Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0032 NTPC Ref no SIM/1/TS/2/32

Sheet 1 of 9

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP) SLNO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STAE OF THE PLANT TEST METHOD COMPLETION CRITERIA APPENDICES a. LOG SHEET

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0032 NTPC Ref no SIM/1/TS/2/32

Sheet 2

of 9

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP) STATUS SLNO 1.0 PLANT DETAIL: Refer to procedure for commissioning of Auxiliary Boiler. 2.0 OBJECTIVE: To commission a) Forced Draft Fan and b) Boiler Feed Pump of auxiliary Boiler. 3.0 PROPOSALS: It is proposed to commission the auxiliaries by conducting trial run for 8 Hrs at low load condition. 4.0 SERVICES REQUIRED: Availability of L.T Power supply. Availability of lighting, auxiliaries area. communication facility around the

Availability of sufficient quantity of DM water. Availability of Service and Instrument air Availability of cooling water. 5.0 SAFETY PRECAUTIONS: Refer Procedure No.PS-DC-186-500-100/SIM/1/TS/2/100 6.0 EMERGENCY PREPARDNESS: Refer Procedure No.PS-DC-186-500-100/SIM/1/TS/2/100 Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0032 NTPC Ref no SIM/1/TS/2/32

Sheet 3 of 9

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)

SLNO 7.0 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 STATE OF THE PLANT: FORCED DRAFT FAN Erection of Fan and Motor completed as per recommended drawing and check lists. Erection of the auxiliary boiler completed including ducts from fan discharge up to chimney completed. All permanent supports are erected as per drawing for both pressure parts & non-pressure part. Suction cum Requlating damper and discharge dampers are erected and are freely operating. Fan bearings are lubricated as per recommended lubrication schedule. All debris and temporary supports inside the fumace and ducts are removed. Electrical connection to FD Fan Motor is completed with recommended protections and the required mock start / stop conducted satisfactorily under Fan and Motor in decoupled condition. Insulation Resistance of the motor measured and confirmed OK. All local and remote instrumentation of the Fan are made ready (List of Indication, Interlock & protection required made mutually by BHEL & NTPC)

STATUS

7.1.8 7.1.9

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0032 NTPC Ref no SIM/1/TS/2/32

Sheet 4

of 9

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP) STATUS SLNO 7.2 7.2.1 7.2.2 BOILER FEED PUMP: Erection of Pump and Motor completed as per recommended drawing and checklist. Erection of Feed water system from Deaerator Feed storage tank, Suction pipe line, discharge pipe line up to Boiler completed. All permanent supports of the Feed Water System are erected as per drawing. Pump bearings are lubricated as per recommended lubrication schedule. Feed storage tank is cleared off debris. Electrical connections to BFP Motor is completed with recommended protections and the required mock start / stop conducted salisjactorily under pump and motor in decompled condition. Insulation Resistance of the motor measured and confirmed OK. All local and remote instrumentation of the pump are made ready. (List of indications, interlocks and protection required made mutually by BHEL and NTPC). CW lines are connected to pump (If applicable)

7.2.3 7.2.4 7.2.5 7.2.6

7.2.7 7.2.8

7.2.9

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0032 NTPC Ref no SIM/1/TS/2/32

Sheet 5

of 9

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP) STATUS SLNO 8.0 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 METHOD: A) FD FAN: condition, start the motor and check

Under decompleted direction of rotation.

Motor started and 8 Hrs trial run completed. During the trial run, observation made for normal vibration and bearing temperatures. Fan and Motor are compled and Air & flue gas ducts are lined up for fan running. Fan started keeping the suction cum regulating damper in minimum and discharge damper in closed condition. Loading of the fan gradually raised to around 20-30% and 8 Hrs trial run carried out. During the trial run, Fan Vibration, load current, bearing temperatures and furnace pressure are logged. B) BFP: Under decoupled condition, start the motor and check direction of rotation. Motor started and 8 Hrs trial run completed. During the trial run, observations are made for normal vibration and bearing temperatures.

8.2 8.2.1 8.2.2

8.2.3

Pump and motor coupled and Feed water system from Deaerator Feed storage Tank to pump ready with RC line open and discharge valve closed.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0032 NTPC Ref no SIM/1/TS/2/32

Sheet 6

of 9

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP) STATUS SLNO 8.2.4 8.2.5 Pump started and put for 8 Hrs trial run through re-circulation line. During the trial run, pump vibration, local current, bearing temperatures, suction and discharge pressures are logged.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0032 NTPC Ref no SIM/1/TS/2/32

Sheet 7

of 9

Plant area: BOILER PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP) STATUS SLNO 9.0 9.1 9.2 COMPLETION CRITERIA: FD Fan run for 8 Hrs trial run satisfactorily. BFP run for 8 Hrs trial run satisfactorily.

Signatures NTPC BHEL

SHEET 8 OF 9 10.0 LOG SHEET DATE: STATION : UNIT NO : ACTIVITY : TRIAL RUN OF FD FAN BEARING TEMPERATOR DE NDE

S.NO.

FAN LOADING IGV AMPS

DISCHARGE FUMACE PRESSURE PRESSURE

Signatures NTPC BHEL

SHEET 9 OF 9

10.0

LOG SHEET DATE:

STATION : UNIT NO : ACTIVITY : TRIAL RUN OF BFP

S.NO

PUMP LOADING AMPS

PRESSURE SUCTION DISCHARGE

BEARING TEMPERATURE DE NDE

Signatures NTPC BHEL

PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (FD FAN & BFP)

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-152 NTPC Ref no SIM/0/TS/4/152

Sheet 01 of 7

Plant area: OFF SITE PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM STATUS SLNO

1.0

PLANT DETAILS: Oil Handling System forms a part of fuel oil plant. Refer to testing schedule No.PS-DC-186-500-0008/(SIM/1/TS/1/007) The plant details of the oil handling system is given in section 1.0 of above referred testing schedule. Technical Specifications of Drain oil System Drain oil System No. of Pumps Capacity Type Tank : : : : 1 10 Cu.M./Hr Vertical, Single Screw. 10 Cu.M

Oil Water Separator System No.of Pumps : 2 Nos, of Oil Recovery Pumps and 2 Nos.of Sump Pumps. Capacity : 10 Cu.M/Hr for ORP & 30 Cu.M / Hr For Sump Pump.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-152 NTPC Ref no SIM/0/TS/4/152

Sheet 2 0f 7

Plant area: OFF SITE PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM STATUS SLNO 2.0 OBJECTIVE To clean and commission the LFO & HFO handling system including the pressurizing pumps and make it available for main unit commissioning and operation . 3.0 3.1 3.1.1 3.1.2 3.13 3.1.4 3.1.5 3.2 PROPOSAL Following proposals will be followed to achieve the objective Cleaning of LFO Handling system. This is further divided into LFO Receiving Terminal (Cleaning by Compressed air at 4-5 KSC) Piping from LFO terminal to suction of LFO Handling Pump. LFO Handling Pump discharge to inlet points of LFO Day tank and LFO storage tank. Sl.No.3.13 and 3.14 are cleaned by card board bursting method as described in section 8.0 Cleaning of HFO handling System Refer to Testing Schedule PS-DC-186-500-0008 / (SIM /1/ TS/1/007)

Signatures

NTPC Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152 NTPC Ref no SIM/0/TS/4/152

BHEL Sheet 3 of 7

Plant area: OFF SITE PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM SLNO STATUS 3.3 Commissioning of all pumps a) Unloading Pumps of LFO / HFO System Trial run for 2 Hrs b) Pressurizing Pumps of LFO / HFO System Trial run for 8 Hrs c) Pumps of Drain Oil System Trial Run for 1 / Hrs (By local recirculation) SERVICES REQUIRED SAFETY PRECAUTIONS EMERGENCY PRECAUTIONS For Sections 4.0, 5.0 & 6.0, refer to the corresponding sections of the following procedures. a) PS-DC-186-500-151 / (SIM / 1 / TS / 4 / 151) b) PS-DC- 186- 500 - 0008 / (SIM / 1 /TS / 1 / 007) 7.0 7.1 STATE OF THE PLANT Hydraulic Test, Support work and Insulation of the following lines are completed. 1. LFO / HFO unloading heoder 2. Line from LFO / HFO unloading heoder to LFO / HFO unloading Pumps 3. Line from LFO / HFO unloading pumps to LFO / HFO storage and Day Tanks. 4. LFO / HFO Storage and Day Tanks to LFO / HFO pressurizing pumps and their respective RC lines 5. Drain oil and oil water Separator system. Signatures

4.0 5.0 6.0

NTPC Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152 NTPC Ref no SIM/0/TS/4/152

BHEL

Sheet 4 of 7

Plant area: OFF SITE PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM STATUS SLNO 7.2 Erection of the following completed as per recommended drawing. 1. LFO /HFO unloading Pumps. 2. LFO / HFO pressurizing pumps. 3. Pumps of Drain oil and Oil water Seperator system 4. LFO / HFO storage and Day tanks. 7.3 7.4 7.5 7.6 7.7 7.8 Auxiliary Boiler is fully ready for supplying Steam Trip valves, Control Valves are not erected and suitable spool pieces are erected at these places Filter elements and NRV internals removed. Temporary exhaust pipe lines for steam blowing erected wherever required, avoiding machinery and Buildings. All vents and drains are properly routed and supported. Local level indicators of LFO / HFO storage and Day tanks are made available.

Signatures

NTPC Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152 NTPC Ref no SIM/0/TS/4/152

BHEL Sheet 5 of 7

Plant area: OFF SITE PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM STATUS SLNO 7.9 7.10 7.11 7.12 8.0 8.1 8.1.1 Road and rail approach to the Oil handling area is complete to facilitate LFO / HFO unloading. All steam lines as well as HFO lines are insulated. No permanent Instruments are erected in lines being steam blown. They are isolated incase erected. All electrical systems required for pump commissioning are made available. METHOD LFO Handling System. LFO receiving Terminal is cleaned by compressed air blowing at a pressure of 4 5 kg / cm. Air admitted at a suitable inlet point and blown one by one through other openings. Sl.No.3.1.3 and 3.1.4 are cleaned by card board bursting method by providing a card board at a suitable location and pressurizing the line to 3 4 KSC. The card board bursts and effects cleaning of the pipe line. Air inlet point and location for putting card board to be decided at site. HFO Handling system Refer to Testing Schedule PS DC 186 500 0008 (SIM / 1 / TS / 1 / 007)

8.1.2

8.1.3 8.2 8.2.1

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-152 NTPC Ref no SIM/0/TS/4/152

Sheet 06 0f 07

Plant area: OFF SITE PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM

SLNO 8.3 8.3.1 8.3.2 8.3.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 STORAGE AND DAY TANKS Hydraulic fill test of Storage and Day Tanks of LFO / HFO system are completed as per suppliers recommandation. After satisfactory hydraulic fill test, water drained and tanks are allowed for drying. The tanks are manually cleaned thoroughly and manhole doors boxed up before pumping LFO / HFO oil into the tanks. COMMISSIONING OF PUMPS Insulation value of the motor measured and ascertained that the valves are satisfactory. Motor bumped and ensured correct direction of rotation. All the motors are trial run for 2 Hrs and during the trial run, motor noload current noted down. After coupling the motor with pump, oil lines are slowly charged / vented / drained to the required amount and the pumps are primed sufficiently. Pump started and put on trial run under recirculation duration as given in section 3.3. During trial run, load current of the pump noted. All the leaks observed during charging and filling up of unloading terminal Header, oil lines, storage and day tanks are attended expediously.

STATUS

8.4.5

8.4.6

Signatures NTPC Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-152 NTPC Ref no SIM/0/TS/4/152 BHEL

Sheet 07 of 07

Plant area: OFF SITE PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM

SLNO 9.0 COMPLETION CRITERIA Cleaning and commissioning of LFO / HFO Handling system including pressurizing pump completed by following the proposals as given in section 3.0 10.0 a) Drawings referred are i) PE DG 186 166 0001 ( P & ID for FO System) ii) PE DG 186 166 0003 ( P & ID for LDO System)

STATUS

Signatures NTPC BHEL

PROCEDURE FOR COMMISSIONING OF OIL HANDLING SYSTEM