Prosedur Start Up Boiler PDF

PLTU 1 Jatim-Pacitan (2315MW) Project
Procedure of Start-up Boiler
Revised as comments
13/11/2010
Liu Gang
Long Sheng
Zeng Bin
Zhang Yaping
For approval
8/2/2009
Liu Gang
Long Sheng
Zeng Bin
Zhang Yaping
Rev.
Description
Date
Prepared
Checked
Reviewed
Approved
Owners DWG
No.
PT.PLN(PERSERRO)
0702-00-M-01-QH-001
PT.PLN(PERSERRO)
JAVA MANAJEMEN KONSTRUKSI
PT REKADAYA
ELEKTRIKA
CONSORTIUM OF
DONGFANG ELECTRIC CORPORATION AND DALLE ENERGY
SiChuan Electric Power
Commissioning & Test Institute
Approval
Review
Date
Check
Design
Scale
PLTU 1 Jatim-Pacitan (2315MW) Project
DETAIL
DESIGN
STAGE

N/A
DWG No.
SCCTI-TS-GL-CS-006-2009A
REV
PLTU 1 Jatim-Pacitan2315MW Project

Commissioning
Procedure
REV B
Page 2 of 44
Table of Contents
1.
Purpose ............................................................................................................. 3
2.
Scope .................................................................................................................. 3
3.
Preparation Basis ................................................................................................ 3
4.
Brief Description of System and Equipment...................................................... 3
5.
Tools and Instrument for Commissioning .......................................................... 4
6.
Prerequisite for Commissioning ......................................................................... 4
7.
Measures for Commissioning Organization....................................................... 7
8.
Commissioning Procedure.................................................................................. 9
9.
Safety Measures................................................................................................ 34
9.1
Safety rules for commissioning ........................................................................ 34
9.2
Personal Risk and Preventative Measures........................................................ 34
9.3
Equipment Risk and Preventative Measures .................................................... 35
10.
Appendix .......................................................................................................... 36
10.1
Appendix 1 Commissioning Condition Checklist............................................ 36
10.2
Appendix 2 Format for Trial Run Record ........................................................ 40
10.3
Appendix 3 Pressure boosting curve-boiling out ............................................. 40
10.4
Appendix 4 Pipeline Blowing System Diagram............................................... 41
10.5
Appendix 5 Check list of dampers ................................................................... 43
10.6
Appendix 6 Check List of Control Dampers.................................................... 44

Commissioning
Procedure
REV B
Page 3 of 44
1.
Purpose
1.1
Provide a guideline and set specifications for the commissioning work of system and
equipment so as to guarantee that the system and equipment will be able to put into operation
normally and safely.
1.2
Check the reliability of electric and I&C interlock protection and signal device.
1.3
Check the operation conditions of equipment. Examine performance of system so as to find

out and eliminate possible defects.
2.
Scope
The procedure is applicable to commissioning of startup boiler, including check and
confirmation of adjustment condition, valve baffle test, interlock protection test, drying,
boiling, pipe blowing and steam tightness test of startup boiler, safety valve calibration,
normal operation and shutdown of the boiler.
3.
Preparation Basis
3.1
Operation Manual for Startup Boiler
4.
Brief Description of System and Equipment
4.1
Brief introduction of the System

One 40t/h oil-fired start-up boiler, produced by Jiangsu Shuangliang Boiler Co., Ltd., is
equipped in PLTU 1 Jatim-Pacitan (2315MW) Project. Model: SZS40-1.25/350-YC water
tube oil-fired package boiler.
4.2
Main Technical Specifications of System Device
4.2.1
Main Technical Specifications of Boiler:

No.
Name
Unit
Values
Boiler Parameter
(1)
Boiler Maximum Continuous Rating
T/h
40
(2)
Outlet Steam Pressure
MPa
1.25
(3)
Outlet Steam Temperate
350
(4)
Inlet Water Temperature of Economizer
20
(5)
Temp of flue gas
160
(6)
Oil Pressure before Furnace
MPa
5.3
Technical Performance
%
92.7
(1)
Boiler Efficiency

Commissioning
Procedure
REV B
Page 4 of 44
No.
4.2.2
Name
Unit
Values
kW
165
%BMCR
30100
(2)
Gross Power of Supporting Auxiliaries
(3)
Load Change Scope
(4)
Steam Temperature Deviation Range
345370
(5)
Boiler Blowdown Rating
(6)
Type and Arrangement of Burner
Split type atomizer

burner, single and front
wall arrangement
Type of Steam Boiler Auxiliaries

(1)
Burner : supplied by boiler manufacturer, RPD90L-R
(2)
Forced draft fan: supplied by boiler manufacturer, GMB-32, 43000m3/h, 6000pa,

110KW, 380v
(3)
Water feed pump: supplied by boiler manufacturer, DG46-308, 46m3/h, 2.0Mpa,

55KW, 380v
(4)
Water box: supplied by boiler manufacturer, QR4025m3
(5) Blowdown flash tank: supplied by boiler manufacturer, 1500, 3.5 m3, 127
5.
Tools and Instrument for Commissioning
5.1
Walkie talkie;
5.2
Handheld vibration meter;
5.3
Digital multimeter;
5.4
Handheld thermodetector
6.
Prerequisite for Commissioning

Before formally beginning system commissioning, commissioning persons should conduct
comprehensive checks on conditions that should be available for commissioning of this
system according to contents listed in Appendix 1 (Commissioning Condition Checklist) and
make well the records.
There are turn over packageTOPfrom contruction that mention contruction already finish
and ready to be commissioned.
Please see Appendix 1 Commissioning Condition Checklist and running parameter table of
the FDF & Water pump (on section No.8.2).
6.1
6.1.1
Prerequisite Required before Trial Operation of System

Flue Gas and Air System
(1)
Boiler air pressure test has been successfully completed through acceptance or each air
leakage has been treated.

Commissioning
Procedure
6.1.2
6.1.3
REV B
Page 5 of 44
(2)
Boiler proper and flue gas duct have been assembled and insulated.
(3)
Individual commissioning and subsystem commissioning of forced draft fan have been
completed.
(4)
All dampers of flue gas and air systems have been inspected, adjusted and accepted.
Fuel Oil System

(1)
System has been assembled and individual commissioning has been completed.
(2)
System hydraulic pressure test and water flushing has been completed successfully.
(3)
Compressed air pipeline and valves for blowing should be assembled and tested.
(4)
All motorized valves and pneumatic valves for systems have been tested and accepted.
(5)
The burner has been assembled and tested.
(6)
All interlock protection simulation test for systems have been successfully completed
(7)
The ON/OFF tests for all oil guns and high-energy igniters have been successfully
completed.
(8)
Static commissioning for all flame detectors has been completed.
(9)
Please see oil gun test table of the boiler (on section No.8.2).
Boiler Proper
(1)
Boiler proper have been installed, insulated and accepted;
(2)
Individual commissioning and interlock protection test for water feed pump have been
completed.
(3)
Hydrostatic tests of the boilers have been successfully completed;
(4)
The drain, vent, blowdown and nitrogen charging systems of the boilers have been
installed and insulated. All motorized valves have been tested and accepted.
(5)
After hydrostatic tests, hydraulic valve spools have been removed from all safety valves
of the drums and superheaters, the safety valves have been restored to original state or
states. Blind plates have been removed from steam and water systems.
(6)
Spring supports and hangers of steam and water pipeline are complete and in good order
and pins have been removed.
(7)
All motorized valves and pneumatic valves on all steam and water pipeline have been
tested and accepted.
(8)
The parties check jointly the boiler proper expansion systems to confirm that boiler
expansion is not restrained.
(9) Ladders, platforms and railing on boiler proper are complete and illuminated sufficiently
and the boiler proper has been cleaned thoroughly.
(10) Drum level gauges have been installed, the level is indicated correctly.
(11) Boiler water samplers and dosing systems have been installed, inspected and accepted
correctly.

Commissioning
Procedure
REV B
Page 6 of 44
(12) Feed water system, desuperheating water systems have been installed and insulated. All
motorized valves and pneumatic valves have been tested.
(13) All manholes and access doors on the boiler proper are complete and closed;
(14)Please see running parameter table of the water pump (on section No.8.2).
6.1.4
Compressed Air System

(1)
6.1.5
6.1.6
6.1.7
6.2
Instrument& service air compressors have passed commissioning individually or as a

subsystem and are ready for use.
Fire Protection System

(1)
All fire fighting facilities are complete, fire water tests have been successfully
completed and the systems are at standby state.
(2)
Fire fighting equipments have been equipped at boiler house, control room and place
with fuel oil systems.
Industrial Water System

(1)
Industrial water systems have been installed and hydrostatic tests have been successfully
completed.
(2)
Commissioning of industrial water pumps and industrial water subsystems have been
completed and pumps and systems are ready for operation.
Chemical Water System

(1)
The chemical system is able to supply water continuously.
(2)
Commissioning of make-up water systems has been completed.
Conditions that must be available with electrical and I&C
Please see running parameter table of the FSSS, sequence control of boiler start and
stop ) and interlock (on section No.8.2).
(1)
(2)
(3)
Cold commissioning of the boiler FSSS (fuel oil systems and the burner) has been
completed
1)
Furnace blowing conditions have been checked and tested;
2)
Fuel oil FSSS tests and interlock test (performed after the FSSS test) have been
completed;
3)
The fuel oil leak test has been completed;
4)
Combustion management systems for all oil guns have been tested.
Sequence control, interlock and protection test of each auxiliary device has been
completed;
1)
Starting conditions, tripping conditions, program-controlled

program-controlled shutdown of forced draft fan
startup
and
2)
Starting conditions, tripping conditions, program-controlled

program-controlled shutdown of water feed pump
startup
and
Electric and I&C have been calibrated and are accurate.

Commissioning
Procedure
6.3
6.4
7.
REV B
Page 7 of 44
(4)
For flue gas and air systems, measuring points of air temperature and pressure, furnace
negative pressure, pressure switch, flue gas temperature and pressure of heating surface
of different grade have been installed and are ready for operation.
(5)
For steam and water systems, measuring points of drum pressure, superheater pressure,
steam temperature, feed water pressure, temperature and flow, steam flow and water
level meter with electric contacts have been installed and tested and are ready for
operation.
(6)
For fuel oil system, measuring points of fuel oil pressure and temperature, flow meters,
compressed air pressure have been installed, tested and are ready for operation.
(7)
Measuring points of auxiliary current, bearing temperature and vibration have been
installed, tested and are ready for operation.
(8)
Commissioning of various protections, alarms and visual and audio signals has been
completed and they are able to generate alarms properly.
Conditions Required for Environment

(1)
The field is leveling; road is clear; cover on trenches are complete; wastes have be
cleared.
(2)
Platforms, ladders, railings protecting sheets are complete; construction scaffold have be
removed.
(3)
Site is sufficiently illuminated. Temporary illumination can be arranged if necessary.
(4)
Communication device is complete. Reliable communication equipment should be

equipped.
Other Conditions Required

(1)
The construction contractor, builder, Owner, Supervisor, Manufacturer and testing

agency inspect the entire units thoroughly to confirm that the unit is ready for ignition.
Problem found must be solved immediately, if any.
(2)
Preparation for trial operation has been completed and operators have been assigned,
trained sufficiently and examined. Operation procedures and system drawings have been
reviewed and approved and operating tools and log are available.
(3)
Chemical products and material required for commissioning have been prepared.
Sufficient amount of chemical water, fuel oil and coal have been prepared according to
the design requirements.
(4)
Necessary maintenance tools and materials are prepared.
(5)
A sound commissioning management organization has been established and the

responsibilities have been clearly defined.
(6)
Commissioning material, tools, instrument and record lists have been prepared.
(7)
Instrument control, electric and engineering personnel are on site.
Measures for Commissioning Organization

This procedure shall be executed under the organization of commissioning contractor. The
construction contractors shall cooperate closely with each other according to their respective
work responsibilities so as to guarantee safe and effective implementation of commissioning.
The division of works is as follows:

Commissioning
Procedure
7.1
REV B
Page 8 of 44
Responsibilities of Commissioning Contractor

Preparation and revision of commissioning procedures;
Preparation of commissioning plan;
Preparation of instruments and equipment required for commissioning;
Hold technical disclosure meeting for commissioning;
Organize the commissioning work to be carried out by various parties;
Give instructions to operators in the operation;
Prepare commissioning report.
7.2
Responsibilities of Installation Contractor

Be responsible for individual commissioning of equipment and provide relevant record and
certificate of commissioning;
Be responsible for inspection, maintenance and defect elimination of equipment under
commissioning;
Prepare maintenance tools and materials necessary for commissioning;
Assist the commissioning contractor in the commissioning of subsystems;
Be responsible for temporary coordination of local I&C components and connection
terminals.
7.3
Responsibilities of Equipment Manufacturers

Representative of manufacturer, if present on the site offering service, shall provide technical
assistance during equipment commissioning.
7.4
Responsibilities of Plant Operator

Prepare tools to be involved in operation;
Prepare operation log and forms;
Operate the system and equipment according to the operating procedures and the instructions
of the commissioning personnel;
Be responsible for patrol inspection, check, and normal maintenance of system and
equipment;
Be responsible for dealing with the accidents occurred in commissioning
7.5
7.6
Responsibilities of Dongfang Electric
Be responsible for supervision and control over commissioning work;
Coordinate with commissioning contractor, the Owner, and other contractors in the
commissioning.
Participate in and witness the commissioning work;
Organize analysis and settlement of major technical issues in commissioning
Responsibilities of Owner

Commissioning
Procedure
REV B
Page 9 of 44
Supervise the execution of commissioning procedures;
Witness the commissioning work;
Accept the results of commissioning
8.
Commissioning Procedure
8.1
Test of Valves
8.2
(1)
Test and accept motorized (solenoid) on off valve, and record data.
(2)
Test and accept pneumatic on off valve and record data.
(3)
Test and accept pneumatic adjustable valve and record data. See Appendix 5 and 6.
Interlock protection and alarm check (note: interlock protection test is subject to the results of
logic discussion)
(1)
Put the power supply of fans and water feed pump at testing position
(2)
Check the flowing items:
(3)
Start the fans or water feed pump on computer and the feedback on computer is right.
(4)
Stop the fans or water feed pump on computer and the feedback on computer is right.
(5)
Operation of the emergency button is reliable.
(6)
Interlock protection of start-up boiler system is as the following:
Record table of water feed pump start and trial operation

Waterfeed pump
Name
Trial operation
unit
Start current
Normal running current
Bearing TEM.
Non Drived side
Motor bearing TEM.
Drived side
First start
no load
Second start
no load
Normal running
Vibration Drived side
mm/s
Vibration pump side
mm/s
Completed By
SEPCTI
Signature
DEC
PLN JASER

Commissioning
Procedure
REV B
Page 10 of 44
Date
Record table of FDF start and trial operation

FDF
Trial operation
Name
First start
no load
unit
Start current
Normal running current
Bearing TEM.Non Drived

side
Motor
bearing
TEM.
Drived side
Second start
no load
Normal running
VibrationDrived side
mm/s
Vibrationfan side
mm/s
Completed By
SEPCTI
PLN JASER
DEC
Signature
Date
Boiler interlock checklist of FSSS

No.
Test item
1.
Action conditions of FSSS Protection
Act emergency shut-off
FDF Stopped
Feed water pump Stopped
Drum water level low (1 of 2),190mm boiler shut-off and

alarm
Oil fuel loss(oil inlet pressure low 2.0MPa or return oil

pressure high 1.0MPa )
Fixed value
button
190mm
Inlet
2.0MPa
Return 1.0MPa
Results
Remarks

Commissioning
Procedure
REV B
Page 11 of 44
Drum and superheater pressure high(1 of 2)(drum 1.33

MPa and superheater 1.29 MPa)
Oil gun has put into service and furnace oil flame detector
no flame (loss flame, delay 8s)
Feed Air pressure low
2.
Boiler Fault reset(or)
Reset button on DCS
Reset button on PLC control cabinet
3.
Furnace purge(conditions meet ,time 2 min.) (and)
The FDF has been running and inlet air damper is opened
to more than 70%
no flame of the flame detector
No FSSS protection action
All oil feed and return valves closed(4 valves)
The lamp of boiler startup is ready for startup
Drum water level is normal
4.
Results of FSSS protection action
Oil gun tripped and closed all oil feed and return valves(4
valves)
Ignitor solenoid valve close and forbid ignitor to fire
5.
Open condition of Oil gun feed valves(and,2valves)
Open instruction of oil gun feed valves give out
No FSSS protection condition
Small gas gun has been running
6.
Trip condition of Oil gun feed valves(or,2valves)
Boiler shut-off instruction give out
Any one of FSSS protection action exists
7.
open condition of Oil gun return valves(and,2valves)
Open instruction of oil gun return valves give out
No FSSS protection condition
1.33MPa
1.29MPa
10mbar

Commissioning
Procedure
REV B
Page 12 of 44
Small gas gun has been running
8.
Trip condition of Oil gun return valves(or,2valves)
Boiler shut-off instruction give out
Any one of FSSS protections action exists
9.
Boiler sequence control
Boiler sequence start:

Boiler startup instruction give out , start FDF motor,
automatically open air damper to more than 70%,
automatically start purging furnace for 1 min.; then
automatically close damper to 20% position, then
program automatically give out light instruction.(details:
first, high power ignitor automatically light, then
automatically light up small gas gun ;after about 3s,
automatically light big oil gun and automatically open oil
4 feed/return valves. after 5s, automatically stop small gas
gun. The flame detector detect flame and exist, mean the
startup process is success. If not, after 5s, the flame
detector is no flame, the startup process is failure.
Boiler sequence stop:

Press shut-off button, automatically close all oil valves,
inlet air damper of FDF automatically open to 70%
position and automatically start purging process for 2
min.. after completed purging, This air damper
automatically close and stop FDF motor.
Completed By
SEPCTI
DEC
PLN JASER
Signature
Date
Interlock checklist of water pump and water& steam system

No.
Test item
1.
Trip condition :(or)
Motor fault tripped
Fixed value
result
remark

Commissioning
Procedure
REV B
Page 13 of 44
2.
Start condition:(and)
Feed water control valve put into less than 10% position
Startup instruction give out
Power control cabinet is ready
3.
Stop condition:(and)
Power control cabinet is ready
4.
Interlock open of Desuperheater control valve
Superheater outlet steam TEM. more than fixed value
5.
Interlock close of Desuperheater control valve
Superheater outlet steam TEM. less than fixed value
6.
Interlock open of Feed water control valve
Drum water level low (less than 230mm)
7.
Interlock close of Feed water control valve
Drum water level high (more than 260mm)
Open of main steam valves (all conditions are met)
Send command to open valve
Power supply of main steam valves is not broken
State of program control
9.
Close of main steam valves (all conditions are met)
Send command to close valves
Power supply of main steam valves is not broken
State of program control
230mm
260mm
Completed By
SEPCTI
Signature
DEC
PLN JASER

Commissioning
Procedure
REV B
Page 14 of 44
Date
Interlock checklist of FDF and system

No.
Fixed
value
Test item
1.
Trip condition :(or)
Send command to stop FDF
MOTOR fault trip
2.
Start condition:(and)
Feed air damper place in less than 10% position
Power supply cabinet is ready
3.
Stop conditionand
Power supply cabinet is ready
result
remarks
Completed By
SEPCTI
DEC
PLN JASER
Signature
Date
Boiler signal alarm checklist

No.
Test item
Drum water level high high, alarm and close feed water
control valve
Drum water level low low, boiler shut down and alarm
Water box water level low low, alarm
Drum pressure high high, boiler shut down and alarm
Superheater pressure high high, boiler shut down and alarm
Fixed value
300mm
190mm
200mm
1.33mpa
1.29mpa
result
remarks

Commissioning
Procedure
REV B
Page 15 of 44
360
Superheater outlet STEAM TEM. High, only alarm
Feed water pump overload, boiler shut down and alarm
FDF overload, boiler shut down and alarm
Main pipe inlet oil pressure low, boiler shut down and alarm
10
Return oil pressure low, boiler shut down and alarm
11
flue gas Temp. high, only alarm
12
Inlet Feed Air pressure low, boiler shut down and alarm
13
Abnormal flame loss, boiler shut down and alarm
14
Startup failure ,boiler shut down and alarm
15
Furnace pressure high, only alarm
2.0mpa
1.0mpa
150
10mbar
5kpa
Completed By
SEPCTI
DEC
PLN JASER
Signature
Date
Test record format for oil valve leakage check

Result (local confirmation)
No.
Tight not leakage
Slight leakage
Serious leakage
1 feed solenoid valve

2 feed solenoid valve
3 return solenoid valve
4 return solenoid valve
Completed By
SEPCTI
Signature
DEC
PLN JASER

Commissioning
Procedure
REV B
Page 16 of 44
Date
Test Record Format for Oil Gun Atomization Output

Atomization inspection
Atomization piece
Specification
(t/h)
FO. press.
1.5-3.5MPa)
A1
1.5 MPa
A1
2.5 MPa
A1
3.5 MPa
Atomization angle
Output determination
Atomization effect
Local
output(t/h)
DCS counted output

(t/h)
Completed By
SEPCTI
DEC
PLN JASER
Signature
Date
8.3
Drying
8.3.1
Purpose
There is moisture in newly-built furnace wall. If putting it into operation directly without slow
drying treatment to increase its strength, the moisture in furnace wall will generate some stress
because of volume expansion caused by sudden evaporation, which may lead to crack,
deformation and damage to furnace wall, even collapse if serious. So, drying under low burning
according to requirements is a must before putting the boiler formally into operation.
According to the special type of water wall, the long period time of boiler installation and
local weather, the boiler maker need not to do the boiler drying work. This information will
provided to owner before system commissioning.
8.3.2
Conditions required before drying

(1)
Boiler proper and its auxiliary device have been installed, insulated and pass the air
leakage test. The waste inside have been cleared and air leak test of furnance wall is
qualfied.
(2)
Main steam pipeline system, water feed system have been installed and pass the
hydraulic pressure test.
(3)
Brick laying, heat insulation and finishing of start-up boiler have been completed. Open
every access door to dry the boiler naturally over 72 hours.
(4)
Device in drum has been completed. For water level meters, level mark is clear, position
is correct, and illumination is sufficient to read the water level.

Commissioning
Procedure
REV B
Page 17 of 44
(5)
Relevant water releasing system have been installed. Water feed pump can feed water to
boiler at any time.
(6)
Remote operation of I&C, sound, light and audio signal, and installed and checked
protection device can be put into operation.
(7)
Feed demineralized water to the drum water level -30mm, and flush the water level
meter clearly.
(8)
Cooling water system has been installed and pass the water test.
(9)
Water discharge system has been completed. And discharge is smooth.
(10) Daily oil tank has been installed. Oil tank has been cleared, and oil pipeline has been
blown clearly.
(11) Fuel oil system between oil tank and start-up boiler has been installed, insulated, blown
throughly by compressed air, are with normal hydraulic pressure and ready for oil
supply.
(12) All auxiliary device, valves and dampers of boiler have been tagged.
(13) Each rotatory machine has passed commissioning as a subsystem.
(14) On and off of steam and water valves, flue gas and air dampers of boiler have been
checked. Their movement is flexible, on-off direction and marks are correct.
(15) Safety protection system of boiler has been tested.
(16) Necessary illumination should be arranged for access road and equipments in
commissioning field. Road is clear; cover on trenches and holes are complete.
Communication is ready for clear liaison.
(17) Steam trap on superheater is on to maintain normal pressure in drying.
(18) Started oil guns of burner on boiler is well atomizedl, burn normally and pass service
test.
(19) The uniform commissioning organization of sufficient number of operators,
maintenance personnel and security personnel shall be built. The operators shall be
trained suitably and be familiar with the associated equipments and systems and
operating methods and aware of commissioning measures, their own responsibilities and
works to prevent incorrect operation.
8.3.3
Methods and Steps

(1)
Close manhole of bottom drum, handhole of header, main steam valves, exhaust steam
valves, blow down valves and drain cock of level meter.
(2)
Inject demineralized water, with temperature lower than 40, into boiler through
economizer to the low water level of boiler (-20-30mm), and close the water feed
valve. When the water level in boiler is stable, observe whether the level decreases and
check whether water leaks from the cover of the handholes, flange joint and blowdown
valves. If not, bolts should be fastend and maintain low water level in
boiler.(-20-30mm)
(3)
Check whether oil tank has oil, oil pipeline leaks and oil and pipeline heaters are put
into operation.
(4)
Start forced draft fans and adjust the damper regulator to blow the furnace.

Commissioning
Procedure
(5)
REV B
Page 18 of 44
Ignite with firewood. Control the combustion intensity by outlet flue gas temperature of
furnace. Control the flue gas temperature strictly. On the first day, the rise does not
exceed 50. Later, the rise does not exceed 80 every day. At last stage, highest
temperature of flue gas does not exceed 160. Highest temperature does not last for
over 24 h. During the drying, the water level of boiler should be maintained normal.
Drying period should be controlled according to the degree of natural drying. During the
drying, do not use hard fire, open exhaust steam valve to release air to keep no pressure
in boiler, and heat slowly to avoid blow hot and cold to prevent the insulating layer of
fire proof material from cracking and damage. Keep no pressure rising in drum, steam
pressure for drying is not higher than 0.1MPa.
Note: Installation contractor should make temporary racks inside boiler to keep wood.
8.3.4
Safety Notice for Drying

During the drying, fully open steam trap on superheater and exhaust steam valve at outlet of
superheater.
(1)
Flame should be controlled from light to strong and burn in the center uniformly to
ensure uniform exotherm. Check furnace wall and expansion state of each part
frequently, report the abnormal situation timely, if found.
(2)
During drying, strictly control the water level in drum, maintain it in normal scope, and
feed water timely.
(3)
Before drying, reserve discharge holes for moisture at proper position.
(4)
After drying, prepare temperature rise curve and relevant records.
Boiler drying record table

Date/time
Drum water levelMM Outlet TEM. of furnace

Remark
Completed By
SEPCTI
Signature
Date
8.4 Boiling out

8.4.1
Purpose
DEC
PLN JASER

Commissioning
Procedure
REV B
Page 19 of 44
Eliminate high temperature oxidation peel-roll, corrosion products, welding slag, silt, oil stain
and other debris produced in rolling, processing, storage and installation. Generate protection
layer in the inner wall to prevent corrosion, maintain the heating surface of boiler clean,
increase the steam and water quality to prevent encrustment and corrosion, save fuel, extend
life span and ensure safe and economic operation of boiler unit.
8.4.2
8.4.3
8.4.4
Scope and process of alkaline boil-out

(1)
Scope: water screen system, lower drum, upper drum (the part under the flushing
centerline of upper drum )
(2)
Washing: three steps are conducted for washing:
Flush with lots of water before washing;
Boil out the boiler with chemicals;
Flush the boiler with hot water after washing.
Conditions required before boiling out

(1)
Hydraulic test has been completed and tested.
(2)
Commissioning of water feed pumps, induced draft fans and forced draft fans has been
completed.
(3)
Chemicals for boiling out and containers for disolution have been prepared.
Commissioning of chemical feed pump has been completed successfully.
(4)
Chemical water system can continuously supply enough demineralized water with
sound quality. Flushing and recovery of dosing system have been completed and the
system is ready for operation at any time.
(5)
Operator of power generator should be on duty and report state of water quality at any
time.
(6)
Temporary indicator lights to indicate high, low and normal water level are equipped at
control room the platform of drum, which have been prepared and accepted.
(7)
Operator and installation and maintenance people can operate and prepare necessary
tools. Inspection and preparation for igntion should be done in advance according to
Operation Specification before boil-out so as to make startup and ignition upon
commands.
(8)
Systems have been tagged. Correct and clear marks is with various equipments, valves
and flow direction of medium.
The following systems should be commissioned before boiling out.

(1)
(2)
Flue Gas and Air System:
The inside has been cleared cleanly, checked and accepted.
Dampers have been adjusted, checked and accepted.
Individual commissioning of forced draft fan has been passed.
Fuel Oil System
Hydraulic pressure test has been passed.
Blowing has been completed;

Commissioning
Procedure
(3)
REV B
Page 20 of 44
Fuel oil circulating is qualified;
Fire control device relevant to fuel oil have been tested and accepted.
Water Feed System
8-hour individual commissioning of water pump has been completed successfully;
Flushing of water feed pipeline has been completed successfully;
Relevant interlock test has been completed successfully.
(4)
Dosing system is ready for operation
(5)
Industrial water system is ready for operation
(6)
Ignition system of boiler
Atomization and service tests have been completed.
Ignition device has been tested normally.
(7)
All instruments of boiler have been assembled tested and are ready for operation.
(8)
Relevant valves of boiler have been assembled tested and accepted.
(9)
Water drainage systems are ready for use.
(10) Water feeding system are ready for use.

(11) Blowdown system of boiler are ready for use.
(12) All other systems that impact ignition of boiler
8.4.5
Method and Procedures

(1)
Boiler working and hydraulic pressure test
1)
Check that the system meets the requirements for hydraulic pressure test
2)
Send water to boiler with water feed pump. In hydraulic test, ambient temperature
should be over 5 above zero. Frost protection measures should be taken when
temperature is under 5. Temperature of water used for hydraulic test should be over
the ambient dewpoint temperature so as to prevent dew formation on the surface of
boiler. The temperature should not be very high in order to prevent evaporation and high
temperature difference. The temperature is usually within 20-70.
3)
Close the air vent when water comes out from them continuously. Boost pressure slowly
at speed within 0.100.15MPa/min. Stop boosting pressure if abnormal situation is
found.
4)
Boost pressure to 0.40MPa and fasten bolts of manholes, inspection holes and flanges.
5)
Boosting pressure to 0.98MPa. Stop to check completely whether leakage or abnormal

situation exists.
6)
If nothing is abnormal, boost pressure continuously to 1.29MPa and maintain for 20min
to check whether leakage or abnormal situation exists.
7)
Hydraulic test is passed if:
No water drops and spray on metal wall or welding.

Commissioning
Procedure
REV B
Page 21 of 44
No residual deformation after the test.
No leakage at connection to economizer.

Boiler Record format Of Hydraulic test
item
result
No water drops and spray on metal wall or welding
Yes No
No residual deformation after the test
Yes No
No leakage at connection to economizer
Yes No
remarks
Completed By
SEPCTI
DEC
PLN JASER
Signature
8)
After passing hydraulic test, release pressure and water. During the pressure reduction,
clean I&C tubes, chemical sample tubes and water drainage pipes.
9)
Flush boiler with water.
(2)
Preparation of chemicals and dosing
1)
After the hydraulic test, feed water to 1/3, Stop and check system and isolate the water
feed and drainage and blowdown system. Add chemicals slowly into the container while
agitating. After the chemicals dissolve, feed the solution to the upper drum. Start the
water feed pump of boiler to send water to the low level in drum.
2)
Dosing amount: sodium hydroxide (NaOH) 4 kg per m3 water; trisodium phosphate

(Na3PO4) 4 kg per m3 water (calculated according to 100% purity quotient). Water
volume is 25m3 (normal operating water volume in manufacturer's specification)
3)
Dosing Requirements:
Before cleaning, feed NaOH or Na3PO4 12H2O slowly to the container at several
times, and feed demineralized water (or soft water) to dissolve chemicals
sufficiently for future use.
No solid chemicals can be fed directly into the boiler.
4)
After feeding chemicals, feed water to flush the container 2 to 3 times.
5)
After ignition, supervise water level in drum to maintain normal level. No full water is
allowed. No water comes into superheater.
6)
Strictly control burning capacity in the first ignition and pressure boosting. Considering
the expansion in the funnel of furnace wall and temperature difference between upper
and lower wall of drum, pressure boosting rate can not be too fast, increasing to
0.2MPa-0.4MPa within 2 hours. Maintain the pressure and flush water level meter.
Inform the installation contractor to tighten the screws in hot state. Boost the pressure to

Commissioning
Procedure
REV B
Page 22 of 44
0.80MPa within 5 to 6 hours. Maintain pressure at 0.8-1.0MPa for boiling out.

7)
Record expansion of each part under the following situation:

Before and after feeding water, 0.4Mpa, 0.8MPa, 1.0MPa. Any part found to impact the
expansion should be reported timely to stop increasing pressure. Continue boosting
pressure after eliminate defect.
8)
Start timing when the pressure raises to 0.8MPa. Maintain pressure within 0.8-1.0MPa
for 24 hours in boiling out. Steam drainage volume is 10%-15% of the rated
evaporation.
9)
After 240hour boiling out, maintain pressure of boiler, and each blowdown point
discharge waste and change water. This moment, strictly supervise water level in drum
and prohibit full and lack of water.
10) After feeding chemicals, take furnace water sample by chemical method to test
alkalinity once every two hours. In the later stage of boiling out, test can be done once
every one hour.
11) Normally shut down boiler after boiling out. Decrease pressure and drain water.
12) After the temperature decreases, open the manholes on upper and lower drum and lower
header of water wall to clear away internal foreign matters.
8.4.6
Boiling precautions
(1)
Agitate homogeneously when adding chemicals. Must not lift alkaline chemicals on
shoulder or with hands. Operators should ware rubber overshoes, gloves and protection
masks. Cold water resource and relevant chemicals should be arranged in place where
prepare and add chemicals.
(2)
No water comes into superheater in boiling out. Strictly supervise the water level in
drums and arrange experienced operators as far as possible to adjust feed water timely.
(3)
Closely watch the state of each rotary machine and expansion of boiler proper. Solve
problems timely, if found.
(4)
In boiling out, one local level meter is set in drum, and one regulated pressure gauge is
used. Assign people to watch the water level and inform water feeder timely.
(5)
Pipeline irrelevant to boiling out should be isolated completely. Prevent washing liquid
in key system from getting into other systems to avoid accident.
(6)
In boiling out, blocked blowndown pipeline and valves should be cleared timely, if
found.
(7)
In field, road should be clear, illumination should be sufficient, warning sign as

"Washing! Dangerous! " etc. should be pasted, and guard rail and fence should be set.
(8)
In washing field, flushing water taps, soaps, towels and emergency medicine (3 L 0.2%
boric solution, vaseline or scream to cure scald) and emergency car should be prepared,
and also take necessary protection measures. If the alkali solution splashes onto skin
or into eyes, flush with fresh water immediately, and then neutralize with 0.2%
boric solution and flush with fresh water again. Ones seriously hurt should be sent
to hospital for rescue immediately.
(9)
After boiling out, the manhole can be opened until the temperature of drum wall
decrease to under 50 with monitoring of people. When the nuts could be loosen after

Commissioning
Procedure
REV B
Page 23 of 44
2 to 3 threads, use a wooden stick to unclench door of manhole (No people face the door
directly). After the inside negative pressure disappears, open the door of manhole and
assemble reticular close board on it.
(10) If no measures are mentioned for some conditions, execute the "Boiler Operation
Specification". If accident occurs, deal with it according to Specification for Accident
Handling.
Boiler record format of boiling-out

Date/time
Drum pressureMPA
3-
OH-
PO4
Remarks
Completed By
SEPCTI
DEC
PLN JASER
Signature
Date
8.5 Steam Purging
8.5.1
Purpose
To ensure the safety and economy operation of the units, the inevitable welding slag, metal
rust and other sundries in the boiler superheater and pipeline of steam system of newly
assembled units shall be purged to the cleanest extent before the formal steam supply.
8.5.2
8.5.3
8.5.4
Scope
Boiler superheater system
Steam pipeline connecting start-up boiler to auxiliary steam header
Purging plan
Purge the boiler superheater system by energy storage (pressure decrease) method.
the Process: steam drum--> superheater--> main steam valve--> main steam pipeline-->
temporary vent pipeline
Purge steam pipeline connecting start-up boiler to auxiliary steam header and boiler
superheater system simultaneously.
Steam parameter for purging

Open main steam valve when the drum pressure reached 0.5~0.6MPa. After fully open main
control valve, drum pressure decreases to 0.4~0.5MPa. At that time, close main steam valve.
8.5.5
Quality standard

Commissioning
Procedure
REV B
Page 24 of 44
According to the new "Technical Code for Erection and Acceptance of Electric Power
Construction (1996 Edition)", while ensuring the purging factor larger than one, the purging
work is qualified as the matter, maximum particle diameter on the target board no more than
0.5mm and number of macroscopic spot no more than 5, happens for twice continuously.
8.5.6
8.5.7
Temporary devices
(1)
The temporary pipeline shall be connected in proper place before plant-service steam
header and be led to safe place for steam exhausting with outlet directed to open space.
Target board shall be installed in the suitable place near regular pipeline. In condition
that the quality of purging is guaranteed, minimize the length of the pipe, elbows and
joints to reduce the resistance for the system.
(2)
Temporary purging pipeline shall be equipped with solid and reliable supports and
hangers and consider the thermal expansion of the pipeline and steam counterforce by
purging.
(3)
Same-diameter short pipe shall be connected instead of main steam flow orifice plate
until the purging work is finished.
Precondition for ignition

(1)
Systems return to normal after boiling and cleanup of upper and lower drum and
sub-header of water wall.
(2)
Main boiler and auxiliary equipments have been installed and insulated. Platform,
handrail and boarding are complete.
(3)
All facilities which affect the expansion have been removed.
(4)
Sufficient illumination is around the boiler proper and auxiliary units.
(5)
Installation of water level meter in drum shall meet the requirements. The local water
level meters are accurate and remote water level meters are regulated and can be put into
use for purging.
(6)
Sundries shall be cleared up inside the furnace and funnel.
(7)
Water charging and supply system shall meet the requirement and be ready to use.
(8)
Purging control valve have been adjusted and temporary pipeline have been completed
according to requirement.
(9)
In boiler house, discharge systems of washing water and overflow have been installed as
per design requirements.
(10) Dosing, sampling, blowdown systems have been installed as per design requirements.
(11) Chemical water treatment system can guarantee to supply qualified demineralized water.
(12) Purging field is tidy, road is clear, trench covers are complete, and scaffolding have been
removed for convenient operation. Operating floor has been completed basically without
any vulnerability such as voids etc.
(13) The utilities system can guarantee the safety and stability of production, construction
and commissioning.
(14) Preparation work has been done for commissioning. Operators, trained and tested, are
qualified. Operation specifications and system diagram have been approved. Operating
tools are fully equipped and commissioning log is prepared.

Commissioning
Procedure
REV B
Page 25 of 44
(15) A sound commissioning management organization has been established, the

responsibilities and liaison system have been clearly defined. Personnel for adjustment,
maintenance and operation are on board. Commissioning measures have been approved
and technical clarification has been performed.
(16) Chemicals materials, chemical water and fuel oil for commissioning are ready.
(17) Fire-fighting equipments and facilities in field shall meet the requirements.
(18) The Installation Contractor, Operation Contractor, Owner, Supervisor, Contractor and
Commissioning Contractor inspect the entire units thoroughly to confirm that the unit is
ready for ignition. Problem found must be solved immediately, if any.
8.5.8
8.5.9
8.5.10
8.5.11
Tests before ignition

(1)
The system valves and dampers for purging shall be inspected completely by operators
to meet the following requirements: flexible operation; on-off direction accords with the
indication; and remote panel conforms with local one.
(2)
Test for interlock protection
Preparation before ignition

(1)
Start up water feed pump until the water level reaches about -30mm in the drum.
(2)
Preparation before ignition should been made as per specifications when receiving
ignition signal.
Notify the electric control room to feed the rotary machine, electric dampers and
electrically operated steam and water valves to be used.
Heating control room feeds the panels and instruments to be used.
Put cooling water system into use.
Ignition is implemented as per specifications.
Purging process
(1)
Ignite and increase the pressure once receiving ignition signal. When the pressure
reaches to 0.2MPa, steam pipeline should be warmed up. After that, trial purging is
started and check if the system expansion and stress state are normal when the pressure
is up to 0.3MPa. If normal, boost pressure continuously to 0.4MPa~0.5MPa for next
purging until the target board is basically qualified. Then shut down and cool the boiler
for 12hr and ignite the boiler and boost the pressure again to purge until the target board
is qualified.
(2)
After purging, to boost pressure for leak test and safety valves adjustment or to shut
down for system recovery is subject to the site conditions.
Safety precaution and instruction

(1)
Keep combustion as stable as possible when purging.
(2)
The drum water level control to avoid severe water shortage or overfall is of the greatest
significance during purging period.
As the control valve opens, the steam pressure decreases sharply, which causes great rise
of drum water level. Actually, it is false appearance, and the water supply shall be
increased suitably rather than being decreased. For the reason that the drum water level

Commissioning
Procedure
REV B
Page 26 of 44
declines greatly even it is invisible when the control valve is closed, increase the water
supply to maintain a visible level when closing the valve. When the water level starts to
rise again, reduce the water supply promptly to avoid rising too high.
To prevent steam from bearing lots of water, the drum water level shall be maintained
around -50mm before opening the control valve in purging.
(3)
No flammable and explosive materials near purging pipeline. No people in area 20m
around steam outlet. Set guard line and assign persons to be on duty.
(4)
Make sure that everyone has left before opening the control valve, especially when
changing the target board. Person unrelated shall keep away from purging pipeline.
(5)
Pipeline shall be warmed up completely before purging. Trial purging, under the
pressure 50%~75% of the regular pressure shall be conducted once or twice to inspect
the conditions of support, expansion and leakage of the temporary system and learn the
control method of water feed flow gradually. Steam trap on main steam pipeline shall be
partially opened while the other is closed during normal purging work..
(6)
A target board shall be put in the pipeline to check the dirtiness of pipeline and the
reliability of board in the first purging.
(7)
All rotary machines shall be monitored by relevant personnel.
(8)
Operation should be conducted in a manner of unity of command. Shut down purging in

case of emergency, and handle accident according to Accident Management Procedure.
(9)
The parts unable to be purged by steam shall be cleaned mechanically and manually.
Safety measures shall be considered to prevent the dirt from recovered welding joint.
(10) 20 pieces of target board, made of aluminum and polished, should be prepared.
Target boar size: no less than 8% of the inner diameter of discharging pipeline in width;
and equal to the inner diameter in length.
Steam purging record format

Date/time
Open valve
Drum
Superheater
PRESS.(MPA
outlet TEM.
Drum
PRESS.(MPA
Close valve
Superheater
outlet PRESS.
MPA
Superheater
outlet TEM.
Completed By
SEPCTI
Signature
DEC
PLN JASER
Target
Yes/No

Commissioning
Procedure
REV B
Page 27 of 44
Date
8.6
Steam Tightness Test
8.6.1
Purpose:
To guarantee the safety operation of the units in future, the steam tightness test, under the
operating pressure at hot state, is to completely inspect the boiler's heating surface, the steam
& water pipeline, steam header, flanges. welded junction, expansion system and load-carrying
capability, displacement and the extension of fixing apparatus or spring supports and hangers.
8.6.2
Test Content:
(1)
Close the main motorized steam valve at the boiler outlet; the pressure boosting rate can
be controlled by the adjustment of fuel oil pressure or the exhaust steam valve. When
pressure rises to 1.29MPa and is at steady state, people specially assigned shall check
the tightness of the boiler proper, auxiliary device and the steam and water pipelines
involved.
(2)
Inspection the tightness of welded joints and flanges of the boiler.
(3)
Inspection tightness of all the steam and water valves of the boiler proper system.
(4)
For steam and water pipeline of the boiler, check its expansion condition, check whether
the load-carrying capability, the displacement and the extension of its supports, hangers
and spring hangers are normal, and check whether any barriers impact the expansion.
Steam tightness test checklist
contents
Check result
Inspection the tightness of welded joints and flanges of the boiler.
Yes No
Inspection tightness of all the steam and water valves of the boiler
proper system.
For steam and water pipeline of the boiler, check its expansion
condition, check whether the load-carrying capability, the
displacement and the extension of its supports, hangers and spring
hangers are normal, and check whether any barriers impact the
expansion.
remarks
Yes No
Yes No
Completed By
SEPCTI
Signature
Date
8.6.3
Testing conditions:
(1)
Purging has been completed.
DEC
PLN JASER

Commissioning
Procedure
8.6.4
8.6.5
REV B
Page 28 of 44
(2)
Areas inside and outside boiler is cleaned. Road is clear.
(3)
All inspection holes and manholes have been closed.
(4)
Tests and inspections before ignition have been completed.
Test Procedure
(1)
Timely adjust combustion intensity and open rate of steam trap. Control temperature and
pressure rise rate according to Operation Specification.
(2)
Record expansion value at the following conditions: before and after water feed,
0.30.4Mpa, 1.0MPa, 1.25MPa.
(3)
Start steam tightness test when pressure of main steam rise to 1.25MPa.
Safety Precautions:
(1)
Strictly control increasing rate of temperature and pressure to ensure sufficient

expansion of each heating part of boiler proper.
(2)
Check the expansion state of each heated part in pressure boosting process. Report
problems if found. Stop increasing temperature and pressure, if necessary, to take
measures to eliminate a hidden danger. Then continue the process.
(3)
Operation should be conducted in a manner of unity of command. Strictly follow orders

and prevent personal injury and damage to equipment. All operating personnel
participating commissioning shall strictly follow Safety Regulations and related safety
provisions at site, thus to ensure safe and reliable commissioning.
(4)
If equipment damage or personal injury may occur, stop works immediately and shut
down the unit if necessary, and then analyze causes and take corrective measures;
(5)
During entire commissioning, personnel of various discplines shall be in place, thus to

ensure equipment operation safety.
8.7
Safety valve setting
8.7.1
Purpose:
Being the primary safety devices for the boiler, safety valves of drum and superheater shall be
adjusted to act accurately and reliably before commissioning to ensure the safe operation of
the boiler unit.
8.7.2
Setting parameter: Refer to attached table.
8.7.3
Preparation before tests
8.7.4
(1)
Safety valves have been installed and checked, which accords with installation
requirements.
(2)
Standard pressure gauges, calibrated and provided by the installation contractor to adjust
the safety valves on site, have been installed (06MPa per one, above grade 0.4).
(3)
Safety valves platform is clean. Road is clear. Illumination is sufficient.
(4)
Adjustment tools, communication tools and record lists are prepared.
Setting procedure
(1)
Start steam discharge test when pressure rise to 0.8MPa-0.9MPa. Check the steam

Commissioning
Procedure
REV B
Page 29 of 44
discharge and action of safety valves. If no problems found, continue boosting pressure
to the setting pressure needed for setting. The setting of safety valves is conducted
before the setting of safety valve of superheater.
8.7.5
(2)
Decrease pressure after the setting of safety valves. Start the setting of safety valves on
the superheater.
(3)
If the trial actuation of the safety valve is not qualified for the first time, decrease
pressure and adjust it again. Then increase pressure to test the trial actuation until it is
qualified.
Safety Precautions:
(1)
During the adjustment of safety valve, operators and safety valve adjustors should act
according to the unified command of commissioning personnel so as to ensure personal
and equipment safety. .
(2)
Participants should keep their post according to work division and take records of
operation, adjustment and check.
(3)
During the adjustment, enough platform and railings should be set around safety valves;
illumination is sufficient.
(4)
Before setting, release the drum water level protection, in case the false level caused by
take-off of safety valve starts the protective action of boiler.
(5)
During pressure boosting, assign people to check the tightness and expansion of boiler.
Report and solve problems found to impact the increasing of pressure and temperature
timely.
(6)
During the adjustment, operator is responsible to maintain the stable working state of
unit, especially the stable pressure. At the moment the safety valves discharge steam,
drum water level changes greatly. So, when adjusting the safety valves, drum water
level should be lower than the normal level. Adjust the water supply to control the drum
water level properly.
(7) Decrease the pressure to 75% of the actuation pressure before adjusting the safety valves.
Experienced operator with protection masks and heating-insulated gloves adjust the
safety valves, and others should be kept away from the field.
(8)
During the adjustment, adjust the weight of safety valves on drums. Remove top cover
of safety valves on superheater, unscrew or wind up spring to reach the set actuation
pressure. Then tighten fastening screw, assemble the top cover and tighten the hexagon
screw.
(9)
Do not hit any parts on the safety valve. Lift handle directly to open the safety valve.
(10) After the adjustment of safety valve, all externally adjusted parts should be marked,
fastened, sealed, recorded and certificated before put into operation.
Attached List:
The hot setting value record format of boiler safety valve
Name/Type
Drum
Safety valve
Design value
Popping Press.
Return Press.
MPa
MPa
1.43
1.33-1.37
Actual setting value

Popping Press.
Return Press.
MPa
MPa
Remarks
4-7%

Commissioning
Procedure
A48Y-25
Super heater
Safety valve
SA48Y-25
1.30
REV B
Page 30 of 44
1.21-1.25
4-7%
Completed By
SEPCTI
DEC
PLN JASER
Signature
Date
Remarks: Actuation value of safety valve is from the Manufacturer's Information.
8.8
Load commissioning
8.8.1
Test purpose:
Load commissioning is main process of unit commissioning. Concerning to the safety, quality
and project period of unit commissioning, load commissioning is a comprehensive
performance evaluation of the unit and complete check and inspection of the sub-system
commissioning at the early stage.
8.8.2
Conditions required before load commissioning

(1)
Drying and boiling out, steam purging, tightness test, safety valve setting of start-up
boiler have been completed.
(2)
All temporary system used in sub system have been removed.
(3)
All defects found in the subsystem commissioning have been eliminated.
(4)
Chemical water system is complete to supply qualified demineralized water at any time.
(5)
Plant-service power system is complete to cut and supply power according to

commissioning requirements at any time.
(6)
Illumination and communication system is complete to communicate at any time. Fire

control equipments are equipped.
(7)
In commissioning field, road is clear, illumination is sufficient, emergency illumination

is reliable.
(8)
Boiler chemical feed, sampling, blowdown and drainage, air vent system have been
installed and insulated.
(9)
All steam and water valves and dampers for boiler have been installed and tested.
On-site open rate is the same as that shown in center control room.
(10) Confirm that the following systems have been installed and can be put into operation.
Boiler air and flue gas system;
Water feed system;

Commissioning
Procedure
REV B
Page 31 of 44
Fuel oil system;
Industry water system;
Chemical sampling system;
Drainage system;
Water supply, drainage and fire control system;
Main steam system and its desuperheating water
(10) All on-site instruments and instruments on operation platform and panels have been
installed and calibrated, and can be put into use.
(11) All interlock protection loop has been installed. After static test, all interlock, protection
and alarm value have been set according to requirements. Visual and audio system has
been adjusted.
(12) Boiler expansion indicator has been installed according to design requirements.
Expansion barriers have been eliminated and expansion indicator has been regulated to
zero.
(13) Observation holes, manhole door and inspection holes have been closed. Explosion door
is complete.
(14) Prepare sufficient fuel oil for commissioning.
(15) Prepare sufficient chemical water and chemicals.
(16) Production preparation has been made. Operators passing training are on duty.
(17) Organization is complete and job division is clear.
(18) Constructor organizes maintenance team and prepare materials and tools for
maintenance.
(19) Operation measures should be approved and clarified under the direction of
commissioning command party. Commissioning, operation, maintenance personnel is on
duty.
(20) Marks of equipment and main pipeline are complete and meet requirements. Tags on
system equipment and valves are complete.
(21) Auxiliary header on the steam supply side has been installed and insulated and are ready
for steam.
8.8.3
Commissioning period
(1)
Non-load period
After the commissioning of all subsystem of start-up boiler, restore the temporary
system and steam can be sent to auxiliary header. The warm-up of pipeline before
supplying steam to the auxiliary header is the non-load commissioning.
(2)
Load period
After the start-up boiler supplies steam to the auxiliary header, adjust the burning
capacity according to steam consumption of users, and adjust the boiler load to keep
pressure steady.
8.8.4

Commissioning
Procedure
REV B
Page 32 of 44
(1)
Non-load procedure
1)
Water feed
Water feed time: winter2 hrs; summer1 hrs. Feed water temperature <40. Before
feeding water, close blowdown valves and open air vent and exhaust steam valve to
release air in boiler. Start water feed pump to inject soft water to the boiler through
economizer. Stop water feed pump when the water level is higher than the low alarm.
After the level is stable, check whether the level decreases. If so, check and deal with it.
2)
Work before ignition: check the conditions required
3)
Ignition of boiler.
Boiler sequence start:
4)
boiler startup instruction give out ,start FDF, set ventilation tunnel.
automatically open inlet air damper of FDF to more than 70% position, the furnace
pressure is about 1000--5000Pa.
program automatically start purging furnace for 1 min.
program automatically close damper to 20% position.
Program automatically give out light instruction.
details: first, high power ignitor automatically light, then automatically light up
small gas gun ;after about 3s, automatically light big oil gun and automatically
open oil 4 feed/return valves. after 5s, automatically stop small gas gun. the flame
detector detect flame and exist, mean the startup process is success. If not, after
5s,flame detector is no flame, boiler startup process is failure.
Pressure boosting
After ignition, adjust the oil pressure of oil gun according to temperature and
pressure rise curve for cold start-up. Increase pressure and temperature of boiler.
At the early stage of pressure boosting, adopt low burning. When boosting the
pressure, temperature can not rise too fast to avoid overlarge heat stress caused by
uneven heating.
After the pressure rises, watch the level in boiler. Level rises because of heating. If
it exceeds the highest level, start blowdown.
When saturated vapour is generated in the drum or drum pressure reaches 0.1MPa,
increase combustion, close exhaust steam valve and flush water level meter and
elbow of pressure gauge at the same time.
When drum pressure rise to 0.1MPa, close corresponding air vent.
Drum pressure rises to 0.2--0.4MPa and operation is steady. Check whether the
boiler is abnormal. Ask installation contractor to tighten screws in hot state. Ask
heating engineering team to flush instrument pipe and regulate the level meter.
Ask the chemical team to flush the sample tube.
When pressure increases gradually, note whether each part makes special sound. If
so, check the state immediately. Shut down furnace to check, if necessary. Start
operation after lifting failure.
Continue boosting pressure. When drum pressure reaches the required value, stop

Commissioning
Procedure
REV B
Page 33 of 44
burning.
5)
Open the valve of superheat steam outlet to put water feed system into operation,
adjust combustion, open desuperheating water, and supply steam formally.
Continuous bolwdown should be carried out during steam supply.
Formal steam supply
When steam pressure reaches working pressure 1.25MPa, supply steam. Before
supplying steam, maintain low drum water level, sufficient pipeline warm-up and
steady combustion in furnace,
Desuperheating water is used to adjust the temperature of superheat steam. When

the temperature of superheater steam is higher than the required value, increase the
desuperheat water to decrease the temperature of superheat steam by motorized
control valve of desuperheating system. When the temperature of superheater
steam is lower than the required value, decrease the desuperheat water to increase
the temperature of superheat steam. Adjust the temperature of superheat steam
within 3455.
(2)
Load period
1)
Adjust the burning capacity according to steam consumption of users and fuel oil
pressure. Maintain steady pressure, combustion, water level of boiler. Keep steam
temperature within regulated scope. The oil temperance and pressure meet the
requirements.
2)
Start thermal adjustment of automatic control system at proper time, according to load
of boiler.
(3)
(4)
Automatic adjustment of drum level
Automatic adjustment of combustion(steam pressure)
Automatic adjustment of desuperheating water(superheater outlet temperature)
Normal operation and maintenance
When boiler is in operation, continue feeding water to keep water level within
normal scope. Water level meter should be flushed at least once each shift.
Note the combustion state frequently. Maintain reasonable air distribution for good
combustion. Keep the furnace pressure between10005000Pa
Supervise and maintain the pressure and temperature of overheat steam, and make
it within normal scope
Note the boiler proper and gas and air flue, and make pressure, gas temperature
and wall temperature of them within normal scope.
Check the reliability of valve action frequently. Patrol equipment and system
frequently. Report or handle with abnormal situation, if found.
Supervise the quality of feed boiler water. Periodical and continuous blowdown
should be executed after receiving the notification of chemical team.
Operator should take records of boiler operation parameter hourly
Normal shut down

Commissioning
Procedure
(5)
8.8.5
REV B
Page 34 of 44
Reduce fuel and corresponding air volume gradually to weaken the boiler capacity.
With the decreasing of the load, reduce water to maintain normal level in drum
When the steam supply is cut off, close the boiler outlet motorized valve. If the
pressure continues boosting, steam release and water fed should be strengthened.
After pressing the shut down button, the burner will turn off oil-gas solenoid valve
automatically. After five minutes, blow the furnace, and the boiler will shut down
automatically. After flameout, check and close flue baffle and manual valves of
fuel oil system. Stop the oil pump. Stop water feed pump when water is stopped.
Before the drum pressure decreases to the atmosphere, temperature of flue gas and
air system and auxiliary device must be supervised continuously.
Occasions for Emergency Shut Down
Pressure over the specified value
Low low water level in drum, and level can't be observed
Water supply device malfunction, fail to feed normally
All level meters malfunction
All safety valve malfunction
Cracks on boiler, blurts of water wall tube, overheat steam pipe and economizer
pipe burst and damage of boiler wall threats the safe operation of boiler severely
Complete trial operation record

For main parameter in trial operation, see the Appendix 2.
9.
Safety Measures
9.1
Safety rules for commissioning
9.1.1
The parties participating in commissioning shall be familiar with and abide by the relevant
safety rules, wear reasonable clothing and appropriate personal protective equipments.
9.1.2
In case of any accident that damages the equipment or hurts person happened or possibly
happen during commissioning, suspend commissioning immediately and put the equipment to
the lowest energy state. Then investigate the cause and take corrective measures.
9.1.3
The parties participating in the commissioning shall obey the command of commissioning
personnel. In case there is an emergency endangering personal or equipment safety, any
person has the right to stop the operating equipment immediately and report to the control
room.
9.1.4
All professional staffs shall be on respective duties during the whole commissioning to
guarantee the safe operation of equipments.
9.2
Personal Risk and Preventative Measures
Rotary machine
In adjustment or test, people may be injured by the rotary machine. So, work carefully
to avoid touching the rotary parts with hands or tools.
Misapplication or non-wearing of helmet

Commissioning
Procedure
REV B
Page 35 of 44
In adjustment or test, injury or death may be caused by object strike. Once in field, wear
helmet and safety belts. Check and eliminate the dangerous thing which may fall from
upper and surrounding area of operation.
Burned by damage of temporary purging pipeline.

All temporary pipeline should be insulated. Before purging, pipeline should be warmed
sufficiently to avoid water hammer accident. Perform trial purging several times under
pressure 40%50% and 70%80% of the purging pressure.
Steam burn and noise pollution at purging steam outlet

Assign people to arrange safety isolation measures strictly at purging steam outlet.
Injured by high temperature flue gas of observation hole and manhole door
Close all observation hole and manhole door. Increase pressure properly before fire
observation on site. In fire observation, stand on the side of the hole, and make metal
preparation for evacuation at any time.
9.3
Equipment Risk and Preventative Measures
Abnormal operation
If it is found that an operating equipment emits abnormal sound or has other abnormal
condition, and such problem may not be eliminated, stop such equipment and report to
the control rooms immediately
Fuel oil system fire

Strict fire-fighting measures should be set during commissioning. No combustibles and
explosives materials are laid around fuel oil system. Sufficient fire control equipment is
equipped on site.
Bad combustion results in flameout; accumulative oil make explosive flame

Fire failure protection must be arranged. Strengthen combustion adjustment to ensure
good combustion. If atomization of oil gun is poor, must clean it manually. After
flameout in furnace, 5-minute purging must be conducted before re-ignition.
Equipment damages and people injuries result from over temperature or pressure
Feed fuel slowly and steadily. Strengthen the monitoring of flue temperature in different
points. In case that burning rate is out of control, shut down boiler immediately. Assume
the pressure-releasing accident in advance. Strictly control the superheater outlet
pressure no more than 1.25MP and the steam temperature no more than 350.
Otherwise, weaken burning or release pressure. Over pressure operation is forbidden,
especially before safety valves are adjusted and put into operation.
Instrument damages result from burning of accumulated oil at tail end

Strengthen combustion adjustment to ensure good combustion; blow the dust on the
heating surface at tail end regularly. After shutting down, normal water lever must be
maintained and the system must be purged heavily before close; Meanwhile, strengthen
the monitoring of the flue temperature at tail end, deal with problems timely, if found.
Irregularly check soot in the end funnel and blow away regularly. Boiler should be
purged with heavy blow before and after restart. Assign people to monitor here, and
temporary fire-fighting equipment fire water system are available.

Commissioning
Procedure
REV B
Page 36 of 44
10.
Appendix
10.1
Appendix 1 Commissioning Condition Checklist
No.
1
Items
Requirements
Result
Conditions for trial commissioning
Flue gas &air

systems
Fuel Oil System
Boiler Proper
Boiler air pressure test has been successfully

completed. Each air leakage has been treated.
Yes No
Boiler proper and flue gas duct have been assembled

and insulated.
Yes No
Individual
commissioning
and
subsystem
commissioning of forced draft fans have been
completed.
Yes No
All damper flue gas and air systems have been

inspected, adjusted and accepted.
Yes No
System has been assembled and

commissioning has been completed.
Yes No
individual
System hydraulic pressure test and water flushing has

been completed successfully.
Yes No
Compressed air pipeline and valves for blowing should

be assembled and tested.
Yes No
All motorized valves and pneumatic valves for systems

have been tested and accepted.
Yes No
The burner has been assembled and tested.
Yes No
All interlock protection simulation test have been

successfully completed
Yes No
The ON/OFF tests for all oil guns and high-energy

igniters have been successfully completed.
Yes No
Cold commissioning for all flame detectors have been

completed.
Yes No
Boiler proper have been installed, insulated and

accepted;
Yes No
Individual commissioning and interlock protection test

for water feed pump have been completed.
Yes No
Hydrostatic tests of the boilers have been successfully

completed;
Yes No
The drain, vent, blowdown and nitrogen charging

systems of the boilers have been installed and
insulated. All motorized valves have been tested and
accepted.
Yes No
After hydrostatic tests, temporary valve plugs have

been removed from all safety valves of the drums and
superheaters, the safety valves have been restored to
original state or states. Blind plates have been removed
from steam and water systems.
Yes No
Spring supports and hangers of steam and water
Yes No
Verified
by
Rema
rks

Commissioning
Procedure
REV B
Page 37 of 44
pipeline are complete and in good order and pins have

been removed.
Compressed Air
System
Fire Control
System
Industrial Water
System
Chemical Water
System
All motorized valves and pneumatic valves on all

steam and water pipeline have been tested and
accepted.
Yes No
The parties check jointly the boiler proper expansion

systems to confirm that boiler expansion is not
restrained .
Yes No
Ladders, platforms and railing on boiler proper are

complete and illuminated sufficiently and the boiler
proper has been cleaned thoroughly.
Yes No
Drum level gauges have been installed, the level is

indicated correctly.
Yes No
Boiler water samplers and dosing systems have been

installed, inspected and accepted correctly.
Yes No
Feed water system, desuperheating water systems have

been installed and insulated. All motorized valves and
pneumatic valves have been tested.
Yes No
All manholes and access doors on the boiler proper are

complete and closed;
Yes No
Instrument& service air compressors have passed

commissioning individually or as a subsystem and are
ready for use.
Yes No
All fire fighting facilities are complete, fire water tests

have been successfully completed and the systems are
at standby state.
Yes No
Fire fighting equipments have been equipped at Boiler

House, Control Room and place with Fuel Oil
Systems.
Yes No
Industrial water systems have been installed and

hydrostatic tests have been successfully completed.
Yes No
Commissioning of industrial water pumps and

industrial water subsystems have been completed and
pumps and systems are ready for operation.
Yes No
The chemical system is able to supply water

continuously.
Yes No
Commissioning of make-up water systems has been

completed.
Yes No
Electric and Heating Control Test

Cold
commissioning
of the boiler
FSSS (fuel oil
systems) has
been completed
Sequence
control, and
protection test of
Furnace blowing test have been completed
Yes No
Fuel oil FSSS tests and interlock test (performed after

the FSSS test) have been completed;
Yes No
The fuel oil leak test has been completed;
Yes No
Combustion management systems for all oil guns have

been tested;
Yes No
Starting
conditions,
tripping
conditions,
program-controlled startup and program-controlled
shutdown of forced draft fan
Yes No

Commissioning
Procedure
each auxiliary
device
Electric and I&C
Various
protections,
alarms
and
visual and audio
signals
REV B
Page 38 of 44
Starting
conditions,
tripping
conditions,
program-controlled startup and program-controlled
shutdown of water feed pump
Yes No
For flue gas and air systems, measuring points of air

temperature and pressure, furnace negative pressure,
pressure switch, flue gas temperature and pressure of
heating surface of different grade have been installed
and are ready for operation.
Yes No
For steam and water systems, measuring points of

drum pressure, superheater pressure, steam
temperature, feed water pressure, temperature and
flow, steam flow and water level meter with electric
contacts have been installed and tested and are ready
for operation.
Yes No
For fuel oil system, measuring points of fuel oil

pressure and temperature, flow meters, compressed air
pressure have been installed, tested and are ready for
operation.
Yes No
Measuring points of auxiliary current, bearing

temperature and vibration have been installed, tested
and are ready for operation.
Yes No
It has been tested and they are able to alarm properly.

Yes No
Conditions for Environment

Field, road and
cover
wastes have be cleared.
Construction
scaffold
complete
have be removed.
Temporary
illumination
can be arranged if necessary
Communication
equipments
complete
Reliable
Other conditions
Inspect the entire units thoroughly to confirm that the
unit is ready for ignition. Problem found must be
solved immediately
The construction
contractor,
Owner,
Supervisor,
Manufacturer
and testing
agency
Operation
procedures
Pass review, operation tools and logs are well prepared
Chemical
product,
material,
ready
have been prepared according to the design
requirements.
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No

Commissioning
Procedure
REV B
Page 39 of 44
chemical water
and fuel oil
4
Overhaul tools
and materials
ready
A sound
commissioning
management
organization
established and the responsibilities have been clearly

defined.
Commissioning
material, tools,
instrument and
record lists
ready
Instrument
control, electric
and engineering
personnel
on site
Yes No
Yes No
Yes No
Yes No
Completed By
SEPCTI
Signature
Date
DEC
PLN JASER

Commissioning
Procedure
10.2
REV B
Page 40 of 44
Appendix 2 Format for Trial Run Record

Content
Unit
Data
Content
Unit
Boiler load
T/h
Main steam temperature
Main steam pressure
MPa
Supply oil pressure
MPa
Main steam flow
T/h
Open rate of #1 oil return valve
Drum pressure
MPa
Current consumption by forced draft fan
Water level in drum
mm
Open rate of damper of forced draft fan
Feed water flow
T/h
Outlet pressure of forced draft fan
KPa
Feed water pressure
MPa
Furnace pressure
PA
Temp. of feed water
Temperature of flue gas at outlet of

superheater
Desuperheatering water flow
T/h
Feed water pump current
Water level in feed water box
mm
Open rate of Feed water control valve
Temperature of flue gas at outlet

convection bank
Open rate of desuperheator control valve
Bearing TEM.OF FDF
Bearing TEM.OF Feed water pump
Motor Bearing TEM.OF FDF
Motor Bearing TEM.OF Feed water pump
Bearing vibrationOF FDF
mm/s
Bearing vibrationOF Feed water pump
mm/s
Completed By
SEPCTI
Signature
Date
10.3
Appendix 3 Pressure boosting curve-boiling out
DEC
PLN JASER
Data
Page 41 of 44
56
52
48
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
40
36
32
28
24
0
Press. MPa
12
16
20
mantainepressure0.8~1.0 MPa
44
Pressure curve boiling out

10.4
Appendix 4 Pipeline Blowing System Diagram
REV B
time
Hot flushing
Commissioning
Procedure

Commissioning
Procedure
REV B
Page 42 of 44
To atmosphere
M
control valve
main steam pipe
superheater
Upper drum
Pipeline Blowing System Diagram
Target board

REV A
Page 43 of 44
10.5
Appendix 5 Check list of dampers
Dampers commissioning record

Local position
indication
Name
Remote
Direction
Feedback
Operating time
On
Off
(Open)
(Close)
Main steam valve

#1 oil inlet valve
#2 oil inlet valve
#1oil return valve
#2 oil return valve
#1 ignition valve
#2 ignition valve
Completed By
SEPCTI
Signature
Date
DEC
PLN JASER
Date
Result
Signature
Remarks

REV A
Page 44 of 44
10.6
Appendix 6 Check list of control dampers

Commissioning record of control dampers
Name
Feedback of ascending and descending instruction values

0%
25%
50%
75%
100%
75%
50%
25%
Control damper of forced

draft fan
Water feed adjustable valve
Waterbox feed adjustable valve
Desuperheatering water
adjustable valve
1#oil return adjustable valve

2#oil return adjustable valve
Completed By
SEPCTI
Signature
Date
DEC
PLN JASER
0%
Date
Result
Signature
Remarks

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PLTU 1 Jatim-Pacitan (2315MW) Project

Procedure of Start-up Boiler

PLTU 1 Jatim-Pacitan (2315MW) Project

Procedure of Start-up Boiler

PLTU 1 Jatim-Pacitan2315MW Project

Procedure of Start-up Boiler

Preparation Basis ................................................................................................ 3

Brief Description of System and Equipment...................................................... 3

Tools and Instrument for Commissioning .......................................................... 4

Prerequisite for Commissioning ......................................................................... 4

Measures for Commissioning Organization....................................................... 7

Safety rules for commissioning ........................................................................ 34

Personal Risk and Preventative Measures........................................................ 34

Equipment Risk and Preventative Measures .................................................... 35

Appendix 1 Commissioning Condition Checklist............................................ 36

Appendix 2 Format for Trial Run Record ........................................................ 40

Appendix 3 Pressure boosting curve-boiling out ............................................. 40

Appendix 4 Pipeline Blowing System Diagram............................................... 41

Appendix 5 Check list of dampers ................................................................... 43

Appendix 6 Check List of Control Dampers.................................................... 44

PLTU 1 Jatim-Pacitan2315MW Project

Procedure of Start-up Boiler

Check the operation conditions of equipment. Examine performance of system so as to find

Operation Manual for Startup Boiler

Brief Description of System and Equipment

Brief introduction of the System

Main Technical Specifications of System Device

Main Technical Specifications of Boiler:

Boiler Maximum Continuous Rating

Outlet Steam Pressure

Outlet Steam Temperate

Inlet Water Temperature of Economizer

Temp of flue gas

Oil Pressure before Furnace

PLTU 1 Jatim-Pacitan2315MW Project

Procedure of Start-up Boiler

Gross Power of Supporting Auxiliaries

Load Change Scope

Steam Temperature Deviation Range

Boiler Blowdown Rating

Type and Arrangement of Burner

Split type atomizer

Type of Steam Boiler Auxiliaries

Burner : supplied by boiler manufacturer, RPD90L-R

Forced draft fan: supplied by boiler manufacturer, GMB-32, 43000m3/h, 6000pa,

Water feed pump: supplied by boiler manufacturer, DG46-308, 46m3/h, 2.0Mpa,

Water box: supplied by boiler manufacturer, QR4025m3

Tools and Instrument for Commissioning

Handheld vibration meter;

Prerequisite for Commissioning

Prerequisite Required before Trial Operation of System

PLTU 1 Jatim-Pacitan2315MW Project

Procedure of Start-up Boiler

Fuel Oil System

The burner has been assembled and tested.

Static commissioning for all flame detectors has been completed.

Boiler proper have been installed, insulated and accepted;

Hydrostatic tests of the boilers have been successfully completed;

PLTU 1 Jatim-Pacitan2315MW Project