C& I For Supercritical

Commissioning of Chemical Dosing System
18-20 March’ 2010

Presentation Contents
Objective
Summary
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Chemical Dosing System Commissioning Instructions
DOCUMENT NO: LS-TSZD-Ⅰ- HX001
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1. Project Overview & Work Quantity
1. The boiler for India ROSA project 2×300MW is of SG1025/17.5-M
type designed and made by Shanghai Boiler Works. It is of subcritical
pressure parameter, natural circulation drum, single furnace, once
through reheating. Boiler continuous steam output is 1025t/h, rated
superheating steam temperature is 541℃, and pressure is 17.57Mpa.
Turbine is of N300-16.67/538/538 type made by Shanghai Turbine
Company, Ltd. It is reversed operation, single shaft, once reheat, two
casings and two steam exhausts, pure condensate type. Its rated
power is 300MW. Generator is of QFSN-300-2 type made by
Shanghai Turbine Generator Co., Ltd, its rated power is 300MW, and
cooling method is water-hydrogen-hydrogen. Boiler makeup water is
DM water.
2. Chemical dosing system for this Unit is provided by Southeast China
Electric Power Equipment Works. Ltd in Zhenjing, China.
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Project Overview and Work Quantity
3. There are 3 sets of chemical dosing system for 2 Units: 1 set of
feedwater and condensate ammonia dosing devices (2 boxes and 6
pumps type), 1 set of feedwater hydrazine dosing whole-set devices (2
boxes and 6 pumps type), 1 set of boiler water phosphate devices (2
boxes and 3 pumps type). Chemicals dosing devices integrate the
functions of mechanical, electric and C&I, and will be located at 0 meter
in main power house. Each system is a complete set of products.
4. Feedwater and condensate ammonia dosing system: ammonia is dosed
automatically; dosing quantity is controlled as per feedwater and
condensate flowing, and regulates dosing quantity as per PH signal sent
by sampling system. Ammonia dosing system is used by 2 Units, and 2
ammonia solution tanks, 3 ammonia dosing pumps to condensate water,
3 ammonia dosing pumps to feedwater, of which 2 pumps are working
and 1 is standby. Ammonia dosing point to condensate water is at mixing
bed outlet header, and ammonia dosing point to feedwater is at
deaerator downcomer.
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5. Hydrazine dosing system to feedwater: hydrazine is dosed automatically;
dosing quantity is controlled as per feedwater flowing, and regulates dosing
quantity as per signal sent by dionic tester (or hydrazine meter) in sampling
system. Hydrazine dosing system is used by 2 Units, and 2 hydrazine
solution tanks, 3 ammonia dosing pumps to condensate water, 3 ammonia
dosing pumps to feedwater, of which 2 pumps are working and 1 is standby.
Hydrazine dosing point to feedwater is at deaerator downcomer, and
hydrazine dosing point to condensate water is at mixing bed outlet header,
hydrazine dosing point to condensate water is at mixing bed outlet header.
6. Phosphate dosing system to boiler water: phosphate dosing is an automatic
system, and dosing quantity is controlled by the signal sent by sampling
system phosphate meter. This system is used by 2 boilers; there are 2
solution tanks, 3 dosing pumps, and 2 pumps are working and 1 is standby.
7. Dosing system for boiler shutdown protection: this system is manual dosing
system and there are 2 solution tanks and 2 dosing pumps. It is used to
dose protection solution to the boiler during shutdown time.
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Main equipment in dosing device and technical parameters
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Commissioning Items
1. Regulation of ammonia dosing system to feedwater
2. Regulation of ammonia dosing system to condensate
water
3. Regulation of phosphate dosing system to boiler water
4. Regulation of dosing system for boiler shutdown
protection
5. Adjustment of dosing pump rating and dosing quantity
6. Adjustment of dosing pump output and dosing quantity
7. Cooperation with use of automatic dosing devices (after
putting into use of sampling system and sampling
devices)
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Commissioning items completion time
Absolute completion time required by
commissioning items is 7 days.
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2. System Function Description
Chemicals dosing devices integrate the functions of
mechanical, electric and C&I, and will be located at 0
meter in main power house, please refer to diagram of
ammonia dosing system for condensate and feedwater,
diagram of hydrazine dosing system for condensate and
feedwater and diagram of phosphate dosing system for
boiler water. This system is use to adjust the water quality
and chemicals according to the chemical water/steam
samplings during boiler startup or operation stage, the
purpose is to guarantee the quality of water in each
equipment meet standard requirement during Unit startup
or operation stage.
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2.1 Chemicals required by dosing system
1. Hydrazine: concentration is 40%, stored in tank
2. Liquid ammonia: ammonia water (in tank) and liquid ammonia (in bottle)
3. Phosphate: crystal type with 95% concentration (with crystallization water)
2.2 Ammonia and hydrazine dosing to feedwater use automatic method;
Ammonia and hydrazine dosing to condensate use manual method;
2.3 Except for the dosing pumps (chosen as per the appendix), other
equipment, pipes and valves (flow section) are of stainless steel.
Equipment pedestal and operation platform shall be of carbon steel
material.
2.4 Water filling test under normal pressure shall be taken to solution tanks.
Hydraulic test with a pressure of 0.6MPa shall be done to the pipes in
front of metering pump; hydraulic test with a pressure of 1.25 times of
the rated pressure shall be made to the pipes after metering pump.
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2.5 Ammonia dosing devices Each Unit has 2 ammonia dosing points: 1 for
condensate and 1 for feedwater. Ammonia dosing for feedwater uses
variable frequency automatic dosing method. The control signal is
420mA DC input signal (input resistance250) coming from feedwater
ratio conductivity meter in water/steam sampling and analyzing device.
When the operating solution tank level is at low position, or the 2 solution
tanks are both at low level position, automatically stop dosing pump and
alarm.
2.6 Hydrazine dosing devices Each Unit has 2 hydrazine dosing points: 1
for condensate and 1 for feedwater. Hydrazine dosing for feedwater uses
variable frequency automatic dosing method. The control signal is
420mA DC input signal (input resistance250) coming from feedwater
hydrazine meter in water/steam sampling and analyzing system. When
the operating solution tank level is at low position, or the 2 solution tanks
are both at low level position, automatically stop dosing pump and alarm.
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2.7 Phosphate dosing devices1）1 phosphate dosing point is set for each
Unit. Phosphate dosing uses manual regulation method. 2）When the
operating solution tank level is at low position, or the 2 solution tanks are
both at low level position, automatically stop dosing pump and alarm.
2.8 PLC is set for ammonia dosing, hydrazine dosing and phosphate dosing
devices respectively. PLC can display the level indication of solution tank,
low level alarming and operation status of each dosing pump, and also
receives the signals from water/steam devices participated in dosing
control. PLC is of CONTROL LOGIX series of AB company temporarily.
PLC system of dosing system (ammonia dosing, hydrazine dosing and
phosphate dosing) shall have the communication interface port for DCS
in central control room, and can be supervised through DCS. Method of
communication interface port shall be confirmed during signing of
technical protocols.
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2.9 Level indicator shall be provided for all solution tanks and
it shall have transmitter for local level indication and remote
420mADC signal. When at low-low level, the pump shall
be stopped automatically.
2.10 Frequency-changer shall be used as automatic control
devices. Frequency-changer is product of AB company.
2.11 Electricity control cabinet can accept 415/240V AC.
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3. Compilation Basis
1. Thermal system drawing for India ROSA Project
2. Boiler manufacturing and usage instructions for India
ROSA Project
3. China-India Contract for India ROSA Project
4. Related drawings provide by GEDI
5. Chemical equipment instructions and related drawings and
technical documents for India ROSA project
6. Dosing system equipment instructions and related
drawings and documents for India ROSA project
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4. Required Conditions & Preparation Before
Commissioning of Chemical Dosing System
Organization and division of work
1. Construction unit: chemicals transportation and chemical dosing
during commissioning stage of dosing system; maintenance, overhaul,
firefighting and defects elimination of the equipment within system
scope
2. Commissioning unit: compilation of commissioning work instructions;
under the guidance of subsection trial run team, organize and
coordinate dosing system commissioning work, and is totally in charge
of the technical issues during trial run; participate inspection,
acceptance and signature work after subsection trial run; fill in the
Dosing system Commissioning/Trial run Quality Supervision
Evaluation Sheet.
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3. Production (operation) unit: under the guidance of commissioning unit,
perform start/stop operations, operation regulation, supervision and
recording of operation parameters during trial run period as per
requirement of commissioning measures and operation regulations;
inspection before startup of equipment/system; in charge of necessary
production preparation work; participating trial run work and acceptance
and certificate signature work.
4. Supervision unit: inspection and supervision of the implementation of this
measure, participation of trial run and signature and acceptance. Each
procedure of commissioning process shall be effectively supervised and
confirmed, and then next procedure can be continued. Each control point
shall be confirmed by supervision unit, and then the next procedure can
be continued. Process control point shall be decided by supervision unit.
5. Commissioning instruction unit: supervision of and technical guidance to
each procedure and method during the whole commissioning process
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Required conditions before commissioning of chemical dosing system
1. techniques clarification has been made to these people
2. DM water is filled to dosing tank; enough chemicals are prepared
3. Discharge pipes of dosing Unit chemicals dosing system is installed and
qualified after hydraulic test. Equipment trial run is qualified and without
leakage point after acceptance, can be put into operation
4. Manual valve of system can be flexibly operated by man, no blocking;
pressure meter and thermometer has correct indication after verification and
are erected
5. Dosing room is clean, lighting and drainage facilities are completed
6. Boiler has been ignited, or feedwater and condensate water system has
started.
7. DM water source is enough and meets design requirement of chemicals
need to be dissolved.
8. Chemical dosing system operation regulations is compiled; chemical test
people can begin to work
9. On-duty schedule for the erection people, chemical operation test people is
arranged, safety and system are erected.
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Deployment & qualification of commissioning people
Equipment and instruments required by commissioning
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Before startup, check system whether it has startup conditions
No
Has startup conditions Optimize startup condition
yes
Washing of dosing sysem
System washing
qualified
no
Check system, when it is OK,continue 5.
Commissioning
yes
fill water to solution tank, startup dosing pump, check its output
and make dosing stroke regulation test
instruction
Y
qualified
No
continue procedure and
ye
method
s
合格 device into use

put automatic dosing
yes
no
qualified continue
yes
completion
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Commissioning instruction procedure and method
 Water washing to the solution tank and dosing tank
 Fill water to the solution tank and dosing tank to the normal level
 Start up dosing pump and check safety valve at pump outlet
 As per nominal ratings of each dosing pump, conduct service test
to dosing pumps
 Regulate the dosing pump stroke, and make dosing pump output
regulation test
 Put automatic dosing device into operation under permissible
conditions.
 Startup and stop operation shall be accord with Chemical dosing
system operation regulations. After Unit startup, boiler ignition,
pressure reaches 0.5-1.0Mpa, make washing to dosing system
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6. Inspection and Acceptance Standards
6.1 Key control points setting
6.2 Quality standard
6.3 Contents to be recorded

Putting-into-operation rate and integrity rate of dosing pumps.
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7.Safety Requirement & Environment Conditions During Commissioning
7.1 Danger factors identification and control during commissioning
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7.2 Environment Conditions During Commissioning
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8. Appendix
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Chemical Sampling Device System Commissioning Instructions
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1 .Project Overview & Work Quantity
1.1 Project Overview
The boiler for India ROSA project 2×300MW is of SG1025/17.5-M type
designed and made by Shanghai Boiler Works. It is of subcritical pressure
parameter, natural circulation drum, single furnace, once through reheating.
Boiler continuous steam output is 1025t/h, rated superheating steam
temperature is 541℃, and pressure is 17.57Mpa. Turbine is of N300-
16.67/538/538 type made by Shanghai Turbine Company, Ltd. It is reversed
operation, single shaft, once reheat, two casings and two steam exhausts,
pure condensate type. Its rated power is 300MW. Generator is of QFSN-
300-2 type made by Shanghai Turbine Generator Co., Ltd, its rated power is
300MW, and cooling method is water-hydrogen-hydrogen. Boiler makeup
water is DM water.
The chemical sampling devices for this Unit is a whole set of products
provided by Emerson Process Control Co. Ltd. 1 set of water/steam
centralized sampling and analyzing devices are provided for each Unit to
supervise water/steam quality in thermal system, including dry disk and wet
disk. Total 2 sets. Wet disk includes: all pipes, valves, cooling devices,
sampling water constant temperature devices, manual sampling devices and
disk rack of temperature and pressure reducing system of all sampling
points.
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Dry disk includes: all measurement instruments and auxiliary wires ( no
sampling water in dry disk, all quality check signals of chemical water are
sent to dry disk by signal cable). Low temperature color is indicated by light
green (front and back sides of dry disk shall be painted with plastic). Material
of all valves and pipes in sampling system is 316 stainless steel. HT HP
valves and electric magnetic valves and safety valves are of famous brands
imported. All measurement points with instruments in sampling system have
over-temperature and over-pressure protection devices and alarm measures
to the sampling water, and silicon meter, phosphorus meter, hydrazine meter,
sodium meter and oxygen meter shall have sampling water interception
protection devices. Sampling water after constant temperature devices shall
reach 25±1℃. Temperature of other sampling water shall be
40℃.Exchange rod is of stainless steel (with observation hole), and color-
changing cation ion exchange resin is within it. Electricity conductivity meter
(no ion exchanging) at economizer inlet shall send 420mADC output signal
to feedwater ammonia dosing devices as control signal, and N2H4 meter
shall send 420mADC output signal to feedwater hydrazine devices as
control signal. 1 set of computer data processing system is for 2 Unit, and
the host computer and display of this system shall be in on-duty room at
chemical test station. Microcomputer data processing system shall provide
feedwater electricity conductivity meter and hydrazine meter signals to
dosing system PLC by hard-wired method.
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This water/steam centralized sampling and analyzing device has self
protection measures and to protect instrument and meter when the
temperature and pressure exceed the limit and water interception. When
sampling water temperature is higher than 400℃, temperature protection
devices start normal function; when sampling water pressure is higher than
0.4MPa, pressure protection devices start normal function. This water/steam
centralized sampling and analyzing device has pre-cooling measure to
protect HP valve.
1) Maximum pressure of HP piping is 25MPa.
2) 2) Pressure reducer shall have a good pressure reducing effect and will not
be blocked in sampling water pipes. Sampling water rated flow at pressure
reducer outlet is 1500～2000 ml/min.
3) 3) Sampling water temperature after cooled by cooler shall not exceed 40℃.
4) 4) Constant temperature method for sampling water is mechanical constant
temperature to all sampling points; constant temperature devices shall be
arranged independently and sampling water temperature at the outlet of
constant temperature device shall be 25±1 ℃. Refrigerant medium used
shall meet national environment protection standards.
5) 5) Manual sampling water flow is constant and shall not exceed 500ml/mi;
flow of sampling water passing each chemical analyzing instrument shall be
300-500ml/min. Sampling water flow at manual sampling point for analyzing
oxygen concentration shall not be lower than 500ml/min.
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6) 6) Transmitting instrument of all analyzing meters shall have
alarm interfaces and can output real-time simulation quantity.
When entering computer system, communication interface
enters DCS system in main power house to achieve
centralized control.
7) 7) Each sampling water route shall have flow meter and
digital indication thermometer. Complete set of chemical
analyzing instruments are provided to water/steam centralized
sampling and analyzing devices, and can meet the
requirement of normal, continuous and stable measurement.
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Note:
(1) all instruments and meters shall have 2 nos. of
interfaces for 4～20mADC output signals
(2) silicon meter (feedwater and steam) is used at
economizer inlet, saturated steam and
superheated steam;
(3) Phosphate radical meter and silicon meter are
commonly used by #1 and #2 Units.
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1.2 Commissioning Items And Completion Time
1.2.1 Commissioning Items

1 Adjustment of sampling circuit putting into use
2 Online instruments putting into operation
1.2.2 Commissioning Items Completion Time

Absolute completion time required by commissioning
items is 3-5 days.
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2 .System Purpose Description
Chemical sampling devices and instrument system is a set
of equipment used to cool and chemically analyze the
water/steam sampling collected from sampling points
during Unit startup and operation stage, and the system
refers to the drawings provide by design institute. The
system will be put into use during boiler startup or under
certain working condition. Through the data from online
and manual sampling analysis, blow down of chemical
dosing system and other system, and adjustment of
working conditions, thus guarantee the quality of water in
the equipment meet the standard requirement during Unit
startup and operation. The system shall be put into use
during boiler steam blowing stage.
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3.1 Thermal system drawing for India ROSA Project
3.2 Boiler manufacturing and usage instructions for India
ROSA Project
3.3 China-India Contract for India ROSA Project
3.4 Related drawings provide by GEDI
3.5 Boiler equipment instructions and related drawings and
3.6 Technical protocols, instructions and related drawings
and primary design information provide by sampling device
and instrument/system manufacturer for India ROSA
project
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4. Required Conditions and Preparations Before Commissioning
of Sampling Devices and Instrument/System
4.1 Organization And Division Of Work
1. Construction unit: chemicals conveying and dosing during sampling
devices and instrument/system commissioning stage, maintenance,
overhaul, firefighting and defects elimination of the equipment within
scope of system.
under the guidance of subsection trial run team, organize and
coordinate commissioning of sampling devices and instrument/system,
and is totally in charge of the technical issues during trial run;
participate inspection, acceptance and signature work after subsection
trial run; fill in the Sampling devices and Instrument/system
Commissioning/Trial run Quality Supervision and Evaluation Sheet.
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4.1 Organization And Division Of Work
3. Production (operation) unit: under the guidance of commissioning unit,
perform start/stop operations, operation regulation, supervision and
recording of operation parameters during trial run period as per
requirement of commissioning measures and operation regulations;
inspection before startup of sampling devices /system; necessary
production preparation; participate trial run work and acceptance and
signature
procedure of commissioning process shall be effectively supervised and
confirmed, and then next procedure can be continued. Each control point
shall be confirmed by supervision unit, and then the next procedure can
be continued. Process control point shall be decided by supervision unit
each procedure and method during the whole commissioning process of
sampling device/equipment/system
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4.2 Required conditions before commissioning of sampling devices
and instrument/system
1. Unit sampling devices/instruments are installed and qualified after
hydraulic test. No leakage point; can be put into operation
2. Manual valve of system can be flexibly operated by man, no blocking,
pressure meter and thermometer has correct indication after verification
and are erected
3. Chemical sampling room is clean, lighting and water discharging system
are complete and are put into use.
4. Boiler is ready for ignition, feedwater and condensate system are started
and put into use
5. Sampling rack and cooling rack can be used; cooling water source is
enough, pressure can meet cooling water design requirement.
6. Sampling points is correctly set, sampling is representative; sampling
devices can meet requirement of water/steam quality supervision
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4.2 Required conditions before commissioning of sampling devices and
instrument/system
7. Sampling Device Operation Regulations is compiled; operation people start
to work
8. Discharge pipe on centralized sampling devices is erected and is smooth;
discharge point connected to discharge header is correct
9. On-duty schedule for the erection people, chemical operation test people is
arranged, safety and techniques clarification has been made to these people
10. Test instrument and chemicals are complete, instruments are qualified after
regulation; medicines used by chemical test are prepared and meet
chemical test requirement
11. Site and control room shall have a good communication; telephones are
arranged in chemical test room and control room
12. Subsection trial run of each system meet the standards requirement and is
completed before Unit whole-set startup
13. Erection and commissioning of online instrument and meter on steam/water
sampling devices is completed in manufactory before whole set startup, and
can be used to online test.
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4.3 Deployment & qualification of commissioning people
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5. Commissioning instruction procedure and method
5.1 Commissioning instruction procedure and method flow chart (diagram blow)
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5.2 Commissioning instruction procedure and method
1. After Unit startup, boiler ignition; booster pressure to 0.5-
1.0Mpa, wash the sampling tubes

2. When washing is completed, manual sampling devices
putting into use

3. When Unit load achieves requirement, put the sampling
instrument into use cooperated with manufacturer

4. After sampling devices putting into use, the conventional
problems shall be treated as per related regulations

5. Abnormal problems shall be the scope of commissioning
people. Commissioning technician, erection people and

operation people shall implement. Notify the superior if there
is any special conditions
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6. Inspection Standards
6.1 Key control point setting
6.2 Quality standard

Putting-into-operation rate of sampling circuit and online instrument shall be recorded.
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7. Safety requirement & environment conditions during commissioning
7.1 danger factors identification and control during commissioning
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7. Safety requirement & environment conditions during commissioning
7.2 Environment conditions during commissioning
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8. Appendix
8.1Chemical sampling devices/instrument system quality evaluation sheet
8.2Chemical sampling device/instrument system acceptance certificate card
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Acceptance Certificate Sheet After Subsection Trial Run
Chemical
sampling
device and
instrument
system
Acceptance and inspection group:

commissioning in charge:
Commissioning implementation
person: Date:
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Chemical
sampling
device and
instrument
system
Acceptance and inspection group:

commissioning in charge:
Commissioning implementation
person: Date:
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Chemical Water/steam Quality
Supervision And Commissioning
Instructions During Whole Set
Startup Period
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1.1 Project overview
The boiler for India ROSA project 2×300MW is of SG1025/17.5-M
type designed and made by Shanghai Boiler Works. It is of subcritical
pressure parameter, natural circulation drum, single furnace, once
through reheating. Boiler continuous steam output is 1025t/h, rated
superheating steam temperature is 541℃, and pressure is 17.57Mpa.
Turbine is of N300-16.67/538/538 type made by Shanghai Turbine
Company, Ltd. It is reversed operation, single shaft, once reheat, two
casings and two steam exhausts, pure condensate type. Its rated
power is 300MW. Generator is of QFSN-300-2 type made by
Shanghai Turbine Generator Co., Ltd, its rated power is 300MW, and
cooling method is water-hydrogen-hydrogen. Boiler makeup water is
DM water.
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Boiler main design parameters
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Feedwater system
 HP feedwater system is used to transfer the feedwater after
deoxidization from deoxidized water tank to economizer inlet
header. Feedwater is used to enhance unit heat rate after
steam extraction in turbine and heated through HP heater.
There are 3 electric speed adjustable feedwater tanks of
50% capacity. Under normal conditions, two are working and
one is standby.
 There are 3 horizontal HP heaters. Bypass is used to isolate
the feedwater near HP heater. All bypass valves and isolation
valves are motorized.
 Feedwater system is divided into 3 parts: LP feedwater pipes,
IP feedwater pipes and HP feedwater pipes.
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Condensate system
Condensate system is used to transfer condensate water
from condenser hot well to deaerator through condensate
water pump, gland seal heater and 4 LP heaters to
guarantee safe operation and high effect. This system also
provides attemperating water, make-up cooling water and
other feedwater. In this system, 2 vertical condensate water
pumps of 100% capacity are arranged.
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Auxiliary steam system
 AUX steam system will provide steam to deaerator during startup, low
loading and tripping period, provide heated steam to boiler bottom; provide
steam to turbine gland seal system during startup or standby time; provide
steam to soot blower during APH startup time; provide heated steam to air
warmer and fuel system.
 Under normal operation condition, AUX steam comes from auxiliary boiler
and reheated cold section steam during first startup of the Unit. When
reheated cold section steam is not sufficient, steam comes from main steam
pipe. During 1st startup of Unit, auxiliary boiler provides startup steam.
There are connection pipes between auxiliary steam headers of two Units.
When 1 Unit is working, steam can be provided to another Unit. Continuous
drain pipes are arranged to steam header to drain water to condenser.
 Each Unit has auxiliary steam header, and under normal working condition,
pressure of auxiliary steam header is 1.20MPa, temperature is 3200℃. 2
safety valves are provided on header.
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Condenser pipe cleaning system
On the circulation pipes before entering to
condenser, foreign matters filter and condenser pipe
cleaning system are installed. 1 pipe cleaning
system is installed on each pipe of condenser,
including 1 rubber ball recirculation pump, 1 ball
collecting net and ball collector and fittings.
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Boiler blowdown and drain system
Continuous blowdown system
Drum will continuously drain unqualified boiler water to continuous
blowdown water tank to separate water and steam. Steam and water coming
into deaerator will be drained to intermittent blowdown flash tank. When
there is failure during operation of continuous blowdown flash tank, drainage
will go into intermittent blowdown flash tank through bypass. If the boiler
water is becoming bad continuously, bypass is also used to increase
continuous blowdown water quantity.
Boiler intermittent blowdown system
As per boiler water quantity, water on boiler bottom header will be directly
discharged into intermittent blowdown flash tank intermittently. After
separation of water and steam, steam will be discharged into atmosphere;
water will be discharged into underground concrete water tank and
discharged after mixing with cooling water.
Water drainage and discharge water system
During Unit startup and stopping, drainage and discharge pipes of each
header will be connected with drainage branches in boiler house, and water
will be discharged into intermittent blowdown flash tank.
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Condenser pipe cleaning system
On the circulation pipes before entering to
condenser, foreign matters filter and condenser pipe
cleaning system are installed. 1 pipe cleaning
system is installed on each pipe of condenser,
including 1 rubber ball recirculation pump, 1 ball
collecting net and ball collector and fittings.
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Chemical dosing, sampling devices and instrument system
 Feedwater and condensate water ammonia dosing system: ammonia is
dosed automatically; dosing quantity is controlled as per feedwater and
condensate flowing, and regulates dosing quantity as per PH signal sent
by sampling system. Ammonia dosing system is used by 2 Units, and 2
ammonia solution tanks, 3 ammonia dosing pumps to condensate water,
3 ammonia dosing pumps to feedwater, of which 2 pumps are working
and 1 is standby. Ammonia dosing point to condensate water is at mixing
bed outlet header, and ammonia dosing point to feedwater is at
deaerator downcomer.
 Hydrazine dosing system to feedwater and condensate: hydrazine is
dosed automatically; dosing quantity is controlled as per feedwater
flowing, and regulates dosing quantity as per signal sent by dionic tester
(or hydrazine meter) in sampling system. Hydrazine dosing system is
used by 2 Units, and 2 hydrazine solution tanks, 3 ammonia dosing
pumps to condensate water, 3 ammonia dosing pumps to feedwater, of
which 2 pumps are working and 1 is standby. Hydrazine dosing point to
feedwater is at deaerator downcomer, and hydrazine dosing point to
condensate water is at mixing bed outlet header, hydrazine dosing point
to closed water is at closed circulation pump outlet header.
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 Phosphate dosing system to boiler water: phosphate dosing is
automatic system, and dosing quantity is controlled by the
signal sent by sampling system phosphate meter. This system
is used by 2 boilers; there are 2 solution tanks, 3 dosing pumps,
and 2 pumps are working and 1 is standby.
 1 set of steam-water sampling devices is set to the Unit,
including cooler support (high temperature support) and
instrument panel (low temperature support). Manual sampling
and online instrument are set. Instrument of sampling system
has function of local indication and signal (simulating quantity
and switch on/off degree) remote transmission. Remote
communication signal will be transmitted to DCS and operation
people can supervise it on CRT in central control room.
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 There are 16 water-steam sampling points for each Unit, including
condensate pump outlet header, deaerator inlet and outlet,
economizer inlet, drum boiler water right/left sides, superheated
steam, reheater inlet/outlet, #6 HP heater drainage, #3 LP heater
drainage, DM water header in main power house, stator cooling
water inlet, closed cooling water. Sampling cooling water is
provided by separate closed circulation cooling water, 2 circulation
water pumps, 1 is working and 1 is standby. Chemical dosing
system for 2 Units includes 3 sets of dosing devices: 1 set of
ammonia dosing devices to feedwater and condensate water, 1
set of ammonia dosing devices to feedwater (2 tanks and 6 pumps
type), 1 set of phosphate dosing devices to boiler water (2 tanks
and 3 pumps type). Dosing devices integrate the function of
mechanical, electrical and C&I, are arranged at 0 meter of main
power house. Each system is of whole set production.
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1.2 commissioning item and completion time
Commissioning items
1Supervision of hydro-test, quality of filling water to the boiler during
Unit trial run period
2Supervision of steam/water quality during boiler 1st ignition and pipe
blowing period
3Supervision of steam/water quality during Unit idle-load startup
period
4Supervision of steam/water quality during Unit loading startup period
5Supervision of steam/water quality during Unit full-load operation
6Supervision of chemical dosing during boiler shutdown
Commissioning items completion time
Absolute completion time required is from starting of boiler pipe steam
blowing to completion of Unit full-load trial run.
64 confidential
2. Purpose of Chemical Steam/Water Quality Supervision
During Pipe Blowing & Whole Set Startup Period
As per design of the Unit of Stage I of ROSA power plant,

Unit water/steam quality shall be supervised and regulated
through adjusting of chemical dosing system and Unit
operation condition, to make the water/steam quality meet
acceptance standards during boiler 1st ignition and pipe
blowing, Unit idle-load trial run, with-load trial and whole
set trial run, full-load trial run period.
65 confidential
1. Thermal system drawing for India ROSA Project
2. Boiler manufacturing and usage instructions for India
ROSA Project
3. China-India Contract for India ROSA Project
4. Related drawings provide by GEDI
5. Chemical equipment instructions and related drawings and
6. Instructions, drawings and documents for boiler, turbine
and auxiliary systems for India ROSA project
66 confidential
4. Required conditions and preparations before
water/steam quality supervision
1. Construction unit: chemicals transportation and chemical dosing during
commissioning stage of sampling and dosing system; maintenance,
overhaul, firefighting and defects elimination of the equipment within
system scope. Submit single machine trial run recording and related
documents
under the guidance of subsection trial run team, organize and coordinate
water/steam quality supervision work, and is totally responsible of the
technical issues during trial run; participate inspection, acceptance and
signature work after subsection trial run; fill in the Chemical Water/steam
Quality Supervision Evaluation Sheet.
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3. Production unit: under the guidance of commissioning unit, perform
start/stop operations, operation regulation, supervision and recording of
operation parameters during trial run period as per requirement of
commissioning measures and operation regulations; inspection before
startup of equipment/system; operation people are in charge of operations of
normal system (i.e. operating system handover, or system of which
operation is taken care of by other team) and chemical inspection, test
supervision during cleaning process.
procedure of cleaning process shall be effectively supervised and confirmed,
and then next procedure can be continued. Each control point shall be
confirmed by supervision unit, and then the next procedure can be
continued. Process control point shall be decided by supervision unit.
each procedure and method during the whole commissioning process
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Required conditions before water/steam quality supervision
1. Work site ground is flat, without debris, scaffolds are removed, ladders and
handrails are set up, lighting at site is good
2. Dosing and sampling room is clean, lighting and drainage facilities are
complete and can be put into operation
3. Unit chemicals dosing system and sampling system are installed and
qualified after hydraulic test. Equipment trial run is qualified and without
leakage point after acceptance, can be put into operation
4. Trial run of chemicals dosing pumps is qualified and has a good dosing
effect. Dosing tank and solution tank shall be washed with DM water until
the drainage water at pipe outlet is clean.
5. Manual valve of system can be flexibly operated by man, no blocking,
pressure meter and thermometer has correct indication after verification and
are erected
6. Sampling points is correctly set, sampling is representative; sampling
69 confidential
enough, pressure can meet cooling water design requirement. Boiler
has been ignited or feedwater and condensate water system has
started.
8. DM water source is enough and meets design requirement of
chemicals need to be dissolved.
9. Blowdown pipes of sampling and dosing system are erected.
Sampling points are correctly set and are representative; sampling
enough, pressure can meet cooling water design requirement. Boiler
has been ignited or feedwater and condensate water system has
started.
11. Chemicals required by dosing system are enough and transferred to
dosing room
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12. On-duty schedule for the erection people, chemical operation test
people is arranged, safety and techniques clarification has been
made to these people
13. Test instrument and chemicals are complete, instruments are
qualified after regulation; medicines used by chemical test are
prepared and meet chemical test requirement
14. Site and control room shall have a good communication; telephones
are arranged in chemical test room and control room.
15. Subsection trial run of each system meet the standards requirement
and is completed before Unit whole-set startup
16. Erection and commissioning of online instrument and meter on
steam/water sampling devices is completed in manufactory before
whole set startup, and can be used to online test.
71 confidential
Equipment & Instruments Required by Commissioning
72 confidential
Before system startup, check whether is has startup conditions
Yes
No
Has startup conditions Optimize startup conditions
5. Commissioning
yes
Water/steam quality supervision during 1st ignition and pipe
blowing stage
Instructions
Yes
Pipe blowing
work
No Boiler shutdown and maintenance, check system, then
pipe blowing
Procedure &
completion
Method
Yes
Water/steam quality supervision during Unit idle-load trial

run stage
5.1 Procedure &
yes
Unit idle-load trial

run completion
No Boiler shutdown and maintenance, check system,
then continue
Method Flow
Chart
y
e
s
Water/steam quality supervision during Unit with-load trial run

stage
ye
s
Unit with-load trial run No Boiler shutdown and maintenance,

completion check system, then continue
yes
Water/steam quality supervision during Unit full load trial

run stage
yes
full load trial run no Boiler shutdown and maintenance, check

completion system, then continue
yes
confidential
Completion
73
5.2 Commissioning instruction procedure and method
1. Boiling filling water chemicals dosing during boiler water filling test
and Unit trial run period
DM water containing ammonia (PH value is 9.5-10.5) and hydrazine (200-
300mg/l) is used in hydraulic test. During Unit trial run period, DM water
above mentioned shall be used as boiler filling water for each ignition of the
boiler, to protect the heating surface of the boiler.
2. Steam/water quality supervision during 1st ignition and pipe blowing
After 1st ignition, start up feedwater and boiler water chemicals dosing
system to dose ammonia and hydrazine to feedwater and trisodium
phosphate to boiler water. Chemicals dosing pump stroke opening degree is
controlled at 30%.
74 confidential
Open the inlet/outlet door of cooling water of sampling cooling rack, observe
and measure the temperature and pressure of cooling water to see whether
they are in accordance with cooling requirement of cooling rack, to
guarantee cooling effect of cooling water. When drum pressure reaches to
2.0Mpa, slowly open primary and secondary valves of steam/water sampling
system and sampling panel, open sampling blowdown valve to discharge.
Steam and water shall be separated and discharged to avoid collision if they
are mixed. Blowdown period shall be 1-2 hours. When blowdown is
completed, close sampling blowdown valve and open sampling regulating
valve used for manual sampling, observe the sampling water. If it’s turbid,
close sampling regulating valve immediately, open sampling blowdown valve
to continue discharge until the water is clean. Regulate the dosing pump as
per sampling test result to make the water/steam quality meet standard
requirement in a short time.
After each ignition, put the chemicals dosing and sampling devices into
operation as per procedures in A.
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Water/steam quality supervision items during 1st ignition and pipe blowing:
Feedwater quality PH：8.8-9.3
Hydrazine 20-50μg/L
Rigidity ≤2.5 μmol/L
Boiler water quality (PO4)**3 = 2-10 mg/L & pH = 9-10
As it is the 1st boiler ignition, the water/steam quality is bad, intermittent and
continuous blowdown work shall be always done to make the quality meet
standard requirement in a short time.
During 1st ignition and pipe blowing and trial run, make sampling and
measurement at an interval of 4-8 hours; if there is any special condition, it
shall be decided by the site commissioning people.
76 confidential
3. Water/steam quality supervision in Unit idle-load startup period
During Unit idle-load trial run, make sampling and measurement at an

interval of 1-2 hours; if there is any special condition, it shall be decided by
site commissioning people.
77 confidential
4. Water/steam quality supervision in Unit with-load startup period
During Unit with-load startup, make sampling and measurement at an

interval of 4-8 hours; if there is any special condition, it shall be decided by
site commissioning people
When silicon in superheated steam is 20 g/kg, limited silicon quantity in
boiler water under each pressure is as following table:
78 confidential
炉 10
炉炉炉
炉 8.0
Si O2 炉炉炉
炉 7.0
炉 6.0 炉
炉炉炉炉炉炉炉
5.5 炉
mg/ L 炉炉
5.0 炉炉
炉
4.5
4.0
3.5
3.0
2.5
2.0
炉炉炉炉炉炉炉
1.5
1.0
0.5
0.4
0.2
0.1
0
5 6 9 12 15 16 17 18
炉炉炉炉炉炉 MPa
Silicon cleaning operation curve diagram
79 confidential
5. Water/steam quality supervision in Unit full-load trial run period (meet
standards required by handover to the Owner for commercial operation)
During Unit idle-load startup, make sampling and measurement at an interval

of 1-2 hours; if there is any special condition, it shall be decided by site
commissioning people
80 confidential
6. Boiler Stop & Protection
As it is trial run of Unit, there is uncertainty for the startup and stopping, and
due to limit of site conditions, ammonia-hydrazine method shall be used to
protect the Unit and prevent rust during boiler shutdown period. The detail
method is:
Maintenance of short-time shutdown: during trial run period, predicted
shutdown time is within 3 days. When the unit is shutdown, dosing pump
(trisodium phosphate) continues to dose to the boiler, adjust the PH value of
boiler water and make it within 10.5-11.0, then stop dosing. Close all valves
and isolate the boiler with outer system, stop water filling and discharging, to
make the boiler in a non-oxygen state. Heating surface will not be corrosive,
thus the maintenance of short-time shutdown purpose is achieved.
Maintenance of long-time shutdown: during trial run period, predicted
shutdown period is more than 4 days. After Unit shutdown, exchange the
water in the boiler and reduce the temperature, when it reduces to 70℃,
discharge boiler water completely, fill the ammonia-hydrazine protection
solution made in 200m3 tank into the boiler. First fill the solution until the
drum is full, then fill to all the valves, then close, to isolate the protection
solution level in boiler and the outer side. During maintenance period, make
one time of sampling and chemical supervision each day. The protection
solution (N2H4) concentration shall be 210mg/L, pH value is 10.0. Protection
solution concentration shall be suitably controlled during shutdown and
maintenance period.
81 confidential
6. Inspection standards (Key control points setting)
82 confidential
6.2 Quality Standards
1. Boiler filling water chemicals doing during boiler hydraulic test and
Unit trial run period
2. Water/steam quality supervision during Unit idle-load startup period
3. Water/steam quality supervision during Unit idle-load startup period
4. Water/steam quality supervision during Unit
5. Water/steam quality supervision during Unit full-load trial run period
6. Protection supervision during boiler shutdown period
83 confidential
1. Supervision and recording of boiler filling water water/steam quality
during boiler hydraulic test and Unit trial run period
2. Supervision and recording of water/steam quality during 1st boiler
ignition and pipe blowing period
3. Supervision and recording of water/steam quality during Unit idle-load
startup period
4. Supervision and recording of water/steam quality during Unit with-load
startup period
5. Supervision and recording of water/steam quality during Unit full load
trial run period
6. Supervision and recording of boiler shutdown and maintenance
84 confidential
7.Safety requirement and environment conditions during
commissioning
7.1 Danger factors
identification &
control during
commissioning
85 confidential
7.2 Environment conditions during commissioning
86 confidential
8. Appendix
87 confidential
88 confidential
89 confidential
90 confidential
Specialty: chemical Item: Chemical water/steam quality supervision for during whole set startup period
91 confidential
Specialty: chemical Item: Chemical water/steam quality supervision for during whole set startup period
92 confidential
93 confidential

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Commissioning of Chemical Dosing System

18-20 March’ 2010

Equipment and instruments required by commissioning

合格 device into use

6.2 Quality standard

6.3 Contents to be recorded

requirement of normal, continuous and stable measurement.

1.2.1 Commissioning Items

1.2.2 Commissioning Items Completion Time

1.0Mpa, wash the sampling tubes

putting into use

instrument into use cooperated with manufacturer

problems shall be treated as per related regulations

people. Commissioning technician, erection people and

6.2 Quality standard

6.3 Contents to be recorded

7.1 danger factors identification and control during commissioning

7.2 Environment conditions during commissioning

Acceptance and inspection group:

Acceptance and inspection group:

As per design of the Unit of Stage I of ROSA power plant,

Water/steam quality supervision during Unit idle-load trial

Unit idle-load trial

Water/steam quality supervision during Unit with-load trial run

Unit with-load trial run No Boiler shutdown and maintenance,

Water/steam quality supervision during Unit full load trial

full load trial run no Boiler shutdown and maintenance, check

During Unit idle-load trial run, make sampling and measurement at an

During Unit with-load startup, make sampling and measurement at an

During Unit idle-load startup, make sampling and measurement at an interval

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