Commissioning Measures Form for Approval

No.YDTD-TS02

Project name

Phase I of 2330MW Project of Tengda Contract Coal-fired Power Plant in India

No.

To: Tengda Project Department of Sichuan Machinery & Equipment Import & Export Corporation
Now it is submitted for the examination and approval with the closed circulating water system commissioning technical measure of phase I of 2330MW project of Tengda Coal-fired power plant in India Document No: QJCS-02.

Appendix: Closed circulating water system commissioning technical measure

Contractor: Sichuan Tongneng Power Technology Co. Ltd.

Project principal Examination and approval opinions of the project supervision department:

Date

Project supervision department (seal)

Supervision engineer:

Date

Chief supervision engineer:

Date

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

Examination and approval opinions of the owner

Legal person of the project (seal):

Owner representative

Date

Contractor: Sichuan Tongneng Power Technology Co. Ltd

Mar. 2008

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India

Closed circulating water system commissioning technical measure

Sichuan Power Industry Commissioning Test Institute Sichuan Tongneng Power Technology Co., Ltd
Mar. 2008

Examination and Approval Record for Documents

Document name Document YDTD-QJCS-02 No. The 1st version Date publication Date The 2nd version Edition no. Date publication The 3rd version of Main revised content publication of Main revised content of
Closed circulating water system commissioning technical measure

M a n a g e r s approval of the commissioni ng project Date:

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

Review of the principal of professional group of Date: commissioni ng project Compiler of the technical document Date

content

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

Compilation purpose .................. Compilation reference ................ Commissioning quality standard and object

Responsibility division .............. System brief introduction ............ Conditions prior to commissioning ....
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

7. 8. 9. 10.

Commissioning work procedure ......... Commissioning step ................... Safety measure ....................... Appendix .............................

1. Compilation purpose
1.1 To instruct and standardize the commissioning work of system and equipment, and guarantee safety and normal operation thereof, this regulation is hereby compiled. 1.2 Inspect the closed circulating water system electric and thermal work protection interlock and signal unit, and determine the reliability of the action. 1.3 Inspect the system and equipment operation status, check the system performance, find out and eliminate the possible defects.

2. Compilation reference
2.1 Thermal Power Plant Basic Construction Engineering Startup and Completion Acceptance Code (1996version) power construction [1996]159# 2.2 Power Construction and Acceptance Technical Specification (Steam

Turbine )DL5011-1992 2.3 2.4 Power Construction and Acceptance Technical Specification (Pipe )DL5031-1994 Standard for Quality Inspection and Evaluation of the Adjustment and Commissioning in Thermal Power Project, Construction Quality [1996]111# 2.5 Regulations for the Startup and Commissioning of the thermal Power Projects, Construction Quality [1996]40# 2.6 Manufactory drawings, installation and operation instructions, quality assurance book and ex-factory certifications 2.7 Design documents, drawings, specifications, and commissioning documents as well as conference summary, etc. 2.8 Equipments supply contract, and the international and national standards stated therein

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

3. Commissioning quality standard and object

3.1 The industrial water system commissioning result conforms to the quality standard of related closed circulating water systems of Standards for the Inspection and Assessment of the Adjustment and Commissioning Quality for Thermal Power Projects (1996 version), and quality requirements of commissioning contract, as well as satisfy with turbine complete set startup requirements. 3.2 The sub-plant trial operation, attestation and acceptance are qualified, and meet the complete set startup requirements.

4. Responsibility division
According to the statements of the administry newly issued Startup Regulation, and the Commissioning Contract, the responsibilities of each party are as following: 4.1 4.1.1 4.1.2 4.1.3 Installation unit: Responsible for individual equipment commissioning and trial operation work. Responsible for isolation work of the system. Responsible for repair, maintenance and defect elimination of the trial operation equipments. 4.1.4 4.1.5 4.1.6 4.2 4.2.1 Prepare the necessary repair tools and materials. Cooperate with the commissioning unit for subsystem commissioning. Responsible for attestation work after trial operation of system sub-section. Manufacturing unit: Responsible for startup/closedown, operation regulation and accident treatment of system trial operation. 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 Responsible for hanging the formal brand mark of the related systems and equipments. Prepare the regulations, tools, and record reports, etc.for operation; Responsible for patrol inspection and normal maintenance during trial opereation. Responsibility of commissioning unit: Responsible for compiling trial operation scheme together with technical clarification. Prepare the apparatuses, instruments and tools for the related tests. Responsible for command and control work of subsystem commissioning. Responsible for test data record and sorting. Fill in trial operation quality evaluation table.
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

4.3.6 4.3.7 4.4

Responsible for attestation work after trial operation of the system and subsystem. Compile the commissioning report. Individual commissioning of pump group will be responsibility of the installation unit, with parcitipation of commissioning unit. The sub-system commissioning of pump group will be responsibility of commissioning unit, with participation and cooperation of the installation unit and other units. The circulating water pump system commissioning will be carried out with uniform instruction of trial operation team, it will be implemented by circulating water system commissioning professional team, the steam turbine discipline will take the lead, with cooperation of electric, thermal control and other disciplines.

5.
5.1

System brief introduction

General description 1# and 2# machine sets of phase I of 2330MW newly built up project o f Tengda

Coal-fired power plant in India are respectively set by three sets of rated capacity 50%

closed circulating water pumps, and three sets of capacity 50% closed circulating cooling water heat exchanges, and one 10m3 expansion water tank, the makeup water of the expansion water tank will be provided by the condensate system and desalt water system. During normal operation, the closed circulating water pump and the closed circulating water heat exchange are all respectively two sets operation and one set standby. Closed circulating water cooling water system will provide the generator stator cooler, generator hydrogen cooler, exciter air cooler, electric feed pump motor cooler, electric feed pump lubricating oil cooler, work oil cooler, anti-flammable oil cooler, condense pump motor cooler, low pressure drainage pump, hydrogen drier, boiler water supply pump bearing cooler, condense transfer pump bearing cooler, electric group mechanical sealing (and cooling chamber) cooling water, and it can also makeup water for the mechanical vacuum pump. In addition, it will also provide boiler side blower, draught fan, primary blower lubricating oil station and bearing cooling water, air preheater bearing cooler, sealing blower cooler, coal grinding machine motor cooler, high pressure oil pump station, and thin oil station cooler cooling water. 5.2 Equipment specification Model 500S-59B
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5.2.1 Closed circulating water pump

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

Mode double suction horizontal centrifugal pump flow 1300 m 3 h lift 58 m efficiency 79.4 necessary net positive suction head 4 m shaft power 273 KW rotating speed 970r/min 5.2.2 closed circulating pump auxiliary motor model 310KW-6 rated power 310KW rated voltage 6KV rated current 39 A synchronous speed 988 r/min

6. Conditions prior to commissioning

6.1 The circulating water system, circulating water makeup system, opening circulating water system can be operated. 6.2 All pipelines and equipments installation of closed water system is completed, and meet design requirements, together with complete installation technical record; 6.3 It has reliable operation power supply and dynamic power supply, and each AC and DC distribution panel has been electrified; 6.4 Each manual gate and automatic gate of the system has been one by one commissioned and inspected, the action is proper and flexible, together with indication of name and switch direction, and it is in the standby status; 6.5 Each instrument, switch and signal has been fully installed, and calibrated properly, they are cleaned up with marking of name, and are ready for use. 6.6 The closed circulating water pump inlet strainer, pump inlet channel and pump outlet pressure pipe will be cleaned up; 6.7 The other pipeline system with relation to the closed circulating water pipeline will be isolated as per requirements; 6.8 The motor and pump bearing will be filled by lubricating oil till the stated oil
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

level. 6.9 The expansion water tank has the qualified desalt water, and it can guarantee the sufficient water supply for flushing, and the drainage system is smooth; 6.10 The trial operation site environemnt is clean, the site hole and channel cover plate are complete, and the temporary hole is mounted by guardrail or cover plate, the platform has normal staircase, channel, bridge walk, handrail and bottom protection board; 6.11 The operation suspended door and important monitoring instruments and meters will be mounted by platform or staircase; 6.12 The firefighting system is in the reliable and standby status; 6.13 The drainage systems and facilities are normal for use. 6.14 The site has formal lighting, accident lighting system, which are complete, reliable and ready for use. 6.15 The communication equipments as telephone, etc. are installed and can be putted into use.

7. Commissioning work procedure

The closed circulating water system commissioning work can be carried out as per following flow chart:

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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

Commissioning technical scheme clarification Commisioning conditions determination; Interlock protectionand alarming test Closed circulating water pump group trial operation Pipeline flushing System putting into operation and dynamic regulation Main equipment installation and individual commissioning are completed Instrument constrol installation and related commissioning are completed; Electric installation and related commissioning are completed; Pipe valve installation and commissioning Safety condition is satisfied Interlock protection test Alarming test

8. Commissioning step
8.1 Prior to system operation, the electric and thermal work professional staffs will carry ou the thermal work and electric interlock protection test (the detailed content please refer to the
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

annexed table). 8.2 Motor individual trial operation The motor individual trial operation work will be carried out by the installation unit,and this content item is only for reference; 8.1.1 7.1.1 8.1.2 8.1.3 8.1.4 Separate the matching wheel between motor and pump; The motor insulation is qualified; The motor spot-drive rotation direction is proper; The motor is operated 2 hours continuously after normal operation; The trial operation will record the bearing vibration, bearing temperature, motor temperature, motor startup/operation current, and cooling water pressure; 8.3 8.3.1 Trial operation of closed circulating water pump; Preparation prior to trial operation:

a) Wheel connection between the motor and pump is completed; b) The water of expansion water tank is filled to the work level. 8.3.2 Closed circulating water pump startup; a) Open the closed cooling water system air valve, and open the closed heat exchange water side air valve. b) The closed circulating water pump is started up at the field. c) Inspect the pump outlet gate and pump operation statuses; d) After the pump capacity is normal, inspect the closed water system pipe, each air valve of the system will be closed when meeting with water, and inspect the leakage status; e) In the trial operation, record the bearing vibration, bearing temperature, motor temperature, motor startup/operation current, pump outlet pressure; f) Pump group trial operation is 8 hours.

8.3.3 Stop operation of closed circulating water pump; a) The field or remote DCS will stop the operation of closed circulating water pump; b) The pump will not be of reverse rotation. 8.4 According to the trial operation site status, it may carry out closed circulating water pump dynamic linkage test. 8.5 Closed circulating water system flushing

8.5.1 The pipe will be separated before each system entering the equipment, and the
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

inlet and outlet gate of the equipment will be short connected; 8.5.2 Start up the closed circulating water pump, maintain the outlet pressure of pump, and continuously flush the system. To maintain the outlet pressure of the pump, each sub-system will be flushed in alternation; 8.5.3 Flush scope: a) Machine side: generator stator cooler, generator hydrogen cooler, exciter air coler, electric feed pump motor cooler, electric feed pump lubricating oil cooler and work oil cooler, electric group mechanical sealing (and cooling room) cooling water inlet, anti-flammable oil cooler, condense pump motor cooler, low pressure heater drainage valve, hydrogen drier, boiler water supply pump bearing cooler, and condense water transfer pump bearing cooler; b) Boiler side: boiler sampling water, coal grinding machine motor cooler, coal grinding machine high pressure oil pump station, seal blower cooler, primary blower lubricating oil cooler, primary blower bearing cooler, draught fan and blower lubricating oil cooler and bearing cooler, air preheater top bearing cooler, etc; 8.5.4 The wate quality is clean and transparent without foreign substances, after the inspection is qualified, the system will be recovered. The water quality will be periodically inspected, if it is not consistent with the requirements, the water will be replaced; 8.5.5 When the system water quality reaches certain extent, the thermal work instrument will be flushed and inputted.

9. Safety measures
9.1 When the closed circulating water pump outlet butterfly is closed, the closed circulating water pump will not be operated; 9.2 Inspect the current and voltage of the closed circulating water pump, and the actual operation work condition of the pump will be in the stated scope, without power-exceeding and motor reverse rotation. 9.3 9.4 Avoid low flow operation of the closed circulating water pump; Prior to startup of closed circulating water pump, it will not have abnormal vibration sound, otherwise the pump will be immediately stopped for inspection and treatment;
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

9.5

The normal operation and accident treatment will be rigidly carried out by poewr plant operation regulation.

10. Appendices
a) Condition inspection table Closed circulating water system trial operation condition inspection table
System description: closed circulating water system Determination and signature No. Condition description Installation party 1 All equipments and pipe installation of the closed cooling water system has been completed, accepted and attested. The thermal work instrument and electric equipment installation and calibration have been completed, together with provision of calibration list of the instruments, and pressure, temperature and vibration switches, etc. The instruments and meters are calibrated and installed. The valve individual commissioning is completed, the switch action is proper, the limit switch location and CRT status display is proper. Commissioning party Supervison party Owner

The closed circulating water pump inlet strainer, pump inlet channel and pump outlet pressure pipe will be cleaned up;
The closed pump motor insulation test is qualified, and the pump and motor bearing have been filled by qualified lubricating grease.

The expansion water tank has the qualified desalt water, and it can guarantee the sufficient water supply for flushing, and the drainage system is smooth; The trial operation site environemnt is clean, the site hole and channel cover plate are complete, and the temporary hole is mounted by guardrail or cover plate, the platform has normal staircase, channel, bridge walk, handrail and bottom protection board; The operation suspended door and important monitoring instruments and meters will be mounted by platform or staircase;
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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

The closed water system flushing temproary pipe has been installed as per requirements. The other pipeline system with relation to the closed circulating water pipe will be isolated.

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The site has formal lighting, accident lighting system, which are complete, reliable and ready for use. The firefighting system is in the reliable and standby status;

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Sichuan Tongneng Power Technology Co. Ltd Date

day

month

2008

b) Logic inspection table Closed circulating water system interlock logic inspection table
No. I. Start up conditions Expansion water tank level is higher, low I value outlet valve of closed water pump turnoff II. Interlock protection conditions Expansion water tank level is lower, III value CRT startup closed water pump CRT stop the closed water pump A pump accident tripping, B pump is inputted for interlock. A pump accident tripping, B pump is inputted for interlock, the outlet main pipe pressure is low. A pump accident tripping, C pump is inputted for interlock. A pump is operated, C pump is inputted into interlock, the outlet main pipe pressure is low. B pump accident tripping, C pump is inputted for interlock. B pump is operated, C pump is inputted into interlock, the outlet main pipe pressure is low. B pump accident tripping, A pump is inputted for interlock.
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Item

Set value

Interlock protection action

closed water pump tripping Linkage opening outlet electric gate Linkage closeing outlet electric gate B pump interlock startup

Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India Closed circulating water system commissioning technical measure

B pump is operated, A pump is inputted into interlock, the outlet main pipe pressure is low. C pump accident tripping, B pump is inputted for interlock. C pump is operated, B pump is inputted into interlock, the outlet main pipe pressure is low. C pump accident tripping, A pump is inputted for interlock. C pump is operated, A pump is inputted into interlock, the outlet main pipe pressure is low.

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