Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 1 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SLNO LIST OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 2 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 1.0 1.1 PLANT DETAILS Auxiliary steam system is designed to provide steam for the turbine auxiliaries, boiler auxiliaries and fuel oil heating system during start-up, low loads and normal running of units. The system comprises of two auxiliary steam pressure reducing and desuperheating stations (PRDS). One High capacity PRDS with tapping off steam from main steam line to meet auxiliary steam requirements during unit start-up, low loads, fuel oil system and F.O. wagon unloading and the other Low Capacity PRDS with tapping off steam from CRH line to meet auxiliary steam requirements during normal running. Spray water required for desuperheating will be tapped off from boiler feed pump discharge. These two stations will reduce the pressure and temperature of the steam tapped off from CRH line and main steam line to 16Kg/ cm2 (abs) & 3200C at the high temperature auxiliary steam header and subsequently to 16 Kg/ cm 2 (abs) & 2100C at the low temperature auxiliary steam header through a suitable desuperheater between the high temperature and low temperature auxiliary steam headers. The two auxiliary steam PRDS comprises of high capacity combined pressure reducing & desuperheating valve AD-22, low capacity PRV, spray water pressure & temperature control valves for high temperature header and low temperature header, a block valve in common spray line and a desuperheater between high temperature header and low temperature header.

1.2

1.3

1.4

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 3 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS Motorized bypass regulating globe valves have been provided for low capacity PRV and LT header spray control valves which can be operated remote manually in case of mal-operation of main control valve.

1.5

The systems which are supplied with Auxiliary Steam from HT Unit auxiliary steam header are a) b) c) d) BFP Turbine & Gland Sealing Seal Steam to main turbine Mill inerting AH Soot blowers

1.6

The systems which are supplied with auxiliary steam from LT Unit Auxiliary Steam Header are a) b) c) d) e) SCAPH F.O Atomisation Deaerator Pegging Fuel Oil Pump House Fuel Oil Storage / Unloading yard.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 4 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 1.7 The change-over from Low capacity PRDS to High capacity PRDS & vice-versa is automatic with manual override facility. During high capacity PRDS operation, low capacity PRDS remains in operation. The low & high capacity PRDS can be operated independently either in auto or remote manually from the unit control desk. However, manual operation overrides the auto operation. Auxiliary steam system is normally operating on unit basis, however auxiliary steam system of both the units are interconnected through HT and LT auxiliary steam headers, so that unit start-up requirement of one unit can be met from other unit or vice-versa. An auxiliary boiler has been envisaged for initial start-up of the unit and fuel oil heating. For starting the units, boiler has to run on light oil and steam thus generated will be used for unit start-up. The control valves in PRDS are of modulating type. Plant item completion list for mechanical, Electrical C&I area to be prepared at site.

1.8

1.9

1.10

1.11 1.12

2.0

OBJECTIVE The objective of this procedure is to commission the Auxiliary PRDS system and make it available for Unit operation.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 5 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 3.0 PROPOSAL Auxiliary PRDS system will be commissioned through the following proposals. 3.1 Commissioning of L.T. Station and Unit Auxiliary Steam Header through Auxiliary Boiler. Commissioning of H.T. Unit and station Auxiliary Steam Header through a) b) 3.3 3.4 High Capacity (HC) Steam line from MS.line Low Capacity (LC) Steam line from CRH

3.2

Safety valve floating of H.T Auxiliary Steam Header Remote / Auto operation of all control System with envisaged interlocks.

4.0 4.1 4.2 4.3 4.4

SERVICES REQUIRED Availability of Auxiliary Boiler for operation. Availability of Main Boiler for operation. Availability of lighting, Communication at PRDS area. Availability of Man Power for conducting the activity.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 6 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 5.0 5.1 5.2 SAFETY PRECAUTIONS Availability of first aid kit at test area. The team commissioning the fan should be aware of the procedure adopted. Agencies working in the boiler area / associated ducting system are informed about the test / cleared from the test area (As per the actual requirement). All loose materials around the fan area are cleared. Required approach stair cases, platforms and hand rails are erected prior to testing. Oil collecting trays and sand buckets are made available at test area. EMERGENCY PRECAUTIONS: The group conducting the test should be aware of action to be taken on the event of injury to personnel. The group shall be aware of operating instruction of portable fire extinguishers. The test team should be aware of the steps to be taken to trip the running equipment in case any emergency / abnormal observations are notified to them.

5.3

5.4 5.5

5.6

6.0 6.1

6.2

6.3

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 7 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 7.0 7.1 STATE OF THE PLANT Installation of H.T and LT Auxiliary Steam Station & Unit headers completed in all respect Namely, a) b) c) d) 7.2 Erection of the headers completed. Hydraulic Test of headers completed Supports completed Insulation completed

Drain lines of the H.T. & L.T. Headers (Station & Unit) are safely routed to an outlet, supported and insulated. Erection of pipe line to different system (Sec 1.5 & 1.6) completed and their respective isolating valves kept closed. Safety valves 3 Nos (As-32, AS-33 and AS-34) are erected and their exhaust, drip pan and drain lines are erected and completed. Suitable exhaust pipe lines are laid for the following Headers / Steam lines for steam blowing. a) b) c) High Capacity (HC) Steam inlet line from M.S line. Low Capacity (LC) Steam inlet line from CRH line H.T Steam headers of both Station and Unit auxiliary system.

7.3

7.4

7.5

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 8 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 7.6 Steam blowing of Steam line from Auxiliary boiler to LT Aux. Steam header completed (Refer to procedure for SB and oil flushing of F.O System) All manual valves in the system are erected and their free operation ensured. All the control valves and motorized operated valves in a) b) c) High Capacity Steam inlet line from MS line Low Capacity Steam inlet line from CRH Desuperheat line to HC and LC steam lines.

7.7

7.8

Are commissioned and are available for remote manual and Auto operation. 7.9 Required local/Remote instrumentation available. (List to be prepared at site) METHOD (Refer Drg.No. PE-DG-186-100-0107) Commissioning of L.T Auxiliary Steam Header Through Auxiliary Boiler 8.1 Prepare and put the auxiliary boiler under Steaming condition at around 25% of its MCR rating inputs are made

8.0

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 9 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 8.2 Charge slowly the Steam line from auxiliary boiler up to L.T. auxiliary steam header in main boiler. All the required drains and vents are lined up before charging and all the outgoing valves from the Auxiliary headers are Kept closed. (Charging done through AS-56, As-48 and AS-47) 8.3 While charging, increase the fuel loading of the auxiliary boiler sufficiently to warm up the line as well as to gradually pressurize the system. The L.T. auxiliary header is charged to around 14-16 KSC at 2002100C. After attaining more or less a steady condition, Steam blowing of a) b) 8.6 Steam line to SCAPH and

8.4

8.5

Steam line to F.O. Atomisation carried out.

Suitable steam exhaus provisions are made for the above two circuits and steam blown for about 10 minutes for two times with a time gap of 15 minutes between the blows.

8.7

Valves AS-45 and the individual system inlet valves are used for this blowing. After completion of steam blowing of the above two system, (Sec.8.5) the steam lines are normalized with the system. Steam line to Deaerator pegging will be steam blown on similar lines as enplaned above. Alternatively, this line can be steam blown by charging L.T. auxiliary steam header through HC/LC steam lines from M.S line / CRH lines respectively.

8.8

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 10 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 8.9 Since AH Soot blowing is required during initial oil firing onwards, AH sootblower steam line connected to H.T. Unit Aux. Steam Hdr is steam blown by charging steam from Auxiliary Boiler via H.T. Auxiliary Station Header. Local / Remote indications are verified for proper display of parameters. Commissioning of H.T. Auxiliary Steam Header through HC Steam line from MSL. 8.11 After ensuring that main boiler is steaming with LDO burners, charge the HC steam line from MSL slowly through valves AS-21 & AS-22 and steam blow the line for two times with 10 minutes blwing duration and 15 minutes gap between the blows. (The inlet pressure to be around 10 KSC). All the required drains and vents are lined up before charging. After the H.T. Unit Auxiliary Steam Header is then charged to around 14-16-KSC at 300-3200C The following steam lines are steam blown from H.T Unit Aux. Steam Header a) b) c) d) Steam line to Mill inerting Steam line to AH sootblower (same as 8.9) Steam line to Main Turbine Gland Seal Steam line to BFP Turbine & Gland Seal.

8.10

8.12 8.13

8.14

(These are steam blown as per erection readiness) Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 11 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 8.15 Suitable steam exhaust provisions are made for the above and Steam blown for about 10minutes for two times with a time gap of 15 minutes between the blows. Valves AS-38, AS-39, AS-40 and AS-41 along with individual system inlet valves are used for this blowing. After completion of steam blowing, the lines are normalized with individual system. Local / Remote indications are verified for proper display of parameters. Commissioning of H.T. Auxiliary Steam Header through LC Steam line from CRH. 8.18 After ensuring that the Unit is put under HP/LP bypass operation, charge the Low Capacity (LC) steam line from CRH slowly through valves AS-28 and AS-29 and steam blow the line for two times with 10 minutes blowing duration and 15 minutes between the blows. The inlet pressure to be around 5 KSC. Required drain and vents kept open prior to steam blowing. After completion of steam blowing, the LC line normalized with HC line vis--vis H.T Aux Steam Header. SAFETY VALVE FLOATING 8.22 Safety valve with higher set pressure will be floated first followed by other two safety valves. Required safety valve gags are put suitably while carrying out safety valve floating. Steam pressure raising and lowering to be done suitably at local.

8.16

8.17

8.19 8.20 8.21

8.23 Signatures

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 12 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 8.24 Procedure for commissioning of Auxiliary boiler to referred for safety valve floating and adjustments. (BHEL Reg: PS-DC-186-500-0030/NTPC ref. No SIM/1/TS/3/30). Remote / Auto operation and Control System Interlocks. The following controls and interlocks for PRDS are made available. 1) 2) 3) 4) Pressure control at 16 KSC by AS-22 or AS-26 Temperature control of HT header by FD-31 Temperature control of LT Header by FD-35 When AS-22 opens more than 2% then auto opening of a) b) 5) AS-21 FD-29,30,31,33,34,35,and 43

When AS-22 is fully closed, then auto closing of a) b) AS-21 FD-29,30,31

6)

When AS-26 opens more than 2%, than the auto opening of a) b) AS 25 FD- 33,34,35 and 43

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0039 NTPC Ref no SIM/1/TS/1/39

Sheet 13 of 13

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM SL.NO STATUS 7) When AS-26 is fully closed, then auto closing of a) AS-25 When both AS-22 & AS-26 are fully closed, then auto closing of a) FD-33,34,35 and 43 9) Operation of AS-26 only when CRH pressure is more than 18 KSC. Auto change over from LC-PRV to HC-PRV and vice versa. Temperature High 3400C& 2300C for HT& LT systems Temperature Very High - 3500C& 2400C for HT& LT systems

8)

10)

11)

12)

9.0 9.1

COMPLETION CRITERIA Commissioning of Auxiliary PRDS system is completed by carrying out all the proposals given in Section 3.0 The system released for regular operation.

9.2

Signatures NTPC BHEL

PROCEDURE FOR COMMISSIONING OF AUXILIARY PRDS SYSTEM