BASICS OF COMMISSIONING

Before putting any auxiliary or system in operation, following points are to be ensured, System is installed fully as per drg./scheme. It is free from any debris/foreign materials. Emergency shut-off/activity suspending arrangements are available.

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All interlock/ protections are incorporated. All the system forming part of closed cycle of main power plant are cleaned, such that pure steam is produced for admission to turbine.

VARIOUS SYSTEMS IN THERMAL POWER STATION

Feed water system. Condensate and drip system. Steam and water system of boiler. Air and flue gas system. MS, CRH, HRH & HP/LP bypass system. Fuel Firing system. Coal milling system. ACW/BCW system.

Pre- boiler system alkali flushing. Chemical cleaning of boiler, consisting of alkali boil-out, acid cleaning, passivation. Steam blowing. Steam dumping. Safety valve floating. Coal firing and full loading.

COMMISSIONING SEQUENCE OF SYSTEMS FOR BOILER

Pre- boiler system alkali flushing

Boiler is fed with water from pre-boiler system, consisting of condenser, CEP, LP Heaters, Deaerator, feed pump suction, feed pump, HP Heaters, Feed control system. For cleaning purpose the system is divided in two systems viz. condensate & drip system and feed water system. For circulation of alkali solution the system is connected suitably with temporary pumping / circulation set up.

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The system is filled/ pressure tested and leakages are attended. First flushed with cold water followed by hot water, alkali solution and then rinsing with hot water and DM water till system is cleaned. Normally cleanliness is declared by physical inspection. PH, turbidity, oil ppm etc. of inlet and outlet.

Chemical cleaning of boiler, alkali boil-out, acid cleaning, passivation.

The circuit from economiser inlet isolation valve to boiler outlet MS stop valve are the the boundary points of boiler. The drains, vents, safety valves, chemical dosing points are all connected to boiler pressure part system. After completion of system it is hydro tested and then flushed two three times for clearing major debris/ muck

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Boiler is made ready for light up by making initial commissioning of all auxiliaries viz. ID Fan, FD Fan, Air & Flue Gas system, fuel oil firing system etc. Boiler drum is filled slightly below normal level and then alkali solution is added in required quantity and then boiler is lighted for alkali boilout.

Acid Cleaning

Acid cleaning is done after the Alkali Boil out is complete After acid cleaning is complete, the system is passivated and preserved with Nitrogen gas till it is used for generation of steam.

Steam Blowing

Steam blowing is done mainly to clean the pipelines that carry steam to the Turbines. The pressure is raised to a fixed value and the steam is let out through temporary pipelines. The debris and scales formed in the pipeline gets cleaned in the process. The completion of the steam blowing process is decided by inspecting the targets plates placed in the pipeline

Safety Valve Floating

This is a mandatory requirement of the Boiler For safety of the operating personnel and Boiler, the safety valve operation is tested againsted actual pressure in the boiler. The boiler pressure is raised and the operation of the safety valve is tested. With the completion of the safety valve floating, the boiler is ready of