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PS-DC-186-500-0036
Sheet 1 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SLNO
LIST OF CONTENTS
2.0 OBJECTIVE
3.0 PROPOSAL
8.0 METHOD
10.0 APPENDICES
a) DRAWINGS
b) LOG SHEET
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 2 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
1.11 Plant item completion list for Mechanical, Electrical and C & I are
to be prepared at site.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 3 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
1.12 For the following system, drawings are enclosed in Section 10.0
d. Deluge system
2.0 OBJECTIVE
3.0 PROPOSAL:
3.1 Acid cleaning & oil flushing of Lub-oil system of support & Guide
bearings.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 4 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
5.3 Man hole doors kept open for inspection should be clearly
guarded from any unauthorised persons entering in to APH. (Test
team leader to ensure this)
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 5 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
7.1 APH and its associated system are erected as per recommended
drawing.
7.4 Power supply system for the pumps are commissioned and
available for operation.
7.6 Cooling water for support and guide bearing lub oil pumps is
available for operation. (Equipment Cooling water System)
7.7 Required local / remote I & C inputs for APH are made available.
(List to be mutually prepared at site).
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 6 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
7.8 Deluge and water wash lines are erected upto APH and drainage
facility is ensured.
7.9 APH fire sensing device commissioned and kept ready for
operation.
7.10 Soot blower and its connected piping are erected and kept ready
for operation. Ensure either steam or air (temporary source) is
made available for commissioning APH during APH start up till
main steam source is made available.
7.11 Oil in support and Guide bearings and fluid coupling are filled up
with recommended oil up to correct level. (Refer O & M Manual).
7.12 All erection log sheets are filled and signed by concerned
agencies
7.13 Flue gas ducts and Air ducts (Primary, Secondary) connections
to APH are completed and ducts are cleared for any loose
material or debris. Expansion bellows connected to APH should
be checked for removal of all temporary braces.
7.15 Main motors (AC-2 Nos) are kept decoupled from fluid coupling.
7.16 Service air line connection to Air Motor is complete with lubricator
cum Regulator.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 7 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
7.18 Oil level in the main gear drive ensured up to its normal level.
Local instrumentation of the gear drive completed.
7.21 Aluminium finger tabs sets installed after seals are set to the
specification.
7.22 Air Seal cover and water shield of support bearing and air seal
cover of guide bearing are erected as per drawing.
7.23 Hot end tracking arrangements are mounted properly and the
system is free to move.
7.25 Light assembly and observation ports are in position and wired.
7.26 Adjuster nuts of sector plates are fully tightened and locked to
specification
7.27 Lock nuts of axial seal plate adjusters are fully tightened.
7.28 Entire APH plant inspected and ensured that all loose material
are removed and all personnel are away from rotating equipment.
7.29 All man hole doors are closed except one or two as decided by
the test team leader.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 8 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
8.0 METHOD:
8.1.1 After completing the erection of the lub-oil system, oil lines are
dismantled and acid cleaned following the steps given in the
procedure No. PS-DC-186-500-0013A.
8.1.2 Motors of Lub-oil system are decoupled from pump and after
ensuring Insulation resistance at satisfactory level, motor started,
direction of rotation checked and put on 4 Hrs trial run. No local
current measured during this trial run.
8.1.3 After completion of motor trial run, both pump and motor are
coupled.
8.1.4 Pump primed sufficiently and then started and ensured that the
entire system is filled and oil circulation established. (In the case
of lub-oil system of both guide and support beaning, the bearing
itself is the oil reservoir and oil circulated back to Bearnigs
through filler and cooler) Leaks attended if noticed during oil
circulation.
8.1.5 Initially, the filters in the System are closely observed in terms
increase in pump discharge pressure and filters are cleaned.
Normally, the pump discharge pressure will be around 2.0 KSC to
3.0 KSC and if an increase of around 1 KSC is observed, it
indicates chocking of the filter and requires cleaning.
8.1.6 Continue oil flushing till the pump discharge pressures stabilises
for a period of 4-6 Hrs.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 9 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
8.1.7 After completing the oil flushing, the filters are cleaned again and
put back in to the system.
8.1.8 Relief valve in the pump (or mounted in the discharge line) are
set at 2.0 KSC above the normal operating pressure of the lub-oil
system.
8.1.9 For safety reasons, the oil flushing activity to be performed during
day time.
8.2.2 Step 8.2.1 to be repeated for both main and standby motor of
APH gear drive assembly.
8.2.3 After completion of motor trial run, motors are coupled to APH
main gear drive through fluid coupling.
8.2.4 Start the lub oil system of guide and support bearing assembly
and establish circulation.
8.2.5 Start the main motor and stop it after about 10-20 secs to
observe for its normal running. Any abnormal sound noticed to be
brought to the notice of the team leader.
8.2.6 Start the main motor again and allow APH to continonsly run.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 10 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
8.2.7 Observe of
8.2.8 Trial run of APH for 2 Hrs each to be carried out with main motor
and stand by motor. Log readings to be made as mentioned in
8.2.6
8.2.9 Auto- start of stand by motor (Between main & standby motors) to
be electrically ensured.
8.3.2 Open the by pass valve manually and slowly operate air motor
vis--vis the APH
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 11 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
8.3.3 Operation of air motor vis--vis APH carried out for about 10
minutes. The same operation carried out by operating the
solenoid valve in the main line and APH operated for 10 minutes.
8.4.2 Ensure
8.4.3 Start the SB motor and observe for the entire operation of steam
nozzle movement from in board location to out board location and
back to in board location (Parking location). (Refer O & M manual
& enclosed drawing)
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 12 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
8.4.5 Charge the air line slowly and blow the SB arm and nozzle
sufficiently.
8.4.6 Ensure the operation of APH SB from remote along with steam
valve opening.
8.5.2 The line is charged up to system inlet isolating valve and flushed
sufficiently through its drain line to plant drain till clear water
observed at drain outlet.
8.5.3 Flushing the system into the APH to be carefully done after
ensuring proper draining facility at the bottom of APH (Through
APH hoppers. At no time, water allowed to get collected in APH
Hoppers)
8.5.4 Flushing through both deluge system and water wash system
carried out one by one sufficiently till clear water observed at
drain outlet.
8.5.5 After completion of flushing, deluge and water wash systems are
isolated and APH allowed for drying (Either by natural or by
running FD Fan and APH)
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0036
Sheet 13 of 16
NTPC Ref no SIM/1/TS/1/36
Plant area: BOILER
PROCEDURE FOR COMMISSIONING OF APH AND ITS AUXILARIES
SL.NO STATUS
8.6 General
Signatures
NTPC BHEL
SHEET 15 OF 16
PROJECT :
UNIT NO.1 :
Signatures
NTPC BHEL
SHEET 16 OF 16
PROJECT :
UNIT NO. :
MOTOR IN VIBRATION
Sl.
TIME SERVICE REMARKS
NO APH GEAR
MAIN/STANBY MOTOR
BOX
Signatures
NTPC BHEL
TECHNICAL SPECIFICATION OF APH
SIMHADRI 2 X 500 MW