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)
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U V
W
X
Blasting f(#cycles) Baking Drying
Boiling
Figure 1: Typical drying, baking, boiling and blasting curve
In attachment, the details for this typical drying, baking, boiling and blasting curve can be
found.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
7
4. PREPARATION TO DRYING-OUT, BOILING-OUT, BAKING AND
BLOWING-OUT
4.1. FURNACE
4.1.1. Combustion chamber
Before starting the drying-out and the baking procedure, a test has to be done to check the
amount of leakage air entering the furnace. During this test, the primary air fan will be
started without using the ID-fan. An overpressure will be created in the furnace. Air leaks
can be checked now by applying liquid soap at welding and other connection elements.
Air leaks have to be repaired before starting the drying-out and baking procedure.
All measurement systems in the furnace zone has to be operational (temperature, pressure,
). All temperature trendings in furnace and post combustion zone have to be printed
and saved.
All sight glasses, measurement systems, cameras, or other elements with a protection
against high temperatures by means of sweeping air, have to be cooled during drying-out
and baking procedure.
4.1.2. Grate
In normal operation, the tiles are cooled by primary air and thermally protected by a waste
layer, which acts as an insulating layer. Since drying-out of the refractory is not possible
and not allowed by waste, the burners have to be used. The grate tiles are not designed to
be exposed to the full heat of the burners; therefore the tiles need to be protected. This
protection remains in the furnace during the entire warm-start up, being the refractory
drying, the boiler boiling-out and the blowing-out of the boiler and steam piping.
The entire feeding and the combustion grates element 1 to 3 must be covered by means of
insulating material (rockwool), thickness at least 100 mm. Above the insulating material a
layer of about 5 cm of sand is put (can be sprayed with a pump). The sand is used to avoid
that the insulating material would fly away due to the draft of the ID-fan. It should be
carefully checked that the complete surface is evenly filled. Also the side wall tiles of the
combustion grate and the inlet guide tiles of the feeding grate have to be completely
covered.
The grate element which are most intensively exposed to heat are grate element number 4
and 5 (at furnace outlet), since the start-up burner is positioned in the back wall. These
elements must be covered with ceramic fiber, with thickness at least 100 mm.
Note: Instead of sand, bricks could be used to maintain the insulation in place.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
8
Caution: The temperature of the feeding and combustion grate may not arise above its
design value (feeding grate = surrounding temperature, combustion grate =
primary air preheating temperature), otherwise severe damage can be caused
to the mechanical structure and the hydraulic drive system (caused by limited
thermal expansion). The procedure to protect the grate, like described below,
has strictly to be followed.
Before starting the drying-out and baking procedure, it is advised to have a final check on
the clearances of the combustion grate tiles. This is necessary to be sure that the
clearances have not been changed during mounting of the grate elements. If clearances
have become smaller than advised on the drawings, there is a risk of blockage of the grate
tiles at normal operating conditions of the grate.
It is advised to test the operation (movement) of the grate elements before drying-out and
baking, to check whether everything works properly. All combustion and feeding grate
elements have to be withdrawn to their rest position.
The feeding grate has to be cooled by opening the inspection door at the back side of the
feeding grate housing. In this way, heat release to the feeding grate can be evacuated to
the environment.
4.1.3. Feeding hopper and chute
To protect the feeding hopper and the feeding chute cover plate system against too high
temperatures, they have to be protected by means of a temporary cover. A frame inside
the chute is made with iron bars. On this framework, hard insulating plates (thickness 40-
50 mm) are put with some bricks to avoid that the plates will fly away. All gaps have to
be closed by means of insulation material (in order to prevent the escape of hot flue
gases). The cover is placed just above the feeding grate where the steel part of the chute
starts to allow drying and baking of the refractory lining in the feeding chute.
The closing gate of the feeding hopper has to be opened, to be able to evacuate the
released heat to the environment.
The chute (closed loop) water circuit must be enabled to allow cooling of the steel plate
through the water jacket.
4.1.4. Start-up burner
The start-up burner should be checked that its flame will never (at each working point of
the burner) touch the grate or the insulation put above it.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
9
4.1.5. Ash extractor and sifting ash conveyors
To prevent heat loss through the ash extractor, the water seal on the ash extractor has to
be operational. Also the water supply system to the ash extractor has to be operational,
because it has to compensate the water loss due to evaporation. The water also protects
the ash extractor against too high temperatures.
The same applies for the wet sifting ash conveyors under the grate.
Caution: The availability of water to the ash extractor and sifting ash conveyors must
be checked regularly (two times per eight hours) as well as their casing
temperature.
4.1.6. Primary, secondary
The butterfly valves of the primary and secondary air are opened partially. This allows
air coming in by suction of the ID-fan. This air can help to evacuate for instance the
water that is evaporated in the air gap of the side wall cooling system of the furnace. It
also protects the air ducts against too high temperatures (sweeping air).
Caution: No primary air can be used during the drying-out and blowing-out
procedure, because the sand and the insulating material might be blown
away and thus exposing the grate directly to the radiant heat of the burners.
The side wall cooling fan has to be operational. It is possible that during the drying-out
and baking procedure, the side wall cooling has to be started.
4.2. BOILER AND STEAM CIRCUIT
Before hot commissioning several measures need to be taken to to protect the critical
items of the boiler. The main steam check valve internals should be removed and steam
flow measurement orifice should be replaced by a temporary simple design plate. Note
that the steam flow needs to be determined during steam blasting in order to evaluate the
blast impuls. The demister of the steam drum should be removed (during boiling-out) and
the insulation bricks of the manholes need to be removed.
All control and safety equipment and plant interlocks required for the activities of hot
commissioining should be operational.
A release note for hot commissioning of the boiler from the local inspection authority
should be available
The boiler pressure parts and control valves must be released.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
10
All measurement systems in the boiler (water-steam side) and post combustion zone (flue
gas side) have to be operational (temperature, pressure, ). All temperature trending
have to be printed and saved.
The support burners must be operational / released. For more detail, refer to O&M
Manual from supplier.
Fuel oil circulation pumps must be operational / released to allow feeding to the support
and start-up burners.
Boiler feeding water pumps must be operational / released. For more detail, refer to
O&M Manual from supplier. Temporary start-up filters can be installed instead of the
(fine) normal filters.
The demin water preparation system must be operational / released to allow feeding of the
pressure parts through the boiler feeding water pumps
The boiler water conditioning system (dosing of sodium phosphate) must be operational /
released.
4.3. FLUE GAS CLEANING PLANT
The flue gas cleaning system has to evacuate the hot flue gases. To protect the flue gas
cleaning against too high temperatures, one can open manholes in the flue gas ducts or at
the reactor, in order to insert air, sucked by the underpressure created by the ID-fan.
The ID-fan has to be operational. The automatic control loop to regulate the furnace
pressure and interlocks should be operational .
Some measurements need to be available for data-logging: CO and water measurement of
flue gases, flue gas flow (if possible).
4.4. COMMON PARTS
Process water and instrument/plant air must be available.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
11
5. HEATING-UP PROCEDURE
This procedure is the heating up procedure, as given by the refractory supplier .
Temperature in the furnace room and boiler first empty pass will be monitored during heating-
up of the furnace. Measurements will be recorded and the actual heating curve will be set up
(only for control and approval by the refractory supplier).
Sufficient supply of consumables should be available: demin water (boiler feed water), fuel,
chemicals for boiler cleaning
Heating up procedure is represented on the curve hereafter :
25
110 110
250 250
360 360
550 550
150
25
0
100
200
300
400
500
600
0 9 33 47 71 78 114 127 151 167 215
TI ME SCHEDULE( Hr )
T
E
M
P
E
R
A
T
U
R
E
(
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
14
6. BOILING-OUT PROCEDURE
Before boiling-out it is advisable to flush the entire boiler one time with demin water to
remove all loose particles still present in the boiler from erection works. The draining of the
boiler after the final pressure test can be considered as the flushing, provided the quality of
the drain water was good (no big particles in the water), the boiler was conserved in a good
way (see related procedures) and no more welding or repair works on pressure parts were
carried out (is not allowed after pressure test).
Boiling-out of the boiler aims at the removal of mechanical impurities, grease and possible
other contamination, if any, from the internal surfaces of the boiler tubes. The superheater is
not boiled-out (is cleaned with flushing and afterwards during steam blasting).
Both processes (boiling-out vs. drying-out/baking) may be carried-out simultaneously
providing that the resulting prolongation of the process, as well as the increase of temperature
and pressure, will not have negative influence upon the results of the boiling-out process.
Caution: The procedure hereafter described is given as an example. The operation of
the boiler during boiling-out should strictly follow the operating instruction
of the boiler supplier.
To ensure uniform concentration of chemical agents in all boiler elements that are included in
the process of boiling-out, an auxiliary installation can be provided consisting in one
circulating pump connected at the suction port with the drains of boiler evaporator bottom
headers, while pump discharge will be connected to the drains of economiser inlet header (see
typical sketch in annex). This pump will also be used for introducing chemical solution into
the boiler from a small
tank. The circulation pump will run about 4 times a day during 1 hour.
The pH of the solution in the boiler will be measured each time after the circulation pumps
have been operating.
Note that the superheaters are not boiled out..
Typical composition of boiling-out solution and amount of chemicals:
Chemical agent : NaOH and Na-phosphate
Concentration : 0,4 kg NaOH/m of water and 0,4kg/m Na
3
PO
4
,12H
2
O
Amount : 20 kg of NaOH (100%) and 20 kg of Na-phosphate
Course of boiling-out process (to be confirmed by boilers supplier):
Fill up the boiler to the lowest operational level in the steam drum. Note that the
superheaters are not allowed to be filled up with the alkaline boiling-out solution.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
15
Prepare the concentrated solution of NaOH and Na-phosphate in the tank (pH of about
11-12).
Start the temporary circulating pump and establish circulation within the system
(circulating pump- economiser- boiler drum- evaporator- circulating pump).
Pump-up the concentrated solution of chemicals to the system.
Continue the circulation for about 2 hours.
Fire the boiler and proceed to refractory drying procedure (see 5).
During the initial stage of drying-out procedure (until the drum pressure does not exceed
4 bar), the boiler evaporator should be blown-down every 6 hours (bottom headers drain
valves to be fully opened one by one for few seconds and than closed again).
The circulating pump should be operated for 30 min. every 6 hours during this stage. At
the drum pressure above 4 bar, the circulating pump suction and discharge isolating
valves should be kept closed. Each time after circulation, the pH of the boiler water
should be checked and the dosing of the chemicals to be adapted accordingly.
The frequency of blowing-down during the further course of refractory drying-out
procedure will be reduced to 1 per 24 hours. At the completion of refractory drying
procedure, the boiler will be drained and flushed with tap water by consequent filling and
draining until the pH value of effluent water is brought down to about 9 (last rising cycle
to be done with demin water).
The drain (boiling-out) water is contaminated with chemicals and should therefore be
disposed taking into account the applicable environmental legislation/regulations.
After cooling-down, the steam drum is made empty and is opened and cleaned /inspected
for the presence of impurities. Loose impurities, if any, should be removed manually.
Inner surfaces of the drum to the operational water level should be free from contaminants
(oil, sand, grease, etc.).
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
16
7. DRYING-OUT AND BAKING
1. First of all the boiler must be filled with demin water up to LL-level at the drum. Flow
control valve to be by-passed during filling.
2. Meanwhile, before the burners are started to dry the refractory lining, the complete gas
path (from furnace to ID-fan) has to be flushed by means of fresh air. This is to evacuate
possible explosive gases out of the plant. The flushing air flow must be three times the
plant volume (vol. furnace + vol. boiler + vol. reactor + vol. filter + vol. flue gas ducting).
The plant is flushed by using the secondary air fan (primary air fan cannot be used sine
grate is covered with insulating material). The flushing flow is measured at the suction
side of the secondary air. Because the (post-) combustion chamber is in overpressure, all
burners will be flushed in the same time.
3. Now the boiler is heating up until a flue gas temperature is reached of about 110 - 120 C.
This can be done by means of the start-up burners (at the backside of the furnace) or by-
means of steam from other combustion line (if applicable). The temperature that is
checked, is the temperature inside the furnace (above the grate).
Caution: During all drying-out and baking procedure (so from the first start of the
burners), temperature controls must be done to avoid possible mechanical
damage (casing, grate, ducting). The following table gives an overview of the
items to be checked and the necessary interventions:
Item to check What to do if temperature is too high
Combustion grate tiles (above Tmax =
300C)
Open inspection doors at the sifting ash
hoppers
)i v x (G
) v x (G
K
n n
d d
1 =
) v x (G
) v x (G
K
n n
d d
2 =
where:
G
d
: steam flow at blowing-out
G
n
: nominal steam flow (at maximum load)
v
d
: specific volume of steam at blowing-out
v
n
: specific volume at normal operation
The parameters (pressure + temperature) for the calculation of the steam specific volume shall
be measured just before the turbine / turbine bypass valve.
8.2.2. Calculation method
In order to determine the steam flow during blowing in absence of the flow measuring orifice,
the following calculation method is applied.
The flow is calculated, based on the measured pressure drop during blasting versus the
pressure drop in the boiler + piping during normal operation at maximum load.
A. Pressure drop formula:
2g
. x w
0 1P =
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
22
with
v
1
. =
v
w
k
2g v
w
0 1P = =
with
F
v D
w =
v D k
v
)
F
v D
(
k 1P o = =
with:
R P : pressure drop (bar)
S : boiler (from drum to piping outlet) resistance coefficient
w : steam velocity (m/s)
T : steam density (kg/m)
v : steam specific volume (m/kg)
F : internal pipe cross-section (m)
D : boiler capacity/ steam flow (kg/h)
B. Steam pressure drop at blowing capacity
b b o b v D k 1P =
with:
D
b
: steam flow at blowing (to be calculated)
v
b
: steam specific volume (to be evaluated from steam tables, based on measured steam
temperature and pressure at piping outlet during blowing)
R P
b
: pressure drop between drum and piping outlet at steam blowing
C. Steam pressure drop at normal boiler load
n n o n v D k 1P =
D. Steam flow during blowing
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
23
The steam flow during blowing is calculated from the ratio of the pressure drop at normal
operation versus the pressure drop during blowing:
b o
n o
b
n
v Db k
v Dn k
1P
1P
=
=
n
b
b
n
n b
1P
1P
x
v
v
D D
8.2.3. Continuous steam blasting
In high pressure boilers, it is easy to obtain high flow disturbance factors K
1
and K
2
at low
steam output and consequently small heat demand. The ratio of drum pressure at blowing to
the nominal drum pressure is low: 0,150,25.
In the case of low pressure boilers, the situation is different. To obtain high values of K
1
and
K
2
factors, one should aim at obtaining high steam flow rate at low drum pressure during
blowing-out.
The first limitation is the steam output during blowing-out or the possibility to supply an
adequate amount of heat to the furnace. In a waste to power boiler, the burners are used as
support burners. The primary fuel is waste and thus burners are not designed for 100%
thermal load. The burner thermal capacity is designed in order to heat-up the boiler up till
850C (requirement by law) at start-up and to keep the temperature of the flue gases above
850C during operation when necessary.
During blowing the auxiliary and start-up burners are used, thus their effective thermal power
determines the maximum steam capacity of the boiler.
Start-up burner : 1 x 4,5 MWth
Auxiliary burners : 1 x 7,5 MWth
Another limitation of the blowing parameters is the pressure drop in the temporary piping and
silencer. Therefore, a silencer should be selected with a low pressure drop (maximum 4 bar),
so that high steam velocities can be obtained.
The lower pressure limitation by the silencer resistance and the upper limitation resulting
from the thermal power of the auxiliary burners, determine the K
1
and K
2
factors.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
24
8.3. IMPACT BLOWING OF BOILER - PIPING
Next to the method of the continuous blowing, impact blowing could be applied for the
cleaning of the superheaters.
8.4. BLOWING-OUT PROCEDURE
The blowing-out of the boiler/piping can be performed in 3 ways: continuous blowing, impact
blowing or a combination of both methods. Only continuous blowing is not sufficient to
achieve the required K2-factors in the boiler.
Different steps in blowing-out procedure:
The boiler should be fired-up (with burners) in accordance with the prescriptions of the
boiler manual.
The gradient of saturation temperature increase in the drum (drum pressure increase)
should be not higher than indicated in the boiler manual/instruction. The heating-up of the
boiler should not exceed the requirements of the refractory (heating-up curve).
The firing-up will be performed with the start-up valve or the temporary valve partially
opened
In case of the combination of the continuous and impact blowing the following procedure is
followed:
By gradual increasing the power of the burners, the pressure and temperature in the boiler
is raised. The temporary valve in the blow-out piping is partially opened. One has to make
sure that the opening of the valve is done in harmony with the burner thermal power so
that the pressure and temperature keep increasing.
Once the parameters for continuous blowing are reached, the blowing-out should be
continued for about 10 min. Afterwards, the temporary gate valves will be partially closed
in order to reach the required drum pressure for impact blowing (24-30 bar).
When the drum pressure is 24-30 bar the temporary valve will be opened at once until a
drum pressure of about 10 bar = impact blowing
Temporary valve will be closed and burner capacity is gradually decreased according to
the cooling down curve of the refractory.
Boiler and piping is cooled down before next blowing is started.
The next blowing procedure should not start earlier than the skin temperature of the
piping has dropped to about 150-200C.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
25
8.5. PRACTICAL MATTERS
- Just before start of impact blowing the level in the steam drum shall be adjusted to low
level. During impact blowing the water level will raise instantly due to the quick
reduction of pressure.
- Sufficient supply of demin water and fuel should be assured
- In normal practice, 2 to 3 steam blastings per day can be carried out. More steam blastings
is not efficient since the cooling down of the superheater, steam piping is very important
(cracking effect). Overnight a thorough cooling down should be carried out.
- Steam blasting will be performed at a flue gas temperature (measured in 1
st
pass) of about
500-550C.
- If the flue gas temperature at the exit of the 1st pass (above the refractory lining) exceed a
temperature of 450C a small amount of steam should be blown off (via PCV ) to ensure a
safe and trouble-free natural circulation of the boiler. If the temperature of the flue gases
before the final superheater reaches 400C, it is required to blow off a small amount of
steam to ensure a good cooling of the superheater tubes. More steam needs to be blown
off when the flue gas temperature further increases
- Before steam blasting, the steam parameters (pressure and temperature) are gradually
increased by increasing the capacity of the burners and by secondary air injection (typical
steam conditions for steam blasting : T = 360-375C, P = 24-30 bar). Meanwhile the
steam piping is preheated up till the silencer. When steam parameters are reached, the
temporary steam blasting valve is fully opened (as quick as possible)
- Cooling down of the boiler after steam blasting should be at approximately 50C/hr
- Before firing up the boiler for start of steam blasting, the following heating-up curve
should be followed (only first part is relevant from 25 to 550C in 32 hrs.).
- Temporary installation for steam blasting consists of temporary steam pipe (should be
very clean), a silencer (low pressure drop), 2 temporary manual open/close valves (1 for
piping to turbine and 1 for piping turbine bypass valve), 2 sample holders for target
plates, sufficient number of target plates, drain valve for temporary piping and connection
for water injection (to reduce noise)
- The cleaning processes and subsequent starting with waste should preferably be executed
in a consecutive way. In case it is not executed in a consecutive, continuous way a proper
conservation of the boiler should be carried out.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
COMMISSIONING MANUAL PART N2
Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
26
25
150 150
550 550
500
550
500
0
100
200
300
400
500
600
0 6 12 32 38 44 50 56
TI ME SCHEDULE( Hr )
T
E
M
P
E
R
A
T
U
R
E
(
\
|
+ = 2 1 sec 2
With :
H2sec : level where the flue gases reach a residence time of 2 seconds (m)
H1 : reference level at the end of the post-combustion zone, as defined above (+xx,x
m).
V : volume of the post-combustion zone (xx m)
Q
real
: real flue gas flow (m/sec)
S : cross sectional area of the first empty pass of the boiler, starting at level H1 (xx,x
m).
For the same example, the following result is obtained for H2sec = xx,xx m.
Note : in case the calculation result from Equation 2 would be lower than H1 (this might be
possible in case of very low flue gas flows in startup phase or in trip conditions), H2sec is set
equal to H1 as a minimum value.
The flue gas temperature after 2 seconds of residence time T2sec can be calculated by linear
interpolation between H1/T1 and H2/T2, see Equation 3 (T1 and T2 first to be corrected for
the shield-effect as mentioned above).
Equation 3 : ( ) 1 sec 2
1 2
1 2
1 sec 2 H H
H H
T T
ct shieldeffe T T
+ + =
Giving the following result for the example above : T2sec = xx,xx C.
Other example : thermal load xx MWth, temperature in top of first pass xxx C, calculated flue
gas flow xxxx Nm/h.
Temperature T1 at level H1 = xx C
Real flue gas flow = xx m/sec
2 seconds level H2sec = xx m
2 seconds temperature T2sec = xx C.
The calculated 2 seconds temperature (xxxx) is shown on the overview screen of the furnace
and the boiler in central control room.
The shield-effect offset parameter is a fixed value in the process control system (start value
+50 C, until verification during first startup of the plant).
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
Page
1
TEST PLAN
1. PROGRAMME ............................................................................................................................................... 2
2. COLD COMMISSIONING............................................................................................................................ 3
3. HOT COMMISSIONING............................................................................................................................... 4
4. RELIABILITY TEST ..................................................................................................................................... 5
5. PERFORMANCE TEST ................................................................................................................................ 6
COMMENT: This document is for typical use only. Project specific periods, durations
and conditions of commissioning/testing, as stated in POYRI Schedules 9 and 11
and agreed upon between TPSCo and Keppel Seghers prevail.
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
Page
2
1. PROGRAMME
One month before the scheduled start of COLD COMMISSIONING, the
CONTRACTOR will provide a detailed programme for the COLD COMMISSIONING,
HOT COMMISSIONING, RELIABILITY TEST, and PERFORMANCE TEST.
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
Page
3
2. COLD COMMISSIONING
COLD COMMISSIONING is defined as the period when individual items of the
INSTALLATION, electrical systems, control and instrumentation systems are checked
and tested.
During this period, activities such as boiler cleaning, refractory drying, cleaning of
pipe work and tank internals are carried out.
Test Sheets shall be developed by the CONTRACTOR to show what tests, checks
and recordings have been carried out. Such Test Sheets shall be submitted to the
EMPLOYER within two weeks after completion of any test.
During the COLD COMMISSIONING, the EMPLOYER will provide a full team of
operators to the CONTRACTOR for training on-site.
Starting Criteria Mechanical Completion
Ending Criteria Completion of COLD COMMISSIONING Tests
Result of Completion Start HOT COMMISSIONING
Note
Depending on the delivery schedule of the turbine, the cold commissioning of the
turbine may take place later than the cold commissioning of the incineration line. If
this occurs, the start of the hot commissioning of the incineration line shall not be
delayed by the turbine.
The cold commissioning and hot commissioning of the incineration line can take
place with steam being sent over the by-pass, i.e. RDF is being incinerated, but
electricity production has not yet started.
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
Page
4
3. HOT COMMISSIONING
HOT COMMISSIONING is started after completion of COLD COMMISSIONING.
During HOT COMMISSIONING the plant will be operated with waste within the
boundaries of the combustion diagram.
The HOT COMMISSIONING tests shall be carried out by the CONTRACTOR and
shall cover in general the following topics :
- test of equipment under normal conditions
- test of control, regulation, protection and alarm systems.
The CONTRACTOR shall present a report of the HOT COMMISSIONING.
During the HOT COMMISSIONING, the EMPLOYER will provide a full team of
operators to the CONTRACTOR, during shift work, for training on-site.
Starting Criteria Completion of COLD COMMISSIONING Tests
Ending Criteria Completion of HOT COMMISSIONING Tests
Result of Completion Start RELIABILITY TEST
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
Page
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4. RELIABILITY TEST
The purpose of the Reliability Test is to demonstrate that the plant is capable of safe
and reliable operation while complying with the emission limits. During this period,
operations and control functions shall be demonstrated to the EMPLOYER.
During the Reliability Test period of two weeks, the trial runs shall include the
following tests :
- start-up and shutdown of the equipment in an economical and well-controlled
manner;
- shut-down of the equipment under emergency conditions;
- stable run at various loads with the design range, under automatic control;
- a 72h run within the boundaries of the combustion diagram.
The CONTRACTOR shall provide all necessary supervision for these procedures.
Commissioning supervisors will be present on site on a 24h basis during the
scheduled period for the Reliability Test. It is the EMPLOYERs responsibility to
provide a full staff of skilled operators in shift operation.
Minor defects, such as instrument faults or equipment faults which require the
standby operation of auxiliary equipment, shall not constitute a failure of the
Reliability Test, provided that the INSTALLATION continues to operate satisfactorily.
Note: During the first months of operation, too much heat may be extracted from the furnace
due to insufficient fouling and incomplete drying of the refractory lining. The fact that it takes
time to reach the normal fouling degree of furnace and boiler may have consequence for every
point of the combustion diagram. Practice has shown that auxiliary fuel can be necessary
during this period within the complete combustion diagram (and thus also at 100% load) in
order to meet the flue gas residence time requirement (850C/2s).
Starting Criteria Completion of HOT COMMISSIONING Tests
Duration 2 weeks
Ending Criteria Successful demonstration of tests
Result of Completion Provisional Acceptance and Start Performance Test
Result of Failure Repetition of Reliability Test.
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
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5. PERFORMANCE TEST
Starting Criteria Not later than 3 months after Provisional Acceptance
Duration see table
Success Criteria The CONTRACTOR shall demonstrate that the plant is
capable of achieving the Performance Guarantees.
Result of Success Final Acceptance
Result of Failure Repetition of tests or
Liquidated Damages for failure to achieve guaranteed
performance
1. Performance test shall be carried out in accordance with the hereafter
described principle. The details to be mutually agreed between the
CONTRACTOR and the EMPLOYER KS to be reflected in a detailed protocol,
established at least 14 days prior to the start of the actual tests.
The protocol shall be in keeping with the current specifications and shall
describe, among other, the type, number and duration of the tests, the
methodology (e.g. measurement technique, number of sample points, expected
accuracy, sampling duration & analysis). It shall also clearly identify the
responsibility of all involved parties with respect to the tests.
2. The performance test shall show that all the performance guarantees as
specified are fulfilled.
3. The CONTRACTOR shall provide all necessary supervision for these
procedures. KS supervisors and specialist engineers will be present on site on a
24h basis during the scheduled performance tests period.
4. It is the EMPLOYERs responsibility to provide a full staff of skilled and trained
operators.
5. Each Party shall carry its own costs for the Performance tests.
6. The Site Representatives and technical personnel of the CONTRACTOR and
the EMPLOYER shall co-operate closely to ensure the smooth execution of the
Performance Tests
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
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7. Records of the test shall be made by the people nominated by the
CONTRACTORs Site Representatives and countersigned by the
Representatives of the EMPLOYER every day.
8. If the Performance Test fails as a whole or in part, parties shall analyse the
reason together and define the responsible party/parties as soon as possible.
The responsible party/parties shall take immediate action to remedy the
cause(s) and will announce their readiness to recommence or continue the
tests as soon as possible.
Depending on the nature and characteristics of the failure of the tests, the
Performance Tests will be redone completely and for the full duration or in part
and for a shorter duration. This matter is to be addressed in general in the
aforementioned protocol but the actual decision is to be reached by agreement
with all parties immediately after the occurrence of the failure.
All parties shall grant their full co-operation to the repetition / extension of the
Performance Tests.
9. The plant has to be operated in accordance with the combustion diagram and in
accordance with the CONTRACTORs operation and maintenance manuals.
10. The RDF should be according to the design specifications as specified in the
AGREEMENT. The time during which no RDF in accordance with the design
specifications is available will be counted with respect to the duration of the
tests, but no guarantees or requirements shall hold. The same holds for
unavailability of RDF (for whatever reason) or unavailability of parts of the plant
that are not in the CONTRACTORs scope.
Variations in the composition, heating value and mechanical properties of the
RDF shall be kept to a level that is representative for modern RDF incineration
facilities. A maximum allowable variation will be agreed upon and included in
the aforementioned protocol. The EMPLOYER will inform the CONTRACTOR
about the RDF supply logistics. The preparation of a stable RDF mixture should
be obtained. The supply of different types of RDF will be spread over the whole
day, and concentrations of specific RDF streams over a long period will be
avoided.
11. During the performance tests, the trained operators (and maintenance
personnel), will be at the CONTRACTORs disposal to operate the plant.
12. The CONTRACTORs representative(s) will be responsible for the instruction of
the plant operation during the performance tests
13. Before a test is carried out, the plant operating conditions shall have been
stable for at least 2 hours (uninterrupted). The stability of the operation will be
verified by means of representative operational parameters (e.g. steam
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
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production, RDF throughput, oxygen contents exit boiler). The limits on the
allowable variation will be included in the aforementioned protocol. The
CONTRACTOR must have the opportunity during at least 4 days to verify the
tuning parameters of the process before the Performance tests start.
14. All parameters shall be continuously recorded during the performance test with
a frequency of at least once a minute.
15. If the contract or the aforementioned protocol is unclear or fails to specify
certain aspects regarding the tests, the industry standard as reflected by the
CONTRACTORs reference plants will be applicable and deemed acceptable.
16. There should be no stoppage during a performance test: the relevant line(s)
shall be in continuous operation from the beginning to the end of the relevant
performance test.
Plant
Performance Test
Test Duration Remarks
Capacity 24 hours Hourly average should be above 90% of
design capacity (or thermal equivalent to 90%
of design capacity).
Average over test duration should be equal to
or higher than design capacity (or thermal
equivalent to design capacity) as long as the
calorific value of the RDF is within the
specified range
Electricity
consumption
24 hours Average power consumption over the test
period shall be compared to the
CONTRACTORs guarantee value
Steam production 24 hours Steam flow is measured with orifice measuring
system.
Heat value of the steam is determined by
pressure and temperature.
The throughput is weighed with the refuse
crane weighing system.
Thermal load can be calculated from all these
values (method to be documented by the
Presented by:
Typical for RDF Power Plant
Version / Date
January 2008
Test Plan
Page
9
CONTRACTOR).
Gross Electricity
Production
24 hours Average power production over the test period
shall be compared to the CONTRACTORs
guarantee value
Combustion
Carbon in Ash
12 samples per
line taken during 6
successive hours,
every half hour
Detailed sampling procedure as per KS
standard.
Detailed ignition loss procedure as per KS
standard.
Emissions 24 hours
Official
independent
measurement
Consumables:
Water
24 hours Average over the test duration.
Consumption shall be compared to the
guaranteed consumption after correction in
relation to the throughput
Correction curves shall be agreed upon prior to
the start of the test
Noise Carried out by
independent and
certified specialist
during a period
relevant for normal
operation (not
necessarily
coinciding with the
tests)
A background noise measurement will be
performed.
COMMISSIONING MANUAL
PART N1 :
PRE- AND COLD COMMISSIONING
WASTE-TO-ENERGY PLANT
TYPICAL
by:
0 10-01-08 RPI Preliminary
Rev. Date By Description Check Appr.
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1. TABLE OF CONTENT
1. TABLE OF CONTENT.................................................................................................................................. 2
2. INTRODUCTION........................................................................................................................................... 4
3. SUB-SYSTEMS AND UNITS ........................................................................................................................ 6
3.1. DEFINITIONS.............................................................................................................................................. 6
3.2. COMMISSIONING STATUS REPORTS ............................................................................................................ 6
4. PRE-COMMISSIONING............................................................................................................................. 10
4.1. PRE-REQUISITES...................................................................................................................................... 10
4.1.1. General .......................................................................................................................................... 10
4.1.2. Testing of wiring ............................................................................................................................ 10
4.2. CHECK-OUT LISTS.................................................................................................................................... 11
4.3. UNIT INSPECTION SHEETS ........................................................................................................................ 12
5. COLD-COMMISSIONING ......................................................................................................................... 13
5.1. PRE-REQUISITES...................................................................................................................................... 13
5.2. LOG BOOK............................................................................................................................................... 13
5.3. LOOP TESTS ............................................................................................................................................. 13
5.4. MOTOR TESTS .......................................................................................................................................... 14
5.5. FUNCTIONAL TESTS.................................................................................................................................. 14
5.6. SPECIFIC FUNCTIONAL CONTROLS............................................................................................................ 15
5.6.1. Feeding and combustion grates..................................................................................................... 15
5.6.2. Ash extractor.................................................................................................................................. 16
5.6.3. Refractory lining............................................................................................................................ 17
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5.6.4. Sifting ash conveyors ..................................................................................................................... 17
5.6.5. Boiler cleaning system................................................................................................................... 17
5.6.6. Hydraulic group............................................................................................................................. 18
5.6.7. Burners .......................................................................................................................................... 18
5.6.8. Smoke testing of the flue gas cleaning........................................................................................... 20
6. ANNEXES...................................................................................................................................................... 23
6.1. ANNEX 1 : LIST OF SUB-SYSTEMS.......................................................................................................... 23
6.2. ANNEX 2 : COMMISSIONING STATUS REPORTS ...................................................................................... 23
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2. INTRODUCTION
This document outlines the sequence of activities required to take the plant from a completed
installation to a fully operational and commissioned plant. The pre-requisites, necessary for
each stage of the commissioning, are described.
The commissioning will, in general, follow the sequence herebelow :
1. Pre-Commissioning (or Unit test): the checking and testing of equipment prior to
their cold commissioning with power and air. Such works shall consist of testing the
alignment and direction of rotating parts, the verification of the wiring and cabling, the
verification of the PLC system, verification of correct mounting of piping, verification of
correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.
Pre-commissioning checks, when completed, will release individual items of equipment to
be powered up and made available for inclusion in the cold commissioning phase.
2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors
and other electrical equipment, flushing and cleaning of tanks and piping if applicable,
adjustment and regulation of protective devices, functional tests, leakage and pressure
tests, inspection of bearings, etc.) and operation of equipment for a period of time. This
will be mainly as individual items, but may involve running some of the equipment in
sequence.
3. Hot Commissioning: this will include the introduction of fuel (waste), process gas and
reagent (including the boiling out of pressure parts, curing of the refractory, blowing of
steam pipe to turbine, etc). The whole plant will be tested, operating in sequence under
full load conditions.
The Commissioning Manual (part n1) includes instructions for the Pre-commissioning and
the Cold Commissioning of the equipment in the Contract.
The Commissioning Manual (part n2) includes instructions for the Hot Commissioning of the
equipment in the Contract. This second part contains specific information for the first start-
up, which differs from a normal plant start-up. For the general operating procedures (allowing
to start-up, operate and shut down the plant under normal conditions), please refer to the
Operation and Maintenance manuals.
Responsibility: Operating instructions specified in this manual are typical procedures. It is
impossible to cover all eventualities, which might occur during the start-up of the plant.
Keppel Seghers cannot take responsibility for damage to any part of the plant, which could
have been avoided if instructions had been followed.
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On the other hand, conditions may arise in which actions must be taken without sticking
strictly to the instructions in this manual, provided that such actions result in safe operation.
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3. SUB-SYSTEMS AND UNITS
3.1. DEFINITIONS
In order to commission the plant in a structured and systematic manner, the plant is divided in
Sub-systems and Units.
Sub-systems correspond with a P&ID.
tbd during detailed engineering
Each Sub-system is then divided in Units, each corresponding with a major equipment part
within the Sub-system (pump, silo, screw, fan, etc.). Valves and instruments attached to this
equipment form part of the Unit. The exact scope of a Unit is to be determined by the
KEPPEL SEGHERS commissioning supervisor, prior to the start of the commissioning. For
systems using the KKS tag numbering, a most convenient way is to define Units as the
aggregate of equipment within the same KKS system code (e.g. HLB10 : primary air fan
element 1, HLB20 : primary air fan element 2, etc.).
Piping and ducting systems, including valves and instruments, also can form a Sub-system or
Unit (e.g. lime milk piping, flue gas ducting, etc.).
3.2. COMMISSIONING STATUS REPORTS
A commissioning status report is compiled for each Sub-system. These reports will be
managed, updated and filed by the KEPPEL SEGHERS commissioning supervisors, based on
the input of the commissioning company. They will enable the engineers to know the status of
each Sub-system at any moment during the commissioning period. Each report gives an
overview of the progress made on the commissioning of each Sub-system, and is composed of
the following documents :
1. Status list
2. P&ID
3. Check-out lists
Equipment checkout list
I/O and SAT tests of control panel
I/O and SAT tests of electrical panel
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Pipes & valves checkout list
4. Unit inspection sheets
5. Punch list
6. Functional description
7. Interlock list / autoconditions
8. Test reports
Status list
The Status List indicates the pre-and cold commissioning status of each Sub-system and their
Units. It also gives an overview and description of all the Units within a Sub-system. When
all Units have reached the status of pre-commissioning (= mechanical complete), the Sub-
system is ready for cold commissioning (loop tests + functional tests).
The Status List is a unique document and is to be updated after each inspection round of the
Sub-system. Date, initials and signature have to be filled in by the KEPPEL SEGHERS
engineer after each inspection round.
P&ID
The latest revision of the P&ID of the Sub-system. The P&ID forms the basis of each
commissioning status report.
Units or equipments (instruments, valves, motors) which are mechanically complete will be
coloured on the P&ID. This quickly gives an idea of the progress on the pre-commissioning
activities for each Sub-system.
Any change between the P&ID and the setup in the field is also to be marked on this P&ID.
It is then important to report this on the Master P&ID, so that the as-built revisions of the
P&IDs can be prepared.
Check-out lists
For each Sub-system there are 4 types of lists : Equipment checkout list, I/O and SAT tests
of control panel, I/O and SAT tests of electrical panel , Piping & Valves checkout list.
The check-out lists are used to verify if the Sub-system is built strictly according to the
project P&IDs, the so-called P&ID check.
Unit inspection sheets
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A standard form (pdf-format) is available for each type of mechanical equipment (pump, silo,
fan, etc.) within the Unit. The inspection sheet is a checklist to verify if the Unit is
mechanically complete, and ready for further cold commissioning.
Punch lists
The punch lists give an overview of items in the Sub-system, which have to be remediated /
solved. The outstanding items on the lists get a qualification of 1, 2 or 3, depending on their
critical character :
Qualification 1 (= pre-acceptance) : prevents the Unit from being released for further
commissioning, to be solved before startup of the equipment. E.g. wrong rotation
direction of a motor, packing missing, lack of pressure safety valve, etc.
Qualification 2 (= post-acceptance) : item can be solved after startup of the equipment.
E.g. tag plate missing, wrong colour, tidiness of the area, etc.
Qualification 3 (= to be discussed) : can not be qualified under 1 or 2. E.g. scope unclear,
general remark or question, discussion between parties about qualification, etc.
A punch list can be made up for a whole Sub-system or for each Unit, this is left to the
convenience of the KEPPEL SEGHERS engineer.
Each punch list that is updated and filed in the Commissioning Status Report is to be dated,
initialed and signed by the KEPPEL SEGHERS engineer.
When a punch list is the result of an inspection round together with the Client and/or a
Subcontractor, it is important that their representatives counter sign the Punch List. This
punch list is then communicated to them for further action / information.
Functional descriptions
The functional description of each Sub-system enables a better understanding of the P&ID,
and it is the basis for the functional tests of the Sub-system.
Interlock list / autoconditions
The Interlock list (including autoconditions, alarm settings, start / stop sequences, loop
controllers, etc.) forms the basis for the cold commissioning of the Sub-systems (I/O tests or
loop testing, sequence testing, etc.).
Test reports
These will include, amongst other :
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- Field pressure test acceptance reports for piping systems
- Field tightness test acceptance report for ducting systems
- Etc.
It should be stressed that the most important documents of the Commissioning Status Reports
are the Status List and the Punch Lists. The Status List for the formal registration of all tests
and inspections, the Punch Lists for the formal registration of outstanding items. The other
documents (P&ID, inspection sheets, ) are tools.
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4. PRE-COMMISSIONING
4.1. PRE-REQUISITES
4.1.1. General
The control panels and the panels for motors up to 3 kW will have been tested
100% by KEPPEL SEGHERS engineers during the FAT tests in the factory of the
panel manufacturer. This means that each IO signal has been checked from the bit
in the PLC up to the input or output terminal for connection of the field wires. This
testing will be reported in the FAT Inspection report.
The electrical panels (MCC) for motors from 3 kW will have been tested 100% by
the responsible during the FAT tests in the factory of the MCC panel manufacturer.
This testing will be reported in the FAT Inspection report.
The electrical site wiring to the plant has to be complete and must have been fully tested
by the electrical contractors. See next section (4.1.2) about testing of wiring and cabling.
The instruments shall be installed and properly connected. This shall be documented by
the instrument installer on the I/O and SAT tests of control panel lists with the
following items for each instrument : mechanical installation, process connection,
pneumatic connection, electrical connection, tag plate.
Power supplies (normal and emergency) to the panels must be available.
The panels shall be in a watertight building.
The DCS system for operator interface of the installation must be available and FAT
tested in the presence of an KS automation engineer. Testing reported in a FAT inspection
report.
Communication network between DCS and control units must be ready.
No gas or reagent, hot or cold, should have been through the equipment.
4.1.2. Testing of wiring
The responsible for the erection of the cabling shall execute tests in order to check all
cable and wire connections. . Only after the completion of these tests, the pre-
commissioning and cold commissioning can start under the supervision of KEPPEL
SEGHERS.
These wiring and cabling checks will be done as follows :
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- For connections between control panel at one side and instruments, valves and all
other equipment at the other side : before connection to the instrument/equipment and
before connection to the control panel, all wires will be invividually shortcircuited
at the instrument/equipment side, and the shorcircuit will be measured at the control
cabinet side. Only after this test, the instrument/equipment may be connected.
- For connections between control panel and motor control and protections circuits :
before connection to the motor contol centre (MCC) and before connection to the
control panel, all wires will be invividually shortcircuited at the MCC side, and the
shorcircuit will be measured at the control cabinet side. Only after this test, a MCC
unit may be connected to the signal cable.
- For power cables to motors/equipment : before connection to the motor/equipment
and after connection to the MCC, all wires will be invividually shortcircuited at the
motor/equipment side, and the shorcircuit will be measured at the MCC side. Also the
isolation resistance of the cables will be measured. Important remark : for
frequency convertors (variable speed drives), these tests will be executed without
the cable connected to the drive unit. Only after these tests, the motor/equipment
may be connected.
The result of each test will be documented by checkmarking on the I/O and SAT tests of
control panel and the I/O and SAT tests of electrical panel lists . After completion, this
lists will be signed and stamped by the responsible of the cabling (installer).
4.2. CHECK-OUT LISTS
One of the first inspection rounds after erection and installation of the equipment will consist
in verifying the completeness of the Sub-system and/or Unit, based on the P&ID and the
corresponding check-out lists, the so-called P&ID check :
Check-out list for Equipments (per P&ID)
I/O and SAT tests of control panel (one per panel) with the following items for each
instrument : mechanical installation, process connection, pneumatic connection, power
cable connection, instrument cable connection. I/O test.
I/O and SAT tests of electrical panel (one per panel) with the following items for each
electrical user : mechanical installation, power cable connection, control cable
connection, insulation test, I/O test.
Check-out list for Pipes & valves (per P&ID)
For each item (reference is made to the TAG-), the commissioning company will complete the
check-out list to give documentary proof that each item of the P&ID has been installed.
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Any missing item or equipment is to be chipped on the check-out list as NOK. It will then
be reported as an open item on the punch list and will be checked together with the Keppel-
Seghers commissioning supervisor.
Every inspection round will be listed on the Status List (date, initials, signature and eventual
remarks). A new check-out list can be used for every new P&ID check.
4.3. UNIT INSPECTION SHEETS
The Unit inspection sheet is used as a checklist when pre-commissioning each Unit of the
Sub-system. A standard form is available for each type of mechanical equipment (pump, silo,
fan, etc.) within the Unit. The list of inspection points on the form is not limitative, the
inspectors are free to add other inspection points which they consider important.
Every inspection round will be listed on the Status List (date, initials, signature and eventual
remarks). A new form can be used for every new inspection. When one or more checks on
the form are rejected, they have to be reported as open items on the punch list.
The Unit is mechanically complete, and ready for further cold commissioning, when all
items with qualification 1 on the punch list are solved. This is to be confirmed by the
KEPPEL SEGHERS engineer on the Status List (date, initials, signature), before one can
proceed with the further cold commissioning.
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5. COLD-COMMISSIONING
5.1. PRE-REQUISITES
The electrical supply should be available and the MCC should have been tested by the
electrical contractors and be ready for service.
The PLC control system should be available and the PLC programming be complete.
The compressed air supply system should be fully available.
No gas, hot or cold, should have been through the plant.
The pre-commissioning checks should be complete.
5.2. LOG BOOK
As the cold commissioning involves the interaction of many people from various disciplines
(mechanical, process, electricity, instrumentation, automation), it is necessary to keep a
Commissioning Log Book, somewhere at a centralized location (e.g. the plants control
room).
This book will contain the day-by-day chronological logging of actions / situations / events
during the commissioning of the plant. The main purpose of the Log Book is to improve
communication between the commissioning people, and more specifically between shift teams
(day and night). Especially with regard to safety, the exposure to unsafe situations is higher
during the commissioning phase than during normal operation. Good communication is a first
step in prevention of unsafe situations.
The Log Book is not to be confused with the Commissioning Status Reports. The Log Book
is covering the whole plant, is chronological and serves better communication. The
Commissioning Status Reports are per Sub-system and keep track of the formal, signed
registration of the commissioning status.
5.3. LOOP TESTS
Loop testings (or I/O tests) have to be realised for all instruments, automatic valves and
motors. The loop testing will be done under the responsibility of the EIA engineer (electricity,
instrumentation & automation) of the installer. The installer will dispatch sufficient technical
staff to solve immediately any wiring encounterd, so that the loop testing can be completed.
The loop testings will be executed on the basis of loop schemes. There is a loop scheme for
every instrument, automatic valve and motor. The EIA engineer keeps a separate file of all
loop schemes of the plant. This is the as built file. Working files used in the field will be
only copies.
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When a loop test is positive, the EIA engineer will date, initial and sign the loop scheme for
approval. Only the approved loop schemes will be included in the Commissioning Status
Report of the Sub-system, as a proof that the I/O test has been successfully executed. I/O
tests which are not successful remain in the file of the EIA engineer.
When all the loop tests within a Sub-system are executed, the EIA engineer will confirm this
on the Status List (date, initials, signature), before one can proceed with the functional tests.
5.4. MOTOR TESTS
For each motor the following tests on the power part will be executed:
Isolation test of the power circuit (with the motor connected). Important remark :
for frequency convertors (variable speed drives), these tests will be executed
without the cable connected to the drive unit.
Powering of the motor and rotation check
These tests are the responsibility of the electrical contractor ; only mechanical supervision
from KEPPEL SEGHERS.
Results will be indicated on the I/O and SAT tests of electrical panel lists.
5.5. FUNCTIONAL TESTS
When all Units within a Sub-system are pre-commissioned and loop tested, each Sub-system
can individually be submitted to functional tests : the programmed software in the PLC
system - already FAT tested - is to be site tested (SAT) by checking all functionalities and
interlocks in the field.
The functional tests will be done under the supervision of KEPPEL SEGHERS. The Client
will dispatch sufficient technical staff to perform the tests.
The tests will consist in verifying :
- Control loops
- Sequences
as described in the Functional Description and the Interlock list (including autoconditions,
alarm settings, start / stop sequences, controllers, etc.).
Most control loops or sequences can be tested under empty or dry conditions by simulating in
the PLC the presence of reagent or product in the Unit. For some of the tests, it will be
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necessary to add reagent or products to the Units or Sub-system (e.g. pumps or mixers that are
not allowed to run dry or empty).
It is imperative to thoroughly follow the instructions in the Operation & Maintenance
Manual of the specific Sub-system, before executing functional tests with reagent or
products.
For some Units, some additional specific functional tests have to be done, as further detailed
under 5.6. Specific functional controls.
5.6. SPECIFIC FUNCTIONAL CONTROLS
The specific functional controls listed hereunder are for Equipment designed by KEPPEL
SEGHERS only. Functional controls for other main equipment like turbine, water tower,
are within the scope of the subcontractor and as such not detailed in this section.
5.6.1. Feeding and combustion grates
Reference is also made to the Operation & Maintenance Manual.
Before starting the operation (movement) of the grate elements, it is advised to have a final
check on the clearances of the combustion grate tiles. This is necessary to be sure that the
clearances have not been changed during mounting of the grate elements. If clearances have
become smaller than advised on the drawings, there is a risk of blockage of the grate tiles at
normal operating conditions of the grate. On the other hand, two large clearances can cause
excessive sifting ash production and primary air by-pass.
The first fillings of all bearings were done by the constructor during pre-assembly of the
grates. Because of the large period of time between grate pre-assembly and
commissioning, all grease points will be verified by adding grease before moving the
grate elements. Refer to the O&M manual regarding the grease qualities (make and type)
of the grease nipples. The greasing positions are shown on the drawing XXXX_239_003.
Once the hydraulic unit has been fully checked for correct mounting and the hydraulic oil
circuit has been completely flushed (see section 5.6.6), the movement of the feeding- and
combustion grates should be tested during at least 8 consecutive hours. During this test, one
has to pay attention to:
Check the fixed time for the tumbling movement (normally between 3 and 6 sec), the time
for withdrawing the feeding grates (typical between 5 - 20sec) and the time for
withdrawing the sliding tiles (typical between 2 to 10 sec).
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Check the stroke of the hydraulic cylinders:
ca. 260 mm for the sliding grates;
ca. 130 mm for the sliding grates of the fifth element.;
ca. 130 mm for the tumbling grates.
Caution: Special attention has to be taken not to run the grates during the furnace
warm-up. In this case, the feeding grates have to stay in their withdrawn
position and the combustion grate must be covered by insulation material.
The cold commissioning of the grate must be supervised by Keppel Seghers qualified
personnel.
5.6.2. Ash extractor
Reference is also made to the Operation & Maintenance Manual.
The first fillings of all bearings were done by the constructor during pre-assembly of the ash
extractor. Because of the large period of time between extractor pre-assembly and
commissioning, all grease points will be verified by adding grease before moving the ash
extractor.
The hydraulic oil to the hydraulic cylinders is delivered by the pumps of the hydraulic group
(see 5.6.6). The oil pressure can be adjusted using the pressure reducing valves at the ash
extractor stand valve :
Pressure to the hydraulic drive unit must be set up at 100 bar
When the hydraulic is connected, all moving parts must be checked to move properly:
movements of the pusher.
After a dry run of a few hours without water, the ash extractor is filled with water and its
movement can be tested during 8 consecutive hours (or more). During this test, one has to pay
attention that:
All moving parts move properly
The level control device in the water tank is properly adjusted so that the water seal is
realized at the sifting ash hoppers
The inspection work on the ash extractor must be supervised by Keppel Seghers qualified
personnel.
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5.6.3. Refractory lining
Reference is also made to the Refractory Lining Supplier Erection & Commissioning Manual.
After installation of the refractory lining, the work must be inspected and approved by
qualified personnel :
Check of lining dimension
Check of the lining surface
Hammer test to check the lining for holes, grains, accumulation, etc.
When checks are completely finished, release notes have to be handed over fully signed by contractor, supplier and clients
representatives.
5.6.4. Sifting ash conveyors
Reference is also made to the Operation & Maintenance Manual.
Before the first starting up of the conveyors, the following points have to be considered :
Be sure that the safety switch is switched off
Check that there are no alien parts lying in the conveyor
Check that there is oil in the gearbox
Activate the greasing device by screwing in the ring bolt in the grease container
Stretch the chain. To do that the conveyor must be started up (dont forget to check the
direction of rotation) and let it run for a while. The chain is sufficiently stretched when
the carriers are leaving the return part without a bang. A bang will occur if the chain is
too slack. On the other hand, if it is stretched too hard the carriers will be lifted before
they reach the bend.
After a couple of days, all of the carriers screw joints is to be follow up drafted, and the
stretching of the chain must be checked.
5.6.5. Boiler cleaning system
Reference is also made to the Operation & Maintenance Manual.
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5.6.6. Hydraulic group
Reference is also made to the Operation & Maintenance Manual.
Before the first start-up of the hydraulic plant, the installation (including all piping) must be
flushed and cleaned to eliminate all contaminants from the system and achieve the required
degree of purity of the oil. The supplier will be responsible for the first cleaning of the
hydraulic equipment and piping, as well as the first filling with hydraulic oil.
The minimum requirements for the hydraulic oil are :
Hydraulic oils with corrosion, oxidation and wear additives : HLP oils according to DIN
51524 part 2
Viscosity class VG46 according to ISO 3448 is obliged.
A list of potential mineral oil makes that can be used for the hydraulic group is annexed in the
O&M manual. Other makes are possible provided that they have similar characteristics.
Commissioning of the hydraulic system will be done under the supervision of the supplier.
This start up will cover (not limitative) :
Cleaning of all piping, reservoirs and ancillaries
Pressure testing
Verification of correct mounting of all equipment
First hydraulic oil filling
Test run of all the equipment, especially for verification of the proper functioning of the
pressure compensated hydraulic proportional flow control valves.
Prevention of oil leakages
5.6.7. Burners
Reference is also made to the Operation & Maintenance Manual.
The start up and commissioning of all burners will be done during drying and baking of the
refractory lining of the furnace, and during boiling out of the boiler and blowing out of the
steam piping (see part 2 of the Commissioning manual).
Drying of the refractory lining will be done by means of the start up burners. During
drying of the refractory lining, the start up burners will be operated at low thermal load.
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At the beginning of this period, the start up burners can be tuned rather roughly, because
operation at maximum thermal load is not allowed, or only during short periods (e.g. some
minutes). The burners will be tuned in a way they can be started and stopped in a reliable
way, and in a way the combustion is visually complete (no formation of soot). Fine-
tuning (e.g. to attain good and complete combustion along the complete working range of
the burners) is not yet required and not yet possible. This rough fine-tuning is expected to
last one working day.
When baking of the refractory lining has started, the load of the start up burners can be
increased gradually. At the end of this period, a fine-tuning of the burner can be allowed,
because operation at maximum load is possible during long time. As drying of the
refractory lining can last some days (at low burner load), and the temperature increase
after drying is very slow, it is possible that there will be some days between the first
commissioning of the start-up burners, and the fine-tuning.
During baking of the refractory lining and boiling-out of the boilers, the auxiliary burners
will be started and operated at low thermal load. At the beginning of this period, the
auxiliary burners can be tuned rather roughly, because operation at maximum thermal
load is not allowed, or only during short periods (e.g. some minutes). The burners will be
tuned in a way they can be started and stopped in a reliable way, and in a way the
combustion is visually complete (no formation of soot). Fine-tuning (e.g. to reach the
required CO- or NO
x
-emission limits, or to verify the fuel/air ratio curves at different
loads) is not yet required and not yet possible. This rough fine-tuning is expected to last
one working day.
When baking of the refractory lining is finished (and the furnace is still hot), auxiliary
burner operation at maximum load can be allowed, as long as temperature changes in the
furnace can be restricted up to the values allowed by the refractory supplier (10 up to 25
C/hr). During this period, a fine-tuning of the burner can be allowed (to reach the
guaranteed emission levels, and to determine the fuel/air ratio curves at all burner loads).
If this fine tuning requires several succeeding intervention days of the burner supplier, it
is advised to combine this activities with the blowing of the steam piping, because
frequent burner modulation can be allowed in this period, and there is enough time
available (one can expect that the auxiliary burners will be operational during at least one
week).
During this period, presence of qualified personnel of the burner supplier will be required.
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5.6.8. Smoke testing of the flue gas cleaning
(a) General
The intent of smoke testing is to detect leaks in the flue gas path of the plant, means from the
outlet of the furnace up to the baghouse filter. Leaks mean that during normal operation, cold
outside air is draught into the system (in underpressure) causing corrosion at the inlet area,
loss of flue gas temperature and an increase in flue gas flow, resulting in a higher electrical
consumption of the ID-fan.
Since it is very difficult to detect these leaks during operation, a smoke bomb test should be
performed during the plant cold commissioning phase as well as after plant start-up on a
regular basis (for instance every year during the annual shutdown)
Smoke testing is performed by blowing a high volume of very low-pressure smoke into the
system at one or more manholes. Plugs, valves, temporary blind flanges are used to confine
the smoke to the section or sections of system being tested. Observation of the emergence of
smoke enables the crew to detect sources of inflow.
The plant building will usually have one or more roof vents from which smoke will emerge.
The roof vents will be used to evacuate the outcoming smoke. The residents and fire
departments must be told to ignore the smoke as well.
Because testing to large sections is less effective and gives the crew too much area to observe
during the relatively short life of the smoke bombs (3 or 5 minutes), it is advised to have
several tests along the flue gas path:
Section 1 : from the combustion chamber (furnace) up to the inlet of the baghouse filter,
Section 2 : from the baghouse filter up to the stack inlet, if there is possibility to confine
this system at the stack side (otherwise the smoke test II will be limited to the baghouse
filter outlet)
(b) Equipment
Smoke testing can be performed using:
Primary, secondary and burner air fans (for section 1)
Mobile blowers (for section 2)
Blowers suitable for smoke testing have a circular flange or plate for mounting on an open
manhole and are gasoline engine driven. Blowers recommended for smoke testing have a free-
air delivery of at least 3.000 m/h.
The static pressure capability of the blowers is less than 2,5 mbar.
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(c) Smoke
Smoke used is cold and very visible (white). The smoke is not hazardous and is free of oil
and coloured particles, which could leave residue and stains. Smoke bombs recommended
for smoke testing are usually 3- or 5-minute duration.
Smoke is introduced into the system either by placing a smoke bomb at the blower inlet or
by lowering the smoke bomb into a manhole in a bucket and blowing air in from above.
The inspector should understand that the smoke bombs are not dangerous and have a limited
shelf life. Once opened, a package of smoke bombs should be used. Smoke bombs exposed to
moisture or humidity may be difficult, if not impossible, to ignite.
(d) Advance notices
Prior to performing smoke testing, plant personnel and residents are notified of the purpose
and approximate date of the work. Residents are told that they will see smoke emerging from
the roof vents.
Local fire and police departments should be advised daily of the areas being tested. Personnel
handling telephone inquiries should be acquainted with the purposes of the smoke-testing
program.
(e) Smoke test procedures
1. Advance notice is given to residents, fire and police departments.
2. The inlet and outlet of the system ducting are blocked, i.e.:
For section 1: hopper feeding chute valve - inlet valves of the baghouse filter
For section 2, inlet of the baghouse filter - inlet of the stack (by means of
temporary flanged plates)
3. The manhole sections to be tested are isolated (sifting ash hoppers, combustion chamber,
feeding grate casing, boiler, flue gas duct, reactor, baghouse filter).
4. The ash extractor and the sifting ash conveyors (in section 1) are filled with water
5. The gate valve for the residue extraction (boiler hoppers, reactor cone, filter hopper) must
be closed
6. The combustion air fans (for primary air, secondary air and for burners) are started in
section 1. In section 2, a smoke blower is set up at an open manhole in the filter and started.
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7. A smoke bomb is ignited, placed in a bucket and lowered into the manhole. The blower is
then positioned on the open manhole and set at full throttle.
8. In less than a minute, smoke will be issuing from the roof vents of buildings and any
directly connected points of inflow.
9. A smoke testing crew usually consists of three persons. One individual operates and
maintains the blower while the other two walk the test area to locate and document inflow
sources indicated by emerging smoke.
10. The crew documents significant and identifiable points of inflow. Sketches, field notes,
portable tape recordings, digital pictures and movies could be used to record test results.
11. Those firms bidding on this type of work should have a documented history of five years
of successful smoke testing. References and dates are to be submitted with bids.
12. All bidders will be licensed contractors and perform a minimum of 60 percent of the
contract.
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6. ANNEXES
6.1. ANNEX 1 : LIST OF SUB-SYSTEMS
See also Error! Reference source not found. on page Error! Bookmark not defined..
- tbd during detailed engineering
6.2. ANNEX 2 : COMMISSIONING STATUS REPORTS
1. Status List
2. P&ID
3. Check-out lists
4. Unit inspection sheets
5. Punch list
6. Functional description
7. Interlock list / autoconditions
8. Test reports
COMMISSIONING MANUAL
PART N2 :
HOT COMMISSIONING
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by:
0 10-01-08 RPI Preliminary
Rev. Date By Description Check Appr.
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1. TABLE OF CONTENT
1. TABLE OF CONTENT.................................................................................................................................. 2
2. INTRODUCTION........................................................................................................................................... 4
3. GENERAL....................................................................................................................................................... 6
4. PREPARATION TO DRYING-OUT, BOILING-OUT, BAKING AND BLOWING-OUT .................... 7
4.1. FURNACE................................................................................................................................................... 7
4.1.1. Combustion chamber ........................................................................................................................... 7
4.1.2. Grate .................................................................................................................................................... 7
4.1.3. Feeding hopper and chute.................................................................................................................... 8
4.1.4. Start-up burner..................................................................................................................................... 8
4.1.5. Ash extractor and sifting ash conveyors............................................................................................... 9
4.1.6. Primary, secondary and wall cooling air............................................................................................. 9
4.2. BOILER AND STEAM CIRCUIT...................................................................................................................... 9
4.3. FLUE GAS CLEANING PLANT..................................................................................................................... 10
4.4. COMMON PARTS ...................................................................................................................................... 10
5. HEATING-UP PROCEDURE ..................................................................................................................... 11
6. BOILING-OUT PROCEDURE ................................................................................................................... 14
7. DRYING-OUT AND BAKING.................................................................................................................... 16
8. BLOWING-OUT (= BLASTING) OF THE BOILER ............................................................................... 20
8.1. GENERAL CONDITIONS............................................................................................................................. 20
8.2. STEAM BLASTING CRITERIA CALCULATION PROCEDURE........................................................................ 21
8.2.1. Distribution factors K-factors. ........................................................................................................ 21
8.2.2. Calculation method ............................................................................................................................ 21
8.2.3. Continuous steam blasting ................................................................................................................. 23
8.3. IMPACT BLOWING OF BOILER - PIPING ...................................................................................................... 24
8.4. BLOWING-OUT PROCEDURE ..................................................................................................................... 24
8.5. PRACTICAL MATTERS .............................................................................................................................. 25
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8.6. TESTING OF STEAM CLEANLINESS ............................................................................................................ 26
9. FIRST START-UP WITH REFUSE ........................................................................................................... 27
9.1. TEMPERATURE AND PRESSURE RISE ........................................................................................................ 27
9.2. SAFETY.................................................................................................................................................... 28
9.3. PREPARATIONS........................................................................................................................................ 29
9.4. START-UP SEQUENCE .............................................................................................................................. 29
9.4.1. Prior Remarks .................................................................................................................................... 29
9.4.2. Start-up common parts....................................................................................................................... 30
9.4.3. Steam circuit (common) ..................................................................................................................... 31
9.4.4. Air preheater ...................................................................................................................................... 31
9.4.5. Start-up furnace (line 1 or 2) ............................................................................................................. 34
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2. INTRODUCTION
This document outlines the sequence of activities required to take the plant from a completed
installation to a fully operational and commissioned plant. The pre-requisites before each
stage of the operation can be commenced are described.
The commissioning will normally follow the sequence below:
1. Pre-Commissioning (or Unit test): the checking and testing of equipment prior to
their cold commissioning with power and air. Such works shall consist of testing the
alignment and direction of rotating parts, the verification of the wiring and cabling, the
verification of the PLC system, verification of correct mounting of piping, verification of
correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.
Pre-commissioning checks, when completed, will release individual items of equipment to
be powered up and made available for inclusion in the cold commissioning phase.
2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors
and other electrical equipment, flushing and cleaning of tanks and piping if applicable,
adjustment and regulation of protective devices, functional tests, leakage and pressure
tests, inspection of bearings, etc.) and operation of equipment for a period of time. This
will be mainly as individual items, but may involve running some of the equipment in
sequence.
3. Hot Commissioning: this will include the introduction of process gas and reagent
(including the boiling out of pressure parts, curing of the refractory, blowing of steam
pipe to turbine, etc). The whole plant will be proved, operating in sequence under full
load conditions.
The Commissioning Manual (part n1) includes instructions for the Pre-commissioning and
the Cold Commissioning of the equipment in the contract.
The Commissioning Manual (part n2) includes instructions for the Hot Commissioning of the
equipment in the contract. These second part contains specific information for the first start-
up, which differ from a normal plant start-up. For the general operating procedures (allowing
to start-up, operate and shut down the plant), please refer to the Operation and Maintenance
manuals.
Responsibility: Operating instructions specified in this manual are typical procedures. It is
impossible to cover all eventualities, which might occur during the start-up of the plant.
Keppel Seghers cannot take responsibility for damage to any part of the plant which could
have been avoided, had instructions been followed.
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On the other hand, conditions may arise in which actions must be taken without sticking
completely to the instructions in this manual, provided that such actions result in safe
operation.
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3. GENERAL
The first start up procedure of the furnace-boiler is strongly different from a general start up
procedure. The reason is that the refractory lining has to be dried and baked in order to reach
its desired strength, and physical and chemical properties.
For this purpose, the temperature in the furnace and the post combustion zone has to be
increased according to a strictly defined procedure. A general sequence for the first start-up is
shown in the figure below with indication of duration of each individual action.
DRYING - BAKING - BOILING - BLASTING PROCEDURE
0
100
200
300
400
500
600
700
800
900
1000
0 2 4 6 8 10 12 14 16 18 20
Time (day)
F
l
u
e
g
a
s
t
e
m
p
e
r
a
t
u
r
e
(
C
)
Start-up
A-B
D
C
E
F
G
H I
J K
L
M
N
O P
Q
R S
T
U V
W
X
Blasting f(#cycles) Baking Drying
Boiling
Figure 1: Typical drying, baking, boiling and blasting curve
In attachment, the details for this typical drying, baking, boiling and blasting curve can be
found.
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4. PREPARATION TO DRYING-OUT, BOILING-OUT, BAKING AND
BLOWING-OUT
4.1. FURNACE
4.1.1. Combustion chamber
Before starting the drying-out and the baking procedure, a test has to be done to check the
amount of leakage air entering the furnace. During this test, the primary air fan will be
started without using the ID-fan. An overpressure will be created in the furnace. Air leaks
can be checked now by applying liquid soap at welding and other connection elements.
Air leaks have to be repaired before starting the drying-out and baking procedure.
All measurement systems in the furnace zone has to be operational (temperature, pressure,
). All temperature trendings in furnace and post combustion zone have to be printed
and saved.
All sight glasses, measurement systems, cameras, or other elements with a protection
against high temperatures by means of sweeping air, have to be cooled during drying-out
and baking procedure.
4.1.2. Grate
In normal operation, the tiles are cooled by primary air and thermally protected by a waste
layer, which acts as an insulating layer. Since drying-out of the refractory is not possible
and not allowed by waste, the burners have to be used. The grate tiles are not designed to
be exposed to the full heat of the burners; therefore the tiles need to be protected. This
protection remains in the furnace during the entire warm-start up, being the refractory
drying, the boiler boiling-out and the blowing-out of the boiler and steam piping.
The entire feeding and the combustion grates element 1 to 3 must be covered by means of
insulating material (rockwool), thickness at least 100 mm. Above the insulating material a
layer of about 5 cm of sand is put (can be sprayed with a pump). The sand is used to avoid
that the insulating material would fly away due to the draft of the ID-fan. It should be
carefully checked that the complete surface is evenly filled. Also the side wall tiles of the
combustion grate and the inlet guide tiles of the feeding grate have to be completely
covered.
The grate element which are most intensively exposed to heat are grate element number 4
and 5 (at furnace outlet), since the start-up burner is positioned in the back wall. These
elements must be covered with ceramic fiber, with thickness at least 100 mm.
Note: Instead of sand, bricks could be used to maintain the insulation in place.
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Caution: The temperature of the feeding and combustion grate may not arise above its
design value (feeding grate = surrounding temperature, combustion grate =
primary air preheating temperature), otherwise severe damage can be caused
to the mechanical structure and the hydraulic drive system (caused by limited
thermal expansion). The procedure to protect the grate, like described below,
has strictly to be followed.
Before starting the drying-out and baking procedure, it is advised to have a final check on
the clearances of the combustion grate tiles. This is necessary to be sure that the
clearances have not been changed during mounting of the grate elements. If clearances
have become smaller than advised on the drawings, there is a risk of blockage of the grate
tiles at normal operating conditions of the grate.
It is advised to test the operation (movement) of the grate elements before drying-out and
baking, to check whether everything works properly. All combustion and feeding grate
elements have to be withdrawn to their rest position.
The feeding grate has to be cooled by opening the inspection door at the back side of the
feeding grate housing. In this way, heat release to the feeding grate can be evacuated to
the environment.
4.1.3. Feeding hopper and chute
To protect the feeding hopper and the feeding chute cover plate system against too high
temperatures, they have to be protected by means of a temporary cover. A frame inside
the chute is made with iron bars. On this framework, hard insulating plates (thickness 40-
50 mm) are put with some bricks to avoid that the plates will fly away. All gaps have to
be closed by means of insulation material (in order to prevent the escape of hot flue
gases). The cover is placed just above the feeding grate where the steel part of the chute
starts to allow drying and baking of the refractory lining in the feeding chute.
The closing gate of the feeding hopper has to be opened, to be able to evacuate the
released heat to the environment.
The chute (closed loop) water circuit must be enabled to allow cooling of the steel plate
through the water jacket.
4.1.4. Start-up burner
The start-up burner should be checked that its flame will never (at each working point of
the burner) touch the grate or the insulation put above it.
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4.1.5. Ash extractor and sifting ash conveyors
To prevent heat loss through the ash extractor, the water seal on the ash extractor has to
be operational. Also the water supply system to the ash extractor has to be operational,
because it has to compensate the water loss due to evaporation. The water also protects
the ash extractor against too high temperatures.
The same applies for the wet sifting ash conveyors under the grate.
Caution: The availability of water to the ash extractor and sifting ash conveyors must
be checked regularly (two times per eight hours) as well as their casing
temperature.
4.1.6. Primary, secondary
The butterfly valves of the primary and secondary air are opened partially. This allows
air coming in by suction of the ID-fan. This air can help to evacuate for instance the
water that is evaporated in the air gap of the side wall cooling system of the furnace. It
also protects the air ducts against too high temperatures (sweeping air).
Caution: No primary air can be used during the drying-out and blowing-out
procedure, because the sand and the insulating material might be blown
away and thus exposing the grate directly to the radiant heat of the burners.
The side wall cooling fan has to be operational. It is possible that during the drying-out
and baking procedure, the side wall cooling has to be started.
4.2. BOILER AND STEAM CIRCUIT
Before hot commissioning several measures need to be taken to to protect the critical
items of the boiler. The main steam check valve internals should be removed and steam
flow measurement orifice should be replaced by a temporary simple design plate. Note
that the steam flow needs to be determined during steam blasting in order to evaluate the
blast impuls. The demister of the steam drum should be removed (during boiling-out) and
the insulation bricks of the manholes need to be removed.
All control and safety equipment and plant interlocks required for the activities of hot
commissioining should be operational.
A release note for hot commissioning of the boiler from the local inspection authority
should be available
The boiler pressure parts and control valves must be released.
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All measurement systems in the boiler (water-steam side) and post combustion zone (flue
gas side) have to be operational (temperature, pressure, ). All temperature trending
have to be printed and saved.
The support burners must be operational / released. For more detail, refer to O&M
Manual from supplier.
Fuel oil circulation pumps must be operational / released to allow feeding to the support
and start-up burners.
Boiler feeding water pumps must be operational / released. For more detail, refer to
O&M Manual from supplier. Temporary start-up filters can be installed instead of the
(fine) normal filters.
The demin water preparation system must be operational / released to allow feeding of the
pressure parts through the boiler feeding water pumps
The boiler water conditioning system (dosing of sodium phosphate) must be operational /
released.
4.3. FLUE GAS CLEANING PLANT
The flue gas cleaning system has to evacuate the hot flue gases. To protect the flue gas
cleaning against too high temperatures, one can open manholes in the flue gas ducts or at
the reactor, in order to insert air, sucked by the underpressure created by the ID-fan.
The ID-fan has to be operational. The automatic control loop to regulate the furnace
pressure and interlocks should be operational .
Some measurements need to be available for data-logging: CO and water measurement of
flue gases, flue gas flow (if possible).
4.4. COMMON PARTS
Process water and instrument/plant air must be available.
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Document Name:
59164_601_002_0- Commissioning manual Part 2
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5. HEATING-UP PROCEDURE
This procedure is the heating up procedure, as given by the refractory supplier .
Temperature in the furnace room and boiler first empty pass will be monitored during heating-
up of the furnace. Measurements will be recorded and the actual heating curve will be set up
(only for control and approval by the refractory supplier).
Sufficient supply of consumables should be available: demin water (boiler feed water), fuel,
chemicals for boiler cleaning
Heating up procedure is represented on the curve hereafter :
25
110 110
250 250
360 360
550 550
150
25
0
100
200
300
400
500
600
0 9 33 47 71 78 114 127 151 167 215
TI ME SCHEDULE( Hr )
T
E
M
P
E
R
A
T
U
R
E
(
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TYPICAL
Subject:
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Document Name:
59164_601_002_0- Commissioning manual Part 2
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14
6. BOILING-OUT PROCEDURE
Before boiling-out it is advisable to flush the entire boiler one time with demin water to
remove all loose particles still present in the boiler from erection works. The draining of the
boiler after the final pressure test can be considered as the flushing, provided the quality of
the drain water was good (no big particles in the water), the boiler was conserved in a good
way (see related procedures) and no more welding or repair works on pressure parts were
carried out (is not allowed after pressure test).
Boiling-out of the boiler aims at the removal of mechanical impurities, grease and possible
other contamination, if any, from the internal surfaces of the boiler tubes. The superheater is
not boiled-out (is cleaned with flushing and afterwards during steam blasting).
Both processes (boiling-out vs. drying-out/baking) may be carried-out simultaneously
providing that the resulting prolongation of the process, as well as the increase of temperature
and pressure, will not have negative influence upon the results of the boiling-out process.
Caution: The procedure hereafter described is given as an example. The operation of
the boiler during boiling-out should strictly follow the operating instruction
of the boiler supplier.
To ensure uniform concentration of chemical agents in all boiler elements that are included in
the process of boiling-out, an auxiliary installation can be provided consisting in one
circulating pump connected at the suction port with the drains of boiler evaporator bottom
headers, while pump discharge will be connected to the drains of economiser inlet header (see
typical sketch in annex). This pump will also be used for introducing chemical solution into
the boiler from a small
tank. The circulation pump will run about 4 times a day during 1 hour.
The pH of the solution in the boiler will be measured each time after the circulation pumps
have been operating.
Note that the superheaters are not boiled out..
Typical composition of boiling-out solution and amount of chemicals:
Chemical agent : NaOH and Na-phosphate
Concentration : 0,4 kg NaOH/m of water and 0,4kg/m Na
3
PO
4
,12H
2
O
Amount : 20 kg of NaOH (100%) and 20 kg of Na-phosphate
Course of boiling-out process (to be confirmed by boilers supplier):
Fill up the boiler to the lowest operational level in the steam drum. Note that the
superheaters are not allowed to be filled up with the alkaline boiling-out solution.
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Document Name:
59164_601_002_0- Commissioning manual Part 2
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Prepare the concentrated solution of NaOH and Na-phosphate in the tank (pH of about
11-12).
Start the temporary circulating pump and establish circulation within the system
(circulating pump- economiser- boiler drum- evaporator- circulating pump).
Pump-up the concentrated solution of chemicals to the system.
Continue the circulation for about 2 hours.
Fire the boiler and proceed to refractory drying procedure (see 5).
During the initial stage of drying-out procedure (until the drum pressure does not exceed
4 bar), the boiler evaporator should be blown-down every 6 hours (bottom headers drain
valves to be fully opened one by one for few seconds and than closed again).
The circulating pump should be operated for 30 min. every 6 hours during this stage. At
the drum pressure above 4 bar, the circulating pump suction and discharge isolating
valves should be kept closed. Each time after circulation, the pH of the boiler water
should be checked and the dosing of the chemicals to be adapted accordingly.
The frequency of blowing-down during the further course of refractory drying-out
procedure will be reduced to 1 per 24 hours. At the completion of refractory drying
procedure, the boiler will be drained and flushed with tap water by consequent filling and
draining until the pH value of effluent water is brought down to about 9 (last rising cycle
to be done with demin water).
The drain (boiling-out) water is contaminated with chemicals and should therefore be
disposed taking into account the applicable environmental legislation/regulations.
After cooling-down, the steam drum is made empty and is opened and cleaned /inspected
for the presence of impurities. Loose impurities, if any, should be removed manually.
Inner surfaces of the drum to the operational water level should be free from contaminants
(oil, sand, grease, etc.).
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TYPICAL
Subject:
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Document Name:
59164_601_002_0- Commissioning manual Part 2
Page
16
7. DRYING-OUT AND BAKING
1. First of all the boiler must be filled with demin water up to LL-level at the drum. Flow
control valve to be by-passed during filling.
2. Meanwhile, before the burners are started to dry the refractory lining, the complete gas
path (from furnace to ID-fan) has to be flushed by means of fresh air. This is to evacuate
possible explosive gases out of the plant. The flushing air flow must be three times the
plant volume (vol. furnace + vol. boiler + vol. reactor + vol. filter + vol. flue gas ducting).
The plant is flushed by using the secondary air fan (primary air fan cannot be used sine
grate is covered with insulating material). The flushing flow is measured at the suction
side of the secondary air. Because the (post-) combustion chamber is in overpressure, all
burners will be flushed in the same time.
3. Now the boiler is heating up until a flue gas temperature is reached of about 110 - 120 C.
This can be done by means of the start-up burners (at the backside of the furnace) or by-
means of steam from other combustion line (if applicable). The temperature that is
checked, is the temperature inside the furnace (above the grate).
Caution: During all drying-out and baking procedure (so from the first start of the
burners), temperature controls must be done to avoid possible mechanical
damage (casing, grate, ducting). The following table gives an overview of the
items to be checked and the necessary interventions:
Item to check What to do if temperature is too high
Combustion grate tiles (above Tmax =
300C)
Open inspection doors at the sifting ash
hoppers
)i v x (G
) v x (G
K
n n
d d
1 =
) v x (G
) v x (G
K
n n
d d
2 =
where:
G
d
: steam flow at blowing-out
G
n
: nominal steam flow (at maximum load)
v
d
: specific volume of steam at blowing-out
v
n
: specific volume at normal operation
The parameters (pressure + temperature) for the calculation of the steam specific volume shall
be measured just before the turbine / turbine bypass valve.
8.2.2. Calculation method
In order to determine the steam flow during blowing in absence of the flow measuring orifice,
the following calculation method is applied.
The flow is calculated, based on the measured pressure drop during blasting versus the
pressure drop in the boiler + piping during normal operation at maximum load.
A. Pressure drop formula:
2g
. x w
0 1P =
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Document Name:
59164_601_002_0- Commissioning manual Part 2
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with
v
1
. =
v
w
k
2g v
w
0 1P = =
with
F
v D
w =
v D k
v
)
F
v D
(
k 1P o = =
with:
R P : pressure drop (bar)
S : boiler (from drum to piping outlet) resistance coefficient
w : steam velocity (m/s)
T : steam density (kg/m)
v : steam specific volume (m/kg)
F : internal pipe cross-section (m)
D : boiler capacity/ steam flow (kg/h)
B. Steam pressure drop at blowing capacity
b b o b v D k 1P =
with:
D
b
: steam flow at blowing (to be calculated)
v
b
: steam specific volume (to be evaluated from steam tables, based on measured steam
temperature and pressure at piping outlet during blowing)
R P
b
: pressure drop between drum and piping outlet at steam blowing
C. Steam pressure drop at normal boiler load
n n o n v D k 1P =
D. Steam flow during blowing
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TYPICAL
Subject:
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Document Name:
59164_601_002_0- Commissioning manual Part 2
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The steam flow during blowing is calculated from the ratio of the pressure drop at normal
operation versus the pressure drop during blowing:
b o
n o
b
n
v Db k
v Dn k
1P
1P
=
=
n
b
b
n
n b
1P
1P
x
v
v
D D
8.2.3. Continuous steam blasting
In high pressure boilers, it is easy to obtain high flow disturbance factors K
1
and K
2
at low
steam output and consequently small heat demand. The ratio of drum pressure at blowing to
the nominal drum pressure is low: 0,150,25.
In the case of low pressure boilers, the situation is different. To obtain high values of K
1
and
K
2
factors, one should aim at obtaining high steam flow rate at low drum pressure during
blowing-out.
The first limitation is the steam output during blowing-out or the possibility to supply an
adequate amount of heat to the furnace. In a waste to power boiler, the burners are used as
support burners. The primary fuel is waste and thus burners are not designed for 100%
thermal load. The burner thermal capacity is designed in order to heat-up the boiler up till
850C (requirement by law) at start-up and to keep the temperature of the flue gases above
850C during operation when necessary.
During blowing the auxiliary and start-up burners are used, thus their effective thermal power
determines the maximum steam capacity of the boiler.
Start-up burner : 1 x 4,5 MWth
Auxiliary burners : 1 x 7,5 MWth
Another limitation of the blowing parameters is the pressure drop in the temporary piping and
silencer. Therefore, a silencer should be selected with a low pressure drop (maximum 4 bar),
so that high steam velocities can be obtained.
The lower pressure limitation by the silencer resistance and the upper limitation resulting
from the thermal power of the auxiliary burners, determine the K
1
and K
2
factors.
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TYPICAL
Subject:
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Document Name:
59164_601_002_0- Commissioning manual Part 2
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8.3. IMPACT BLOWING OF BOILER - PIPING
Next to the method of the continuous blowing, impact blowing could be applied for the
cleaning of the superheaters.
8.4. BLOWING-OUT PROCEDURE
The blowing-out of the boiler/piping can be performed in 3 ways: continuous blowing, impact
blowing or a combination of both methods. Only continuous blowing is not sufficient to
achieve the required K2-factors in the boiler.
Different steps in blowing-out procedure:
The boiler should be fired-up (with burners) in accordance with the prescriptions of the
boiler manual.
The gradient of saturation temperature increase in the drum (drum pressure increase)
should be not higher than indicated in the boiler manual/instruction. The heating-up of the
boiler should not exceed the requirements of the refractory (heating-up curve).
The firing-up will be performed with the start-up valve or the temporary valve partially
opened
In case of the combination of the continuous and impact blowing the following procedure is
followed:
By gradual increasing the power of the burners, the pressure and temperature in the boiler
is raised. The temporary valve in the blow-out piping is partially opened. One has to make
sure that the opening of the valve is done in harmony with the burner thermal power so
that the pressure and temperature keep increasing.
Once the parameters for continuous blowing are reached, the blowing-out should be
continued for about 10 min. Afterwards, the temporary gate valves will be partially closed
in order to reach the required drum pressure for impact blowing (24-30 bar).
When the drum pressure is 24-30 bar the temporary valve will be opened at once until a
drum pressure of about 10 bar = impact blowing
Temporary valve will be closed and burner capacity is gradually decreased according to
the cooling down curve of the refractory.
Boiler and piping is cooled down before next blowing is started.
The next blowing procedure should not start earlier than the skin temperature of the
piping has dropped to about 150-200C.
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Document Name:
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8.5. PRACTICAL MATTERS
- Just before start of impact blowing the level in the steam drum shall be adjusted to low
level. During impact blowing the water level will raise instantly due to the quick
reduction of pressure.
- Sufficient supply of demin water and fuel should be assured
- In normal practice, 2 to 3 steam blastings per day can be carried out. More steam blastings
is not efficient since the cooling down of the superheater, steam piping is very important
(cracking effect). Overnight a thorough cooling down should be carried out.
- Steam blasting will be performed at a flue gas temperature (measured in 1
st
pass) of about
500-550C.
- If the flue gas temperature at the exit of the 1st pass (above the refractory lining) exceed a
temperature of 450C a small amount of steam should be blown off (via PCV ) to ensure a
safe and trouble-free natural circulation of the boiler. If the temperature of the flue gases
before the final superheater reaches 400C, it is required to blow off a small amount of
steam to ensure a good cooling of the superheater tubes. More steam needs to be blown
off when the flue gas temperature further increases
- Before steam blasting, the steam parameters (pressure and temperature) are gradually
increased by increasing the capacity of the burners and by secondary air injection (typical
steam conditions for steam blasting : T = 360-375C, P = 24-30 bar). Meanwhile the
steam piping is preheated up till the silencer. When steam parameters are reached, the
temporary steam blasting valve is fully opened (as quick as possible)
- Cooling down of the boiler after steam blasting should be at approximately 50C/hr
- Before firing up the boiler for start of steam blasting, the following heating-up curve
should be followed (only first part is relevant from 25 to 550C in 32 hrs.).
- Temporary installation for steam blasting consists of temporary steam pipe (should be
very clean), a silencer (low pressure drop), 2 temporary manual open/close valves (1 for
piping to turbine and 1 for piping turbine bypass valve), 2 sample holders for target
plates, sufficient number of target plates, drain valve for temporary piping and connection
for water injection (to reduce noise)
- The cleaning processes and subsequent starting with waste should preferably be executed
in a consecutive way. In case it is not executed in a consecutive, continuous way a proper
conservation of the boiler should be carried out.
WASTE-TO-POWER PLANT
TYPICAL
Subject:
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Document Name:
59164_601_002_0- Commissioning manual Part 2
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25
150 150
550 550
500
550
500
0
100
200
300
400
500
600
0 6 12 32 38 44 50 56
TI ME SCHEDULE( Hr )
T
E
M
P
E
R
A
T
U
R
E
(
\
|
+ = 2 1 sec 2
With :
H2sec : level where the flue gases reach a residence time of 2 seconds (m)
H1 : reference level at the end of the post-combustion zone, as defined above (+xx,x
m).
V : volume of the post-combustion zone (xx m)
Q
real
: real flue gas flow (m/sec)
S : cross sectional area of the first empty pass of the boiler, starting at level H1 (xx,x
m).
For the same example, the following result is obtained for H2sec = xx,xx m.
Note : in case the calculation result from Equation 2 would be lower than H1 (this might be
possible in case of very low flue gas flows in startup phase or in trip conditions), H2sec is set
equal to H1 as a minimum value.
The flue gas temperature after 2 seconds of residence time T2sec can be calculated by linear
interpolation between H1/T1 and H2/T2, see Equation 3 (T1 and T2 first to be corrected for
the shield-effect as mentioned above).
Equation 3 : ( ) 1 sec 2
1 2
1 2
1 sec 2 H H
H H
T T
ct shieldeffe T T
+ + =
Giving the following result for the example above : T2sec = xx,xx C.
Other example : thermal load xx MWth, temperature in top of first pass xxx C, calculated flue
gas flow xxxx Nm/h.
Temperature T1 at level H1 = xx C
Real flue gas flow = xx m/sec
2 seconds level H2sec = xx m
2 seconds temperature T2sec = xx C.
The calculated 2 seconds temperature (xxxx) is shown on the overview screen of the furnace
and the boiler in central control room.
The shield-effect offset parameter is a fixed value in the process control system (start value
+50 C, until verification during first startup of the plant).