Presentation On Commissioning of CFBC Boiler

ACTIVITIES OF COMMISSIONING
Air Leakage Test

Hydro Test Commissioning Checkpoints Equipments Trial Run Refractory Dry Out
Chemical Cleaning
Boiler Safety Protection Checking
Grid Air pressure Drop Study

Control Instrumentation Checking Boiler Light up & Coal Firing Steam Blowing Safety Valves Floating
Steam Dumping
Synchronization
Auto loop commissioning

Reliable Test run Performance test run
Air Leakage Test
Pressure parts
The aim of air leak test is to ensure that erection

of the pressure parts is completed and no major leaks are there.
Air leak test is conducted by introducing air into

the boiler pressure parts at a pressure of
approximately 7 - 8ksc
Air Leakage Test
Non Pressure parts
The purpose of air leak test of air, gas ducting & ESP
is to ensure leakage proof in ducts, welding joints, flange joints to ensure efficient operation of fans, boiler
Hydro Test All the pressure parts of the boiler, which are
subjected
to
high
operating
pressure
during
operation, should be checked to ensure that they withstand the high pressure so hydraulic test is conducted
Commissioning Checkpoints
Checklist have to be prepared for all equipments and all activities. After completion of equipments erection, check points to be made and the trial run of equipments
shall commence
Equipments Trial Run
No-load trial & load trials of following equipments are
completed after fulfilling the commissioning checkpoints
ID fan SA fan Loop seal blower
PA fan Feed pumps
Fuel feeders
Refractory Dry Out
In a boiler furnace, during the phase of erection

refractory is laid in many areas like furnace, second pass areas, cyclones, bed ash cooler etc,
Refractory drying is to be carried out by utilizing either light oil or gas
Chemical Cleaning During the process of erection, there might be entrainment of unwanted material like rust, dirt, mill
scale etc.
The internal surfaces of a boiler where demineralized water of high purity is to be evaporated, should be maintained free of all material which come in the way of efficient heat transfer and thus effect generation.
Chemical Cleaning cleaning procedures aim to removal of rust, dirt,
The
sand and also any foreign material entrained in the contour.
The
cleaning can be achieved by an alkali boil out or
alkali flushing and acid cleaning.
Boiler Safety Protection Checking Check the following equipments are having
interlocks
ID fan-I & I vs. loop seal blower
loop seal blower delivery damper open vs. loop

seal blower
IID Fan vs. SA Fan
ID Fan vs. PA Fan
interlocks
PA Fan vs. Fuel Feeders
Drum Level very LOW vs. MFT

Deaerator Level Low vs. Feed pump Drum level Very High vs. Turbine
Furnace pressure Very high vs. MFT
interlocks
Furnace pressure Very low vs. MFT
Grid Air pressure Drop Study Grid air pressure drop study is nothing but finding out the pressure drop across grid nozzle at different
air flows
The pressure drop values measured in grid pressure drop study are used to find out the bed height when the boiler is in running condition. i.e. at a particular air flow
Control Instrumentation Checking

Before boiler light-up, all control instruments have to
be checked i.e. to ensure whether the remote

operation of all equipments is in proper condition
Boiler Light up & Coal Firing Start up sequence
Steam Blowing
The objective of steam blowing is to remove dirts, loose
material, cutting bars etc, that might have been

entrapped in Super Heaters, Steam piping, re-heaters during manufacture, storage, erection at site.
Failure to remove the debris may result in damage to turbine blades, valves etc
Safety Valves Floating

The objective of the Testing Schedule is to test the safety valves by actually floating and ensuring that safety valves lift at recommended values.
Steam Dumping Steam dumping is nothing but allowing steam from re-heater through MSL and by by-passing the HP turbine the steam is send to re-heater via HRH line
and from re-heater it is send to condenser via CRH

line by by-passing IP turbine and LP turbine.
During initial commissioning steam dumping is done to achieve steam purity.
Steam Dumping Till achieving purity, the steam can be allowed to drain from CEP O/L to open drain. After achieving purity it can be taken to close circuit.
Synchronization After completion of all activities synchronization of the unit shall commence Synchronization is nothing but matching the
generator frequency with grid frequency using

syncro-scope
Reliable test Run Reliability run is Seven (7) days of Continuous Power Plant operation at various loads in which 72
hrs at full load and 2 hrs at 110% MCR capacity to be

demonstrated.
During this period two tripping allowed and after tripping
of the plant is plant to be
synchronization within 4 hrs to be demonstrated,
Performance test Run
Boiler performance test run is conducted
For For
understanding the current level of performance
of the boiler,
any trouble shooting of the boiler for
performance deviations
For proving the performance guarantees

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ACTIVITIES OF COMMISSIONING

Air Leakage Test

Grid Air pressure Drop Study

Auto loop commissioning

Air Leakage Test

The aim of air leak test is to ensure that erection

Air leak test is conducted by introducing air into

Air Leakage Test

Non Pressure parts

Equipments Trial Run

No-load trial & load trials of following equipments are

completed after fulfilling the commissioning checkpoints

ID fan SA fan Loop seal blower

PA fan Feed pumps

Refractory Dry Out

In a boiler furnace, during the phase of erection

Refractory drying is to be carried out by utilizing either light oil or gas

Chemical Cleaning cleaning procedures aim to removal of rust, dirt,

sand and also any foreign material entrained in the contour.

cleaning can be achieved by an alkali boil out or

alkali flushing and acid cleaning.

ID fan-I & I vs. loop seal blower

loop seal blower delivery damper open vs. loop

IID Fan vs. SA Fan

ID Fan vs. PA Fan

PA Fan vs. Fuel Feeders

Drum Level very LOW vs. MFT

Furnace pressure Very high vs. MFT

Furnace pressure Very low vs. MFT

Control Instrumentation Checking

be checked i.e. to ensure whether the remote

Boiler Light up & Coal Firing Start up sequence

material, cutting bars etc, that might have been

Safety Valves Floating

and from re-heater it is send to condenser via CRH

During initial commissioning steam dumping is done to achieve steam purity.

generator frequency with grid frequency using

hrs at full load and 2 hrs at 110% MCR capacity to be

During this period two tripping allowed and after tripping

of the plant is plant to be

synchronization within 4 hrs to be demonstrated,

Performance test Run

Boiler performance test run is conducted

understanding the current level of performance

For proving the performance guarantees

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