Doc. No.

: CC-MAS
Cold Commissioning Procedure Rev. No. : 00

Main Air System Date : 16-01-2010

Page : 1 Of 5

COLD COMMISSIONING PROCEDURE

MAIN AIR SYSTEM

Procedure # Revision # / Date Prepared By: Reviewed By: Approved By:

CC-MAS 0 / 16-Jan-2010 SSH SSH MJ

 Doc. No.: CC-MAS
Cold Commissioning Procedure Rev. No. : 00

Main Air System Date : 16-01-2010

Page : 2 Of 5

COLD COMMISSIONING PROCEDURE

Main System: MAIN AIR SYSTEM, CP-B01 (DRI Plant)

Sub System: Main Air Blower

System Description:

Centrifugal blower or fan that provides combustion air to the main burners of the reformer and
as a back up supply for auxiliary burners.

Start-up Conditions:

Equipment protection checks and interlocks:

• Confirm machinery cooling water flow to bearings > FAL M53.1 and .2.
(FAL M53.1 and .2 = 1.0 m3/h)

• Confirm motor bearing and winding temperature < UAH-B04.

(UAH-B04 = Set by Vendor)

• No Field Stop on HS-B01.1 or .2.

• No Field Stop on HS-B01.
• No Electric Fault.
• Main Air Blower Guide Vanes PV-B02-1 closed. (ZSC-BO2.1 CLOSED signal is
indicated)
• Main Air Blower control valve PV-B07 closed. (ZSC-B07 CLOSED signal is indicated)
• Dilution Air Block Valve SOV-C05-1 closed.(ZSC-C05-1 CLOSED signal is indicated)
• Auxiliary air back-up valve HV-B15.2 closed. (ZSC-B15.2 CLOSED signal is indicated)
• Main Air Blower vent valve PV-B02.2 open. (ZSO-B02.2 OPEN signal is indicated)
 Doc. No.: CC-MAS
Cold Commissioning Procedure Rev. No. : 00

Main Air System Date : 16-01-2010

Page : 3 Of 5

• Fan outboard bearing temperature is <TSHH-B64.1 and fan inboard temperature is

<TSHH-B64.2.
• (TSHH-B64.1 and .2 = 907 0C)
• Ejector stack fan CP-C11 running.

Field checks:

Open all hand valves on the combustion air lines to the heat recovery system.

Pre-start conditions:

• Energize switch gear in MCC.

• Put Main Air Blower discharge pressure controller PCB02 in MANUAL and dial output to
0%.
(Inlet guide vane PV-B02.1 will close and CLOSED signal is indicated)

• Put Main Air flow controller FC-B07 in MANUAL and dial output to 0%. (E9-31) (FV-B07
CLOSED signal is indicated)

System Start-up:

• Put software selector for Main Air Blower to READY/RUN. (READY signal is indicated)
• Start Main Air Blower by putting software selector to START. (RUN signal is indicated)
• Input Main Air Blower discharge pressure set-point using controller PC-B02 in AUTO
(PC-B02 set-point = 0.18 barg).
• After testing the main blower through vent line, divert the main air flow from vent line to
dilution air line by opening dilution air block valve SOV-C05-1. (ZSO-C05-1 open signal is
indicated). (Note: Auxiliary air back up valve SOV-C05 2 should be closed)
• Gradually open the temperature control valve of flue gas TV-C02 1 in manual mode and
close vent valve PV-B02 2.
 Doc. No.: CC-MAS
Cold Commissioning Procedure Rev. No. : 00

Main Air System Date : 16-01-2010

Page : 4 Of 5

• Gradually open main air flow control valve FV-B07 and close temperature control valve
of flue gas TV-C02 1 and record the main air flow. (Note: Main burners natural gas should be
closed.)

• Gradually open temperature control valve TV-B36 1 (cold combustion air pre heater
bank-1 by pass line) and close manual hand valve BF-04 on cold combustion air pre heater
bank-1 &2.
• Gradually open hand valve HV-B15.2 on main air back up line to auxiliary air main
(Auxiliary air hand valve HV-B15.1 & auxiliary air to after burner hand valve BF-04 should be
closed) and close temperature control valve TV-B36 1 (cold combustion air pre heater bank-1
by pass line). Now open reformer temperature control valve TV-B22 to test main air flow through
auxiliary burners. (Note: Auxiliary burners natural gas should be closed)

Shutdown Interlocks:

Main Air Blower will shut down if Emergency Stop is pushed or:

• Fan Bearing Vibration > VSHH-B01.1 or .2. (VSHH-B01=7mm/sec “Main Air Blower High
Vibration Shutdown” will annunciate)
• Fan Bearing Vibration > VSHH-B01.3 or .4. (VSHH-B01=7mm/sec. “Main Air Blower
High Vibration Shutdown” will annunciate)
• Fan Bearing Temperature > TSHH-B64.1 or .2. (TSHH-B64=900C “Main Air Blower
Bearing High Temperature Shutdown” will annunciate)
• Ejector Stack Fan CP-C11 shuts down. (“Main Air Blower Shutdown” will annunciate)
• Electrical fault. (“Main Air Blower Shutdown” will annunciate)

System Shutdown by Operator:

To transfer dilution air supply to Aux Air Blower and shut down Main Air Blower:

• Decrease the set-point for main air blower discharge pressure PC-B02 to bring it closer
to the auxiliary air blower discharge pressure per PC-B09.
• Put software selector for DILUTION AIR SUPPLY to AUX. AIR when controller PC-B02
stabilizes. (ZS-C05.1B CLOSED signal is indicated, ZS-C05.2A OPEN signal is indicated)
 Doc. No.: CC-MAS
Cold Commissioning Procedure Rev. No. : 00

Main Air System Date : 16-01-2010

Page : 5 Of 5

• Put Main Air flow controller FC-B07 in MANUAL and dial output to 0%.
(“Closed” signal is indicated)

• Put Main Air Blower discharge pressure controller PCB02 in MANUAL and dial output to
0%. (Inlet guide vane PV-B02.1 will close and CLOSED signal is indicated, Main Air Blower vent
valve PV-B02.2 will open and OPEN signal is indicated)
• Stop Main Air blower by putting software selector to position “0”
(“Main Air Blower Shutdown” will annunciate)

• Isolate electrically if required.

Reference Drawings: M5- 011, 012, 030 and E9-030, 031