Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-156
NTPC Ref No. SIM/0/TS/4/156
Sheet 1 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF COMPRESSED AIR SYSTEM (SA/IA)
SLNO
LIST OF CONTENTS
1.0
PLANT DETAILS
2.0
OBJECTIVE
3.0
PROPOSAL
4.0
SERVICES REQUIRED
5.0
SAFETY PERECAUTIONS
6.0
EMERGENCY PROCEDURE
7.0
STATE OF THE PLANT
8.0
METHOD
9.0
COMPLETION CRITERIA
10.0
APPENDICES
a) DRAWINGS
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-156
NTPC Ref No. SIM/0/TS/4/156
Sheet 2 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF COMPRESSED AIR SYSTEM (SA/IA)
SL.NO
STATUS
1.0
PLANT DETAILS:
Compressed Air System for the plant consists of
1) service Air System and
2) Instrument Air System.
The pipe lines are mainly of galvanized and of ERW type. Service
air and Instrument air lines emanating from compressor House
connects all the points in the Power Plant where the requirement
of this two type of air is envisaged. The normal working pressure
of these system is 7.5 KSC.
The various locations to which Service Air and Instrument air
Connected are given below.
SERVICE AIR SYSTEM:
(OFF SITE AREA)
-
CPU Regeneration Bldg
CW Pump House
Chlorination Plant
Water Treatment plant
Fire Water P.H
Canteen
Permanent Store.
Auxiliary Boiler
F.O.P.H
Coal Settling Pond
CMB (Central monitoring Basin)
Signatures
NTPC
BHEL
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-156
NTPC Ref No. SIM/0/TS/4/156
Sheet 3 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF COMPRESSED AIR SYSTEM (SA/IA)
SL.NO
STATUS
- Sewage Treatment plant.
- Ash Water & slurry PH
- Workshop Bldg
- Gate House
- Administrative Bldg
- Service Bldg.
- Spare points
BOILER AREA
-
Feeders
Mills
FTP (Furnace Temperature Probe)
Atomising air
APH (Primary & Secondary APH – Air Motor, Fire Sensing
Device, APHSB)
Accoustic Pyrometer
HEA Ignitors
Spare points
TG AREA
-
Bus Duct Pressurisation
Spare Points
INSTRUMENT AIR SYSTEM:
OFF SITE AREA
-
CPU Regeneration Bldg
CW Pump House
DM Plant Air Receiver ( 2Cu.m)
Chlorination plant
Water Treatment plant
Auxiliary Blr.
Signatures
NTPC
BHEL
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-156
NTPC Ref No. SIM/0/TS/4/156
Sheet 4 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF COMPRESSED AIR SYSTEM (SA/IA)
SL.NO
STATUS
- Hydrogen Generation plant.
- F.O.P.H
- Air Receiver (Unit I/Unit II) (10 Cu.m)
- Spare points
BOILER AREA
-
FSSS System
SADC System
Milling system
All pneumalic control valves / Drain valves.
All control instruments
Control Dampers
Spare points
TURBINE AREA
2.0
All control valves
Generator purging
Spare points
OBJECTIVE:
The objective of the testing schedule is to ensure cleanliness of
the entire SA and IA system and make it available progressively
for unit commissioning.
3.0
PROPOSAL:
The objective is achieved by the following proposals.
3.1
Pressure Test of the air system at 7.5 KSC
3.2
Cleaning the piping system by blowing compressed air (5 minutes
duration for main headers & 3 minutes for each tap-offs)
maintaining at least 5 KSC at outlet point of compressor House /
Air receivers. Blowing repeated till clear air observed at the
blowing end.
Signatures
NTPC
BHEL
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-156
NTPC Ref No. SIM/0/TS/4/156
Sheet 5 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF COMPRESSED AIR SYSTEM (SA/IA)
SL.NO
STATUS
3.3
Alternatively, cleaning the piping system (only the main header)
by card board bursting (Two times) method and the individual
tap-off by contions blowing by air (3 minutes duration for each
circuit) (Card board bursting at 3-4 KSC)
4.0
SERVICES REQUIRED:
4.1
Availability compressors
4.2
Availability of ECW
4.3
Availability of Electric supply for compressors.
4.4
Availability of work force for attending leakage / air blowing.
4.5
Availability of required communication, lighting and approaches at
location where air blowing planned.
5.0
SAFETY PRECAUTIONS:
5.1
Ensure platforms / approaches wherever required for air blowing.
5.2
The agencies working in the blowing are to be informed about air
blowing
5.3
Clear communication to be made available among the test team
in controlling the activities of air blowing / Card board bursting.
5.4
First aid kits to be made available near the test area
5.5
Safety appliances such as helmet, gloves, ear mufflers are to be
made available to the test team / work force.
Signatures
NTPC
BHEL
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-156
NTPC Ref No. SIM/0/TS/4/156
Sheet 6 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF COMPRESSED AIR SYSTEM (SA/IA)
SL.NO
STATUS
6.0
EMERGENCY PRECAUTIONS:
6.1
The test team should be generally aware of the entire lay-out /
part lay-out where blowing done, in order to react to any
emergency notified to them.
6.2
The test team should be aware of steps to be taken in case of
any injury to personnel / damage to any section of air line or any
machinery connected to the air system as a result of the
proposed activity.
7.0
STATE OF THE PLANT:
7.1
Piping scheme of both SA and IA are erected and all the supports
are provided as per recommended drawing.
7.2
Drain lines with valves / auto drain traps, wherever envisaged in
IA scheme are provided.
7.3
Suitable openings are left open in the main air headers for air
blowing requirements.
7.4
Identifications are made at strategic locations to indicate the layout of SA and IA lines.
8.0
METHOD:
8.1
Pressure Test
8.2
By running the service air compressor, slowly fill up the SA/IA
system and raise the air pressure to 7.5 KSC.
8.3
Identify and attend to all leaking locations and repeat the test.
Signatures
NTPC
BHEL
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-156
NTPC Ref No. SIM/0/TS/4/156
Sheet 7 of 7
Plant area: OFF SITE
PROCEDURE FOR COMMISSIONING OF COMPRESSED AIR SYSTEM (SA/IA)
SL.NO
STATUS
8.4
The pressure test repeated till all leakages are attended.
8.5
Cleaning of Pipe Lines
8.6
After ensuring that all the tap-offs from the main header are
closed and suitable opening kept open in the main header charge
the SA/IA main headers slowly and air blow for about 5 minutes.
8.7
After ensuring closing of openings provided as above in the main
header, commence air blowing of individual tap-off for about 3
minutes.
8.8
Air blowing given is Sec. 8.6 & 8.7 to be repeated, if required, till
clean air visually observed at the outlet of blowing point.
8.9
After completing air blowing, both SA/IA system normalized /
released for connecting to the end usage point.
9.0
COMPLETION CRITERIA
9.1
Cleanliness of SA/IA piping is achieved by carrying out the
proposals given in section 3.0.
10.0
APPENDICES:
a)
Drawing referred
i) PE-DG-186-555-0005
ii) PE-DG-186-555-0006
iii) PC-DG-186-555-0004
iv) PC-DG-186-555-0006
Signatures
NTPC
BHEL
PROCEDURE FOR COMMISSIONING OF
COMPRESSED AIR SYSTEM (SA/IA)