Commissioning Procedure Air Pre Heater

Indiabulls
Indiabulls
COMMISSIONING PROCEDURE
AIR PRE HEATER
NASHIK POWER PROJECT

INDIABULLS POWER LTD.
5 X 270 MW
COMMISSIONING PROCEDURE AIR PREHEATER
S No. LIST OF CONTENT

1 PLANT DETAIL
2 OBJECTIVE
3 PROPOSAL
4 SERVICES REQUIRED
5 SAFETY PRECAUTIONS
6 EMERGENCY PROCEDURE
7 STATE OF THE PLANT
8 METHOD
9 COMPLETION CRITERIA
10 APPENDICES
a) LOG SHEET
INDIABULLS CONTRACTOR
MECHANICAL MECHANICAL
ELECTRICAL ELECTRICAL
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COMMISSIONING COMMISSIONING
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S No. STATUS
1 PLANT DETAIL
Rotary Air Preheaters supplied are of Tri-Sector type and

Separate APH (2 Nos.in each circuit) are given for Primary &
Secondary Air Circuits.
Rotary Air- Preheater generally comprises the following.
1.1 A.C Driven Motor – 1 No
1.2 Air Motor – 1 No. (with connected pipings & fittings)
1.3 Drive Gear Box.
1.4 Rotating elements with support and guide bearing

arrangement
with forced lubrication system.
1.5 Soot blower system.
1.6 Fire Sensing device.
1.7 Deluge system
1.8 Water wash system
1.9 Observation ports and light arrangement
1.10 Rotor stoppage alarm
1.11 Plant item completion list for Mechanical, Electrical and C & I
are to be prepared at site.
1.12 Oil carry over probe.
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1.12 For the following system, refer drawings mentioned.
a) Guide Bearing Lub-oil System

b) Support Bearing Lub-oil system
c) SB swivel arm sweep
d) Deluge system
e) Water wash system
f) Air Supply to Air Motor
2 OBJECTIVE
To commission the rotary air Preheater and make it available

for commissioning and operation of the main plant.
3 PROPOSAL
Commissioning of the rotary air preheater is proposed in the

following steps.
3.1 Acid cleaning & oil flushing of Lub-oil system of support &
Guide bearings.
3.2 Trial Run of Main Drive Motor for 8 Hrs.
3.3 Trial run of APH through main motor for 4 Hrs.
3.4 Commissioning of Air Motor and APH operation for 10

minutes
through Air Motor. Commissioning of rotation of rotor.
3.5 Commissioning of soot Boiler system
3.6 Flushing of Deluge and Water wash system.
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4 SERVICES REQUIRED
4.1 Availability of manpower with required Tools for attending to

any leak, cleaning of filters.
4.2 Availability of operating personnel to co-ordinate the

activities.
4.3 Availability of lighting arrangements and communication in

the
operating floors.
4.4 Availability of portable fire fighting equipments near test area.
4.5 Availability of service water
4.6 Availability of L.T supply
4.7 Availability of Equipment cooling water.
4.8 Availability of sufficient quantity of lub oil.
4.9 Availability of plant air.
4.10 Availability of steam for soot blowing.
5 SAFETY PRECAUTIONS
5.1 Debris in and around APH shall be removed
5.2 Approach / stair case / platform wherever required are made

available.
5.3 Manhole doors kept open for inspection should be clearly

guarded from any unauthorized persons entering in to APH.
(Test team leader to ensure this)
5.4 First aid test available near test area.
5.5 Operation of local start / stop PB is ensured for perfect

operation to facilitate stopping of APH in case of necessity.
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6 EMERGENCY PROCEDUES
6.1 The test team should be aware of the procedure to be

adopted in case of damage to machinery or injury to any
personnel
connected to the activity.
6.2 The test team should be well aware of procedures to be

adopted in case any abnormality in the activity.
7 STATE OF THE PLANT
7.1 APH and its associated system are erected as per

recommended drawing.
7.2 Acid cleaning of support and guide bearing Lub-oil line

completed.
7.3 All local instrumentation of Lub-oil system completed.
7.4 Power supply systems for the pumps are commissioned and
available for operation.
7.5 Plant Air is available upto APH.
7.6 Cooling water for support and guide bearing lub oil system is
available for operation. (Equipment Cooling water System)
7.7 Required local / remote C & I inputs for APH are made
available. (List to be mutually prepared at site).
7.8 Deluge and water wash lines are erected upto APH and
drainage facility is ensured.
7.9 APH fire sensing thermocouples are 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
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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 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.
7.14 Dampers at inlet and outlet of APH (flue gas) are made free
and connected to its drive. All loose materials / debris lying on
the dampers are cleared.
7.15 Main motor (AC-1 No) is kept decoupled from fluid coupling.
7.16 Service air line connection to Air Motor is complete with

lubricator cum Regulator.
7.17 Filters in the lub-oil system cleaned and put in position.
7.18 Oil level in the main gear drive ensured up to its normal level.
Local instrumentation of the gear drive completed.
7.19 Insulation of APH should be completed in all respect before

boiler light up with special attention given to Guide bearing
area.
7.20 Platforms, Ladders and other structures around APH are

inspected and thermal expansion of APH casing in all direction
ensured.
7.21 Aluminum 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
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system is free to move.
7.24 Breathers of bearing are checked for clean condition.
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 manhole doors are closed except one or two as decided by
the test team leader.
7.30 Oil carry over probe with cooling arrangement erected.
7.31 Air preheater “standstill” alarm system is made ready.
7.32 Air receiver tank is ready and filled with air.
8 METHOD
8.1 All related standard check list are duly filled.
8.2 Ensure all P&I checks are complete and are kept in service.
8.3 Acid cleaning and Oil Flushing of lub-oil system of support and
Guide Bearing system.
8.3.1 After completing the erection of the lub -oil system, oil lines are
dismantled and acid cleaned following the steps given in the
procedure.
8.3.2 Motors of Lub-oil system are decoupled from pump and after
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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.
8.3.3 After completion of motor trial run, both pump and motor are
coupled.
8.3.4 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 bearing, the
bearing itself is the oil reservoir and oil circulated back to
Bearings through filler and cooler) Leaks attended if noticed
during oil circulation.
8.3.5 Initially, the filters in the System are closely observed in terms
of 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.
Continue oil flushing till the pump discharge pressures stabilizes

for a
period of 4-6 Hrs
8.3.6 After completing the oil flushing, the filters are cleaned again
and put back in to the system.
8.3.7 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.
8.3.8 For safety reasons, the oil flushing activity to be performed

during day time.
8.4 Air pre Heater (A.C. Motor)
8.4.1 After ensuring the insulation resistance of the motor at

satisfactory level, motor bumped and direction of rotation
observed. After correcting the direction of rotation, if found
necessary, the motor put on 4 Hrs trial run. Motor no load
current and vibration are noted once during the trial run.
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8.4.2 After completion of motor trial run, motors are coupled to APH
main gear drive through fluid coupling.
8.4.3 Start the lub – oil system of guide and support bearing
assembly and establish circulation.
8.4.4 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.
8.4.5 Start the main motor again and allow APH to continuously run.
8.4.6 Observe of
a) Load current (To be logged)
b) Vibration of motor and gear unit (To be logged)
c) Rubbing of Seals / Aluminium finger taps.
(Rubbing of Seals do take place in cold condition and the team

leader to ensure that such rubbings are normal / abnormal)
8.4.7 Trial run of APH for 2 Hrs to be carried out with AC motor. Log
readings to be made.
8.4.8 Auto- start to be electrically ensured.
8.5 Air Preheater (With Air Motor)
8.5.1 Ensure:
a) Required air pressure (Around 5.0 KSC) at the supply
header to Air motor
b) Lubricator filled with oil.
c) Operation of solenoid valve
d) Pressure gauge in the Air supply line to Air motor.
8.5.2 Open the bypass valve manually and slowly operate air motor
vis-à-vis the APH
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8.5.3 Operation of air motor vis-à-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.
8.5.4 Interlock operation of APH running through Air motor checked

by creating the condition of electrical motor tripping.
Note: Normally, the air motor is commissioned during erection

of APH to facilitate erection process.
8.5.5 Rotate APH with manual handle.
8.6 APH Soot Blower
8.6.1 After ensuring the insulation value of the motor winding at

satisfactory level, the SB motor started and put on 4 Hrs trial
run. No load current logged once during the trial run.
8.6.2 Ensure:
a) Coupling of motor with speed reducer

b) Coupling of Speed reducer & gear box
c) Erection completion of swivel link arrangement with
gear
d) box and swivel arm.
e) Limit switches for sweep limit with its electrical
connections.
f) Recommended lubrication of speed reducer & gear
box.
g) Cleanliness of the nozzles.
h) Air line connection to APH SB
8.6.3 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.
8.6.4 Set the limit switches for:
a) Operating steam valve and

b) Stopping the SB at its parking location.
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8.6.5 Charge the air line slowly and blow the SB arm and nozzle
sufficiently.
8.6.6 Ensure the operation of APH SB from remote along with steam
valve opening.
8.7 Flushing of Deluge & Water wash system
8.7.1 Deluge and water wash system are similar in lay-out.
8.7.2 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.
8.7.3 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)
8.7.4 Flushing through both deluge system and water wash system
carried out one by one sufficiently till clear water observed at
drain outlet.
8.7.5 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)
8.8 General
8.8.1 Other miscellaneous system:
a) Rotor stoppage alarm

b) Oil carry over unit
c) Manual rotating of the rotor.
d) Light assembly for observation port
e) Interlocks with other systems of the boiler. All these
systems are commissioned separately through respective
sections in the O & M manual.
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9 COMPLETION CRITERIA
9.1 Air Preheater commissioning completed by carrying all the

proposals given in section 3.0 (Section 3.1 to 3.6)
LOG SHEET - I
PROJECT : -
UNIT NO. :
ACTIVITY: -
S No. TIME PUMP IN SERVICE DISCHARGE REMARKS

A B PRESSURE
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LOG SHEET - II
PROJECT : -
UNIT NO. :
ACTIVITY: -
S No. TIME MOTOR IN SERVICE VIBRATION REMARKS

MAIN / STAND BY
MOTOR APH GEAR
BOX
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Indiabulls

NASHIK POWER PROJECT

S No. LIST OF CONTENT

7 STATE OF THE PLANT

Rotary Air Preheaters supplied are of Tri-Sector type and

Rotary Air- Preheater generally comprises the following.

1.1 A.C Driven Motor – 1 No

1.2 Air Motor – 1 No. (with connected pipings & fittings)

1.3 Drive Gear Box.

1.4 Rotating elements with support and guide bearing

1.5 Soot blower system.

1.6 Fire Sensing device.

1.7 Deluge system

1.8 Water wash system

1.9 Observation ports and light arrangement

1.10 Rotor stoppage alarm

1.12 Oil carry over probe.

1.12 For the following system, refer drawings mentioned.

a) Guide Bearing Lub-oil System

To commission the rotary air Preheater and make it available

Commissioning of the rotary air preheater is proposed in the

3.2 Trial Run of Main Drive Motor for 8 Hrs.

3.3 Trial run of APH through main motor for 4 Hrs.

3.4 Commissioning of Air Motor and APH operation for 10

3.5 Commissioning of soot Boiler system

3.6 Flushing of Deluge and Water wash system.

4.1 Availability of manpower with required Tools for attending to

4.2 Availability of operating personnel to co-ordinate the

4.3 Availability of lighting arrangements and communication in

4.4 Availability of portable fire fighting equipments near test area.

4.5 Availability of service water

4.6 Availability of L.T supply

4.7 Availability of Equipment cooling water.

4.8 Availability of sufficient quantity of lub oil.

4.9 Availability of plant air.

4.10 Availability of steam for soot blowing.

5.1 Debris in and around APH shall be removed

5.2 Approach / stair case / platform wherever required are made

5.3 Manhole doors kept open for inspection should be clearly

5.4 First aid test available near test area.

5.5 Operation of local start / stop PB is ensured for perfect

6.1 The test team should be aware of the procedure to be

6.2 The test team should be well aware of procedures to be

7 STATE OF THE PLANT

7.1 APH and its associated system are erected as per

7.2 Acid cleaning of support and guide bearing Lub-oil line

7.3 All local instrumentation of Lub-oil system completed.

7.5 Plant Air is available upto APH.

7.9 APH fire sensing thermocouples are commissioned and kept

source) is made available for commissioning APH during

7.16 Service air line connection to Air Motor is complete with

7.17 Filters in the lub-oil system cleaned and put in position.

7.19 Insulation of APH should be completed in all respect before

7.20 Platforms, Ladders and other structures around APH are

system is free to move.

7.24 Breathers of bearing are checked for clean condition.

7.25 Light assembly and observation ports are in position and

7.30 Oil carry over probe with cooling arrangement erected.

7.31 Air preheater “standstill” alarm system is made ready.