COMMISSIONING PROCEDURE
1 X 23.1 TPH
WASTE HEAT RECOVERY BOILER (AQC-3) ON CEMENT KILN
SUPPLIED TO
M/s ULTRATECH CEMENT LIMITED
RAJASHREE CEMENT, MALKHED, KARNATAKA
TBWES PROJECT NO.: PL 1862
SUPPLIED BY
THERMAX BABCOCK & WILCOX ENERGY SOLUTIONS PVT. LTD.
PUNE, INDIA
RECORD OF REVISIONS:
REV.
DATE
PREPARED BY
REVIEWED BY
APPROVED BY
0
12.08.2021
SP
Executive – FE
CSG
Sr. Manager – FE
CSG
Sr. Manager – FE
Note: This is a computer generated document and hence requires no Signature.
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
1.
BOILER COMMISSIONING ACTIVITIES SEQUENCE......................................... 3
2.
PRE-COMMISSIONING CHECK LIST ................................................................ 4
3.
FLUSHING OF BOILER, PIPING AND VESSELS .............................................. 11
4.
TRIAL OF AUXILIARIES / EQUIPMENT’S....................................................... 13
5.
REFRACTORY DRY OUT & ALKALI BOIL OUT ................................................. 14
A.
B.
INPUTS REQUIRED FROM CUSTOMER ........................................................................................... 14
CHECKLIST PRIOR TO ALKALI BOIL OUT ACTIVITY ....................................................................... 15
REFRACTORY DRY OUT AND ALKALI BOIL OUT CURVE.....................................................20
6.
STEAM BLOWING OF MAIN STEAM PIPING .................................................. 21
INPUTS REQUIRED FROM CUSTOMER: ................................................................................................... 21
PROCEDURE FOR STEAM BLOWING ....................................................................................................... 22
PRESSURE RAISING CURVE.................................................................................................................... 26
SKETCH FOR STEAM BLOWING ARRANGEMENT ..................................................................................... 27
ACCEPTANCE CRITERIA FOR STEAM BLOWING ...................................................................................... 28
LOG SHEET FOR STEAM BLOWING:........................................................................................................ 29
7.
SAFETY VALVE SETTING ................................................................................ 30
PROCEDURE .......................................................................................................................................... 30
Commissioning Procedure | WHRB
Page 2
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
1. BOILER COMMISSIONING ACTIVITIES SEQUENCE
Commissioning of the boiler would proceed as under
1. Pre-commissioning Check list
2. Flushing of piping and vessels
3. Trials of auxiliaries and equipment
4. Refractory Dry-out & Alkali boil out
5. Steam blowing of main steam piping
6. Safety valve setting
Commissioning Procedure | WHRB
Page 3
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
2. PRE-COMMISSIONING CHECK LIST
AREAS TO BE CHECKED
S.
No
1.
DESCRIPTION
AREAS TO BE CHECKED
AVAILABILITY
OF DOCUMENTS
1. O & M Manual comprising :
General procedures, Operation, Maintenance and trouble
shooting. Basic drawings with latest rev. for pressure
parts, P&I Diagram, Thermal expansion drawing etc.,
Mechanical components manual, General assembly
Drawing, Data sheets, Process flow data, Electrical and
Instruments components manual and data sheets, logic
write-ups, valve & instrumentation schedule, wiring
diagram.
2. Approved design calculations & analysis reports for
piping, structural stability etc.
3. Calibration certificates & handing over protocols &
inspection dossier.
4. Commissioning procedures.
5. Reference drawings.
6. Vendor list / contract details, nearest agent.
7. Commitment of inputs & outputs operating condition.
8. Handing over documents. (Completion of mechanical
checklist points).
1. Installation checks.
2. Boiler, casing & supporting.
3. Piping & supports.
4. Structure and platforms.
5. Mechanical auxiliaries.
6. E & I auxiliaries.
7. Customer scope items.
8. Inputs for commissioning.
9. General & Safety.
1. With respect to P & I Diagram of latest revision :
• Check instrument type, location and quantity.
• Piping connection and size.
• Input condition with respect to operating data.
• Sampling points.
• Location and connection of Mechanical components (like
valves, safety valves etc.)
2. With Thermal Expansion Drawing :
• Position of pointers to measure expansion for Boiler and
Riser and down comers.
• Check clearance / provision available for : Pressure parts
• Buck-stay assembly, Casing & Ducting, Supports etc.
• Ensure proper expansion clearance for steam drum /
supporting main down comers.
3. With Boiler General Assembly Drawing :
• General Layout.
2.
AREAS OF
CHECK
3.
INSTALLATION
CHECK
Commissioning Procedure | WHRB
STATUS
Page 4
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
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4.
BOILER
PRESSURE
PARTS / CASING
/ SUPPORTING
1.
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2.
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5.
PIPING AND
SUPPORTS
Commissioning Procedure | WHRB
1.
•
•
•
Location of Mechanical and Electrical & Instruments and
its accessories.
Expansion bellows.
Routing of Ducting.
Access.
Co current & reverse current of flow (steam/water) with
respect to the flue gas.
Draining facility from all bottom headers and venting
facility for top header.
Steam Drum Internal:
Sparger pipe location, orientation of holes, supporting as
per steam drum internal drawing.
Demister pad as per specification sheet, condition and
mounting arrangement.
Availability of proper manhole gaskets.
Installation of Baffle plates, and its tightening with
proper hardware as per internals drawing.
Inspect for any blockage of ports for mountings &
instrument tapping points.
Internal cleaning & removal of foreign material.
Coils hanging support arrangements:
Check for alignment.
Check for locking arrangement.
Check for deflection.
Check for gaps.
Check for hardware.
Check completion of welding for stiffeners and corners
(as per drawing).
Clearance and stopper removal.
Check completion of coil guide support.
Spring supports for Risers and Down comers
Check for proper support (Type) with tag nos.
Check for expansion clearance and movement and
cleats.
Check for removal of temporary supports.
De-locking.
Casing :
Seal welding inspection and leak test acceptance.
Cleaning inside casing and inspection,
Box-up manholes, hand – holes, inspection doors, peep
holes, hopper slide gates, etc., with proper gaskets and
hardware (with spring washers if required).
Plug / blind additional / temporary instrument tapping
point openings.
Piping :
Clearance for insulation.
Clearance for Thermal expansion.
Cleaning / Flushing before installation of on-line
instruments (like Control Valve, Flow element, Pressure
Indicators.)
Page 5
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
•
•
•
2.
•
6.
7.
STRUCTURE
MECHANICAL
AUXILIARIES
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1.
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2.
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3.
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•
Commissioning Procedure | WHRB
Availability of vents and drains and its plugs (wherever
applicable).
Box-up with proper Gasket and hardware.
Orifice – installation check :• Orientation of taping.
• Provision of orifice plate in proper direction.
• Jack bolts.
• Attemperator spray water nozzle check.
Pipe Supports :
Installation checks of all supports with respect to final
drawing and data sheets for type, expansion clearance,
anchoring etc.
Removal of temporary supports.
De-locking of spring supports.
Pointers to measure expansion.
Foundation bolts tightening.
Final grouting.
Provision of brazing as per drawing.
Proper hand – railing and its rigidity. Finishing and
flushing of welding joints.
Access to valves, manholes, inspection doors etc.
Toe guards and closing of opening on platform.
Check tightness of all hardware (if provided).
SAFETY VALVES :
Clean and obstruction free inlet and outlet nozzle and
piping.
Check name plate detail with respect to data sheet.
Supporting and drain line of outlet piping.
Availability of test gag tool.
DEAERATOR:
Check installation with respect to P & I diagram.
Open manhole and check all internals, welding,
supporting and orientation of nozzle Sparger pipes.
Clean the tank, any plugging of nozzles.
Checks spray nozzles and orientation.
Accessibility for instruments and manhole.
Insulation clearance.
Supporting of instruments & impulse line.
Expansion feasibility (provide scale on sliding saddle).
Fixed saddle should have firm bolting.
Nozzles are free from piping stresses.
Proper gaskets and hardware for connections and
manholes.
DOSING SYSTEMS (LP/ HP):
Check as per P & ID.
No load trails of motor / direction / agitator trail run.
Pump alignment, foundation bolt tightening.
Strainer.
Cleaning and flushing of unit.
PRV setting.
Page 6
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
•
•
•
4.
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•
Metering & discharge quantity measures.
Start Up Procedure.
Snubber & diaphragm for PI.
EXPANSION BELLOWS :
Dimensional checks.
Joints / fastener as per drawing.
Tightening of bolts.
Removal of transportation lock, and check again for
dimension.
• Refractory / ceramic lining / bolster installation (If
provided / if applicable) check.
• Record and mark cold condition and verify with hot
condition marking.
5. BOILER FEED WATER PUMPS:
• O & M manual of BFW pump should be studied before
installation and commissioning of pump. Installation,
start up and shut down procedure should be strictly
followed.
• Check foundation provided is as per foundation drawing.
• Check actual pipe routing and installation (NRV, isolation
valves) with respect to final piping drawing, and in case
of deviation, get approval from design dept. for piping
stress analysis.
• During pre-commissioning and line flushing, there is a
possibility of strainer chocking due to the mill scale and
particles left in the pipe. So the discharge pressure
gauge and DP gauge across the strainer (if provided)
should be closely monitored to detect the choking of the
suction strainer. The strainer may have to be cleaned
several times before the suction line is fully flushed.
• Check strainer size with respect to Strainer spec / and
for crack or puncher.
• Ensure that the suction and discharge pipe is thoroughly
flushed and cleaned before hook up with pump for
operation.
• Proper flushing of cooling water inlet and outlet pipes to
pump.
• Ensure proper quality and adequate quantity of cooling
water to the pump.
• Check for pump alignment as per pump O & M.
• Check for direction of rotation.
• Ensure pump is primed and free from air and vapor
before starting.
• Suction valve must be fully open. Keep discharge valve
closed before starting the pump and open the valve
gradually as soon as pump is started.
• Check functioning have and hook up of extra low-level
switch in suction vessel before commissioning of pump.
This is to trip the pump in case of level low.
• Check feed water quality as per spec.
Commissioning Procedure | WHRB
Page 7
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
8.
E&I
AUXILIARIES
Commissioning Procedure | WHRB
•
•
1.
•
•
•
Checks pump O & M for specific installation details.
Check the no load and over load current of pump.
Field Instruments
Check instruments with data sheets / parts catalogues.
Calibration.
Proper isolation, snubbers, siphons (for PI’s) wherever
required.
• Installation as per hook up diagram.
• Box-up with proper gaskets and hardware.
• Mounting and supporting.
• Access with platform.
• Immersion length (U) and insertion contact for
Temperature sensors.
• All spare cable entries to be plugged.
2. Control Valves
• Check instruments with data sheets / parts catalogues.
• Flow direction and air fail condition.
• Pneumatic testing of tubing.
• Box-up with proper gaskets and hardware, properly
greased.
• Check condition of tubing, Air Filter Regulators and
Pressure Indicators.
• Protect diaphragm vent from foreign particles and
moisture.
• Stroke checking, action check (direct / reverse).
• Safety interlocks checking.
3. Transmitters :
• Check instruments with data sheets / parts catalogues.
• Installation checks with respect to hook-up diagram and
supporting of tubing, condensate pots and transmitter.
• Hydro test of impulse lines.
• Power supply cabling, gland and ferrule fixing.
• Plugs for open ends (drains, flushing connection etc.)
• Calibration and configuration check.
• Continuity checking and loop checking.
4. MCC Panel :
• Cabling check with respect to Cable Schedule, wiring
diagrams.
• Installation checks for rigidity of mounting and weather
and dust protection.
• Earthling.
• Meager check.
• O/L relay setting.
• Local push button – accessibility.
• No-load trail, Motor direction of rotation.
• Avoid crossing of power and signal cable.
• Ensure proper ferruling and tagging foe easy identity.
• Ensure proper lugs are provided and crimped.
• Check for proper tightness of termination.
Page 8
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
9.
INPUTS
REQUIRED TO
BE COMPLETED
BEFORE
COMMISSIONIN
G (TBWES &
Customer scope
Of work)
11
GENERAL AND
SAFETY
(Customer
Scope)
Commissioning Procedure | WHRB
5. Control Panel :
• Cabling check with respect to Cable Schedule, wiring
diagram.
• Installation check for rigidity of mounting.
• Earthling.
• Logic check / simulation.
• UPS hook – up and trial run.
6. Lighting (Customer scope):
• Location of fixture as per layout drawing.
• Cabling as per Cable Schedule
• Installation of lighting distribution board.
• Protection area.
7. Motors.
• Proper installation.
• Cabling check.
• No load and load trials.
• Statutory formalities and approval.
• Pre-commissioning check of items in customer’s scope.
• Availability of adequate feed water.
• Availability of required quantity of all utilities.
• Availability of dosing, alkali boil-out and preservation
chemicals (if required).
• Obtaining periodical sampling and water analysis.
• Overall operation of Boiler and logging readings.
• DCS commissioning and fine tuning of instruments.
• Availability and management of input parameters of flue
gas.
• Availability of Boiler operators and BOEs.
• Availability of communication devices.
• Interfacing with mother plant (Cement Kiln control
room) operation.
• First fill lubricants and greasing.
• Greasing of all bolt and nuts.
• Manpower and resource requirement & shift
arrangement for commissioning and operation.
• Pre-commissioning checks.
• Pre-commissioning and Commissioning procedures.
• Preparation of Start Up Procedures If required
• Loop checking.
• Safety interlocks checking.
• Inspection during commissioning.
• Personal Protective Equipment.
• Safety gear at different locations.
• Plant illumination.
• General housekeeping.
Page 9
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
THERMAL EXPANSION DIAGRAM
Expansion Tramp quantity required (will be decided by commissioning engineer during
commissioning). Pointer holders to be fixed / welded on boiler part. Pointer is set move
freely inside the holder. Reference plate shall be fixed to a non-moving permanent boiler
structure as available nearby. These tramps are preferably fixed in presence of
commissioning engineer, just before the commissioning of boilers.
15 NB Pipe SCH 40
Length: 50 mm
M.S. FLAT PLATE
50 x(>500*)x3 mm
Pointer:
M.S. Rod
Dia. 12 mm &
150 mm long
This needs to be
welded to boiler
part : Drums/
sidewall peephole
box
M.S. Plate
Dimension: 100 X 100 X
10
This plate has to be
firmly supported from
platform / permanent
structure
Commissioning Procedure | WHRB
Page 10
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
3. FLUSHING OF BOILER, PIPING AND VESSELS
OBJECTIVE
The purpose of carrying out flushing is to remove foreign matter, mill scale dirt etc.
resulting out of manufacturing, storing, fabrication & erection from boiler, vessels & piping.
Such deposits in the piping walls sometimes restrict flow through the pipes/tubes causing,
overheating and pressure/flow fluctuations and even failures.
PRE-REQUISITES
In order to commence flushing following prerequisites / inputs have to be made available:
♦ Flushing will be carried out with DM water @ ambient temperature with pH of 8.5
preferably at 6-kg/cm2 (g) pressure.
♦ Mechanical completion of piping including supports to be flushed.
♦ Identify the system to be flushed e.g. flushing is carried out for steam, feed water and
drain piping & economiser assembly and mark the flushing circuits on P & IDs etc.
commissioning engineer will identify the piping system/circuit to be flushed during site
visit.
♦ Check for adequate illumination and personnel safety in and around the piping flushing
area.
♦ Check for adequate supports and expansion loops, as per piping drawings. Supports are
to be completed before beginning of flushing activity. If temporary supports are
required, they should be provided, as reactive forces resulting from flushing/blowing off
media, are more than normal conditions.
♦ Completion of line flushing up to the battery limit.
♦ Check for flushing media isolating valve in good working order.
♦ Remove all strainers (if provided), NRV plugs (except the main steam line) /internals,
control valves (provide spool pieces in place PCV/FCV, orifice plate / Flow nozzle).
♦ Connect flushing media to the starting point of piping.
♦ Isolate / remove instruments e.g. pressure gauges, pressure switches, flow meters.
♦ Cordon off the area where flushing is to be done and preferably post a person for
vigilance. As a safety measure, install signboards of caution.
PROCEDURE
♦ Ensure that flushing media to the starting point of piping is connected.
♦ Ensure that flushing media isolating valve in good working condition.
♦ Remove all strainers, NRV plugs/internals, control valves (provide spool pieces in place
Pressure Control Valve/Flow Control Valve, Orifice plate / Flow nozzle.
♦ Isolate/remove instruments e.g. temperature gauges, pressure switches, flow meters.
♦ Cordon off the area where flushing is to be done and preferably post a person for
vigilance. As a safety measure, install signboards of caution to working personnel.
Commissioning Procedure | WHRB
Page 11
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
♦ Piping will be flushed with DM water @ Ambient Temperature with pH of 8.5 by
installing a temporary flushing pump and a loop connecting to deaerator. Slowly open
the isolating valve of the flushing media, allow the piping circuit to fill and allow muck,
etc. to get removed. Then continuous or intermittent flushing can be carried out at the
specified pressure. Intermittent quick opening and shutting off isolating valves will help
in clear off loose mill scales, silica and dirt with shocks. Once clear media comes out of
the final point of the circuit flushing can be stopped.
♦ Instrument air lines shall be flushed with Air only.
♦ After completing the flushing activities, Replace control valves, strainers etc., which had
been removed during the flushing operation.
SAFETY PRECAUTIONS
♦ Clear out/cordon off the area where flushing is being carried out as live pressurized
steam will flush off through the system end point.
♦ Please make available plenty of safety gear e.g. asbestos hand gloves, ear mufflers,
transparent eye protective goggles and first aid kit.
Note: - If control valves/isolating valves to be kept in on line position, while steam
flushing, keep their position to 100% open to avoid damage to seat of the valves or
accumulation of dirt.
Commissioning Procedure | WHRB
Page 12
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
4. TRIAL OF AUXILIARIES / EQUIPMENT’S
OBJECTIVE
Boiler auxiliaries trials are conducted for equipment like motors, feed water pumps, etc.
PRE-REQUISITES
Ensure the availability of instruction manual for different auxiliaries from their respective
manufacturers.
It is essential that the persons conducting trials of auxiliaries must go through the
manufacturer’s instruction manuals, before starting any work.
Ensure complete erection of equipment is over and complete the pre-commissioning checks
as per equipment supplier’s recommendations, quality plan / drawing details.
Ensure the driven equipment and the prime mover/driving equipment is released for testing
/ conducting trial run.
Ensure that no load trial has been completed for prime mover / driving equipment and is
cleared for auxiliary trial run.
Ensure the availability of concerned inspection authorities and ensure the availability of
calibrated instruments for recording the relevant data.
DESCRIPTION
Run the equipment/auxiliary at specified conditions for specified number of hours as per
equipment supplier's recommendations, and record the parameters.
Check whether actual site parameters, are matching with the design parameters. Note
deviations if any, for reference towards corrective action (refer supplier's instruction manual
for corrective action).
Release the equipment/auxiliary for continuous operation.
Note:
Approach TBWES commissioning engineer, available at site for any clarifications on the
trials. During the trial runs record all relevant data in specified formats available with
TBWES Commissioning engineers.
Commissioning Procedure | WHRB
Page 13
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
5. REFRACTORY DRY OUT & ALKALI BOIL OUT
A.
INPUTS REQUIRED FROM CUSTOMER
Sr.No Description
1.
Boiler feed water
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Power supply for all drives
UPS for control room
Operator - Field
Panel
Communication arrangement
(Walkie Talkie & telephone etc)
Manpower / Operating staff.
Mechanical Engineer & E & I
Engineer
Illumination of Boiler and
surroundings.
Water analysis laboratory
Chemicals for normal Boiler
water treatment
(for LP & HP Dosing units)
Instrument air & cooling water
Assistance of Mechanical &
Electrical maintenance dept.
Operational spares
First aid
550 m3 (For flushing,
ABO and Rinsing)
Quantity Required
Remarks
Quality as
specified in the O
& M manual.
As required
As required
6 (2 per shift)
3 (1 per shift)
4 nos.
8 hours shift
Field & control
room
3 each (8 hrs/shift) +
1 reliever
As required
As required
As required
As required
As and when required
As required
As required
2. Alkali Boil-out Chemicals
Sr.No
1.
2.
3.
Description
Hydrous Tri - Sodium Phosphate – 4600 ppm
Na3PO4 12H2O
An hydrous Di - Sodium Phosphate – 1000 ppm
Na2HPO4
Wetting agent (non - foaming detergent )
Commissioning Procedure | WHRB
Quantity (In Kg)
90
20
5
Page 14
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
B.
CHECKLIST PRIOR TO ALKALI BOIL OUT ACTIVITY
Status of
Comp.
DESCRIPTION OF ACTIVITY
a)
PRE – ALKALI BOIL OUT (ABO) CHECKLIST:
1. Ensure all the Pre-commissioning checks are completed. Complete trial runs and
ensure proper operation of all the accessories. Sign out all the necessary
protocols.
2. Install all the Pressure, Temperature and Level Instruments / local indicators for
the complete system. Mark or explain to the operator regarding the LG for %
levels with permanent marker for the sake of clarity.
3. Complete hydro test for all the Boiler parts and piping, light penetration test for
the flue gas path if applicable, and thorough flushing with Boiler quality water
for all Boiler pressure parts & piping. Sign out the necessary protocols.
4. Ensure availability of required quantity of DM water, uninterrupted power supply
(UPS), Power supply for all drives and proper area & plant illumination.
5. Ensure availability of Utilities like cooling water for sample cooler & Blow down
tank, Instrument air for Control valves, plant air (if applicable), etc.
6. Ensure availability of sample bottles & water analysis laboratory at site.
7. Ensure availability of experienced operators (3 per shift) round the clock. Decide
on manpower planning and individual responsibilities required from all related
agencies. Give adequate training on the commissioning activities to all
concerned.
8. Necessary communication devices to be made available. Decide on the mode of
usage. All concerned should be familiar with its usage.
9. Ensure availability of drain and vent system from various parts of Boiler and their
routing to trench / safe location. Decide and determine the mode of disposal of
water after Alkali Boil Out.
10. Check the sparger pipe holes for chocking, if required remove the sparger pipes
for thorough flushing and re-fix the same after flushing. Check whether the
orientation of sparger pipes and its supporting are OK. Clean the steam drum
thoroughly and carryout joint inspection. Firmly box-up the steam drum manhole
with new gaskets.
11. Ensure that the flow orifice at steam piping is not installed as the same will be
installed after completion of steam blowing.
12. Make ready the temporary chemical charging tank & keep ready near the steam
drum so that chemical for Alkali Boil Out (ABO) can be charged in to the steam
drum.
13. Ensure availability of required chemicals and solution tank for mixing of
chemicals for the ABO. Ensure availability of adequate quantity of personnel
protection equipment (PPE’s) required for chemical charging.
14. Box up all the manholes in the flue gas path after joint internal inspection. Sign
out the necessary protocols.
15. Check freeness of operation of bypass damper and flue gas isolation damper &
Air dilution damper. Mark the damper position externally with respect to inside
Commissioning Procedure | WHRB
Page 15
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
configuration (whether open / close).
16. Insulation of Boiler casing, steam drum, and necessary ducting should be
completed. Provide personal protection guards for hot areas where insulation is
not feasible.
17. Ensure installation of expansion pointers for measurement of Boiler thermal
expansion. Mark the pointer location in cold condition. Ensure that the delocking for spring supports is done and mark location of cold load setting.
18. Ensure that all transportation clamps / cleats of fabric and metallic expansion
joints are removed.
19. One of the drum transmitters for pressure, levels on the steam drum and feed
water piping instruments can be kept on line. Ensure and confirm whether all
the necessary safety interlocks are implemented and tested for reliable
operation. One of the level gauges can be kept on line for cross checking.
20. The following equipment’s should be made operational
•
Feed water control valves
•
Isolation valves in the Feed water line in the feed water control station on
the BFW pump discharge
•
Isolation valve on start up vent line
•
Main steam stop valve on the main steam piping
21. Take all the Instruments in the flue gas path on line and check for proper
indications on DCS panel. Ensure operation of all control / shut off valves as
listed above is made available from DCS.
22. Ensure that the HP dosing unit is ready so that the same can be taken on line.
Chemicals for HP dosing can be prepared just before taking the unit on line.
23. All necessary parameters to be logged periodically in the log sheet enclosed for
along with this procedure. Also important events to be recorded.
24. Ensure Flue gas isolation damper at the Boiler inlet is made operational from
local & also from the DCS.
Commissioning Procedure | WHRB
Page 16
PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
b) POSITION OF VALVES BEFORE COMMENCING OF ABO:
1. All root valves on the Instrument tapping in the steam drum to be kept isolated
except for the following items
•
One of the level indicators on the steam drum.
•
Pressure indicator on the steam drum.
•
One of the level gauges can be kept on line for cross checking.
2. The Steam drum vents valves to be kept open.
3. The entire instruments in the flue gas path should be on line.
4. Keep all the drain valves on the SH & MSL piping in open condition.
5. Isolate the Main Steam Stop Valve on SH outlet piping and keep the isolation
valves on start up vent piping open.
6. Isolate valves on HP dosing skid.
7. Also keep the CBD line isolation valves and in closed condition.
8. All isolation valves of the sample cooler on the boiler feed water line, on the
main steam piping, on the CBD piping to be kept in closed position.
9. All sample coolers cooling water isolation valves at inlet & outlet should be in
open condition. Ensure that there is enough water flow.
PROCEDURE FOR ALKALI BOIL OUT
Sr.
No.
a.
Description of Activities
Water filling in the boiler:
1. Gradually charge Boiler feed water in boiler through feed water lines.
2. Water will get in to the steam drum and flow through the down comers to evaporator
modules.
3. Fill water up to minimum visible level in the steam drum. Ensure steam drum vent is
in open position.
4. Keep the chemicals and the solution tank near steam drum.
b.
Pre – Requests:
1. Isolate all the pressure and level instruments from the system. Only the drum
pressure gauge and level transmitter will be in line.
2. Ensure the chemical mixing tank is ready.
3. Ensure the entire super heater vents, start up vent & MSL drain are in open condition.
c.
Commencing Refractory Dry Out:
1. During refractory dry out process, the bypass damper will be in fully open condition. If
required the same can be closed partially or fully according to the requirement of
process.
2. During refractory dry out and Chemical Boil out period the flue gas intake will be
controlled according to the requirement only.
3. Gradually allow the flue gas to enter in to the WHRB to raise the flue gas temperature
Commissioning Procedure | WHRB
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
Sr.
No.
Description of Activities
at WHRB inlet @ 25 Deg C/Hour to 100 to 120 Deg C. During initial startup
temperature controlling is difficult; however try to maintain the rate of increase as
specified. During this initial time the bypass damper will also be in open condition.
Continue to maintain the flue gas temperature at WHRB inlet duct between
100 to 120°C for 24 Hours. This is to drive out all the moisture present the
refractory.
d.
Chemical charging:
1. At the end of this 100 to 120 °C cycle, stop the flue gas intake by closing the inlet
damper.
2. Prepare chemical solution and charge into the steam drum through the drum
manhole. After the chemical charging close the drum manhole.
3. Start the flue gas intake by opening the flue gas inlet damper. Monitor the WHRB inlet
temperature & gradually increase the flue gas intake in order to maintain temperature
as required.
e.
Warming-up of water and raising the steam drum pressure:
1. Increase flue gas intake and raise the flue gas temperature at boiler inlet duct @ 25
Deg C/Hour to 300 Deg C. Maintain the temperature for 8 Hours.
2. As the flue gas temperature is increased, steam will start coming from steam drum
vents and through super heater (S.H) drains. When steam drum pressure raises above
2 kg/cm2 (g) close steam drum vents. When drain is removed completely close the
superheater & main steam drain valve. Now, steam will be coming from start-up vent
on S.H outlet piping. Partially close the valve on start-up vent valve and keep it
throttled.
3. Maintain the steam drum level between 45% to 55% constantly. Drum level need to
be maintained manually. Adjust the flue gas damper opening so as to raise the steam
drum pressure gradually as per the startup curve enclosed. Maintain the flue gas
temperature (at boiler inlet) at 300 Deg C for a period of 8 hours.
4. Open the CBD valve for few seconds in every 4 hours to avoid line blockage.
5. As the HP steam drum pressure reaches at ~ 9 Kg/cm2 (g), take sample from CBD
sample cooler point and analyze for pH, Conductivity/TDS, Phosphate, Fe2O3, oil
content.
6. The steam generated is circulated through S.H and vented out through start up vent.
By adjusting the opening of start up vent valve, maintain the steam drum pressure at
around 9 kg/cm2 (g).
f.
Alkali Boil Out:
1. Along with maintaining the flue gas temperature, maintain the steam drum pressure
to around 9 kg/cm2 (g). Effective alkali boil out (internal cleaning of boiler)
commences. Hold the pressure for 12 hours (min.). Take sample from CBD once in 2
hours.
2. The effectiveness of alkali boil out will be identified by change in phosphate ppm and
Oil and Fe2O3 content from the initial value. The phosphate will be consumed to
remove oil/grease and loose iron particles.
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
Sr.
No.
Description of Activities
3. At the end of this procedure, the phosphate, oil level will stabilize and there is some
residual phosphate level which indicates completion of boil out. With the result of the
phosphate stability, we can declare the process is completed.
4. When the HP boiler pressure is around 9 kg/cm2(g) note down the boiler expansion
readings. Measure and mark the boiler locations in hot condition. Also observe and
mark the location of hot condition for spring supports.
g.
Completion of Alkali Boil Out and carry out on line flushing
1. After completion of ABO close the damper, box up the WHRB and allow the unit to
cool by natural cooling.
2. When the drum pressure drops to 2-kg/cm2 (g), open the start up vent and drum air
vent
3. At the above pressure take a blow down from the blowdown valves one by one for not
more than 10 seconds per drain valve. While this is being done it must always be
ensured that the drum level does not fall below the normal working level and the
water level is always visible in the level gauge. If the steam drum level drops
substantially stop draining at once and maintain drum level as specified (45 to 55%).
4. Keep the valve on CBD line in open position and carry out on line flushing. Replenish
with fresh boiler feed water and keep close watch to maintain the steam drum level.
5. Rinsing is done until feed water pH is in close proximity with drain water sample’s pH.
When the drum pressure drops to atmospheric, start draining the boiler slowly and in
the meantime make up the level with feed water. Stop rinsing when the drain water
sample pH is in close proximity with the inlet feed water pH.
6. Dilute the blow down tank content with water and divert the solution to a predetermined safe location.
7. After rinsing Open the steam drum manholes and remove the sediments (if any).
8. Protocol for Alkali Boil out will be jointly signed by customer & TBWES representative.
h.
Cooling down and inspection:
1. Drain water from boiler. Open steam drum manhole. Open all the manholes in boiler
inlet duct / casing.
2. Carry out joint inspection of steam drum inside and the boiler inlet duct refractory
lining. Also check the condition of S.H and Evaporator supporting arrangement.
3. Clean the steam drum thoroughly. Flush the Blow down piping / de choking (if any).
i.
Reinstating:
1. Results of water samples collected after alkali boil-out and rinsing is analyzed for
following :
a) Stable phosphate (min 50ppm) and oil content & Fe2O3 level at the end of
alkali boil-out,
b) No traces of oil content at the end of flushing procedure after the end of alkali
boil-out (oil content < 5 ppm is acceptable in the boiler water after boil out).
2. Thoroughly check for cleanliness and stability of steam drum internals. Flush and
Commissioning Procedure | WHRB
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
Sr.
No.
Description of Activities
clean (if required) the steam drum nozzles.
3. After complete cleaning box-up steam drum manholes with proper gasket.
4. Flush the drum level gauge glass after alkali boil out.
REFRACTORY DRY OUT AND ALKALI BOIL OUT CURVE
Not To Scale
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
6. STEAM BLOWING OF MAIN STEAM PIPING
INPUTS REQUIRED FROM CUSTOMER:
Sr.no
Description
Quantity Required
1
Boiler feed water
2
Power supply for all drives
As Required
3
UPS for control room
As Required
5
Operator - Field
6 (2 per shift)
Panel
7
Communication arrangement
(Walkie Talkie & telephone etc)
8
Manpower for operating staff.
Mechanical Engineer
Approx. 450 m3 for
steam blowing
3 (1 per shift)
4 nos.
Remarks
Quality as specified
in the O & M
manual.
8 hours shift
Field & control room
3 each (8 hrs/shift) + 1
reliever
E & I Engineer
9
Illumination of Boiler and
surroundings.
As Required
10
Water analysis laboratory
As Required
11
Dust handling from the Conveyor
As Required
12
Chemicals for normal Boiler water
treatment(for HP & LP Dosing
units)
As Required
13
Instrument air & cooling water
As Required
14
Assistance of Mechanical &
Electrical maintenance dept.
As and when required
15
Operational spares
As Required
16
First aid
As Required
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
PROCEDURE FOR STEAM BLOWING
A.
Pre-requisites :
Status of
1. Alkali boil out activity is successfully completed and inspection is completion
satisfactory. Boiler is reinstated for further activities.
2. DCS should be completely operational. Necessary communication devices
for co-ordination with commissioning engineers are available.
3. Steam piping to be mechanically completed. All pre-commissioning checks
shall be checked and satisfied by commissioning team.
4. Ensure that all pipe supports are provided and welded as per drawing.
5. Do not carry out insulation for superheated steam piping.
6. Commission all the instruments in flue gas path. Check and certify for loop
checking and stroke checking of all instruments on waterside.
7. Take all the instruments on Boiler feed piping, evaporator, super heater
and steam drum on line.
8. Line up De-aerator level control and fill water in steam drum up to 50%
level through feed water line. Carry out on line checking of steam drum
level control and safety interlocks in waterside.
9. Line up spray water piping to attemperator and complete loop checking.
10. Do not install flow nozzle on Main (Super Heater) steam piping.
11. Mark the sliding supports for cold position for measuring thermal expansion
of steam piping.
12. Disconnect main steam piping from common header and provide
temporary piping arrangement (with less bends) to safe location as shown
in steam blowing arrangement. Firmly support the piping. Keep necessary
hardware and gaskets for temporary piping ready.
13. Install sacrificing valve as shown in steam blowing arrangement diagram.
14. Fix the target plate holding assembly as shown in the steam blowing
diagram.
15. Provide anchor support very close to steam blowing point(s) to take care of
sudden / abnormal variation in piping stresses during blowing. These
supports need to be removed after successful completion of steam
blowing.
16. Keep sufficient target plates (Aluminium & SS).
17. Record all important parameters in the log sheet (prepared for steam
blowing) periodically.
18. Take all measures for safe blowing. Carry out steam blowing only during
day, when daylight is available.
19. All the instruments in boiler and steam piping shall be taken for operation
except steam flow measurement.
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
B
Valve positions:
1. Keep main steam stop valve on main superheated steam piping closed.
2. Keep CBD valves in crack open position.
3. Line up H.P. Dosing unit and keep its isolation valve near steam drum open
along with the respective valves in dosing unit.
4. All drain valves in evaporator to be kept closed.
5. All drain and vent valves in super-heater to be kept open.
6. Keep the isolation valves on upstream of steam trap closed and open the
bypass valves. Steam Traps (if any) should be fitted after completing the
steam blowing.
7. All the control valves circuit will be operational.
8. Position of other valves to be as specified in the boiler start-up procedure.
C
Boiler start up and warming up of steam piping :
1. Follow Boiler start up procedure mentioned in start-up procedure (O&M
Manual).
2. Ensure the availability of flue gas from the Cement kiln.
3. Then start the boiler as per the startup procedure.
4. As steam comes out continuously from steam drum puppy header vent and
steam drum pressure rises to 2 kg/cm2 (g), close the same. Allow the
steam to vent through start up vent valve.
5. Maintain flue gas temperature at boiler inlet less than 300°C until the
steam starts flowing through the super heater and the boiler pressure
raises up to 5 kg/cm2(g) min.
6. Maintain steam drum water level at 50% +/- 5%.
7. Check auto operation of the (Attemperator control) and take it on line. Set
TCV on auto mode for super heater steam temperature.
8. Increase flue gas temperature and gradually raise the steam drum
pressure as per the boiler pressure raising curve up to 8 Kg/cm2(g).
Maintain the steam drum pressure by throttling the start up vent valve.
9. Closely watch superheated steam temperature. This should not be allowed
to exceed beyond rated temperature by de-superheating and adjusting the
steam flow through start up vent.
D
Steam blowing of main steam piping:
1. Ensure all the pre-requisites are completed.
2. Ensure the operation of the MSSV in remote mode. And keep the valve in
closed condition.
3. Ensure operation of sacrificing valve.
4. Gradually open the by-pass valve of the Main steam stop valve and allow
the steam to warm up the main steam piping. Ensure no steam is coming
out from the drains points.
5. Initially, the steam blowing cycle (i.e. releasing the pressure) is done
Commissioning Procedure | WHRB
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
slowly to watch carefully for the thermal expansion while releasing the
pressure. In case of any abnormal noise / restriction for thermal expansion
close the valve and open the start up vent. Implement remedial measures.
Repeat the exercise and confirm integrity. For the initial blow maintain the
drum pressure at 8 kg/cm2(g).
6. After warming up the line throttle the start-up vent valve and
simultaneously open the main steam stop valve and maintain steam drum
pressure at 8 kg/cm2(g).
7. Just before blowing drop the steam drum level to ~35 % and close the
attemperation spray water to avoid carry over.
8. Ensure there is no condensation in the line & dry steam is coming out
through all the drains and from the main steam piping.
9. Open sacrificing valve and close start up vent valve. Drop steam pressure
up to 5 kg/cm2 (G). This is the 1st blowing cycle. Stop blowing by closing
the sacrificing valve and opening startup vent simultaneously. MSSV to be
closed afterwards.
10. Whenever the steam drum pressure is relieved suddenly, the steam drum
level will shoot up which happens by swelling as the steam drum pressure
drops. This is false indication of level and a momentary phenomenon.
Subsequently the level will drop. Hence allow feed water flow gradually to
make up the steam relieved.
11. Check the condition of main steam piping supports. If required rectify the
supports and proceed for the second cycle. Ensure all the supports are in
good condition.
12. Leave sufficient interval (~ 2 to 3 hours) in between steam blowing cycle
so that the main steam piping cools down i.e., pipe skin temperature
should drop at least by 100 Deg C.
13. Initially, the steam blowing cycle (i.e. releasing the pressure) is done
slowly to watch carefully for any abnormal noise/ thermal expansion while
releasing the pressure. Implement remedial measures to avoid any
abnormalities. Once this is ensured the steam blowing (releasing the
pressure) can be done suddenly, which will flush the pipe effectively.
14. Closely watch the steam drum level in the field as well as in DCS. Monitor
piping support.
15. As the drum pressure drops to 5 kg/cm2(g), close sacrificing valve and
keep start-up vent valve in throttled position and raise drum pressure
again to 14 kg/cm2(g). Maintain drum level at 50% +/- 5%.
16. Repeat the above steam blowing exercise several times as long as you
could visually observe the steam blowing is clear.
17. Now, isolate sacrificing valve and insert soft metal target plate in the target
plate holder provided for temporary piping. Raise steam drum pressure to
14 kg/cm2 (g). Repeat the blowing one time with the target plate. Close
sacrificing valve and remove target plate. If target plate is not clean,
repeat steam-blowing cycle for 4 to 5 times without target plate.
Subsequently, soft metal target plate can be inserted and checked.
18. Target plate will be checked as per the acceptance criteria. Up on
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
acceptance, the steam blowing is said to be completed.
19. Remove temporary piping and supports provided for steam blowing.
Reinstate the main steam piping.
20. Now the flow nozzle can be installed.
Note:
Please read this document along with the following documents:
1. Pressure raising curve.
2. Acceptance criteria for target plate after steam blowing.
3. List of inputs required from TBWES and Customer.
4. Log sheet for recording parameters during steam blowing.
5. P&ID Drawing.
6. Steam blowing scheme along with the sketches.
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
PRESSURE RAISING CURVE
Commissioning Procedure | WHRB
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
SKETCH FOR STEAM BLOWING ARRANGEMENT
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
ACCEPTANCE CRITERIA FOR STEAM BLOWING
It is recommended to install the target plate after completing few blows of the critical
pipelines without the target plate. For evaluating the cleanliness and termination point of
the steam blowing, target plate of aluminum / stainless steel is to be used.
Indications for the result of each blowing period are the number of pitting found on the
target plate. The highest velocity of steam is in the center of the pipe. Hence judgment
should be made for the end point of steam blowing in the target plate area. The area for
the above is 3/4th of the discharge pipe diameter at the center.
The result of the blowing operation can be judged by the absolute number of pitting on the
target plate in the central zone. The piping is considered clean if there are not more than 3
dents of 1 mm diameter in 1sq. cm area. Besides this there shall be no pitting in the rim
zone and shall not have any deformed edges.
Note:
Protocol for steam blowing shall be jointly signed by TBWES and customer.
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
LOG SHEET FOR STEAM BLOWING:
Date
Cycle
No.
Before blowing
Time
Steam SH steam
Drum
temp.
pressure
Commissioning Procedure | WHRB
After blowing
Time
Steam SH steam
Drum
temp.
pressure
Target
plate
fitted
Y/N
Observation /
Remarks
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PROJECT: M/s Ultra Tech Rajashree Cement, Karnataka (PL 1862)
7. SAFETY VALVE SETTING
OBJECTIVE
The objective of this procedure is to outline the procedures involved in setting the safety
valves to the designed set pressures before allowing the boiler to go for commercial
steaming.
PRE - REQUISITES
Ensure proper mounting of the safety valve exhaust pipe, such that no load is coming to the
safety valves. Follow instructions of vendor for safety valve exhaust piping support. Check
for the proper opening and closing of the start-up vent. Ensure the drain of main steam line
is kept open. Close all other vents and drains.
Normally the highest set pressure valve is floated first (i.e. drum safety valve) While setting
this valve the other drum safety valve and the safety valve on the super heater outlet line
are gagged.
PROCEDURE
Start the boiler as per cold start up procedure on low fire. When the drum pressure reaches
about 75% of operating pressure, gently tighten gags on one of the drums and main steam
safety valves. Raise pressure slowly by throttling the start-up vent valve. When 80% of
popping up pressure is reached manually operate the safety valve under test. This will blow
off any debris or dust left over in the valve internals. Always maintain water level 50mm
below normal level in the drum.
Raise the boiler pressure by increasing the flue gas quantity. When the valve pops, reduce
the gases and open start up vent valve. When the valve sits back, note down the pop up
and re-set pressure. Restore drum level.
The set pressure is adjusted by either tightening or loosening the adjusting nut (by reducing
or increasing the spring tension). Tightening of the nut increases the set pressure and vice
versa. Blow down which is the difference between set & reset pressure should normally be
within 5% of the set pressure.
In order to adjust the blow down notched rings (Nozzle ring and Guide ring) are provided
near the seat of the safety valve. To increase the blow-down the blow-down ring is to be
rotated towards left (lower the ring) to decrease the blow down the ring to be rotated vice
versa.
Note down the expansion reading and record in the protocol.
REFERENCE
Read carefully the supplier's O & M Manual before starting the activity and familiarize
yourself with the components of the equipment
A detailed description of the key features of safety valves is provided in the safety valve
manual, compiled in operation & maintenance manual.
NOTE
♦ All the procedures mentioned are guidelines for carrying out the boiler pre commissioning and commissioning activities.
♦ Due to various reasons there may be variations in the actual procedures
followed at site and all the deviations to be jointly (by customer and TBWES)
recorded in commissioning protocols deviation report for references.
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