Commissioning Procedure For Boiler Unit Startup
Commissioning Procedure For Boiler Unit Startup
Commissioning Procedure For Boiler Unit Startup
CONTENTS INDEX
2. REFERENCE DOCUMENT............................................................................................ 1
APPENDIX I CHECKLIST.................................................................................................. 1
1. SCOPE OF COMMISSIONING
There are 3 stages in boiler unit startup period that are no load, partial load and full
load. This procedure is to provide the commissioning procedure for boiler unit startup,
ensure that boiler unit could complete trial operation and put into commercial running.
2. REFERENCE DOCUMENT
The 660MW boiler which designed and manufactured by Harbin Boiler Company Ltd
(HBC) for India Talwandi power plant adopts the supercritical boiler technology developed
by HBC itself. The boiler is π type outdoor arrangement supercritical boiler with variable
pressure operation, single intermediate reheat, single furnace, balanced draft, dry ash
removal and total steel frame suspending structure. It has atmospheric flash type startup
system without recirculating pump and adopts tangential firing, low NOx combustion
burners, 24 burners are arranged in 6 layers. The boiler is equipped with 6 BBD4760
double-ended ball mills direct-fired system of Shanghai Heavy Machinery Co.Ltd, under
BMCR condition, 5 mills are in operation 1 mill is standby.
3.1 Boiler technical specification
Main design parameters of boiler are shown as below:
Main design parameters of boiler
Contents Unit BMCR Load TMCR Load
Superheated steam flow t/h 2140 2003.1
SH outlet steam pressure MPa.g 25.4 25.24
SH outlet steam temperature ℃ 571 571
Reheat steam flow t/h 1732.99 1630.07
Reheat steam inlet pressure MPa.g 4.815 4.529
Reheat steam outlet pressure MPa.g 4.605 4.332
Reheat steam inlet temperature ℃ 330.9 324.3
Reheat steam outlet temperature ℃ 569 569
Main feedwater pressure MPa.g 29.00 28.46
Feedwater temperature ℃ 293.4 289
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Commissioning Procedure for Boiler Unit Startup
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Commissioning Procedure for Boiler Unit Startup
Six double-in and double-out Ball tube pulverizers are applied in this project, together
with raw coal bin and feeder system. Two sets of primary fans of 50% capacity which
supplies primary cold and hot air for pulverized coal transmission
The boiler combustion system consists of 24 burners which are distributed in 6 layers
and each layer has four burners which are from same mill
Each burner is equipped with a set of High-Energy Spark Ignition system to ignite the
fuel oil automatically. This device consists of ignition exciter unit, ignition rod, ignition
cable, screened spark plug, oil gun and modular propulsion unit etc. Each igniter is
equipped with an oil gun, which could be used to ignite the burner, warm up the furnace,
increase the boiler load and pressure and stabilize the combustion.
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Commissioning Procedure for Boiler Unit Startup
(8) Equipment, pipes and valves are labeled with tag hanged.
(9) Communication system is OK.
(10) Pipes are painted and accepted.
(11) Air conditioning and ventilating facility are OK.
(12) Elevator is in service.
(13) Fuel system and coal transfer system have been put into service.
(14) Coal bunker, ash hopper and boiler inner are clean.
4.2 Subsystem condition
4.2.1 Defects removed
Gas and air system has been put into service during boiler steam blowing period,
whose Defects have been removed.
4.2.2 Water and steam system
(1) Steam blowing temporary pipes have been resumed.
(2) Hydraulic pressure pins of safety valves of main pipe and RH pipe have been
removed.
(3) Defects of drainage system, blow down system and air discharge system have
been removed.
(4) Expansion indicators are all OK.
4.2.3 Coal pulverizing system (no put into service during steam blowing period)
(1) Mills have been installed with motor running and static check completed.
(2) Individual commissioning of Coal feeder has been completed with belt balance
verified.
4.2.4 Fuel oil system
(1) Defects during steam blowing period have been removed.
(2) Flame detector of oil is OK.
(3) Inserting and withdrawing test of oil gun.
(4) Logic function check of oil gun.
4.2.5 Coal transfer system
Individual operation of coal transfer system has been completed which is satisfied
with coal supply.
4.2.6 Ash handling system
Ash handling system can be put into service.
4.2.7 Slag handling system
Slag handling system can be put into service.
4.2.8 Soot blowing system
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Commissioning Procedure for Boiler Unit Startup
Static action of soot blower is normal and soot blowing logic function is eligible.
4.2.9 Chemical dosing and sampling system
Chemical dosing and sampling system, periodic blow down and continuous blow
down system, drainage system, air discharge system, anti-flush system and filling nitrogen
system have all been installed.
4.2.10 Auxiliary equipment logic
SCS and FSSS check have been finished.
4.2.11 Flame detector and flame TV can be put into service.
4.2.12 Gas temperature probe
Furnace gas temperature probe has been tested and adjusted with flexible and
credible operation.
4.2.13 BTG test
BTG test of unit have been completed and eligible with correct action.
4.3 Other condition
(1) Chemical making up water system can supply eligible demineralized water.
(2) Compressed air system can supply eligible compressed air.
(3) Auxiliary power supply system in service.
(4) Lighting and communication system is OK.
(5) Center air-conditioning is OK.
(6) Safety electrical source can be put into service.
(7) Circulating cooling water can be put into service.
(8) Closed cooling water of auxiliary equipment can be put into service.
SEPCO1 provides the necessary supports, such as offering fuel oil and coal,
equipment maintenance, and organization of the commissioning assignment.
Professional engineers from HEPERI take in charge of the test.
Operators from JINGMEN Power Plant are responsible for operation.
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Commissioning Procedure for Boiler Unit Startup
7. SAFETY PRECAUTIONS
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Commissioning Procedure for Boiler Unit Startup
be below 80℃.
(17) Pay attention to steam temperature and pressure, load, surface temperature and
flue gas temperature changes after coal throwing, and avoid temperature excess.
(18) At the beginning of coal firing, slag removing should be one time each shift.
(19) Check bearing temperature, lube level, cooling water, etc. of rotary equipment.
(20) Facilities should be checked regularly and no more than twice each shift.
8. COMMISSIONING PROCEDURES
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Commissioning Procedure for Boiler Unit Startup
out blowdown when separator pressure is about 0.2~0.3MPa, where separator water
level change should be observed.
4) Check expansion of boiler and pressure rising should be paused when expansion
abnormal.
5) Keep stable for a while when pressure up to 0.4MPa to screw down bolt
connecting.
6) Send steam into auxiliary steam main pipe, deaerator and gland sealing system
when superheated/reheated steam pressure is up to 0.6MPa and temperature is up to
150~200℃.
7) Close air valve of main steam pipe when separator pressure is 0.7MPa.
8) Close drain valves of SH/RH when main/reheated steam pressure is 1.0MPa.
9) When separator temperature is about 190℃, flush boiler with demineralized water
in hot state until qulity of boiler water is acceptable.
10) Soot blower of APH should be put into service when oil gun runs.
11) The gas temperature out of furnace should be controlled below 540℃ before
turbine rolling.
12) Keep separator temperature difference no more than 40 ℃ and ensure wall
temperature of SH and RH no excess.
13) When main steam pressure is 5MPa and temperature is 380℃, insure there is
enough HP bypass opening. Control reheated steam pressure 1.5MPa and temperature
360℃ by use of LP bypass.
14) Analyze water and steam quality and get ready for turbine rolling.
(4) Turbine rolling and generator synchronization
1) Keep boiler parameters for turbine rolling.
2) Cooperate with electrical test when turbine reaches 3000rpm.
3) Generator synchronization.
4) Preliminary load and generator disconnection for turbine over speed test.
(5) Boiler RH safety valve setting
Stop turbine when the over speed test is over and keep boiler operation to start
boiler RH safety valve setting. (Refer to Commissioning Procedure for Boiler Steam
Tightness and Safety Valve Setting)
8.3.2 Partial load stage
(1) 25% ECR
1) From boiler startup to synchronization operation refer to no load period.
2) Control boiler temperature and pressure rising speed against turbine metal
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Commissioning Procedure for Boiler Unit Startup
temperature.
3) Close feed water bypass CV instead by main feed water pipe valve when load rise
to 10%.
4) Start coal pulverizing system when primary air temperature out of APH is above
180℃.
5) Put ESP, ash and slag handling system into service.
6) Combustion adjustment. (Refer to Commissioning Procedure for Boiler
Combustion Adjustment And Lower Load Steady Combustion)
7) Record boiler operation parameters at this load.
(2) 50% ECR
1) Raise load to 50%ECR with 0.1MPa/min pressure rising speed and 2.4MW/min
load rising speed. Keep main steam pressure and temperature stable.
2) Put superheated steam temperature auto controlling into service.
3) Put reheated steam temperature auto controlling into service.
4) Put other correlative auto controlling into service.
5) Combustion adjustment. (Refer to Commissioning Procedure for Boiler
Combustion Adjustment And Lower Load Steady Combustion)
6) Record boiler operation parameters at this load.
(3) 75% ECR
1) Raise load with 3MW/min load rising speed and keep steam temperature 568℃-
570℃.
2) Put OFA damper into auto controlling when load is up to 70%.
3) Combustion adjustment. (Refer to Commissioning Procedure for Boiler
Combustion Adjustment And Lower Load Steady Combustion)
4) Boiler oil cut-off test.
5) Boiler steam temperature and pressure adjustment and gas temperature
adjustment.
6) Keep boiler operation to start boiler SH safety valve setting. (Refer to
Commissioning Procedure for Boiler Steam Tightness and Safety Valve Setting)
7) Record boiler operation parameters at this load.
(4) 100% ECR
1) Bearing temperature and vibration measurement of main rotary machine.
2) Raise load to 90%ECR and keep stable 10~15min, and then to 100%ECR.
3) Put soot blowing sequence controlling and carry out sootblowing overall once.
4) Record boiler operation parameters when load is 100%ECR.
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Commissioning Procedure for Boiler Unit Startup
9. COMMISSIONING CHECKLISTS
Boiler and its’ subsystem should operate normally and stablly. All the operation
parameters are less than alarm values.
12. APPENDIX
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Commissioning Procedure for Boiler Unit Startup
APPENDIX I CHECKLIST
保护试验
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Commissioning Procedure for Boiler Unit Startup
联锁试验
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Commissioning Procedure for Boiler Unit Startup
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Commissioning Procedure for Boiler Unit Startup
锅炉整套启动参数
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Commissioning Procedure for Boiler Unit Startup
PAF current(A/B)
A
一次风机电流(A/B)
Outlet air pressure of PAF(A/B)
kPa
一次风机出口压力(A/B)
Seal air fan current
A
密封风机电流
Outlet air pressure of seal air fan
kPa
密封风机出口压力
Primary air pressure
kPa
一次风压
Primary air temp.
℃
一次风温
Secondary air and furnace DP
kPa
二次风与炉膛差压
Secondary air temp.
℃
二次风温
total air flow
t/h
总风量
Inlet gas temp. of APH
℃
空预器进口烟温
outlet gas temp. of APH
℃
空预器出口烟温
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Commissioning Procedure for Boiler Unit Startup
Load
MW
负荷
Oil gun number
/
运行油枪数量
Coal feeder output
t/h
给煤机出力
Mill current
A
磨电流
Inlet air temp. of mill
℃
磨进口一次风温
Inlet air press of mill
kPa
磨进口一次风压
Hot air door opening
%
热风调门开度
Cold air door opening
%
冷风调门开度
Primary air door opening(A/B)
%
容量风门开度(A/B)
Bypass air door opening(A/B)
%
旁路风门开度(A/B)
Outlet air temp. of mill
℃
磨出口温度
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