boiler auxilaires check list

GVK Goindwal Site BHEL Ref. No. : BHEL/PSNR/ TSX/BOILER/ Sheet 1 of 18

Plant area: BOILER AUXILARIES

BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR NORTHERN REGION

TECHNICAL SERVICES Plot no 25, Sector 16A, Noida –U.P. 201301

DOC NO.: BHEL/PSNR/TSX/BOILER:001:01:2012 EFF DATE : 08.08.2012

PREPARED BY REVIEWED BY

APPROVED BY

ISSUED TO :

COPY NO. : ISSUED BY

(NAME, DESGN. /DEPT.) (SIGN.) DATE OF ISSUE :


Plant area: BOILER & AUXILIARIES

Remarks:-

Name Signature B.H.E.L. Erection B.H.E.L. Commissioning CUSTOMER

TABLE OF CONTENT

1. CHECK LIST OF COMMISSIONING OF LUB OIL SYSTEM .................................................. 3

2. COMMISSIONING OF HT MOTORS .................................................................................... 4

3. COMMISSIONING OF FD FAN / PA FAN – AXIAL ............................................................ 5

4. COMMISSIONING OF AIR PREHEATER .............................................................................. 6

5. COMMISSIONING OF ID FAN ............................................................................................ 7

6. COMMISSIONING OF FUEL OIL PUMPS ............................................................................. 9

7. BOILER LIGHT UP ................................................................................................................. 10

8. COMMISSIONING OF BOWL MILL .................................................................................... 13

9. COMMISSIONING OF GRAVIMETRIC FEEDER ................................................................. 15

10. STEAM BLOWING .............................................................................................................. 16

11. SAFETY VALVE FLOATING ............................................................................................... 18



Remarks:-


1. CHECK LIST OF COMMISSIONING OF LUB OIL SYSTEM

S No. Activity Status Remarks 1 Ensure completion of erection of lub oil tank, lines, pump,

instrumentation, etc. 2 Ensure acid cleaning of lub oil piping is completed 3 Clean and inspect lub oil tank before oil filling ( flushing oil ) 4 Ensure hydraulic test of coolers (either at works or at site) 5 Ensure availability of flushing oil in tank with proper level

(quantity). 6 Ensure completion of cabling, earthing, local push button, etc. 7 Ensure that local instruments (indicators, switches, etc.) are

calibrated and set points are set. 8 Ensure that heaters, if provided, are connected to the switching

module. 9 Ensure mechanical freeness of the pump and motor. 10 Ensure that the arrangements for lub oil flushing (like bypassing

bearings etc.) are complete. 11 Ensure that Insulation Resistance values of LOP motor are O.K. 12 Ensure that the Motor Control Centre (MCC) is commissioned &

motor protections are available 13 Ensure that the local start / stop provisions are available. 14 Ensure clearance from concerned Erection Engineer. 15 Ensure proper line up of the LOPs and start one LOP. Check its

direction of rotation. 16 Check the oil flow, if indicator is provided. 17 Check the current drawn by the motor. 18 Check for any other abnormalities. 19 During flushing monitor filter differential pressure gauge and clean

the filter if filter DP is more 20 If filter DP is stable for 8 hrs, stop the pump and drain the flushing

oil from tank, coolers, filters 21 Clean and inspect lub oil tank, suction filter and discharge filter 22 Fill up fresh oil ( correct grade ) in tank up to correct level 23 Normalise the lub oil piping to bearing, servosystem etc. (wherever

applicable ) 24 Run lub oil pump and check for any leakage. Adjust lub oil

pressure as required 25 Check and set the pressure of the relief valves.



Remarks:-


2. COMMISSIONING OF HT MOTORS

S No. Activity Status Remarks 1 Ensure completion of erection of motor including grouting. 2 Ensure that the direction of rotation marked over motor is matching

with that of driven equipments 3 Ensure completion of HT, LT & instrumentation cabling and earthing,

Local push button. 4 Ensure that the high voltage test is completed for cable. 5 Ensure lubrication of motor bearings. 6 Ensure that the local instruments are calibrated. 7 Ensure that HT switchgear is commissioned and motor protections

are available. 8 Ensure that indication of motor winding temperatures is available. 9 Ensure that indication of motor bearing temperatures is available.

10 Ensure that IR, Polarisation Index (PI) & absorption Coefficient (K) values are O.K.

11 Ensure that provision of local start / stop is available. 12 Ensure that the cooling water lines, if provided, are flushed and the

same is available. 13 Ensure mechanical freeness of the motor. 14 Ensure clearance from the concerned Erection Engineer. 15 Start the motor and check its direction of rotation. 16 Record the current in the 3 phases and voltage across different

phases. 17 Record the vibration at Driving End (DE) and Non - Driving End

(NDE) bearings. 18 Record the bearing temperatures and winding temperatures every

hour for 8 hrs. 19 Check for any abnormality. 20 Record the coasting down time after switching off the motor.



Remarks:-


3. COMMISSIONING OF FD FAN / PA FAN – AXIAL

S No. Activity Status Remarks 1 Ensure completion of erection of Fan, Suction hood. 2 Ensure completion of erection of discharge damper and discharge

duct along with supports. 3 Ensure that the Motor trial run is over and the motor is aligned and

coupled. 4 Ensure that all quality log sheets related to erection of fan have been

filled up. 5 Ensure that lub oil flushing is over and the lub oil lines have been

normalised. 6 Ensure that cooling water lines to coolers have been flushed. 7 Ensure that the instrument air line to pneumatic drives has been

blown. 8 Ensure that cabling for instrumentation is complete. 9 Ensure that local instruments are calibrated and available. 10 Ensure that discharge damper is commissioned. 11 Check for blade pitch variation. 12 Ensure that pneumatic (or electrical, as the case may be) drive is

aligned and is connected to the blade pitch control. 13 Ensure that pneumatic (or electrical) drive for blade pitch control is

commissioned. 14 Ensure that all protections & interlocks are available. 15 Ensure that the indication of fan parameters (temperatures, pressure,

current, etc.) is available at control room. 16 Ensure that suction & discharge ducts are clean. 17 Ensure that all access doors & inspection doors on the fan body are

closed. 18 Ensure that instrument air and cooling water are available. 19 Line up the discharge path so that certain minimum air flow (for an

axial fan) is possible. 20 Ensure clearance from concerned Erection Engineer. 21 Run Lub oil pumps. Set the oil pressure and oil flow. 22 Run the fan. Record no-load current. 23 Load the fan to approx. 15 % to 20 % 24 Record current, blade pitch position, discharge pressure, vibration of

fan & motor. 25 Record bearing temperatures and winding temperatures every hour

for 8 hrs. 26 Record time for coasting down after switching off the motor.



Remarks:-


4. COMMISSIONING OF AIR PREHEATER

S No. Activity Status Remarks

1 Ensure completion of erection of Air Preheater. 2 Ensure completion of erection of Lub Oil Pumps and lub oil piping. 3 Ensure completion of erection of APH Soot Blowers. 4 Ensure installation of rotor stoppage alarm and fire detecting

thermocouples. 5 Ensure erection of fire fighting and water washing line and oil

detection probe inside APH housing. 6 Ensure that all works inside the duct connected to APH are complete,

all temporary supports, platforms, etc. are removed. 7 Ensure that all quality log sheets related to erection of Air Preheater

have been filled up. 8 Ensure all local instruments in lub oil system and service air lines are

calibrated and available. 9 Ensure that the trial run of lub oil pumps and lub oil flushing is over.

10 Ensure that cabling, earthing and local push buttons are completed. 11 Ensure that Insulation Resistance value of motors are O.K. 12 Ensure that the Motor Control Centre (MCC) is commissioned and

motor protections are available. 13 Ensure that trial run of main driving motor and stand by motor (if

provided) are completed, the directions are O.K. and the motors are coupled.

14 Ensure that the service air line to air motor is completed, the line blown and normalised. Ensure lubrication in lubricator.

15 Ensure proper oil level in guide bearing, support bearing and drive mechanism.

16 Ensure clearance from concerned erection engineer. 17 Run the air preheater a few revolutions with the air motor and check

for any abnormality. 18 If O.K., run the air preheater with main motor. 19 Check the direction of rotation of Air Preheater. 20 Record the current drawn by the motor. 21 Record Guide bearing and Support bearing temperatures every hour

for 8 hrs. 22 Check whether the pump in the drive mechanism is circulating oil.

23 Check for any abnormality.



Remarks:-


5. COMMISSIONING OF ID FAN

S No. Activity Status Remarks 1 Ensure erection of fan is complete in all respects 2 Ensure tightness of all foundation bolts of fan/motor, bearing housing. 3 Ensure flushing of cooling water lines for lub oil coolers, Hydraulic

coupling coolers and bearing cooling 4 Ensure no water leakage inside bearing housing. 5 Ensure hydraulic test of lub oil coolers/hydraulic coupling coolers

(either at works or at site). 6 Ensure flushing of lub oil system 7 Ensure that the instrument air line to pneumatic drives has been

blown. 8 Ensure power cylinder/actuator for proper actuation of suction

damper (Full open to full close) from local/UCB 9 Ensure proper operation of hydraulic coupling scoop from local/UCB. 10 Ensure proper operation of inlet damper/gate 11 Ensure proper operation of outlet damper/gate 12 Ensure free rotation of rotor without any mechanical rubbing. 13 Ensure removal of all transport stiffeners (Yellow painted) 14 Ensure no foreign material inside fan casing. 15 Ensure no loose pieces/foreign material in the suction duct of the fan. 16 Ensure motor trial run is completed with proper direction of rotation

as per fan. 17 Ensure calibration of all instruments for fan/motor. 18 Ensure correct level and recommended grade of lub oil for the

bearing/Hydraulic coupling. 19 Ensure proper functioning of lub oil system 20 Ensure proper functioning of local/remote indications 21 Ensure proper functioning of interlocks 22 Ensure proper functioning of protections 23 Ensure proper functioning of emergency push button 24 Ensure the alignment of hydraulic coupling with motor after motor trial

run. 25 Ensure tightness of coupling bolts of motor and hydraulic coupling 26 Ensure that all quality log sheets related to erection of ID Fan have

been filled up. 27 Take short trial run of fan hydraulic coupling with motor. 28 Ensure the alignment of fan with hydraulic coupling



Remarks:-


S No. Activity Status Remarks 29 Ensure tightness of coupling bolts of fan and hydraulic coupling

30 After ensuring above checks, fan may be put on trial run and record

the following parameters: a) Starting time. b) Starting current c) No load current d) Motor current e) Bearing temperature (check for any abnormal temperature rise) f) Motor winding temperature g) Vibration level

31 Record time for coasting down after switching off the motor.



Remarks:-


6. COMMISSIONING OF FUEL OIL PUMPS

S No. Activity Status Remarks 1 Ensure completion of erection of pumps, suction lines and discharge

lines, tracing lines (if provided) etc. 2 Ensure the pipelines are hydraulically tested, steam blown/card board

bursted with compressed air, normalised and insulated (if reqd.) 3 Ensure completion of cabling, earthing and local push button etc.

4 Ensure that Insulation Resistance value of motor is O.K. 5 Ensure that Motor Control Centre (MCC) is commissioned and motor

protections are available. Ensure lubrication ( greasing ) of motor bearings / pump bearings 6 Ensure Motor Trial run is over, the direction of rotation is O.K. and the

motor is coupled. 7 Ensure that the auxiliary steam lines (if required) to the pump house

and inside the pump house are erected, hydraulically tested, insulated and steam blown.

8 Ensure that instrument air lines to the pump house and inside the pump house are erected and air blown.

9 Ensure that Recirculation valve is commissioned from local / remote.

10 Ensure that local instruments are calibrated and available.

11 Ensure availability of sufficient quantity of oil in the tank and the oil is heated to pumping temperature (if reqd.)

12 Ensure alignment of pump and motor 13 Ensure suction filters / discharge filters are clean 14 Line up the suction line and recirculation line to tank. Charge the

tracing lines and steam jackets of the pump (if provided). 15 Ensure mechanical freeness of pump and motor. 16 Prime the suction line through the air vents of the suction strainer. 17 Run the pump. Check the pressure developed. Record the current

drawn by the motor. 18 Check and set the pressure relief valve at the pump body.



Remarks:-


7. BOILER LIGHT UP

S No. Activity Status Remarks 1 Ensure that the erection of Secondary air and flue gas ducts, ESP (at

least one pass) is over. 2 Ensure that trial runs of FD Fan, ID Fan and Scanner Air Fans are

over. 3 Ensure that refractory and skin casing work of pressure parts are

complete. 4 Ensure that Air Tightness Test of ducts, boiler and ESP are over.

5 Ensure that the Hydraulic Test of boiler has been completed. Ensure

that erection of fine fittings is completed. 6 Ensure that boiler pressure parts, fine fittings, ducts, ESP are

insulated. 7 Ensure that trial run of Air preheaters are over. Ensure availability of

APH fire fighting and water washing system. 8 Ensure that fuel oil, atomising air and atomising steam lines are

steam / air blown and air dried. 9 Ensure trial run of both AC & DC Scanner air fans are over. 10 Ensure that trial run of fuel oil pumps (light oil) are over. 11 Ensure that valves and dampers required for light up are

commissioned and their operations are available in control room. 12 Ensure that ESP (at least one pass) is commissioned. 13 Ensure that all the temporary supports are cut & removed. 14 Ensure that all the hangers are unlocked and set to their respective

cold values. 15 Ensure that there is no restriction for expansion of pressure parts and

ducts. 16 Ensure the work in bottom ash hopper is complete and water in seal

trough is available. 17 Ensure the work in chimney is complete and the same is cleared by

concerned agency. 18 Ensure that cooling water is available. 19 Ensure that instrument air and service air are available. 20 Ensure that indications of various parameters required for light up are

available in control room. 21 Ensure that air conditioning of control room is available. 22 Ensure that Secondary Air Dampers control (SADC) is

commissioned.



Remarks:-


Sl No. Activity Status Remarks 23 Ensure that FSSS (required for oil firing) is commissioned and dry

simulation has been conducted. 24 Ensure that all local instruments in pressure parts, ducts, fuel oil

system, fans etc. are calibrated and available. 25 Ensure that lights at the local gauge glass in drum are available. 26 Ensure that PRDS is steam blown; insulated and auxiliary steam is

available. (Not applicable for green field units.) 27 Ensure that auxiliary steam line to SCAPH is blown and line

normalised. (Not applicable for green field units.) 28 Ensure that APH soot blowers are commissioned; air line/ steam

lines to the blowers are blown. 29 Ensure that the setting of critical dimensions for oil guns, igniters, etc.

has been done. 30 Ensure that the burner tilt angles have been checked. 31 Ensure that the critical dimensions of wall blowers and Long

Retractable Soot Blower have been set. 32 Ensure that the LRSBs, wall deslaggers and furnace temperature

probes are in retracted position. 33 Ensure that the expansion indicators are installed at various

locations. 34 Ensure clearance from concerned erection engineer. 35 Ensure that the interlock and protections of boiler have been

checked. 36 Ensure availability of boiler drains, storm water drains. 37 Ensure availability of fire fighting system. 38 Ensure readiness of IBD tank with vent and drain. 39 Line up the secondary air path and flue gas path with one air

preheater and one pass of ESP 40 Line up the fuel oil and atomising air / steam system at the pump

house and at the boiler front. 41 Run one ID Fan, one FD Fan, air preheater, A.C. Scanner air fan,

one fuel oil (light oil) pump. 42 Maintain air flow between 30% & 40% of full load air flow and furnace

draft between -5 to -10 mm WC. Ensure that the burner tilt is in horizontal position.

43 Fill up the boiler up to normal drum level. 44 Ensure that boiler drum, SH air vents and SH start-up vents are

open. Ensure that Main Steam Stop Valves, their bypass valves, economiser inlet valve and its bypass valve are closed.



Remarks:-


Sl No. Activity Status 45 Ensure that SH header drains are open. 46 Ensure that water wall bottom ring header drains are closed

47 Ensure that cooling water to sample coolers is available.

48 Light up the boiler with one pair of oil guns. Keep the initial firing rate

low. 49 Check for free expansion of boiler and ducts. Measure the

expansions at various locations.



Remarks:-


8. COMMISSIONING OF BOWL MILL

S No. Activity Status Remarks 1 Check that erection of mill is complete in all respects 2 Check erection completion of lub oil system. 3 Check that acid cleaning of lub oil piping is completed. 4 Check lub oil flushing is completed. 5 Check calibration/proper functioning of pressure gauges of lub oil

system. 6 Check calibration/proper functioning of pressure switches of lub oil

system. 7 Check calibration/proper functioning of temperature gauges of lub oil

system. 8 Check calibration/proper functioning of temperature switches of lub

oil system. 9 Check hydraulic test of coolers of lub oil system is completed (either

at works or at site). 10 Check erection of cooling water piping to lub oil system is completed 11 Check flushing of cooling water piping of lub oil system is completed 12 Ensure adequate clearance between stationery and rotating parts as

per erection check list 13 Check seal air piping to dust guard seal, trunnion shaft etc. 14 Check correct grade of oil is filled in mill gear housing up to correct

level. 15 Check correct grade of oil is filled in all roller journals after removal of

preservative up to correct level. 16 Check that all three roller journal pressure springs are compressed to

same value (design value). 17 Check the trunnion end cap is positioned at initial value i.e. ‘1’ is in

line with arrow on journal cover for all rollers. 18 Check all the rollers are having gap w.r.t. bowl. 19 Ensure trial run of motor is completed with correct direction of

rotation. 20 Ensure alignment of main motor and mill worm shaft after motor trial

run. 21 Check that bull ring segments are properly seated. 22 Check that all classifier vanes are open to the same extent. 23 Check that all flange joints and packing are properly placed and

adequately tightened.



Remarks:-


S No. Activity Status Remarks 24 Ensure that all quality log sheets related to erection of Bowl Mill have

been filled up. 25 Ensure that all protections & interlocks are available.

26 Start Mill and check for any abnormality. 27 Record the current drawn by the motor. 28 Record bearing temperatures and winding temperatures every hour

for 8 hrs. 29 Set Ring – Roll clearance in mill running condition.

30 Adjust clearance between journal head and spring seat.

31 Ensure completion of steam inerting piping before coal firing.

32 Ensure completion of fire fighting piping before coal firing.



Remarks:-


9. COMMISSIONING OF GRAVIMETRIC FEEDER

S No. Activity Status Remarks 1 Ensure completion of erection of feeder and connected line. 2 Ensure grouting of feeder 3 Ensure completion of coal valve and down spout. 4 Ensure completion of feed pipe from feeder to pulveriser. 5 Ensure proper installation of paddles for the coal on belt & feeder

discharge pluggage and set their limit switches. 6 Ensure that belt drive gear box and clean out conveyor (COC) drive

gear box are filled with correct grade of oil up to normal level. 7 Ensure completion of electrical cabling. 8 Ensure earthing of motors and feeder control cabinet. 9 Ensure setting of belt tension and sag of COC chain. 10 Ensure no foreign material inside feeder. 11 Ensure proper gap between skirt plate and belt. 12 Ensure proper installation of load cell. 13 Ensure centre weighing roll is in level with weigh Span roll. 14 Check IR value & winding resistance of main drive motor & COC

motor. 15 Ensure correct setting of thermal over load relays of main motor and

COC motor. 16 Check correct direction of rotation of main drive motor & COC motor.

17 Run feeder at different speeds and observe belt position, if required

belt tracking to be done. 18 Run feeder for 8 hrs and measure main motor & COC motor currents. 19 Check for proper functioning of remote indication and interlocks. 20 Calibrate feeder after trial run. 21 Ensure completion of seal air connection with butterfly valve. 22 Ensure completion of water quenching line. 23 Ensure completion of compressed air supply for cleaning bulls’ eye.



Remarks:-


10. STEAM BLOWING

S No. Activity Status Remarks 1 Availability of Steam Blowing Procedure

2 Completion of MS, CRH, HRH, HPBP & LPBP lines

3 Completion of Stress Relieving and Radiography of MS, CRH & HRH

lines

4 Completion of Hydraulic test of MS, CRH, HRH, HPBP, LPBP lines & Reheater

5 Completion of permanent Hangers & Supports of MS, CRH, HRH,

HPBP & LPBP lines

6 Removal of temporary supports of MS, CRH, HRH, HPBP & LPBP lines

7 Insulation of MS, CRH, HRH, HPBP & LPBP lines and temporary

lines

8 Unlocking and setting of cold values of Hangers & Supports of MS, CRH, HRH, HPBP & LPBP lines

9 Steam Blowing Devices are installed in HP & IP stop valves

10 Temporary pipes for blowing are erected as per scheme

11 Proper supports for temporary pipes to take care of reaction forces

during blowing

12 Spool pieces to be installed in place of breakdown orifice, flow measurement devices on HPBP lines

13 NRV, if any in the system, not to be installed or its flap to be removed

14 Control valve, if any in the system, not to be installed

15 Availability of chemical dosing system

16 All temporary supports / locking of Boiler and pressure parts removed

and Boiler is free for expansion as per expansion movement diagram



Remarks:-



17 Readiness of arrangement for measuring boiler expansion

18 Minimum one BFP is commissioned with all interlocks and protections

19 Availability in control room of drum level instruments, instruments in steam & water circuit, instruments in sec. air & flue gas circuit, instruments in fuel oil circuit and instruments in deaerator & BFP.

20 Availability of operation of Electrically operated temporary valve from

control room

21 Availability of operation of MS stop valves, drain valves in MS, CRH, HRH, HPBP & LPBP lines from control room

22 Availability of operation of Feed Control Station from Control Room

23 Availability of sufficient number of polished target plates

24 Availability of deaerator filling / make up system

25 Availability of sufficient quantity of DM water

26 Availability of sufficient quantity of Fuel Oil

27 Availability of Hydrazine and Ammonia 28 MS & HRH strainer elements are not in position

29 MS, CRH, HRH & HPBP line drains are connected to a temporary

header routed to atmosphere

30 System is ready for steam blowing as per procedure

31 Boiler is ready for operation with all interlocks/protections



Remarks:-


11. SAFETY VALVE FLOATING


1 Hydrostatic plug of safety valves to be removed and discs to be installed

2 Silencers, exhaust piping of safety valves along with fixed and guide supports are erected as per drawing

3 Proper offset of safety valve drip pan and exhaust pipe has been

maintained

4 Safety valves drain and vent arrangement have been provided as per drawing

5 Reaction supports for Safety valves has been provided as per drawing

6 ERV controllers have been mounted, impulse line erected, cabling

and remote operation of ERVs solenoid coils has been checked

7 Availability of calibrated local pressure gauges for drum, main steam, cold reheat and hot reheat system

8 Steam Blowing of the particular circuit in which safety valves to be

floated is over

9 Arrangement for hand popping with pulley and rope is made.

10 Gagging of all the safety valves in the circuit except the one being floated

11 Availability of HPBP & LPBP system for floating of RH safety valves

boiler auxilaires check list

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