within the

specified range

Electricity

consumption

24 hours Average power consumption over the test

period shall be compared to the

CONTRACTOR’s guarantee value

Steam production 24 hours Steam flow is measured with orifice measuring

system.

Heat value of the steam is determined by

pressure and temperature.

The throughput is weighed with the refuse

crane weighing system.

Thermal load can be calculated from all thesevalues (method to be documented by the


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CONTRACTOR).

Gross Electricity

Production

24 hours Average power production over the test period

shall be compared to the CONTRACTOR’s

guarantee value

Combustion

Carbon in Ash

12 samples per

line taken during 6

successive hours,

every half hour

Detailed sampling procedure as per KS

standard.

Detailed ignition loss procedure as per KS

standard.

Emissions 24 hours

Official

independent

measurement

Consumables:

Water

24 hours Average over the test duration.

Consumption shall be compared to the

guaranteed consumption after correction in

relation to the throughput

Correction curves shall be agreed upon prior to

the start of the test

Noise Carried out by

independent and

certified specialist

during a period

relevant for normaloperation (not

necessarily

coinciding with the

tests)

A background noise measurement will be

performed.


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COMMISSIONING MANUALPART N°1 :

PRE- AND COLD COMMISSIONING

WASTE-TO-ENERGY PLANT

TYPICAL

by:

0 10-01-08 RPI Preliminary

Rev. Date By Description Check Appr.


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COMMISSIONING MANUAL – PART N°1

Document Name:

59164_601_001_0- Commissioning manual Part 1 Page:

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1. TABLE OF CONTENT

1. TABLE OF CONTENT................................................... ........................................................... .................... 2

2. INTRODUCTION.................... ............................................................ ........................................................... 4

3. SUB-SYSTEMS AND UNITS ................................................... ........................................................... .......... 6

3.1. DEFINITIONS ..................................................... ............................................................ ............................. 6

3.2. COMMISSIONING STATUS REPORTS .......................................................... .................................................. 6

4. PRE-COMMISSIONING.......................................................... ........................................................... ........ 10

4.1. PRE-R EQUISITES ......................................................... ............................................................ ................. 10

4.1.1. General ................................................... ............................................................ ........................... 10

4.1.2. Testing of wiring ......................................................... ........................................................... ........ 10

4.2. CHECK -OUT LISTS ....................................................... ............................................................ ................. 11

4.3. U NIT INSPECTION SHEETS ..................................................... ........................................................... ........ 12

5. COLD-COMMISSIONING ...................................................... ........................................................... ........ 13

5.1. PRE-R EQUISITES ......................................................... ............................................................ ................. 13

5.2. LOG BOOK ........................................................ ............................................................ ........................... 13

5.3. LOOP TESTS ...................................................... ............................................................ ........................... 13

5.4. MOTOR TESTS ................................................... ............................................................ ........................... 14

5.5. FUNCTIONAL TESTS ..................................................... ............................................................ ................. 14

5.6. SPECIFIC FUNCTIONAL CONTROLS .................................................. .......................................................... 15

5.6.1. Feeding and combustion grates ...................................................... ............................................... 15

5.6.2. Ash extractor.............. ........................................................... ......................................................... 16

5.6.3. Refractory lining ......................................................... ........................................................... ........ 17


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5.6.4. Sifting ash conveyors .................................................. ........................................................... ........ 17

5.6.5. Boiler cleaning system .......................................................... ......................................................... 17

5.6.6. Hydraulic group...................................... ............................................................ ........................... 18

5.6.7. Burners ............................................................. ........................................................... .................. 18

5.6.8. Smoke testing of the flue gas cleaning...................................................... ..................................... 20

6. ANNEXES........................................... ........................................................... ................................................ 23

6.1. ANNEX 1 : LIST OF SUB-SYSTEMS .......................................................... ................................................ 23

6.2. ANNEX 2 : COMMISSIONING STATUS R EPORTS .......................................................... ............................ 23


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2. INTRODUCTION

This document outlines the sequence of activities required to take the plant from a completed

installation to a fully operational and commissioned plant. The pre-requisites, necessary for

each stage of the commissioning, are described.

The commissioning will, in general, follow the sequence herebelow :

1. Pre-Commissioning (or “Unit test”): the checking and testing of equipment prior to

their cold commissioning with power and air. Such works shall consist of testing the

alignment and direction of rotating parts, the verification of the wiring and cabling, the

verification of the PLC system, verification of correct mounting of piping, verification of

correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.

Pre-commissioning checks, when completed, will release individual items of equipment to be powered up and made available for inclusion in the cold commissioning phase.

2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors

and other electrical equipment, flushing and cleaning of tanks and piping if applicable,

adjustment and regulation of protective devices, functional tests, leakage and pressure

tests, inspection of bearings, etc.) and operation of equipment for a period of time. This

will be mainly as individual items, but may involve running some of the equipment in

sequence.

3. Hot Commissioning: this will include the introduction of fuel (waste), process gas and

reagent (including the boiling out of pressure parts, curing of the refractory, blowing of

steam pipe to turbine, etc). The whole plant will be tested, operating in sequence under

full load conditions.

The Commissioning Manual (part n°1) includes instructions for the Pre-commissioning and

the Cold Commissioning of the equipment in the Contract.

The Commissioning Manual (part n°2) includes instructions for the Hot Commissioning of the

equipment in the Contract. This second part contains specific information for the first start-

up, which differs from a normal plant start-up. For the general operating procedures (allowing

to start-up, operate and shut down the plant under normal conditions), please refer to the

Operation and Maintenance manuals.

Responsibility: Operating instructions specified in this manual are typical procedures. It is

impossible to cover all eventualities, which might occur during the start-up of the plant.

Keppel Seghers cannot take responsibility for damage to any part of the plant, which could

have been avoided if instructions had been followed.


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On the other hand, conditions may arise in which actions must be taken without sticking

strictly to the instructions in this manual, provided that such actions result in safe operation.


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3. SUB-SYSTEMS AND UNITS

3.1. DEFINITIONS

In order to commission the plant in a structured and systematic manner, the plant is divided in

Sub-systems and Units.

Sub-systems correspond with a P&ID.

tbd during detailed engineering

Each Sub-system is then divided in Units, each corresponding with a major equipment part

within the Sub-system (pump, silo, screw, fan, etc.). Valves and instruments attached to this

equipment form part of the Unit. The exact scope of a Unit is to be determined by the

KEPPEL SEGHERS commissioning supervisor, prior to the start of the commissioning. For

systems using the KKS tag numbering, a most convenient way is to define Units as the

aggregate of equipment within the same KKS system code (e.g. HLB10 : primary air fan

element 1, HLB20 : primary air fan element 2, etc.).

Piping and ducting systems, including valves and instruments, also can form a Sub-system or

Unit (e.g. lime milk piping, flue gas ducting, etc.).

3.2. COMMISSIONING STATUS REPORTS

A commissioning status report is compiled for each Sub-system. These reports will be

managed, updated and filed by the KEPPEL SEGHERS commissioning supervisors, based on

the input of the commissioning company. They will enable the engineers to know the status of

each Sub-system at any moment during the commissioning period. Each report gives an

overview of the progress made on the commissioning of each Sub-system, and is composed of

the following documents :

1. Status list

2. P&ID

3. Check-out lists

• Equipment checkout list

• “I/O and SAT tests of control panel”

• “I/O and SAT tests of electrical panel”


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• Pipes & valves checkout list

4. Unit inspection sheets

5. Punch list

6. Functional description

7. Interlock list / autoconditions

8. Test reports

Status list

The Status List indicates the pre-and cold commissioning status of each Sub-system and their

Units. It also gives an overview and description of all the Units within a Sub-system. When

all Units have reached the status of pre-commissioning (= ”mechanical complete”), the Sub-

system is ready for cold commissioning (loop tests + functional tests).

The Status List is a unique document and is to be updated after each inspection round of the

Sub-system. Date, initials and signature have to be filled in by the KEPPEL SEGHERS

engineer after each inspection round.

P&ID

The latest revision of the P&ID of the Sub-system. The P&ID forms the basis of eachcommissioning status report.

Units or equipments (instruments, valves, motors) which are “mechanically complete” will be

coloured on the P&ID. This quickly gives an idea of the progress on the pre-commissioning

activities for each Sub-system.

Any “change” between the P&ID and the setup in the field is also to be marked on this P&ID.

It is then important to report this on the Master P&ID, so that the “as-built” revisions of the

P&ID’s can be prepared.

Check-out lists

For each Sub-system there are 4 types of lists : Equipment checkout list, “I/O and SAT tests

of control panel”, “I/O and SAT tests of electrical panel” , Piping & Valves checkout list.

The check-out lists are used to verify if the Sub-system is built strictly according to the

project P&ID’s, the so-called “P&ID check”.

Unit inspection sheets


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4. PRE-COMMISSIONING

4.1. PRE-REQUISITES

4.1.1. General

• The control panels and the panels for motors up to 3 kW will have been tested

100% by KEPPEL SEGHERS engineers during the FAT tests in the factory of the

panel manufacturer. This means that each IO signal has been checked from the bit

in the PLC up to the input or output terminal for connection of the field wires. This

testing will be reported in the FAT Inspection report.

• The electrical panels (MCC) for motors from 3 kW will have been tested 100% by

the responsible during the FAT tests in the factory of the MCC panel manufacturer.

This testing will be reported in the FAT Inspection report.

• The electrical site wiring to the plant has to be complete and must have been fully tested

by the electrical contractors. See next section (4.1.2) about testing of wiring and cabling.

• The instruments shall be installed and properly connected. This shall be documented by

the instrument installer on the “I/O and SAT tests of control panel” lists with the

following items for each instrument : mechanical installation, process connection,

pneumatic connection, electrical connection, tag plate.

• Power supplies (normal and emergency) to the panels must be available.

• The panels shall be in a watertight building.

• The DCS system for operator interface of the installation must be available and FAT

tested in the presence of an KS automation engineer. Testing reported in a FAT inspection

report.

• Communication network between DCS and control units must be ready.

• No gas or reagent, hot or cold, should have been through the equipment.

4.1.2. Testing of wiring

• The responsible for the erection of the cabling shall execute tests in order to check all

cable and wire connections. . Only after the completion of these tests, the pre-

commissioning and cold commissioning can start under the supervision of KEPPEL

SEGHERS.

• These wiring and cabling checks will be done as follows :


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- For connections between control panel at one side and instruments, valves and all

other equipment at the other side : before connection to the instrument/equipment and

before connection to the control panel, all wires will be invividually “shortcircuited”

at the instrument/equipment side, and the shorcircuit will be measured at the controlcabinet side. Only after this test, the instrument/equipment may be connected.

- For connections between control panel and motor control and protections circuits :

before connection to the motor contol centre (MCC) and before connection to the

control panel, all wires will be invividually “shortcircuited” at the MCC side, and the

shorcircuit will be measured at the control cabinet side. Only after this test, a MCC

unit may be connected to the signal cable.

- For power cables to motors/equipment : before connection to the motor/equipment

and after connection to the MCC, all wires will be invividually “shortcircuited” at the

motor/equipment side, and the shorcircuit will be measured at the MCC side. Also the

isolation resistance of the cables will be measured. Important remark : for

frequency convertors (variable speed drives), these tests will be executed without

the cable connected to the drive unit. Only after these tests, the motor/equipment

may be connected.

• The result of each test will be documented by checkmarking on the “I/O and SAT tests of

control panel” and the “I/O and SAT tests of electrical panel” lists . After completion, this

lists will be signed and stamped by the responsible of the cabling (installer).

4.2. CHECK-OUT LISTS

One of the first inspection rounds after erection and installation of the equipment will consist

in verifying the completeness of the Sub-system and/or Unit, based on the P&ID and the

corresponding check-out lists, the so-called “P&ID check” :

• Check-out list for ‘Equipments’ (per P&ID)

• “I/O and SAT tests of control panel” (one per panel) with the following items for each

instrument : mechanical installation, process connection, pneumatic connection, power

cable connection, instrument cable connection. I/O test.

• “I/O and SAT tests of electrical panel” (one per panel) with the following items for each

electrical user : mechanical installation, power cable connection, control cable

connection, insulation test, I/O test.

• Check-out list for ‘Pipes & valves’ (per P&ID)

For each item (reference is made to the TAG-), the commissioning company will complete the

check-out list to give documentary proof that each item of the P&ID has been installed.


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Any missing item or equipment is to be chipped on the check-out list as “NOK”. It will then

be reported as an open item on the punch list and will be checked together with the Keppel-

Seghers commissioning supervisor.

Every inspection round will be listed on the Status List (date, initials, signature and eventual

remarks). A new check-out list can be used for every new “P&ID check”.

4.3. UNIT INSPECTION SHEETS

The Unit inspection sheet is used as a checklist when pre-commissioning each Unit of the

Sub-system. A standard form is available for each type of mechanical equipment (pump, silo,

fan, etc.) within the Unit. The list of inspection points on the form is not limitative, the

inspectors are free to add other inspection points which they consider important.

Every inspection round will be listed on the Status List (date, initials, signature and eventual

remarks). A new form can be used for every new inspection. When one or more checks on

the form are rejected, they have to be reported as open items on the punch list.

The Unit is “mechanically complete”, and ready for further cold commissioning, when all

items with qualification 1 on the punch list are solved. This is to be confirmed by the

KEPPEL SEGHERS engineer on the Status List (date, initials, signature), before one can

proceed with the further cold commissioning.


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5. COLD-COMMISSIONING

5.1. PRE-REQUISITES

• The electrical supply should be available and the MCC should have been tested by the

electrical contractors and be ready for service.

• The PLC control system should be available and the PLC programming be complete.

• The compressed air supply system should be fully available.

• No gas, hot or cold, should have been through the plant.

• The pre-commissioning checks should be complete.

5.2. LOG BOOK

As the cold commissioning involves the interaction of many people from various disciplines

(mechanical, process, electricity, instrumentation, automation), it is necessary to keep a

Commissioning Log Book, somewhere at a centralized location (e.g. the plant’s control

room).

This book will contain the day-by-day chronological logging of actions / situations / events

during the commissioning of the plant. The main purpose of the Log Book is to improve

communication between the commissioning people, and more specifically between shift teams

(day and night). Especially with regard to safety, the exposure to unsafe situations is higherduring the commissioning phase than during normal operation. Good communication is a first

step in prevention of unsafe situations.

The Log Book is not to be confused with the Commissioning Status Reports. The Log Book

is covering the whole plant, is chronological and serves better communication. The

Commissioning Status Reports are per Sub-system and keep track of the formal, signed

registration of the commissioning status.

5.3. LOOP TESTS

Loop testings (or I/O tests) have to be realised for all instruments, automatic valves and

motors. The loop testing will be done under the responsibility of the EIA engineer (electricity,

instrumentation & automation) of the installer. The installer will dispatch sufficient technical

staff to solve immediately any wiring encounterd, so that the loop testing can be completed.

The loop testings will be executed on the basis of loop schemes. There is a loop scheme for

every instrument, automatic valve and motor. The EIA engineer keeps a separate file of all

loop schemes of the plant. This is the “as built” file. Working files used in the field will be

only copies.


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necessary to add reagent or products to the Units or Sub-system (e.g. pumps or mixers that are

not allowed to run dry or empty).

It is imperative to thoroughly follow the instructions in the Operation & MaintenanceManual of the specific Sub-system, before executing functional tests with reagent or

products.

For some Units, some additional specific functional tests have to be done, as further detailed

under 5.6. Specific functional controls.

5.6. SPECIFIC FUNCTIONAL CONTROLS

The specific functional controls listed hereunder are for ‘Equipment’ designed by KEPPELSEGHERS only. Functional controls for other main equipment like turbine, water tower, …

are within the scope of the subcontractor and as such not detailed in this section.

5.6.1. Feeding and combustion grates

Reference is also made to the Operation & Maintenance Manual.

Before starting the operation (movement) of the grate elements, it is advised to have a final

check on the clearances of the combustion grate tiles. This is necessary to be sure that theclearances have not been changed during mounting of the grate elements. If clearances have

become smaller than advised on the drawings, there is a risk of blockage of the grate tiles at

normal operating conditions of the grate. On the other hand, two large clearances can cause

excessive sifting ash production and primary air by-pass.

• The first fillings of all bearings were done by the constructor during pre-assembly of the

grates. Because of the large period of time between grate pre-assembly and

commissioning, all grease points will be verified by adding grease before moving the

grate elements. Refer to the O&M manual regarding the grease qualities (make and type)

of the grease nipples. The greasing positions are shown on the drawing XXXX_239_003.

Once the hydraulic unit has been fully checked for correct mounting and the hydraulic oil

circuit has been completely flushed (see section 5.6.6), the movement of the feeding- and

combustion grates should be tested during at least 8 consecutive hours. During this test, one

has to pay attention to:

• Check the fixed time for the tumbling movement (normally between 3 and 6 sec), the time

for withdrawing the feeding grates (typical between 5 - 20sec) and the time for

withdrawing the sliding tiles (typical between 2 to 10 sec).


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• Check the stroke of the hydraulic cylinders:

• ca. 260 mm for the sliding grates;

•

ca. 130 mm for the sliding grates of the fifth element.;• ca. 130 mm for the tumbling grates.

Caution: Special attention has to be taken not to run the grates during the furnace

warm-up. In this case, the feeding grates have to stay in their withdrawn

position and the combustion grate must be covered by insulation material.

The cold commissioning of the grate must be supervised by Keppel Seghers’ qualified

personnel.

5.6.2. Ash extractor


The first fillings of all bearings were done by the constructor during pre-assembly of the ash

extractor. Because of the large period of time between extractor pre-assembly and

commissioning, all grease points will be verified by adding grease before moving the ash

extractor.

The hydraulic oil to the hydraulic cylinders is delivered by the pumps of the hydraulic group(see § 5.6.6). The oil pressure can be adjusted using the pressure reducing valves at the ash

extractor stand valve :

• Pressure to the hydraulic drive unit must be set up at 100 bar

When the hydraulic is connected, all moving parts must be checked to move properly:

movements of the pusher.

After a dry run of a few hours without water, the ash extractor is filled with water and its

movement can be tested during 8 consecutive hours (or more). During this test, one has to pay

attention that:

• All moving parts move properly

• The level control device in the water tank is properly adjusted so that the water seal is

realized at the sifting ash hoppers

The inspection work on the ash extractor must be supervised by Keppel Seghers’ qualified

personnel.


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5.6.3. Refractory lining

Reference is also made to the Refractory Lining Supplier Erection & Commissioning Manual.

After installation of the refractory lining, the work must be inspected and approved by

qualified personnel :

• Check of lining dimension

• Check of the lining surface

• Hammer test to check the lining for holes, grains, accumulation, etc.

When checks are completely finished, release notes have to be handed over fully signed by contractor, supplier and client’s

representatives.

5.6.4. Sifting ash conveyors


Before the first starting up of the conveyors, the following points have to be considered :

• Be sure that the safety switch is switched off

• Check that there are no alien parts lying in the conveyor

•

Check that there is oil in the gearbox• Activate the greasing device by screwing in the ring bolt in the grease container

• Stretch the chain. To do that the conveyor must be started up (don’t forget to check the

direction of rotation) and let it run for a while. The chain is sufficiently stretched when

the carriers are leaving the return part without a bang. A bang will occur if the chain is

too slack. On the other hand, if it is stretched too hard the carriers will be lifted before

they reach the bend.

• After a couple of days, all of the carriers screw joints is to be follow up drafted, and the

stretching of the chain must be checked.

5.6.5. Boiler cleaning system



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5.6.6. Hydraulic group


Before the first start-up of the hydraulic plant, the installation (including all piping) must be

flushed and cleaned to eliminate all contaminants from the system and achieve the required

degree of purity of the oil. The supplier will be responsible for the first cleaning of the

hydraulic equipment and piping, as well as the first filling with hydraulic oil.

The minimum requirements for the hydraulic oil are :

• Hydraulic oils with corrosion, oxidation and wear additives : HLP oils according to DIN

51524 part 2

•

Viscosity class VG46 according to ISO 3448 is obliged.

A list of potential mineral oil makes that can be used for the hydraulic group is annexed in the

O&M manual. Other makes are possible provided that they have similar characteristics.

Commissioning of the hydraulic system will be done under the supervision of the supplier.

This start up will cover (not limitative) :

• Cleaning of all piping, reservoirs and ancillaries

• Pressure testing

•

Verification of correct mounting of all equipment• First hydraulic oil filling

• Test run of all the equipment, especially for verification of the proper functioning of the

pressure compensated hydraulic proportional flow control valves.

• Prevention of oil leakages

5.6.7. Burners


The start up and commissioning of all burners will be done during drying and baking of the

refractory lining of the furnace, and during boiling out of the boiler and blowing out of the

steam piping (see part 2 of the “Commissioning manual”).

• Drying of the refractory lining will be done by means of the start up burners. During

drying of the refractory lining, the start up burners will be operated at low thermal load.


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At the beginning of this period, the start up burners can be tuned rather roughly, because

operation at maximum thermal load is not allowed, or only during short periods (e.g. some

minutes). The burners will be tuned in a way they can be started and stopped in a reliable

way, and in a way the combustion is visually complete (no formation of soot). Fine-tuning (e.g. to attain good and complete combustion along the complete working range of

the burners) is not yet required and not yet possible. This rough fine-tuning is expected to

last one working day.

• When baking of the refractory lining has started, the load of the start up burners can be

increased gradually. At the end of this period, a fine-tuning of the burner can be allowed,

because operation at maximum load is possible during long time. As drying of the

refractory lining can last some days (at low burner load), and the temperature increase

after drying is very slow, it is possible that there will be some days between the first

commissioning of the start-up burners, and the fine-tuning.

• During baking of the refractory lining and boiling-out of the boilers, the auxiliary burners

will be started and operated at low thermal load. At the beginning of this period, the

auxiliary burners can be tuned rather roughly, because operation at maximum thermal

load is not allowed, or only during short periods (e.g. some minutes). The burners will be

tuned in a way they can be started and stopped in a reliable way, and in a way the

combustion is visually complete (no formation of soot). Fine-tuning (e.g. to reach the

required CO- or NOx-emission limits, or to verify the fuel/air ratio curves at different

loads) is not yet required and not yet possible. This rough fine-tuning is expected to last

one working day.

• When baking of the refractory lining is finished (and the furnace is still hot), auxiliary

burner operation at maximum load can be allowed, as long as temperature changes in the

furnace can be restricted up to the values allowed by the refractory supplier (10 up to 25

°C/hr). During this period, a fine-tuning of the burner can be allowed (to reach the

guaranteed emission levels, and to determine the fuel/air ratio curves at all burner loads).

If this fine tuning requires several succeeding intervention days of the burner supplier, it

is advised to combine this activities with the blowing of the steam piping, because

frequent burner modulation can be allowed in this period, and there is enough time

available (one can expect that the auxiliary burners will be operational during at least one

week).

During this period, presence of qualified personnel of the burner supplier will be required.


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5.6.8. Smoke testing of the flue gas cleaning

(a) General

The intent of smoke testing is to detect leaks in the flue gas path of the plant, means from the

outlet of the furnace up to the baghouse filter. Leaks mean that during normal operation, cold

outside air is draught into the system (in underpressure) causing corrosion at the inlet area,

loss of flue gas temperature and an increase in flue gas flow, resulting in a higher electrical

consumption of the ID-fan.

Since it is very difficult to detect these leaks during operation, a smoke bomb test should be

performed during the plant cold commissioning phase as well as after plant start-up on a

regular basis (for instance every year – during the annual shutdown)

Smoke testing is performed by blowing a high volume of very low-pressure smoke into thesystem at one or more manholes. Plugs, valves, temporary blind flanges are used to confine

the smoke to the section or sections of system being tested. Observation of the emergence of

smoke enables the crew to detect sources of inflow.

The plant building will usually have one or more roof vents from which smoke will emerge.

The roof vents will be used to evacuate the outcoming smoke. The residents and fire

departments must be told to ignore the smoke as well.

Because testing to large sections is less effective and gives the crew too much area to observe

during the relatively short life of the smoke bombs (3 or 5 minutes), it is advised to haveseveral tests along the flue gas path:

• Section 1 : from the combustion chamber (furnace) up to the inlet of the baghouse filter,

• Section 2 : from the baghouse filter up to the stack inlet, if there is possibility to confine

this system at the stack side (otherwise the smoke test II will be limited to the baghouse

filter outlet)

(b) Equipment

Smoke testing can be performed using:

• Primary, secondary and burner air fans (for section 1)

• Mobile blowers (for section 2)

Blowers suitable for smoke testing have a circular flange or plate for mounting on an open

manhole and are gasoline engine driven. Blowers recommended for smoke testing have a free-

air delivery of at least 3.000 m³/h.

The static pressure capability of the blowers is less than 2,5 mbar.


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(c) Smoke

Smoke used is cold and very visible (white). The smoke is not hazardous and is free of oil

and coloured particles, which could leave residue and stains. Smoke “bombs” recommendedfor smoke testing are usually 3- or 5-minute duration.

Smoke is introduced into the system either by placing a smoke “bomb” at the blower inlet or

by lowering the smoke “bomb” into a manhole in a bucket and blowing air in from above.

The inspector should understand that the smoke bombs are not dangerous and have a limited

shelf life. Once opened, a package of smoke bombs should be used. Smoke bombs exposed to

moisture or humidity may be difficult, if not impossible, to ignite.

(d) Advance notices

Prior to performing smoke testing, plant personnel and residents are notified of the purpose

and approximate date of the work. Residents are told that they will see smoke emerging from

the roof vents.

Local fire and police departments should be advised daily of the areas being tested. Personnel

handling telephone inquiries should be acquainted with the purposes of the smoke-testing

program.

(e) Smoke test procedures

1. Advance notice is given to residents, fire and police departments.

2. The inlet and outlet of the system ducting are blocked, i.e.:

• For section 1: hopper feeding chute valve - inlet valves of the baghouse filter

• For section 2, inlet of the baghouse filter - inlet of the stack (by means of

temporary flanged plates)

3. The manhole sections to be tested are isolated (sifting ash hoppers, combustion chamber,

feeding grate casing, boiler, flue gas duct, reactor, baghouse filter).

4. The ash extractor and the sifting ash conveyors (in section 1) are filled with water

5. The gate valve for the residue extraction (boiler hoppers, reactor cone, filter hopper) must

be closed

6. The combustion air fans (for primary air, secondary air and for burners) are started in

section 1. In section 2, a smoke blower is set up at an open manhole in the filter and started.


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7. A smoke bomb is ignited, placed in a bucket and lowered into the manhole. The blower is

then positioned on the open manhole and set at full throttle.

8. In less than a minute, smoke will be issuing from the roof vents of buildings and anydirectly connected points of inflow.

9. A smoke testing crew usually consists of three persons. One individual operates and

maintains the blower while the other two walk the test area to locate and document inflow

sources indicated by emerging smoke.

10. The crew documents significant and identifiable points of inflow. Sketches, field notes,

portable tape recordings, digital pictures and movies could be used to record test results.

11. Those firms bidding on this type of work should have a documented history of five years

of successful smoke testing. References and dates are to be submitted with bids.

12. All bidders will be licensed contractors and perform a minimum of 60 percent of the

contract.


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6. ANNEXES

6.1. ANNEX 1 : LIST OF SUB-SYSTEMS

See also Error! Reference source not found. on page Error! Bookmark not defined..

- tbd during detailed engineering

6.2. ANNEX 2 : COMMISSIONING STATUS REPORTS

1. Status List

2. P&ID

3. Check-out lists

4. Unit inspection sheets

5. Punch list

6. Functional description

7. Interlock list / autoconditions

8. Test reports


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COMMISSIONING MANUAL

PART N°2 :

HOT COMMISSIONING

WASTE-TO-ENERGY PLANT

TYPICAL

by:

0 10-01-08 RPI Preliminary

Rev. Date By Description Check Appr.


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59164_601_002_0- Commissioning manual Part 2 Page

2

1. TABLE OF CONTENT

1. TABLE OF CONTENT................................................... ........................................................... .................... 2

2. INTRODUCTION.................... ............................................................ ........................................................... 4

3. GENERAL.................................................... ........................................................... ........................................ 6

4. PREPARATION TO DRYING-OUT, BOILING-OUT, BAKING AND BLOWING-OUT .................... 7

4.1. FURNACE.......................................................... ............................................................ ............................. 7

4.1.1. Combustion chamber ...................................................... ........................................................... .......... 7

4.1.2. Grate ........................................................... ........................................................... .............................. 7

4.1.3. Feeding hopper and chute..................................... ........................................................... .................... 8

4.1.4. Start-up burner.............. ............................................................ ........................................................... 8

4.1.5. Ash extractor and sifting ash conveyors....................................................... ........................................ 9

4.1.6. Primary, secondary and wall cooling air........................ ........................................................... .......... 9

4.2. BOILER AND STEAM CIRCUIT........................................................... ........................................................... 9

4.3. FLUE GAS CLEANING PLANT ............................................................ ......................................................... 10

4.4. COMMON PARTS ......................................................... ............................................................ ................. 10

5. HEATING-UP PROCEDURE ............................................................ ......................................................... 11

6. BOILING-OUT PROCEDURE .......................................................... ......................................................... 14

7. DRYING-OUT AND BAKING........................................................... ......................................................... 16

8. BLOWING-OUT (= BLASTING) OF THE BOILER ................................................... ............................ 20

8.1. GENERAL CONDITIONS.......................................................... ........................................................... ........ 20

8.2. STEAM BLASTING CRITERIA – CALCULATION PROCEDURE...................................................... .................. 21

8.2.1. Distribution factors – K-factors. ........................................................ ................................................ 21

8.2.2. Calculation method ......................................................... ........................................................... ........ 21

8.2.3. Continuous steam blasting ........................................................ ......................................................... 23

8.3. IMPACT BLOWING OF BOILER - PIPING ...................................................... ................................................ 24

8.4. BLOWING-OUT PROCEDURE ............................................................ ......................................................... 24

8.5. PRACTICAL MATTERS ........................................................... ........................................................... ........ 25


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8.6. TESTING OF STEAM CLEANLINESS .................................................. .......................................................... 26

9. FIRST START-UP WITH REFUSE ............................................................ ............................................... 27

9.1. TEMPERATURE AND PRESSURE RISE ........................................................ ................................................ 27

9.2. SAFETY................................................... ............................................................ ..................................... 28

9.3. PREPARATIONS ........................................................... ............................................................ ................. 29

9.4. START-UP SEQUENCE ........................................................... ........................................................... ........ 29

9.4.1. Prior Remarks ....................................................... ........................................................... .................. 29

9.4.2. Start-up common parts .................................................... ........................................................... ........ 30

9.4.3. Steam circuit (common) ............................................................ ......................................................... 31

9.4.4. Air preheater ......................................................... ........................................................... .................. 31

9.4.5. Start-up furnace (line 1 or 2) .................................................... ......................................................... 34


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2. INTRODUCTION

This document outlines the sequence of activities required to take the plant from a completed

installation to a fully operational and commissioned plant. The pre-requisites before each

stage of the operation can be commenced are described.

The commissioning will normally follow the sequence below:

1. Pre-Commissioning (or “Unit test”): the checking and testing of equipment prior to

their cold commissioning with power and air. Such works shall consist of testing the

alignment and direction of rotating parts, the verification of the wiring and cabling, the

verification of the PLC system, verification of correct mounting of piping, verification of

correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.

Pre-commissioning checks, when completed, will release individual items of equipment to

be powered up and made available for inclusion in the cold commissioning phase.

2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors

and other electrical equipment, flushing and cleaning of tanks and piping if applicable,

adjustment and regulation of protective devices, functional tests, leakage and pressure

tests, inspection of bearings, etc.) and operation of equipment for a period of time. This

will be mainly as individual items, but may involve running some of the equipment in

sequence.

3. Hot Commissioning: this will include the introduction of process gas and reagent

(including the boiling out of pressure parts, curing of the refractory, blowing of steam

pipe to turbine, etc). The whole plant will be proved, operating in sequence under full

load conditions.

The Commissioning Manual (part n°1) includes instructions for the Pre-commissioning and

the Cold Commissioning of the equipment in the contract.

The Commissioning Manual (part n°2) includes instructions for the Hot Commissioning of the

equipment in the contract. These second part contains specific information for the first start-

up, which differ from a normal plant start-up. For the general operating procedures (allowing

to start-up, operate and shut down the plant), please refer to the Operation and Maintenance

manuals.

Responsibility: Operating instructions specified in this manual are typical procedures. It is

impossible to cover all eventualities, which might occur during the start-up of the plant.

Keppel Seghers cannot take responsibility for damage to any part of the plant which could

have been avoided, had instructions been followed.


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On the other hand, conditions may arise in which actions must be taken without sticking

completely to the instructions in this manual, provided that such actions result in safe

operation.


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4. PREPARATION TO DRYING-OUT, BOILING-OUT, BAKING AND

BLOWING-OUT

4.1. FURNACE

4.1.1. Combustion chamber

• Before starting the drying-out and the baking procedure, a test has to be done to check the

amount of leakage air entering the furnace. During this test, the primary air fan will be

started without using the ID-fan. An overpressure will be created in the furnace. Air leaks

can be checked now by applying liquid soap at welding and other connection elements.

Air leaks have to be repaired before starting the drying-out and baking procedure.

• All measurement systems in the furnace zone has to be operational (temperature, pressure,

…). All temperature trendings in furnace and post combustion zone have to be printed

and saved.

• All sight glasses, measurement systems, camera’s, or other elements with a protection

against high temperatures by means of sweeping air, have to be cooled during drying-out

and baking procedure.

4.1.2. Grate

• In normal operation, the tiles are cooled by primary air and thermally protected by a waste

layer, which acts as an insulating layer. Since drying-out of the refractory is not possibleand not allowed by waste, the burners have to be used. The grate tiles are not designed to

be exposed to the full heat of the burners; therefore the tiles need to be protected. This

protection remains in the furnace during the entire warm-start up, being the refractory

drying, the boiler boiling-out and the blowing-out of the boiler and steam piping.

The entire feeding and the combustion grates element 1 to 3 must be covered by means of

insulating material (rockwool), thickness at least 100 mm. Above the insulating material a

layer of about 5 cm of sand is put (can be sprayed with a pump). The sand is used to avoid

that the insulating material would fly away due to the draft of the ID-fan. It should be

carefully checked that the complete surface is evenly filled. Also the side wall tiles of thecombustion grate and the inlet guide tiles of the feeding grate have to be completely

covered.

The grate element which are most intensively exposed to heat are grate element number 4

and 5 (at furnace outlet), since the start-up burner is positioned in the back wall. These

elements must be covered with ceramic fiber, with thickness at least 100 mm.

Note: Instead of sand, bricks could be used to maintain the insulation in place.


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Caution: The temperature of the feeding and combustion grate may not arise above its

design value (feeding grate = surrounding temperature, combustion grate =

primary air preheating temperature), otherwise severe damage can be causedto the mechanical structure and the hydraulic drive system (caused by limited

thermal expansion). The procedure to protect the grate, like described below,

has strictly to be followed.

• Before starting the drying-out and baking procedure, it is advised to have a final check on

the clearances of the combustion grate tiles. This is necessary to be sure that the

clearances have not been changed during mounting of the grate elements. If clearances

have become smaller than advised on the drawings, there is a risk of blockage of the grate

tiles at normal operating conditions of the grate.

• It is advised to test the operation (movement) of the grate elements before drying-out and

baking, to check whether everything works properly. All combustion and feeding grate

elements have to be withdrawn to their “rest” position.

• The feeding grate has to be cooled by opening the inspection door at the back side of the

feeding grate housing. In this way, heat release to the feeding grate can be evacuated to

the environment.

4.1.3. Feeding hopper and chute

• To protect the feeding hopper and the feeding chute cover plate system against too high

temperatures, they have to be protected by means of a temporary cover. A frame insidethe chute is made with iron bars. On this framework, hard insulating plates (thickness 40-

50 mm) are put with some bricks to avoid that the plates will fly away. All gaps have to

be closed by means of insulation material (in order to prevent the escape of hot flue

gases). The cover is placed just above the feeding grate where the steel part of the chute

starts to allow drying and baking of the refractory lining in the feeding chute.

• The closing gate of the feeding hopper has to be opened, to be able to evacuate the

released heat to the environment.

• The chute (closed loop) water circuit must be enabled to allow cooling of the steel plate

through the water jacket.

4.1.4. Start-up burner

• The start-up burner should be checked that its flame will never (at each working point of

the burner) touch the grate or the insulation put above it.


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4.1.5. Ash extractor and sifting ash conveyors

• To prevent heat loss through the ash extractor, the water seal on the ash extractor has to

be operational. Also the water supply system to the ash extractor has to be operational, because it has to compensate the water loss due to evaporation. The water also protects

the ash extractor against too high temperatures.

• The same applies for the wet sifting ash conveyors under the grate.

Caution: The availability of water to the ash extractor and sifting ash conveyors must

be checked regularly (two times per eight hours) as well as their casing

temperature.

4.1.6. Primary, secondary• The butterfly valves of the primary and secondary air are opened partially. This allows

air coming in by suction of the ID-fan. This air can help to evacuate for instance the

water that is evaporated in the air gap of the side wall cooling system of the furnace. It

also protects the air ducts against too high temperatures (sweeping air).

Caution: No primary air can be used during the drying-out and blowing-out

procedure, because the sand and the insulating material might be blown

away and thus exposing the grate directly to the radiant heat of the burners.

• The side wall cooling fan has to be operational. It is possible that during the drying-outand baking procedure, the side wall cooling has to be started.

4.2. BOILER AND STEAM CIRCUIT

• Before hot commissioning several measures need to be taken to to protect the critical

items of the boiler. The main steam check valve internals should be removed and steam

flow measurement orifice should be replaced by a temporary “simple” design plate. Note

that the steam flow needs to be determined during steam blasting in order to evaluate the

blast impuls. The demister of the steam drum should be removed (during boiling-out) and

the insulation bricks of the manholes need to be removed.

• All control and safety equipment and plant interlocks required for the activities of hot

commissioining should be operational.

• A release note for hot commissioning of the boiler from the local inspection authority

should be available

• The boiler pressure parts and control valves must be released.


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• All measurement systems in the boiler (water-steam side) and post combustion zone (flue

gas side) have to be operational (temperature, pressure, …). All temperature trending

have to be printed and saved.

• The support burners must be operational / released. For more detail, refer to O&M

Manual from supplier.

• Fuel oil circulation pumps must be operational / released to allow feeding to the support

and start-up burners.

• Boiler feeding water pumps must be operational / released. For more detail, refer to

O&M Manual from supplier. Temporary start-up filters can be installed instead of the

(fine) normal filters.

• The demin water preparation system must be operational / released to allow feeding of the

pressure parts through the boiler feeding water pumps

• The boiler water conditioning system (dosing of sodium phosphate) must be operational /

released.

4.3. FLUE GAS CLEANING PLANT

• The flue gas cleaning system has to evacuate the hot flue gases. To protect the flue gas

cleaning against too high temperatures, one can open manholes in the flue gas ducts or at

the reactor, in order to insert air, sucked by the underpressure created by the ID-fan.

• The ID-fan has to be operational. The automatic control loop to regulate the furnace

pressure and interlocks should be operational .

• Some measurements need to be available for data-logging: CO and water measurement of

flue gases, flue gas flow (if possible).

4.4. COMMON PARTS

• Process water and instrument/plant air must be available.


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5. HEATING-UP PROCEDURE

This procedure is the heating up procedure, as given by the refractory supplier .

Temperature in the furnace room and boiler first empty pass will be monitored during heating-

up of the furnace. Measurements will be recorded and the actual heating curve will be set up

(only for control and approval by the refractory supplier).

Sufficient supply of consumables should be available: demin water (boiler feed water), fuel,

chemicals for boiler cleaning

Heating up procedure is represented on the curve hereafter :

25

110 110

250 250

360 360

550 550

150

25

0

100

200

300

400

500

600

0 9 33 47 71 78 114 127 151 167 215

TI ME SCHEDULE( Hr )

T

E M P E R A T U R E (

Figure 2: Typical heating up curve

1. Heating up at ± 10°C/hr until a temperature is reached of about 110 - 120°C.

2. Staying at a constant temperature of 110 - 120°C during at least 24 hours. This period is

needed to dry the refractory, to evaporate all the water in the refractory lining.

3. Heating up at ± 10°C/hr until a temperature is reached of about 260°C.

4. Staying at a constant temperature of 260°C during at least 24 hours. This period is needed

to partially “bake” the refractory, this means to have a reaction that gives the refractory

lining its desired strength and physical and chemical properties.

5. Heating up at ± 15°C/hr until a temperature of 360°C


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6. Staying at a constant temperature of 360°C during 36 hours. This is the second baking step

of the refractory material.

7. Heating up at ± 25°C/hr until a temperature is reached of about 550°C.

8. Staying at a constant temperature of 550°C during at least 24 hours.

9. After baking and drying-out, the refractory can be cooled down at a rate of about 25-

30°C/hrAll above parameters are valid for the refractory in the furnace. Concerning the

boiler refractory lining, the exact value of these parameters depends on the refractory

materials applied in the boiler. Only the refractory supplier can give a guaranteed drying-

out and baking procedure.

Caution: A drying-out and baking procedure is a continuous procedure, 24 hours / 24

hours, 7 days / 7 days. It can not be stopped halfway, and a sudden stop (asudden decrease in temperature) can cause damage to the refractory lining.


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Figure 3: Typical heating up and cooling down curve (maximum rate)

25

850 850

25

0

100

200

300

400

500

600

700

800

900

0 16 0 16

TI ME SCHEDULE( Hr )

T E M P E R A T U R E (


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6. BOILING-OUT PROCEDURE

Before boiling-out it is advisable to flush the entire boiler one time with demin water to

remove all loose particles still present in the boiler from erection works. The draining of the

boiler after the final pressure test can be considered as the flushing, provided the quality of

the drain water was good (no big particles in the water), the boiler was conserved in a good

way (see related procedures) and no more welding or repair works on pressure parts were

carried out (is not allowed after pressure test).

Boiling-out of the boiler aims at the removal of mechanical impurities, grease and possible

other contamination, if any, from the internal surfaces of the boiler tubes. The superheater is

not boiled-out (is cleaned with flushing and afterwards during steam blasting).

Both processes (boiling-out vs. drying-out/baking) may be carried-out simultaneously

providing that the resulting prolongation of the process, as well as the increase of temperature

and pressure, will not have negative influence upon the results of the boiling-out process.

Caution: The procedure hereafter described is given as an example. The operation of

the boiler during boiling-out should strictly follow the operating instruction

of the boiler supplier.

To ensure uniform concentration of chemical agents in all boiler elements that are included in

the process of boiling-out, an auxiliary installation can be provided consisting in one

circulating pump connected at the suction port with the drains of boiler evaporator bottom

headers, while pump discharge will be connected to the drains of economiser inlet header (see

typical sketch in annex). This pump will also be used for introducing chemical solution into

the boiler from a small tank. The circulation pump will run about 4 times a day during 1 hour.

The pH of the solution in the boiler will be measured each time after the circulation pumps

have been operating.

Note that the superheaters are not boiled out..

Typical composition of boiling-out solution and amount of chemicals:

• Chemical agent : NaOH and Na-phosphate

• Concentration : 0,4 kg NaOH/m³ of water and 0,4kg/m³ Na3PO4,12H2O

• Amount : 20 kg of NaOH (100%) and 20 kg of Na-phosphate

Course of boiling-out process (to be confirmed by boiler’s supplier):

• Fill up the boiler to the lowest operational level in the steam drum. Note that the

superheaters are not allowed to be filled up with the alkaline boiling-out solution.


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• Prepare the concentrated solution of NaOH and Na-phosphate in the tank (pH of about

11-12).

• Start the temporary circulating pump and establish circulation within the system

(circulating pump- economiser- boiler drum- evaporator- circulating pump).

• Pump-up the concentrated solution of chemicals to the system.

• Continue the circulation for about 2 hours.

• Fire the boiler and proceed to refractory drying procedure (see § 5).

• During the initial stage of drying-out procedure (until the drum pressure does not exceed

4 bar), the boiler evaporator should be blown-down every 6 hours (bottom headers drain

valves to be fully opened one by one for few seconds and than closed again).

• The circulating pump should be operated for 30 min. every 6 hours during this stage. At

the drum pressure above 4 bar, the circulating pump suction and discharge isolating

valves should be kept closed. Each time after circulation, the pH of the boiler water

should be checked and the dosing of the chemicals to be adapted accordingly.

• The frequency of blowing-down during the further course of refractory drying-out

procedure will be reduced to 1 per 24 hours. At the completion of refractory drying

procedure, the boiler will be drained and flushed with tap water by consequent filling and

draining until the pH value of effluent water is brought down to about 9 (last rising cycle

to be done with demin water).

• The drain (boiling-out) water is contaminated with chemicals and should therefore be

disposed taking into account the applicable environmental legislation/regulations.

• After cooling-down, the steam drum is made empty and is opened and cleaned /inspected

for the presence of impurities. Loose impurities, if any, should be removed manually.

Inner surfaces of the drum to the operational water level should be free from contaminants

(oil, sand, grease, etc.).


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7. DRYING-OUT AND BAKING

1. First of all the boiler must be filled with demin water up to LL-level at the drum. Flowcontrol valve to be by-passed during filling.

2. Meanwhile, before the burners are started to dry the refractory lining, the complete gas

path (from furnace to ID-fan) has to be ‘flushed’ by means of fresh air. This is to evacuate

possible explosive gases out of the plant. The flushing air flow must be three times the

plant volume (vol. furnace + vol. boiler + vol. reactor + vol. filter + vol. flue gas ducting).

The plant is flushed by using the secondary air fan (primary air fan cannot be used sine

grate is covered with insulating material). The flushing flow is measured at the suction

side of the secondary air. Because the (post-) combustion chamber is in overpressure, all

burners will be flushed in the same time.

3. Now the boiler is heating up until a flue gas temperature is reached of about 110 - 120 °C.

This can be done by means of the start-up burners (at the backside of the furnace) or by-

means of steam from other combustion line (if applicable). The temperature that is

checked, is the temperature inside the furnace (above the grate).

Caution: During all drying-out and baking procedure (so from the first start of the

burners), temperature controls must be done to avoid possible mechanical

damage (casing, grate, ducting). The following table gives an overview of the

items to be checked and the necessary interventions:

Item to check What to do if temperature is too high

Combustion grate tiles (above Tmax =

300°C)

• Open inspection doors at the sifting ash

hoppers

•

Primary air coming out the opened

inspe

app d commissioning plan

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