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    Boilers Commisioning: BY Thermax Babcock & Wilcox

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    Bv Rao
    The document discusses the commissioning process for boilers. Commissioning brings the boiler and its auxiliary systems to life and makes them operational. It finds potential trouble areas before operation to ensure optimum performance. The commissioning process involves pre-commissioning activities like installation checks. It also involves commissioning activities like system cleanliness checks, auxiliary trials, leak testing, refractory drying, alkali boilouts, steam blowing, and safety valve testing. Performance testing is then done to ensure the boiler is operating as designed.

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    Download as PPT, PDF, TXT or read online from Scribd

    Boilers Commisioning: BY Thermax Babcock & Wilcox

    Uploaded by

    Bv Rao
    404 views20 pages
    The document discusses the commissioning process for boilers. Commissioning brings the boiler and its auxiliary systems to life and makes them operational. It finds potential trouble areas before operation to ensure optimum performance. The commissioning process involves pre-commissioning activities like installation checks. It also involves commissioning activities like system cleanliness checks, auxiliary trials, leak testing, refractory drying, alkali boilouts, steam blowing, and safety valve testing. Performance testing is then done to ensure the boiler is operating as designed.

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    Boiler commissioning

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    © Attribution Non-Commercial (BY-NC)

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    The document discusses the commissioning process for boilers. Commissioning brings the boiler and its auxiliary systems to life and makes them operational. It finds potential trouble areas before operation to ensure optimum performance. The commissioning process involves pre-commissioning activities like installation checks. It also involves commissioning activities like system cleanliness checks, auxiliary trials, leak testing, refractory drying, alkali boilouts, steam blowing, and safety valve testing. Performance testing is then done to ensure the boiler is operating as designed.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    404 views20 pages

    Boilers Commisioning: BY Thermax Babcock & Wilcox

    Uploaded by

    Bv Rao
    The document discusses the commissioning process for boilers. Commissioning brings the boiler and its auxiliary systems to life and makes them operational. It finds potential trouble areas before operation to ensure optimum performance. The commissioning process involves pre-commissioning activities like installation checks. It also involves commissioning activities like system cleanliness checks, auxiliary trials, leak testing, refractory drying, alkali boilouts, steam blowing, and safety valve testing. Performance testing is then done to ensure the boiler is operating as designed.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 20
    At a glance
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    The key takeaways are that commissioning involves bringing systems online and ensuring they meet performance requirements. It includes activities like pre-commissioning checks, trials of auxiliaries, leak testing, drying refractories, steam blowing, and performance testing.

    The purpose of pre-commissioning activities is to ensure the installation meets critical design dimensions and tolerances by checking aspects like alignments, supports, expansion clearances, tapping points, and access for operation and maintenance.

    The main steps involved in commissioning a boiler are system cleanliness checks, trials of auxiliaries, leak testing, drying refractories, alkali boil out, steam blowing, setting safety valves, tuning operation parameters, and performing performance trials.

    BOILERS COMMISIONING

    BY
    THERMAX BABCOCK & WILCOX
    WHAT IS COMMISSIONING?

    MEANS

    • BRING LIFE INTO THE BOILER


    AUXILLIARIES AND ASSOCIATED
    SYSTEMS.
    • MAKES THE BOILER & SYSTEMS
    OPERATIONAL.

    trg\comison.ppt 2
    COMMISSIONING - WHY?

    • FIND ALL THE POSSIBLE AREAS OF


    TROUBLE BEFORE OPERATION AND
    RECTIFY.
    • TUNE THE UNIT FOR OPTIMUM
    PERFORMANCE

    trg\comison.ppt 3
    PROCESS Commissioning

    CONTROLS
    Customer's order, OTF, MOM of KOM, contract change COMMISSIONING
    document, IBR.
    PROCESS
    OBJECTIVES To ensure that the boiler performance meets the stated (and implied)
    customer's expectations.

    INPUTS PROCESS OUTPUTS

    Advise from project Depute commissioning PG test report and H/O


    for commissioning engineer - carry out document.
    start(in any form). inspection for erection
    completion-prepare punch
    list,if needed- finalize
    commissioning schedule with
    Boiler ready for the customer at the site - List of pending items.
    commissioning. execute and review
    comm.plan and update -
    handing over of boiler to
    customer.

    Punch list for feed back on DDP


    pending items. item, if any.

    MECHANISM / RESOURCES PROCESS MEASURES

    Expertise in boiler operation Throughput Time plan v/s actual.


    process engineering support,
    calibrated instruments, customer Annual report of total number of boilers
    support and readiness. commissioned v/s plan.

    ISO references for this process.

    Clause: 6.2 Human resources. 7.2.3 : Customer communication. 7.3.6 : Design and
    development validation. 8.2.4 Monitoring and measurement of product.

    trg\comison.ppt 4
    METHODS

    • PRE-COMMISSIONING
    • COMMISSIONING
    • LOAD TRIALS
    • PERFORMANCE TESTING

    trg\comison.ppt 5
    COMMISSIONING DOCUMENTS

    • O & M MANUALS
    • ISO MANUALS
    • CHECK SHEETS / QAP
    • DESIGN DATA SHEETS
    • STAGE PROTOCOLS
    • FEED BACK - CAR / IOM

    trg\comison.ppt 6
    PRE-COMMISSINING

    • OBJECTIVE

    • TO ENSURE THE INSTALLATION


    COMPLIANCE TO CRITICAL
    DIMENSIONS AND TOLERANCES AS
    PER DESIGN DOCUMENTS.

    trg\comison.ppt 7
    WHAT TO LOOK FOR ?

     INSTALLATION AS PER DESIGN SPECS.


     ALIGNMENT
     SUPPORTS & SPRING HANGERS SETTING
     EXPANSION CLEARANCES
     PROCESS TAPPING POINTS
     ACCESS FOR OPERATION & MAINTENANCE
     REFRACTORY & INSULATION
     OTHERS CASE TO CASE BASIS – CHECK LISTS

    trg\comison.ppt 8
    COMMISSIONING ACTIVITIES

     SYSTEM CLEANLINESS CHECK


     TRIAL OF AUXILIARIES
     LEAK TEST
     REFRACTORY DRY OUT
     ALKALI BOIL OUT
     STEAM BLOWING
     SAFETY VALVE FLOATING
     TUNING - PARAMETERS AND INSTRUMENTS.
     PG TEST
    trg\comison.ppt 9
    SYSTEM CLEANLINESS

    • OBJECTIVE
    • TO ENSURE THE SYSTEMS ARE
    CLEAN WITHOUT ANY FOREIGN
    MATERIALS LIKE MILL SCALE,
    CONSTRUCTION MATERIALS,
    SCRAPES, TEMPORARY SUPPORTS
    ETC.

    trg\comison.ppt 10
    TRIAL OF AUXILIARIES

    • OBJECTIVE
    • TO ENSURE THAT THE PRIME
    MOVERS AND EQUIPMENTS ARE
    PERFORMING AS PER
    REQUIRMENTS

    trg\comison.ppt 11
    LEAK TEST OF DUCT & SYSTEM

    • OBJECTIVE

    • TO ENSURE THAT THE SYSTEM IS


    PROPERLY INSTALLED TO AVOID
    ANY LEAKAGES OF FLUID FROM
    AND TO THE SYSTEM.

    trg\comison.ppt 12
    LEAK TEST OF DUCT & SYSTEM
    • LEAK TEST AREAS
    • AIR & FLUE GAS PATH
     FURNACE
     WATER & STEAM CIRCUIT
     OIL CIRCUIT
     GAS CIRCUIT
     OTHERS – IF SPECIFIED

    trg\comison.ppt 13
    REFRACTORY DRYOUT

    • OBJECTIVE

    • TO ENSURE PROPER DRYING AND


    CURING OF REFRACTORY APPLIED
    IN THE CUMBUSTOR AND OTHER
    COMPONENTS

    trg\comison.ppt 14
    ALKALI BOILOUT

    • OBJECTIVE

    • TO ESTABILISE THE PRESSURE


    PARTS INTERNAL CLEANLINESS –
    FREE FROM OIL & GREASE WITH
    THE HELP OF CHEMICAL BOILOUT

    trg\comison.ppt 15
    STEAM BLOWING….

    • OBJECTIVE
    • TO ENSURE THE CLEANLINESS OF
    SUPERHEATERS AND MAIN STEAM
    LINE FREE FROM RUST, DIRT, AND
    MILL SCALE TO GET THE
    REQUIRED QUALITY STEAM FROM
    BOILER FOR PROCESS.

    trg\comison.ppt 16
    SAFETY VALVE SETTING

    • OBJECTIVE :

    • TO ENSURE THAT THE SAFETY


    VALVES FUNCTIONING PROPERLY
    AT THE DESIGNED / SET
    PRESSURES.

    trg\comison.ppt 17
    COMMERCIAL STEAMING…..

    • BOILER TUNING
     OPERATION PARAMETERS
    SETTING
     AUTO OPERATIONS
    • MATCH DESIGN VS ACTUAL
    PARAMETERS.

    trg\comison.ppt 18
    PERFORMANCE TRIALS

    • OBJECTIVE

    • TO ENSURE THE UNIT IS


    OPERATING AT DESIGNED /
    GUARANTEED CONDITIONS.

    trg\comison.ppt 19
    THANK YOU

    trg\comison.ppt 20

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