Boiler IDF and System

Commissioning Procedure

Compiled by:

Reviewed by:

Approved by:

2014

Qingdao Huachen Weiye Electric Power Technology

Engineering Co., Ltd.


Catalogue
1. OVERVIEW ...................................................................................................3
2. MAIN EQUIPMENT TECHNIQUE SPECIFICATION...3
3. COMMISSIONING BASIS AND STANDARD .....................7
4. COMMISSIONING PURPOSE ...........................................................8
5. COMMISSIONING CONDITION..................................8
6. COMMISSIONING PROCESS AND METHOD.......8
7. COMMISSIONING INSTRUMENT AND EQUIPMENT
.....................................................................................................................................11
8.

COMMISSIONING QUALITY AND

ASSESSMENT STANDARD....................................................................................11
9. ENVIRONMENT, OCCUPATIONAL
HEALTH AND SAFETY CONTROL PROCEDURE...........................................12
10 ORGANIZATION AND DIVISION..............................................12
11. APPENDIX..................................................................................................15


Boiler IDF and System Commissioning Procedure
1.

Overview
ZMTP 2150MW
2510t/h

The project is Zambia ZMTP 2150MW coal fired power plant, located at
Maamba coal mine, Sinazongwe, Southern Province. The boiler is produced by
Dongfang Boiler Company, which is 2*510t/h high temperature, super high pressure
circulating CFB boiler. Here the procedure is for the boiler IDF and system
commissioning.

Each boiler is matched with two sets of centrifugal IDF, controlled by damper
and hydraulic coupling; two sets of centrifugal PAF, controlled by damper and
hydraulic coupling; two sets of centrifugal FDF; controlled by damper and hydraulic
coupling; three sets of HP fluidized blower, controlled by motor butterfly damper and
3

hydraulic coupling, which are all produced by Shanghai Blower Works Company.

2.

Main equipment technique specification

2.1
Boiler specification
Zambia MCL 2150MW Coal Fired Power Plant 2 510t/h

150MW

Zambia MCL 2150MW Coal Fired Power Plant is provided with two sets of
510t/h super high pressure, natural circulating CFB steam drum boilers, which is
single furnace, single medium reheating, thermal isolation cyclone separator, tubetype air preheater, balanced draft, end part double flue, suspension structure, halfunsheltered layout, solid state deslagging, complete steel structure, matched with
150MW condense turbine-generator. The boiler adopts CFB combustion and
limestone desulfurization technique that low pollution and high efficiency.

Boiler main parameter sheet

Item

Main steam flow

Main steam pressure

Unit
T/H

BMCR

BECR

510

485.73

MPa

14.32

14.32


Main steam temp.

LP RH inlet pressure

LP RH inlet temp.

HP RH inlet pressure

HP RH inlet temp.

RH flow

Feed water temp.

Feed
water
temp.
exclusive all HP
#1
Feed
water
temp.
exclusive #1 HP
#2
Feed
water
temp.
exclusive #2 HP
(LHV)
Boiler
guaranteed
efficiency (LHV)

Boiler
desulfurization
efficiency

540

540

MPa

2.85

2.85

334

334

MPa

2.7

2.7

540

540

T/H

420.42

400.4

248

248

171

228.6

207.3

90

92.3

2.2
Fan technique parameter

IDF system mainly comprises following equipment: two IDFs, two IDF
motors, two hydraulic couplings, two sets of auxiliary equipment of hydraulic
5

coupling, control and protection.

IDF mode and type

Mode: centrifugal
1854AZ/1715
Type: 1854AZ/1715

Blade mode: dual-draft mode, wing shaft blade.
2
Rotation direction: two sets turn to right, while two sets turn to left (see from
motor to air fan)
24
Layout mode: symmetry laying, two sets for each boiler, and total four sets for
the project.
1150SVNL
Hydraulic coupling type: 1150SVNL

STMKK50-6L
The fan is mainly composed of shell, admission box, air inlet, transmission
mechanism, blade wheel, bearing, control mechanism, etc. The fan is linked by
junction box and hydraulic coupling, driven by motor, which the type is STMKK506L, produced by Xiangtan Motor Company.
1
Sheet 1: IDF design parameter

Performance

IDF flow

Inlet temp.

Inlet negative Full

pressure
Pa

point
Nm /h
3

TB
T, B point

load

pressure rising
Pa

425020

153.4

-7461

7700

354185

138.4

-5181

5300

BMCR
Design
(BMCR)
2
Sheet 2: IDF regulation

No.

Manufacturer filling

Item
1

Mode

Dual-draft,
supporting, centrifugal
2

IDF quantity for each boiler

%

88.7

Selected point efficiency (full pressure)

%
4

%
Guaranteed

pressure)

point

88.6

efficiency

(full

kg/h
Quality flow (kg/h)

548401

dual

m3/h

764856

Capacity flow (m3/h)

kPa

8207

Total head pressure (kPa)

148.8

working

Inlet medium temp. ()

kW

1900.9

condition

Shaft power (kW)

TB
Selec

8
ted
9

TB

10

kg/h

457040

Quality flow (kg/h)

m3/h

599004

Capacity flow (m3/h)

kPa

1082.3

Total head pressure (kPa)

133.8

working

Inlet medium temp. ()

kW

1045.7

condition

Shaft power (kW)

11
12
13

BMCR
Calculat
ed

14

15

(BMCR)

Q235A

16

Shell material
mm

10

17

Shell thickness (mm)

45#

18

Shaft material
/

15MnV

19

Blade wheel material

/

10

20

Blade wheel service life ( 10,000 hour)

t

9000

Rotor weight (t)

8

21

35000

22

Total weight (t)

23

Bearing mode

Rolling bearing

24

Bearing lubricating mode

m3/h

Oil bath lubricating

40000

25

Allowed minimum stable flow (m3/h)

Manufacturer

Xiangtan motor
YKK710-6

Type
kW

2100

Rated power (kW)

V

6600

29

Voltage (V)
r/min

980

30

Rotation speed (r/min)

IP55

31

Protection grade

32

Cooling code

Air-air cooling

33

Bearing mode

Sliding bearing

26
27
28

Drive
n motor

Neutral
34

point

current

Dalian Zhongguang

transformer

Flow control mode

Inlet damper + hydraulic

coupling

3
Sheet 3: hydraulic coupling performance parameter
9

Name

Unit

Rated load

Max.

Design value

KW

Output power

Slip

KW

Slip loss

KW

Fixed loss

KW

Input power

r/min

Input speed

r/min

Output speed

Rotation

According to owner requirement

direction

Driving shaft

Rotating direction is identical with the motor.

Driven shaft

Rotating direction is identical with the motor.

Speed

control

range

As

per As

operation

operation

plan

plan

Working

oil

pump mode

Lube oil pump

10

per

Name
mode

Unit

Rated load

Max.

Design value

Startup oil pump

mode

Working

MPa.g
oil

pressure

l/min

Working oil flow

MPa.g

Lube oil pressure

l/min

Lube oil flow

Oil cooler
MPa.g
Design

pressure

of

working oil cooler

MPa.g
Design

pressure

of

lube oil cooler

OC

Design temperature of
working oil cooler

OC

Design temperature of
lube oil cooler

Cooling

area

m2

of

Shall be submitted
11


Name
working oil

Unit

Rated load

Max.

Design value
after
signing
agreement.

m2

Cooling area of lube

Shall be submitted

oil

after

signing

agreement.

Cooling water

Water

flow

t/h

of

Shall be submitted

working oil cooler

after

MPa.g

agreement.

Cooling

Shall be submitted

pressure

water
drop

of

working oil cooler

after

signing

signing

agreement.

t/h

Water flow of lube oil

Shall be submitted

cooler

after

MPa.g

agreement.

Cooling

Shall be submitted

water

pressure drop of lube

after

oil cooler

agreement.

signing

signing

Introduction:
1.TB(test block)
TB (test block): allowance shall be reserved for air flow and pressure in TB
working condition.
2.BMCR BMCR
12

BMCR: boiler maximum continuous rating. The fan parameter shall be

checked under BMCR working condition.
3.
Above air flow and pressure data has been modified to selected state.
4. 180
The IDF can bear 180 of medium temperature in failure condition, and can
operate safely under the temperature.
5.
The IDF is controlled by hydraulic coupling.

3.

Commissioning basis and standard

3.1 DL/T5437-2009
Code for Fossil Power Construction Project from the Unit Commissioning to
Completed Acceptance by National Energy Administration DL/T5437-2009
3.2 DLT852-2004
Guide for Boiler Start-Up Commissioning Test by NDRC DLT852-2004
3.3 DL5009.1-2002
Code of Safety Operation in Power Engineering Construction Part 1:
Steam Power Plants by Electric Power Industry Standard
3.4 DLT
5210.2-2009
Code for Construction Quality Acceptance and Evaluation of Electric Power
Construct. Part 2: Boiler Unit by National Energy Administration DLT 5210.2-2009
3.5 1996
Standard for Quality Inspection and Evaluation on the Commissioning of
Thermal Power Plant (1996 version)
3.6 1996
Regulations on the Start-up commissioning of Thermal Power Plant Projects
(1996 version)
3.7
Relevant contracts, design drawings, manufacture introduction, technique
13

agreement and other documents.

3.8 MCL 2150MW
Commissioning outline of Zambia MCL 2150MW coal fired power plant
project.

4.

Commissioning purpose
4.1

In order to guide and regulate system and equipment commissioning, and put into
operation safely and normally, hereby the procedure is compiled.
4.2
Check electric and I&C protections interlock and signal devices, and confirm the
action reliability.
4.3
Check equipment operation and systems performance, find and remove the possible
problems.

5.

Commissioning condition
1

Before commissioning, the commissioning staff shall check the provided

14

condition completely for the system as per appendix 1 content and make recording.

6.

Commissioning process and method

IDF system commissioning work can be carried out as per following flow chart:

Technique handover

Main equipment, I&C, electrical

and air channel and valve erection
and single commissioning are

Condition confirm

completed.
Safety condition are satisfied.
15

Interlock protection test

Interlock protection

Alarm test

alarm test

IDF test running

System blowing and

tightness check

System into operation

and dynamic control

Chart 1: Commissioning flow chart

6.1
Actuator check
6.1.1
Check and accept motor air valve dampers, record data;
16

6.1.2
Check and accept motor control air valves, record data.

6.2
Thermal signal check
6.2.1

Check and accept analog and switching value signal, record data.
6.2.2

For above signal, on site position shall be considered to analyze the reality of
collected signal, if not, response and suggest to construction unit.
6.2.3
Air fan emergency button test.

The air fan emergency button erection and wire connection shall be complete
and correct, and the emergency button simulation test can make air fan trip.

6.3
Interlock protection and alarm signal check
6.3.1
IDF power switch shall be at test position.
6.3.2
Check following items:
DCS DCS
Start IDF on DCS with correct response;
DCS DCS
Shutdown IDF on DCS with correct response;
6.3.3
17

Emergency button works normally.

6.3.4
IDF protection test shall be completed as per content of interlock protection sheet,
which shall work normally.
6.3.5
IDF and its system commissioning
6.3.5.1
Following conditions shall be checked, confirmed and satisfied:
a)
Covers for ditch and channel shall be complete; stairs, path way and guard rail
shall be complete; all sundries shall be cleaned up.
b)
Communication system commissioning shall be completed and qualified.
c)
Industrial and emergency illumination shall be complete and sufficient.
d)
Confirm that IDF and its system erection are completed.
e)
Air channel of IDF shall be cleaned up without any foreign materials that may
cause air fan damage.
f)

Manholes of IDF outlet air channel and body shall be closed.

g)
Air valves and dampers shall be checked and qualified.
h)
I&C erection and verification shall be qualified.
i)

Interlock protection driving test related to IDF shall be qualified, and protection
and alarm setting shall be completed.
18

j)

Electrical test and electrical interlock test shall be completed.

k)
IDF emergency button driving test shall be completed and qualified.
l)

Manual turning IDF and its rotor shall be normal.

m)
Insulation resistance of the motor shall be measured and qualified.
6.3.5.2
Protection or interlock that does not affect safety shall be cut off and recorded.
6.3.5.3
IDF startup preparation
a)
Carry out check as per auxiliary code before startup, which shall be qualified.
b) CRT
Confirm that IDF inlet and outlet dampers shall work well, and local opening shall
be identical with CRT display.
c)
Confirm that IDF bearing is filled with qualified lube oil.
6.3.5.4
Switch on IDF power and check
a)
Whether IDF rotation direction meet design requirement or not;
b)
Whether exist abnormal sound or not;
c)
Whether the system exists obvious leakage or other abnormal situation.
6.3.5.5 30

19

 DCS
If no abnormal situation, restart IDF after 30 minutes, then gradually control
parameter of IDF control damper and hydraulic coupling, supervise IDF current to
prevent overcurrent operation. Record all operation parameter (local and DCS data
shall be recorded separately).
6.3.5.6
Operation parameter shall be supervised during operation, which shall be in normal
range.
6.3.5.7
Check the system leakage and air channel vibration.
6.3.5.8 8

IDF and its system commissioning shall be kept for 8 hours, then shutdown the IDF
and record the idle hour.
6.3.5.9
After IDF shutdown, cut off IDF power.
6.3.5.10
The air channel shall be freely flowing to prevent vibration caused by air valve
misoperation closing.

6.3.6
System operation during the complete set operation
6.3.6.1 168

The system reliability shall be checked as per no load stage, on-load stage, full load
stage and 168 hours operation.
6.3.6.2
The system dynamic control.
6.3.6.3
20


The equipment supervision shall be enforced during system operation, especially
during furnace negative pressure control to ensure that the system in optimal
operation condition.
6.3.6.4
Fill in commissioning record.

7.

Commissioning instrument and equipment

Vibration gauge

Revolution meter

Infrared radiation thermometer

Clip-on ammeter

Phonometer

8.

Commissioning quality and assessment standard

1996

21

 100% 90%

Quality standard requirements of the system and equipment shall be satisfied

according to Standard for Quality Inspection and Evaluation on the Commissioning
of Thermal Power Plant (1996 version), with 100% qualified rate and 90% excellent
rate, meeting the unit startup requirements.

The air fan operation shall be stable and normal; bearing bush temperature and
vibration, cooling water system and motor coil temperature are normal.

Professional commissioning staff and supervisor shall strictly check and control
the important process of commissioning quality, and report to higher level leader
when find out any problems to solve it under coordination to guarantee operation
successfully.

9.
Environment, occupational health and safety control procedure
9.1

When IDF and its system first startup, relevant staff shall be on equipment site to
supervise strictly with reliable communication to control room.
9.2 ,

When IDF test running, startup time and current shall be supervised strictly,
22

instantly shutdown if startup current is too long or current fluctuates rapidly.

9.3

If equipment damage or personal casualty maybe happened or has been existed,

instantly stop commissioning and analyze the cause to propose resolution
measures.
9.4
When IDF starting, rotation direction shall be monitored, if the direction is
reverse, instantly shutdown.
9.5

On-site safety regulation shall be carried out strictly by all commissioning staff
to guarantee the reliability.
9.6
If abnormal situation happens during the commissioning, instantly adjust it and
report it to headquarter.
9.7
Pay attention on supervising change of bearing vibration and temperature to
prevent heavy accident.
9.8

Safety helmet shall be worn during on-site commissioning, and possible danger
work shall be analyzed by person in charge on site and eliminate hidden danger.
9.9

Relevant systems, such as inlet and outlet flue channel, ESP, desulfurization,
denitration, steel inner shell of flue, etc. shall be closed and checked to ensure
that there are no person in above area.
23

10

Organization and division

10.1
Erection unit
10.1.1
In charge of organization of subsystem commissioning.
10.1.2
In charge of the system isolation and closing.
10.1.3
In charge of maintenance, overhaul and troubleshooting of commissioning
equipment.
10.1.4
Prepare necessary overhaul tools and material.
10.1.5
Coordinate with the commissioning unit to carry out subsystem commissioning.
10.1.6
In charge of temporary mark on relevant system and equipment.
10.1.7
In charge of check and acceptance after subsystem commissioning.

10.2
Construction unit
10.2.1
In charge of equipment startup, shutdown, operation control and accident elimination
during the commissioning.
24

10.2.2
In charge of formal mark for relevant systems and equipment.
10.2.3
Prepare operation regulation, tools and record sheet.
10.2.4
In charge of inspection and normal maintenance for commissioning equipment.

10.3
Commissioning unit
10.3.1
In charge of compiling commissioning procedure and technique handover.
10.3.2
Prepare relevant measuring instrument, apparatus and tools.
10.3.3
Engage in subsystem commissioning.
10.3.4
In charge of test data recording and filing.
10.3.5
Fill in inspection and qualification sheet of commissioning quality.
10.3.6
Engage in check and acceptance after subsystem commissioning.
10.3.7
In charge of compiling commissioning report.

10.4
Supervisory company
10.4.1

In charge of supervisory work during starting and commissioning as per the contract,
25

supervise the procedure execution, engage in the commissioning, check and

acceptance.
10.4.2
In charge of organization of system isolation and acceptance.
10.5

IDF subsystem commissioning and single commissioning shall be charged by

erection unit, and coordinated by commissioning unit and other relevant units. The
IDF and its system commissioning shall be carried out by professionals, coordinated
by boiler, electrical and I&C, commanded under headquarter.

26

11.

Appendix
1
Appendix 1: Checking list for IDF commissioning condition

Checking content

Requirement

Remark

Date

Result

No.
1-1

Complete with recording

IDF and its system erection

27

Checking content

Requirement

Remark

Date

Result

No.
1-2

Complete

IDF and air channel erection

1-3

Complete

IDF and air channel cleaning

1-4

Lube oil quantity of all

Normal

bearings
1-5

Cooling water system

Qualified water pressure,

in operation.

1-6

Desulfurization area and air

flue closing and check

Complete,

closing

document is accepted.
1-7

Denitration area and air flue

closing and check

Complete,

closing

document is accepted.
2-1

Motor electrical test

Test is qualified with

correct direction after 2
hour no load running.

28

Checking content

Requirement

Remark

Date

Result

No.
2-2

IDF and its system air valves

Flexible

operation,

correct direction.
2-3

Measuring meter

Correct indication, after

verification.

2-4

Test is qualified.

Electrical
protection,

and
interlock

I&C
and

signal device
2-5

Inlet control damper

Qualified

control

and

correct direction.
2-6

3-1

Power

Reliable

On-site road

The road is unblocked

with

sufficient

illumination

and

emergency illumination.
4-1

On-site

Convenient and available

communication

equipment
4-2

Firefighting facilities

Sufficient

29

Checking content

Requirement

Remark

Date

Result

No.
4-3

Enough and trained

Maintenance staff (including

electrical and thermal staff)
4-4

Maintenance

tools

and

Enough

material
4-5

Operation

tools

and

Readied

recording sheet
4-6

Test

instrument

and

Readied

apparatus

Responsible person of commissioning unit:

Responsible person of supervisory unit:

Responsible person of production unit:

Responsible person of erection unit:

Responsible person of construction unit:

Date:

30

 2
Appendix 2: Commissioning record IDF system air valves
KKS

Name

Remote

Time

KKS

operation

Chec

Chec

Sign

Re

No.

Local

king

king

atur

mar

date

result

indic
ation
corre
ct
XXXX

XXXX

Op

Clo

Corre

Corre

en

se

ct

ct

direct

respo

ion

nse

A IDF inlet
damper
XXXX

XXXX

A IDF outlet
damper

XXXX

XXXX

B IDF inlet
damper

XXXX

XXXX

B IDF outlet
damper

XXXX
XXXX

31

XXXX
XXXX
XXXX
XXXX
XXXX
XXXX

3
Appendix 3: IDF system interlock protection test card

No.

Test content

Re

sult

IDF

Startup permitted condition

1

<5%
IDF frequency converter feedback <5%

<5%
IDF inlet damper opening <5%

IDF outlet damper complete open

;
IDF no stop and protection action signal

Interlock shutdown
32

Re
mark

No.

Test content

Re

sult
1

75

Any bearing temperature of IDF front and rear bearings is

above 75 , (IDF protection interlock into operation)

80

Any bearing temperature of IDF motor front and rear

bearings is above 80 , (IDF protection interlock into
operation)

XY
4.6mm/s2S
If any IDF front and rear bearing vibration is over
4.6mm/s to X or Y direction, 2s time delay, (IDF
protection interlock into operation)

63
145
IDF motor stator coil temperature is above 145 (3
selected from 6), (IDF protection interlock into operation)

120
IDF operation outlet damper close, 120s time delay.

MFT32
MFT action and furnace negative pressure low low (select
2 from 3

Introduction

Set up on/off switch for IDF protection interlock

IDF protection action first out

II

IDF inlet air valve

Interlock shutdown: IDF trip

33

Re
mark

No.

Test content

Re

sult

III
1

IDF motor connection air valve

Interlock input: air fan into operation completely

Interlock shutdown: air fan single side operation

34

Re
mark