Station: NTPC- Simhadri BHEL Ref No.

PS-DC-186-500-0039 A
Sheet 1 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SLNO
LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 2 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

1.0 PLANT DETAILS

1.1 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.

1.2 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.

1.3 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.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 3 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

1.4 The systems which are supplied with Auxiliary Steam from HT
Unit auxiliary steam header are

a) BFP Turbine & Gland Sealing

b) Seal Steam to main turbine

c) Mill inerting

d) AH Soot blowers

1.5 The systems which are supplied with auxiliary steam from LT Unit
Auxiliary Steam Header are

a) SCAPH

b) F.O Atomisation

c) Deaerator Pegging

d) Fuel Oil Pump House

e) Fuel Oil Storage / Unloading yard.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 4 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

1.6 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.

1.7 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.

2.0 OBJECTIVE

The objective of this procedure is to commission the Auxiliary

Steam system and make it available for Unit operation.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 5 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

3.0 PROPOSAL

Auxiliary Steam system will be commissioned through the

following proposals.

3.1 Commissioning of L.T. Station and Unit Auxiliary Steam Header

through Auxiliary Boiler.

3.2 Commissioning of H.T. Unit and station Auxiliary Steam Header

through

a) High Capacity (HC) Steam line from MS.line

b) Low Capacity (LC) Steam line from CRH

3.3 Safety valve floating of H.T Auxiliary Steam Header

( For Remote / Auto operation of all control System with

envisaged interlocks , refer to Commissioning Schedule BHEL
ref. No. PS-DC-186-500-0039 )

4.0 SERVICES REQUIRED

4.1 Availability of Auxiliary Boiler for operation.

4.2 Availability of Main Boiler for operation.

4.3 Availability of lighting, Communication at PRDS area.

4.4 Availability of Man Power for conducting the activity.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 6 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

5.0 SAFETY PRECAUTIONS

5.1 Availability of first aid kit at test area.

5.2 The team commissioning the fan should be aware of the

procedure adopted.

5.3 Agencies working in the boiler area / associated ducting system

are informed about the test / cleared from the test area (As per
the actual requirement).

5.4 All loose materials around the fan area are cleared.

5.5 Required approach stair cases, platforms and hand rails are
erected prior to testing.

5.6 Oil collecting trays and sand buckets are made available at test
area.

6.0 EMERGENCY PRECAUTIONS:

6.1 The group conducting the test should be aware of action to be

taken on the event of injury to personnel.

6.2 The group shall be aware of operating instruction of portable fire

extinguishers.

6.3 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.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 7 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

7.0 STATE OF THE PLANT

7.1 Installation of H.T and LT Auxiliary Steam Station & Unit headers
completed in all respect Namely,

a) Erection of the headers completed.

b) Hydraulic Test of headers completed

c) Supports completed

d) Insulation completed

7.2 Drain lines of the H.T. & L.T. Headers (Station & Unit) are safely
routed to an outlet, supported and insulated.

7.3 Erection of pipe line to different system (Sec 1.5 & 1.6) completed
and their respective isolating valves kept closed.

7.4 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.

7.5 Suitable exhaust pipe lines are laid for the following Headers /
Steam lines for steam blowing.

a) High Capacity (HC) Steam inlet line from M.S line.

b) Low Capacity (LC) Steam inlet line from CRH line

c) H.T Steam headers of both Station and Unit auxiliary

system.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 8 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM 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)

7.7 All manual valves in the system are erected and their free
operation ensured.

7.8 Required local/Remote instrumentation inputs are made

available. (List to be prepared at site)

8.0 METHOD

(Refer Drg.No. PE-DG-186-100-0107)

8.1 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

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.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 9 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

The L.T. auxiliary header is charged to around 14-16 KSC at 200-

2100C.

8.4 After attaining more or less a steady condition, Steam blowing of

a) Steam line to SCAPH and

b) Steam line to F.O. Atomisation carried out.

8.5 Suitable steam exhaust 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.

8.6 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.

8.7 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 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.

8.9 Local / Remote indications are verified for proper display of

parameters.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 10 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

Commissioning of H.T. Auxiliary Steam Header through HC

Steam line from MSL.

8.10 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).

8.11 All the required drains and vents are lined up before charging.

8.12 After the H.T. Unit Auxiliary Steam Header is then charged to
around 14-16-KSC at 300-3200C

8.13 The following steam lines are steam blown from H.T Unit Aux.
Steam Header

a) Steam line to Mill inerting

b) Steam line to AH sootblower (same as 8.9)

c) Steam line to Main Turbine Gland Seal

d) Steam line to BFP Turbine & Gland Seal.

(These are steam blown as per erection readiness)

8.14 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.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 11 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

8.16 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.

8.17 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.

8.19 The inlet pressure to be around 5 KSC.

8.20 Required drain and vents kept open prior to steam blowing.

8.21 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.

8.23 Steam pressure raising and lowering to be done suitably at local.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 12 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM 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).

8.25 Remote / Auto operation and Control System Interlocks.

Refer to commissioning schedule BHEL ref . no.PS-DC-186-

500-0039 //// NTPC ref.no. SIM/1/TS/1/39 for the above.

Signatures

NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0039 A
Sheet 13 of 13
NTPC Ref no SIM/1/TS/1/39 A
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF AUXILIARY STEAM SYSTEM
SL.NO STATUS

9.0 COMPLETION CRITERIA

9.1 Commissioning of Auxiliary Steam system is completed by

carrying out all the proposals given in Section 3.0

9.2 The system released for regular operation.

Signatures

NTPC BHEL
PROCEDURE FOR COMMISSIONING OF
AUXILIARY STEAM SYSTEM