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COMMISSIONING
Commissioning
is the term to describe activities involved during later stage of erection up to the completion of 72 hours trial run on full load leading to commercial operation of plant.
COMMISSIONING ACTIVITIES
Before declaration of commercial operation of unit, it is essential to ensure that the plant has been thoroughly tested prior to normal operation so that initial performance can be guaranteed and all the remaining defects and omissions are identified. Separate team that one handling the project activities is necessary to monitor commissioning activities and to set up organization/ systems for subsequent regular O&M of the plant.
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PURPOSE OF COMMISSIONING
Target
dates should be achieved To ensure that plant is supplied and erected as per design. Quality of erection and commissioning should be maintained. To check that plant operates reliably, safely and meets the design performance. To establish reasons for any failure to achieve design performance or any other limitations.
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ORGANIZATION/ SYSTEMS
VARIOUS TEAMS
Working teams are formed early in erection stage to perform various tasks.
1. 2.
3. 4. 5.
6. 7. 8. 9.
To promote quick & effective communication. To support erection team & contractors in efficient & safe commissioning of the plant. To make clear, operational & safety requirements To implement policies & priorities decided by Incharge To report progress, shortage & delays due to staff shortages, safety requirements, plant access, incorrect test procedures, lack of coordination & incorrect plans. To define operation procedures. To define safety requirements. To define maintenance requirements. To define drawings & manuals to be handed over.
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10.
To define, agree and provide the number, type & contents of commissioning documents To define an erection and commissioning program To define formats for progress, defects and omissions To decide joint testing teams and terms of tests. To monitor performance & effectiveness of test teams To define and issue necessary certificates which record the stage of completion of erection and commissioning in accordance with agreed procedure.
Pre-commissioning check ups. Trial Run of equipments Gas Tightness and air leak test of Boiler Hydraulic Test of Boiler Alkali Boil Out Thermal Flow test Chemical cleaning of Boiler Steam Boil Out Safety Valve setting Commissioning of Boiler Reliability run of boiler
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Trial of ID & FD Fans Trial run of Air Heater & readiness of AH soot blowing system- Fire Fighting system. Readiness of light Oil System for Firing. Trial run of ignitor Fans. Trial run of rapping mechanism of ESP. Gas Distribution test on ESP. Air Load test of ESP. Readiness of Feed Pumps. FSSS simulation for bottom elevation. Boiler Interlock & Protection checks. Readiness of bottom Ash Protection and water seal. Trial run Acid Circulation System
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Straightness of collecting electrodes rows Check for any foreign materials between electrodes Correct position of gas screen Correction in collecting electrodes guides Connectivity of suspension tube w.r.to screen tube Emitting electrodes in centre of collecting electrodes Gap between collecting electrodes and vertical beams Tension of emitting electrodes Tack welding of all Nuts and Bolts Rapping system of Collecting Electrodes Hammer hitting position on the shock pads Lateral shifts of hammers with in +/- 5 mm Setting Fixing Emitting Rapping Condition of shaft insulator Hammer Hitting position & other settings 11
Constructional:
All erection protocols are to be checked for quality audit and handing over note is prepared covering all drawings, T&P and commissioning spares supplied with equipments. Pre-commissioning:
Inspection of Fans (Mechanical, Electrical & instruments) Ensure tightness of all bolts those fixing impeller, bearings, motor as well as tightness of pressure parts. Lubrication checks on the pump & motor. Checking on the setting of relief valves (Lubricating system) Operational checks on valves & fittings Rotational checks on motor Flushing of oil system & cooling system Final inspection of Fan.
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Commissioning:
The starting & operation of Lubrication Oil system with protection & interlocks.
Operational checks of inlet vanes and discharge dampers Operational checks of all valves, strainers and other
devices.
Starting and operational checks of Fan along with its major components
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Air and gas tightness test of boiler is conducted, prior to taking up insulation work, to detect air ingress / leakage points through the fin, attachment welds, flange joints etc, and attend the same. The total area covered is boiler combustor pass, wind box for burners, Duct works and entire ash path up to economizer outlet damper.
Prior to start of the test ensure work completion on the following fronts: Completion of welding area wise. Completion of hydraulic test. Refractory areas/ Pour able, cast able insulation works.
I) Visual Inspection Visual inspection of the entire system is carried out first and noted defects, erection omissions are attended. This work is done by an identified supervisory audit team and Protocol made accordingly.
The critical areas checked are for Completion of fin to fin welding. Completion of fin to fin welding.
ii) Air Tightness Test The entire system, after executing necessary blanking arrangements, is pressurized and checked for air leakage points, physically and later on with soap solution. The boiler is checked is stages and the leakage points, elevation wise, are noted. Depressurize and attend to all the identified defects. Repeat the test, till all the all the points are attended to the satisfaction of the supervisory audit team A protocol is made and boiler is normalized and released for insulation work.
A.R.SAOJI, arsaoji@gmail.com