Documente Academic
Documente Profesional
Documente Cultură
PRESENTATION ON
SHISHIR SAXENA
1
TOPICS COVERED
STAGES OF COMMISSIONING
EFFICIENCY CALCULATION
COMMISSIONING STAGES
11-PG Test
2- Hydro test
3. Duct Leak
test
10-Commercial
steaming
STEPS OF
COMMISSIONING
9-Steam
Blowing
4-Motor Trial
5-Trial run of
rotating
equipment
8-Safety Valve
Floating
7-Alkali
boil out
6-Refractory
Dry Out
HYDRAULIC TEST
WHY ??
To check the strength of all welding carried out as well as parts
strength.
CARE TO BE TAKEN
Boiler should be in cold condition.
Water used must be as near as possible at the temperature of the boiler
pressure parts temperature & difference should not be more then 50 deg.
Maintain boiler water pH between 8.5 to 10.5 & hydrazine to approximately
150 ppm.
Boiler must be hydro tested to 1.5 Times design pressure only for first time
test after completion of erection as per Regulation requirement.
WHY
To ensure smooth working of Motors, Auxiliaries
CARE TO BE TAKEN
Proper Electrical connection to motors.
All necessary Electrical protection in place.
Motor No Load trial for 4-8 hrs
Final alignment of motor with rotating equipment
Load trial with Rotating equipment for 8 hrs.
Measure Vibration.
Watch Bearing temperature.
Chemicals used must never be introduced in solid form but must first be
dissolved in water and introduced in to the boiler system.
Alkali boil out is carried in Two stages : Atmospheric boil out at low pressure
for pre cleaning followed by pressure boil out at 75% of working pressure of
40 kg/cm2 whichever is less.
The atmospheric boil out is carried for 12 hours giving blowdowns from all
header and drum drains every two hours.
Pressure boil out is declared complete when oil level in sample falls below 5
ppm or after a minimum of 12 hours.
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11
STEAM BLOWING
WHY
To descale and remove foreign materials from steam pipes leading to turbine
IF NOT DONE THEN:
Damage to turbine blades from such material in the course of normal operation.
PRINCIPLE
STEAM BLOWING IS CARRIED OUT BY PUFFING METHOD TO:
Dislodge rust/scales from pipe work by thermal shocks.
High momentum of expanding steam in the pipe work purges out the loosened
material.
It is required to create a higher momentum during steam blowing than
possible during operation of the unit. This is applicable for all steam piping
leading to turbine.
Care to be taken to terminate the discharge to a safer place
Steam blowing completion criteria to be discussed & decided as per the
application of steam
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13
COMMERCIAL STEAMING
PRE-START CHECK
1.. Filling the boiler
If hot water is used the boiler, care should be exercised to feed slowly to
avoid severe temperature strains.
Make sure that all drains are closed prior to filling the boiler and that the
unit is adequately vented during filling procedure.
Fill until water is visible in the gauge glass. The steam drum vent should
remain open during the filing operation and during initial firing.
It shall not be closed until all the air is vented from the unit and an
appreciable quantity of steam is issuing therefore.
The unit may be considering free of air when the drum pressure reaches 2
kg per cm sq.
14
The super heater should be drained prior to lighting off through lines free from
back pressure.
The super heater drain should be closed, the super heater outlet vent which
must remain open to assure a flow of steam in order to protect the super-heater
elements from overheating until the boiler has gone on the line and is carrying
load.
The vent valve may be throttle some what when the boiler pressure becomes
sufficient to assure considerable flow through the super heater.
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17
18
20
EFFECTIVE START UP
21
EFFECTIVE START UP
DO NOT INCREASE THE STEAM FLOW > 50% TILL THE WATER QUALITY IS
BY
UNDER CONTROL.
MAKE SURE THAT ALL THE ASH HANDLING SYSTEM IS RUNNING RIGHT
FROM THE BEGINNING
EFFICIENCY CALCULATION
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24
CO2
44
3.667
3.667 C
S + O2 ---- SO2
32 32
64
1
1
2
S
S
2S
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27
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35
36
EFFICIENT OPERATION
FACTORS
BOILER
AFFECTING
PERFORMANCE
Deaerator in service
OF
37
EFFICIENT OPERATION
GAS TEMPERATURE LEAVING AIR HEATER
38
EFFICIENT OPERATION
EXCESS AIR
39
EFFICIENT OPERATION
UNBURNT CARBON
Small portion of carbon gets entrapped in ash and get carried away
from furnace
40
EFFICIENT OPERATION
UNBURNT CARBON
Any reduction in unburnt loss during operation will help to improve the
boiler efficiency and saving in fuel
41
EFFICIENT OPERATION
In
practice
as
boiler
operates
at
negative
pressure
42
Prevent any leakage in furnace, ducting etc. Ingress of air into the
furnace will reduce efficiency and increase power consumption.
EMERGENCIES
&
TROUBLE SHOOTING
44
LOSS OF DRAUGHT
If the forced draught is lost for any reason i.e. power or mechanical
failure the combustion efficiency will be lost resulting in heavy smoke
from stack.
In this event the boiler must be shut down until full draught conditions
are restored. If an I.D. Fan is provided it may be possible to operate on
this solely under reduced boiler load
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48
In case boiler level falls below low-low level it will trip on auto. In case it
does not trip following action has to be taken to avoid water starvation in
pressure parts of the boiler.
Shut off the fuel supply to extinguish the fire in furnace as quickly as
possible.
Close the CBD line.
Shut off the steam being discharged from the unit by closing the
header isolation valves.
Feed water supply to the boiler is to be restored after identifying and
rectifying the problem.
The make up of water to steam drum can be done as soon as problem is
rectified, if some water is available in steam drum.
In case no water is available in the drum, water should not be taken until the
temperature of pressure parts reduces to safe level.
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50
ACTIONS
Check the attemperator water flow.
Reduce fuel-firing rate.
Check the water level in the drum.
Decrease the temperature of combustion air.
Increase consumption of steam from boiler , if necessary by opening the
startup vent valve Causes for the failure of super heater temperature
control are.
52
ACTIONS
Reduce fuel-firing rate.
Open the start up vent.
Observe the steam flow of the super heater . If there is no flow , trip the
boiler.
Maintain the steam drum level.
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