POWER PLANT COMMISIONING

Commissioning:
Setting the plant to function smoothly and safely
Pre-commissioning activities of boiler:
1.
2.
3.
4.

Pre-commissioning check-ups.
Trial run of equipments.
Pre-commissioning tests.
Chemical cleaning.
1. Alkali boil-out.
2. Acid cleaning.
3. Neutralisation.
4. Passivation.
5. Thermal flow test.
6. Steam blowing.
7. Hydro test.
8. Safety valve setting.
9. Commissioning.
10. Trial run of boiler.

Pre-commissioning check-ups:
It is done to carry out the commissioning programme with out unnecessary delay
by finding out the problematic points and taking corrective actions against those them.
Trial run of equipments:
To check the behaviour of equipments and their suitability to put tem in to
service, all the equipments are made to safe run for 8 hours with all the indications,
interlocks and protections etc., Items like dampers, gates and valves, their freeness of
movements, full travel and full closure are checked individually along with drives.
Pre-commissioning tests:
Gas and air tightness tests are carried out to identify and rectify the leakage points
in the system. Smoke generators are used to find out the leakage points. FD fan will be
operated, if it is necessary to slightly pressurise the furnace. At this stage, the repeat
hydraulic test on boiler pressure parts is also carried out by erection and commissioning
agency.

Chemical cleaning:
Dos:
1.
2.
3.
4.

All drum internals should be removed except steam separator.

DM water supply required.
Oil burners are required.
Mills and turbines are not required.

Alkali boil-out:
It is to remove oil, grease and impurities, adhering into the interior of the
pressure parts. Alkali is effective under elevated pressure. So it is performed at 40
kg/cm2 with 500 ppm of di-sodium phosphate and 1000 ppm of tri-sodium
phosphate for 16/ 20/ 24 hours. Boiler is fired for this activity. After alkali boilout, rinsing will be done with DM water.
Acid cleaning:
1.
2.
3.
4.

Acid washing.
DM water rinsing
Critical acid washing.
DM water rinsing.

(Note: Super heaters and reheaters tubes are excluded in this process)
Chemicals used:
1.
2.
3.
4.
5.

HCl, 4 - 6 % concentration or Hydro fluoric acid

Ammonium tri-fluoride, 1 % concentration.
Nitrogen gas.
Critical acid, 0.2 % by weight. (To nullify the effect of strong acid)
Sodium carbonate.

Passivation:
Passivation is done to form magnetite coating over the inner surface of the
tube material to avoid the formation of metal oxides when exposed to atmosphere.
DM water at 850C with 200 - 300 ppm of hydrazine and ammonia to maintain PH
value of 9.6 is circulated in the boiler tubes for 24 hours.
Thermal flow test:
It is used to find out the rate of cooling of tubes of water walls, economizer and
super heaters. It is also to detect the possible chocking in boiler tubes such as water

walls, economizer and super heaters tubes. The fluid velocity during this test is selected
in between 0.15 and 3.0 m/s.
Steam blowing:
It is to remove mill scales, iron burrs, foreign material and weld beads of various
critical pipes. Steam purging of SH and other critical pipe lines is carried out by puffing
method. RH safety valves are floated at this stage. Its principle is applying thermal shock
over obstruction in the line. The abrasion on the target plate fixed in the exit pie indicates
the effectiveness of steam blowing.
Stage-I
Stage-II
Stage-III
Stage-IV
Stage-V
Stage-VI

: SH, MS lines AND auxiliary PRDS are covered. (Up to ESV)

: MS transfer piping from ESV to HPT control valves.
: CRH lines and HP bypass lines are covered.
: HRH lines covered. At the end RH safety valve is floated.
: RH transfer piping from interceptor valve to IPT control valves.
: LP bypass system is covered.

Hydro test:
DM water with 200 ppm hydrazine (N2H4) and 10 ppm ammonia is used for this
activity. PH value is maintained around 10. After this hydro test, boiler will be kept under
the nitrogen blanket at a pressure of 0.5 kgf / cm2. Pressure for hydro test is as per IBR.
1.
2.
3.
4.
5.

The rate of pressure rise is 2 ksc / min up to 100 ksc.

The rate of pressure rise is 1 ksc / min beyond 100 ksc.
The highest pressure will be 1.5 times the design pressure.
The hydro test pressure should be maintained for 0.5 hour.
Check for any puncture or/and cracks.

Safety valve setting:

1.
2.
3.
4.
5.
6.
7.

RH safety valve is floated after 4th stage of steam blowing.

Drum pressure after 3rd stage should be 20 kgf / cm2.
All safety valves should be gaged except the one to be floated.
Drum and SH safety valve are floated after 5th stage of steam blowing.
ESV (Electromatic Safety Valve) is to be tested from UCB.
Set pressure of safety valve is equal to 1.15 times of design pressure.
Best place to locate safety valve is at HRH line. So that system losses can be
minimised and it serves the purpose.