DEH SYSTEM COMMISSIONING

Contents

1 Purpose
2 Basis for Preparation
3 Brief introductions of system and equipment
4 Commissioning Contents and Acceptance and Evaluation Standard
5 Work Division
6 Instrument and Equipment
7 Necessary Conditions for Trial Operation
8 Commissioning Procedure
9 Safety Attentions
10 Optimization Measures and Suggestions
11 Annexure

1 Purpose
This manual is applicable for instructing the trial operation after the complete
erection of of DEH oil pump and its system so as to ensure the erection of DEH oil
pump and its auxiliary equipment and system erection is correct, equipment status is
good and system works normally. Check the electric, C & I protection interlock and
signal device to ensure its activity is reliable to provide fine condition to entire unit
start-up.

2 Basis for Preparation

2.1 Contract for India Lanco Amarkantak 2300MW Thermal Power Station Project
2.2 Relevant drawings and data from NWEPDI
2.3 Manufacturer data of relevant equipment for Lanco Amarkantak 2300MW
Thermal Power Station Project

3 Brief introductions of system and

equipment
HP DEH system supply oil for the actuator of regulating security system of main
steam turbine and small turbine with two sets of pressure compensative variable
plunger pump, medium is phosphate ester EH oil; EH oil system is separate oil
system which can lessen the activity time constant of the actuator of digital
electrohydraulics system and security system and improve reliability of system
activity.
Accumulator is designed for this system; while the unit is in load rejection or
emergency shutdown, the auto main steam valve and regulating oil servo motor will
swiftly closed and large amount of oil are required, the accumulator can immediately
supply oil to system to compensate the short oil supply of oil pump.
In order to ensure the normal usage of phosphate EH oil and make reliable operation
of hydraulic regulating security system, consecutive operating EH oil cooling system
and regeneration system.
The EH oil system is composed of EH oil supply system and regeneration device;
The oil supply device includes EH oil tank, EH oil pump (2sets), regeneration oil
pump (1set), oil cooler (2sets), cooling circulation pump (1set), HP accumulator
(2sets), LP accumulator (4sets), globe valve, oil level gauge, oil filter, low working oil
pressure shutoff device, overflow valve, and etc.
Regeneration system includes regenerating device, gear pump, LP overflow
valve, diatomite filter, curly fibre oil filter.
3.2 Technical requirement to main equipment
3.2.1 EH oil pump
Motor
Type: pressure compensative plunger pump Type: Y200L-4
Pressure MPa 14 Current A 56.8
Flow L/min 100 Voltage V 380
Rotary speed r/min 1470 Power kW 30
3.2.2 Accumulator
In this system, there are two sets of HP accumulators and four sets of LP
accumulators.
Voltage of the HP nitrogen to be filled in 10.00.2MPa
HP accumulator
Voltage of the LP nitrogen to be filled in 0.2MPa
LP accumulator
3.3 System basic process
 Oil supply: EH oil tank EH oil pump

EH oil tank system oil return pipe

Regeneration: EH oil tank strainer regeneration device

Oil cooling system: EH oil tank strainer circulating pump oil cooler

Oil filter

4 Commissioning Contents and

Acceptance and Evaluation Standard
4.1 Commissioning contents
Interlock and protection test of EH oil pump. Trial operation of individual oil pump.
4.1.2 Circulating flushing of EH oil system and put it into operation
4.1.3 Put EH oil system into operation
4.2 Acceptance and evaluation standard
4.2.1 Vibration of pump set shall be less than 60um.
4.2.2 Indication of current shall be not more than rated current.
4.2.3 Temperature rise of pump set shall be less than 80.
4.2.4 Each item shall reach Quality acceptance and evaluation requirement.

5 Work Division
5.1 Commissioning company is responsible for the compiling of commissioning
scheme, tell technical intentions to related personnel, instruct operators to operate
and prepare recording sheet and measuring instrument.
5.2 Erection company is responsible for the completion of EH oil system erection and
EH oil system flushing, prepare enough tools and material for examination and
repair. Special personnel shall be assigned during the period of equipment flushing
and trial operation.
5.3 Operator shall be familiar to operating regulation, have recording notebook and
communication equipment and know the operation and equipment maintenance;
watcher shall be at construction field.

6 Instrument and Equipment

SR.
Equipment Type Usage Remarks
No.
1 Vibration meter TK-81 or Vm63 For measuring
 vibration
Infrared For measuring
2 PM series
thermometer temperature

7 Necessary Conditions for Trial

Operation
7.1 Sampling oil quality from oil tank is qualified with test report, the acid number must
be less than 0.1mgkoH/g.
7.2 Adopt measures to prevent water entering EH oil system (periodically get
sampling from the bottom of oil tank and at oil discharging place of oil cooler).
7.3 The heating equipment above 120 cannot be used for raising the EH oil
temperature.
7.4 Solenoid valve test is agile with reliable activity.
7.5 Nitrogen charge valve is reliable, the accumulated gas is not leaking after
stopping charging nitrogen; two to four Nitrogen cylinders are standby.
7.6 Fluid level of EH oil tank is normal.
7.7 Special regenerant for regeneration system shall be matched with the EH oil
type.
7.8 Erection of all the equipment of EH oil system has been complete and gotten
acceptance and evaluation sheet mutually signed.
7.9 Valve activity test of valves inside system has been complete, it is agile without
jam. 7.10 The erection and verifying of I & C instruments have been complete and it
can be put into use; calibration of local instruments is complete and those
instruments are put into use, the primary valve is to be opened by erectors.
7.11 Relevant I & C and electric loop commissioning work have been complete.
7.12 Construction field is cleaned, passage is clear, lighting is enough at the field of
trial operation and communication is smooth.
7.13 The commissioning of open water system and circulation water system is
complete.
7.14 Safety measures and fire fighting measures for personnel and equipment have
been fulfilled.
7.15 Only rotate the single motor for two to four hours with correct rotary direction,
the parameter such as vibration, temperature rise, current, etc. shall be normal, shaft
alignment shall comply with requirement after connecting coupling with coupling
encloser covered.
7.16 Before starting up pump, construction team, quality department, first party and
commissioning personnel must mutually check it to see if it has start up conditions.

8 Commissioning Procedure
8.1 Inspection before starting up EH oil system
 8.1.1 Oil scale indication of EH oil tank is identical with actual oil level, oil level is
normal.
8.1.2 Systems related valves have been opened, no obstruction is in system.
8.1.3 Check electric instrument loop is normal, switch on and switch off test shall be
good, motor insulation is qualified.
8.1.4 Inform electric specialty to supply power and operating power.
8.2 Put EH oil system into operation
8.2.1 Start up circulation cooling pump, put EH oil regeneration system into use,
raise the oil temperature to be above 20.
8.2.2 Start up EH oil pump to raise oil temperature to be above 405 working
temperature; pay attention to current and vibration situation during start up, there
shall be no leakage at inspection tube; pay attention to check the pump bearing and
motor temperature rise situation during operation, after starting up pump, slowly
open pumps outlet valve to be fully opened according to current situation, check
pumps outlet pressure to comply with design requirement.
8.2.3 Charge nitrogen to accumulator, pressure of charging nitrogen is 10 Mpa; close
the overflow valve while putting accumulator into use and then slowly open inlet
valve.
8.3 Flushing of EH oil system
8.3.1 Remove servo-valve (or erecting plate) from the oil servo motor of MSVCV
IV, install flushing valve and locate it in the middle place.
8.3.2 Close all the valves on the oil filter of each oil servo motor.
8.3.3 Select one oil servo motor which is at highest position, and start up its oil filter
inlet and outlet valve.
8.3.4 Replace the original filter element of following oil filter with flushing filter
element:
1Front strainer of oil servo motor12pcs.
2EH oil pump outlet oil filter1pc for each set.
3EH oil circulation pump outlet oil filter1pc.
4EH oil return oil filter (1pc)
8.3.5 Remove all flow orifice and unloading valves from each oil servo motor, hang
label on them and lay them at safe and clean place, install special flushing fittings.
8.3.6 Flushing to oil supply pipes and oil return pipes of oil servo motor
1To ensure oil temperature is more than 24.
2Start EH oil pump, adjust pump pressure compensator to make the EH oil pump
outlet pressure be less than 4.1Mpa; start the two EH oil pumps simultaneously
during flushing period.
3Slowly start isolation valve of oil supply pipe, check system leaking situation, and
the oil level of oil tank shall be in normal range.
4During flushing period, any oil filter whose differential pressure reaches setting
value shall be replaced immediately.
5Start up inlet and outlet isolation valves of oil servo motor one by one to carry
out flushing.
6Slowly start isolation valve and discharge valve of each accumulator to flush for
above one hour.
7When the differential pressure of all oil filters is stable, flushing can be end,
stop two EH oil pumps.
8Replace corresponding unloading valve and flow orifice of each oil servo
motor, close the discharge valve of each accumulator, and then carry out next stage
flushing.
9Start EH oil pump, by use of flushing valve, make the oil servo motor from
closing to opening status, and then from opening to closing status for eight to twelve
times to ensure enough flow through oil cylinder. Carry out flushing at least eighteen
hours; get sampling after differential pressure is stable for analysis, carry on flushing
in the mean time waiting for the analysis result. Flushing can be end until the
samplings analysis result complies with requirement.
8.4 Adjustment of EH oil pressure
8.4.1 After oil circulation, system is fully restored; close the isolation valve on oil
supply pipeline.
8.4.2 Start EH oil pump A, adjust pressure compensator to make its setting value at
14Mpa.
8.4.3 Slowly start the isolation valve on oil supply pipeline, check entire system and
there shall be not leakage, and then stop pump.
8.4.4 Use the same method to adjust pressure compensator of Oil Pump B.
8.4.5 Close isolation valve on oil supply pipeline
8.4.6 Start one EH oil pump, adjust pressure compensator and pumps outlet safety
valve to make its setting value slowly raised to 17Mpa, and then slowly open
isolation valve, check if there is leakage in the system.
8.4.7 Again set safety valve to be at 17Mpa, and adjust the pressure compensator to
make its setting value restored at 14Mpa, and then stop pump.
8.4.8 Start circulation pump, and then adjust overflow valve to make its setting value
at 0.5Mpa.
8.4.9 Start regeneration pump, and adjust the overflow valve to make its pressure
setting value at 0.6Mpa.

9 Safety Attentions
9.1 Cleanness after oil flushing of EH oil system is complied with the requirements in
instruction book.
9.2 During oil flushing period, carry out filtration by use of the clearance in
regenerating oil system or oil filter and paper oil filter without installing regenerant.
9.3 As per requirement, change regenerative adsorbent, use different regenerative
adsorbent for different type of EH oil.
9.4 Avoid skin contact with EH oil; once contact it, clean skin in time.
9.5 Control EH oil acid value by use of regeneration system during operating.
9.6 Preliminarily start EH oil pump, persons are forbidden to stand at both sides of the
pump; special personnel shall be assigned to watch the emergency button.
 9.7 Pay attention to oil level of oil tank, when the oil level is decreased sharply during
operation, stop the pump and check it.
9.8 If the EH oil temperature is too low, this will make oil viscosity increased and then
cause overload to motor, conversely, if the oil temperature is too high, it will make
precipitation and gel in oil, so the oil temperature in operation shall be controlled
within 3554.
9.9 Stop the pump immediately if any following situation happens:
9.9.1 Strong vibration or abrasion to EH oil pump or motor;
9.9.2 The temperature of EH oil or motor is sharply increased or beyond the limits;
9.9.3 The current is increased and beyond the rated value, setting is invalid.

10 Optimization Measures and

Suggestions
10.1 Tap oil pipes at different part of pipeline by wood stick at regular intervals during
the flushing period;
10.2 New oil is not qualified oil so it shall be not directly filled in after the completion
of flushing;
10.3 In the original design, there is only one uniline solenoid valve for controlling the
water filling into cooler water; if the water quality is not good during operation, the
solenoid valve will be blocked and cannot be opened, this will cause the EH oil
temperature cannot be maintained. So it is suggested to increase one line manual
valve bypass for the solenoid valve to resolve this problem.

11 Annexure
Annexed Table-1 Inspection and verification for EH oil system before commissioning
Annexed Table-2 List of temporary equipment and system recovery
Annexed Table-3 List of interlock protection test
Annexed Table-1
Inspection and Verification for EH oil system before commissioning
Equipment and System EH oil system
Ambient environment
Sunny Cloudy Rainy Snowy Temperature
Verification content and item
SR.
Content and Item Qualified Unqualified
No.
No damage to equipment and system, they are clean with
1
clear nameplate.
Erection of equipment and system is complete as per design
2
requirement.
Erection of pipes supports and hangers is complete and
3
adjusted to normal status.
Erection of remote and local instruments for equipment and
4
system is complete.
5 Oil quality in bearing chamber is qualified, oil level is normal.
6 No oil or water leaks in equipment and system.
Equipment and systems drain, discharge system is
7
unblocked, trench is unblocked.
Surrounding of equipment and system is clean, passage is
8
clear, lighting is adequate.
Complete pipes insulation, painting, nameplate and mark of
9
medium flow.
Agile activity of manual valve, electric valve and solenoid
10
valve.
Activity of I & C protection, interlock, alarming and
11
emergency button test is normal.
12 DCS operating start-up and stop test is normal.
Only the motor of EH oil pump have been turned for two to
13 four hours, the rotary direction is correct; bearing vibration,
temperature and current is complying with requirement.
14 Alignment of coupling is complying with requirement.
Protection encloser is firm and reliable after connecting
15
coupling.
Take measures to avoid the possibility of any water entering
EH oil system. (Get sampling from the bottom of oil tank and
16
oil discharging place of cooler at regular intervals and
analyze it.)
The heating equipment above 120 cannot be used for
17
raising EH oil temperature.
Erection of all the equipment of EH oil system is complete
18
and accepted with signature.
Oil sample from oil tank is qualified and have test report, the
19
acid value must be less than 0.1mgkoH/g.
 Equipment and System EH oil system
Ambient environment
Sunny Cloudy Rainy Snowy Temperature
Verification content and item
SR.
Content and Item Qualified Unqualified
No.
Nitrogen filling valve is reliable, the accumulated gas is not
20 leaking after stopping filling gas; two to four nitrogen
cylinders are standby.
Special regenerant for EH oil regeneration system shall be
21
matched with the type of EH oil.
Commissioning of open/closed water system and circulation
22
system is complete.
Acceptance sheet and record of each item for individual test
23
of equipment and system are complete.
Special devices for flushing of each servo-valve have been
24
removed and replaced by formal device.
Verifier Date:

Annexed Table-2
List of temporary equipment and system recovery
SR. Recovery
Temporary equipment Recovery content Inspection result
No. requirement
After completion of Clean the pipe
Temporary flushing valve flushing, remove the joint and there
1
for flushing temporary flushing shall be not
valve and restore leakage after
 servo-valve. recovery

Clean the pipe

Temporary pipes for
2 shall be not
flushing
3 Filter element for flushing
After completion of
joint and there
flushing, restore all
flow orifice and
leakage after
unloading valve.
recovery.
After completion of
flushing, restore all There shall be
the formal filter not leakage after
element of all the oil recovery.
filters.

Inspector Date:

Annexed table-3
List of interlock protection test
SR.
Content and item Qualified unqualified
No.
1 Interlock of EH oil pump
Operating pump trips, start up standby pump.
EH oil pressure 11.20MPaassociated start up
standby pump.
EH oil pressure 7.8MPastop themselect two in
three
2 Oil level interlock
Alarm if the oil level of EH oil tank is at the high value-
-680mm.
Alarm if the oil level of EH oil tank is at low value
320mm.
If the oil level of EH oil tank is at low value
220mm, stop EH oil pump.
3 Oil temperature interlock
EH oil temperature 32, start circulation pump,
automatically start electric heater.
EH oil temperature 50automatically stop electric
heater.
If EH oil tank oil level low value and low value
are exist simultaneously, associated stop electric
heater.

Verifier Date: