369051174-Basic-of-Commissioning.pdf

VT4 Project
Commissioning Dept.
Technology Transfer
[Day1-1] Basic of Commissioning

1
Index
1.1 What is Commissioning
1.2 Terminology of Commissioning
1. Summary of Commissioning
2. Commissioning Sequence
2.1 Pre-Commissioning
2.2 Cold Commissioning
2.3 Hot Commissioning
1.3 Individual system and equipment test

2
1.2 Terminology of Commissioning
1. Summary of Commissioning
Contents

3
The primary objective of metallurgical plant commissioning is to ensure that all
systems and equipment of a plant are installed, tested, operated, and
maintained according to the operational requirements of the client. For large
projects, this process usually comprises planning, execution, and control of
thousands of inspection and test activities on sections to be com-missioned,
and these include instrumentation, control loops, and all electrical and
mechanical equipment.
The process of commissioning is integrated into various phases. This is
executed by the project team and includes the plant operational and
engineering staff as well as the con-tractors responsible for the installation and
cold commissioning. The overriding factor is the attention to detail required
with respect to safety of people, protection of equipment and the environment.

4
1.2 Terminology
1.2.1 Pre-Commissioning
Pre-Commissioning activities start when the plant, or system, achieves
Mechanical Completion. Frequently however, Pre-Commissioning
activities overlap Mechanical Completion activities and for this reason
the plant should be separated into easily manageable system package,
each system package will be Pre-Commissioned as a whole and
isolations at the boundaries of the system package will be maintained
until the completion of Pre-Commissioning activities.
Pre-Commissioning activities include: checking for design conformity,
checking the status of electrical, mechanical and instrument such as
calibration, loop check, line check, insulation resistance, relay setting,
flushing , blowing and cleaning activities.

5
1.2 Terminology
2. Cold-Commissioning
Cold Commissioning means individual equipment and system
commissioning and initial startup such as CCW system, compressed air
system and feed water system etc.
Cold Commissioning activities include: checking for design conformity,
checking the status of individual equipment and system capability,
function, interlock and reliability.

6
1.2 Terminology
3. Hot-Commissioning
Hot commissioning means the commissioning of the plant level. In
general, the commissioning activity after initial firing belongs to the hot
commissioning
Hot Commissioning activities include : Initial firing, Steam blowing,
Turbine bypass operation, Synchronizing and plant level function test.

7
1) Check list before the test
① Switch Gear Status
② Shaft turning by manual
③ Start the space heater
④ Lubrication oil pump start (if applicable)
⑤ Check the insulation resistance
⑥ Motor solo test start at DCS HMI
2) Check list during the test
① Direction of rotation
② Starting current
③ Operating current
④ Vibration of Motor bearing
⑤ Temperature of Motor bearing
⑥ Temperature of Motor Winding
Solo Test
1

8
No-load Test / Minimum Load Test
1) No-load Test and Minimum Load Test
① No-load Test
No-load Test means equipment's running with that has no flow through
the Fan in case of discharge or suction damper are closed when fan is
running.
② Minimum Load Test
Minimum Load Test means equipment’s running with that has
minimum flow through the pump in case of suction valve open,
minimum flow valve open and discharge valve closed
2) Check Point During No-Load Test and Minimum Load Test
② Starting current and Operating current
③ Vibration of Motor bearing
④ Temperature of Motor bearing
⑤ Temperature of Motor Winding
⑥ Suction/Discharge Pressure
⑦ Flow (if applicable)
2

9
Load Test
1) Load Test
The Load test is a test that is performed when the fluid flows normally to the
pump or fan.
2) Check Point During Load Test
② Starting current and Operating current
③ Vibration of Motor/Pump (Fan) bearing
④ Temperature of Motor/Pump (Fan) bearing
⑤ Temperature of Motor Winding
⑥ Suction/Discharge Pressure
⑦ Discharge Flow
3

10
Contents

11
① Visual Inspection as per P & ID that check point is physical refection status
and instruments installation status
② Cleaning of erected and installed system such as air and flue gas inside
and outside and all area where works performed so that no erection
parts disturb moving equipment and program cycles.
③ Flushing or Blowing the pipelines, including process media pipelines and
impulse piping6. Checking for the possibility of stretching and extension
for pipe lines and cables
④ Checking and preparation for operation of the spring suspensions and
compensators and removing of spring loaded bolts
⑤ Lubrication for operation according to manufacture’s instructions.
Pre-Commissioning Check List
1

12
⑥ Checking the alignment of machinery and structure (example;
expansion joints),and provide appropriate documents.
⑦ Leak tests and Hydraulic Test (gas, solid and fluids) of Duct or Pipe Line
⑧ Calibration for Instrument, Control Valve, MOV and Switch.
⑨ Safety Valve and Pressure Relief Valve Setting.
⑩ Signal/loop check from DCS to fields device, including check of
measurement ranges and moving the appropriate equipment from DCS
(stroke test).
⑪ Check all operating and alarm limits in field in system and set fixed
initial values in program for startup, using set point and alarm list.
⑫ Relay Setting, PT and CT Checking for Switch Gear
Pre-Commissioning Check List
1

13
Contents
 BOP and Common Facilities
 Boiler and Auxiliary System
 Turbine and Auxiliary System

14
Power Receiving
1) Objective
Electrical power back feed from the grid for generating unit startup.
2) Commissioning Sequence
First of commissioning
3) Major System
① GIS or AIS
② TR
③ Switch Gear
④ DC and UPS
1

15
Water Treatment System (WT)
1) Objective
The water treatment facility treats the raw water and then supplies the
necessary water to the plant. Depending on the application Demin. Water,
Service Water, Potable Water..
after power receiving
3) Major System
① Raw Water Treatment System (Clarifier, RO, MSF)
② Potable Water Treatment System
③ Demin. Water Treatment System
2

16
Waste Water Treatment System (WWT)
1) Objective
WWT is a facility to purify wastewater from the plant to meet environmental
standards.
after complete power receiving and water treatment system commissioning.
3) Major equipments
① Waste Water Pond
② Oily Waste Water Treatment System
③ Chemical Waste Water Treatment System
④ FGD Waste Water Treatment System
⑤ Coal Yard Waste Water Treatment System
3

17
Closed Cooling Water System (CCW)
1) Objective
CCW is to supply cooling water to individual devices.
after Power Receiving, WT, WWT.
3) Major equipments
① CCW Head Tank
② CCW Pump
③ CCW Heat Exchanger
4

18
Compressed Air System
1) Objective
Compressed air system is a facility that produces instrument air and service air to
drive pneumatic equipment such as control valve..
after Power Receiving, WT, WWT.
3) Major equipments
① Air Compressor
② Drier
③ Air Receiving Vessel for Instrument Air
④ Air Receiving Vessel for Service Air
5

19
Circulating Water System or Main Cooling Water System (CW or MCW)
1) Objective
Circulating Water System is supplied cooling water to condenser, closed cooling
water heat exchanger, etc.
after Power Receiving
3) Major equipment's
① Intake
② Trash Rack
③ Traveling Screen and washing pump
④ Chlorination Generation System and Injection System
⑤ Circulating Water Pump (CWP) or Main Cooling Water Pump (MCWP)
⑥ Debris Filter
⑦ Condenser Tube Cleaning System
⑧ Discharge Culvert
⑨ Auxiliary Cooling Water Pump
6

20
Auxiliary Steam System
1) Objective
Auxiliary Steam System is to provide for necessary steam of plant startup and
operation as below System
 Turbine Seal Steam and Rotor Pre-Warming
 Turbine Driven BFP
 Deaerator
 Steam Coil Air Heater
 SCR Ammonia Vaporizer
 Air Pre-Heater Soot Blower
 Pulverizer Inerting Steam etc.
after Power Receiving
① Auxiliary Boiler (if applicable)
② Auxiliary Steam Header
③ Auxiliary Pressure Reducing Station for CRH to Aux. Steam Header
④ Auxiliary Pressure Reducing for Main Steam to Aux. Steam Header
7

21
Condensate System
1) Objective
Condensate System is to transfer condensate from condenser to deaerator
After Water Treatment System commissioning is completed
① Condensate Extraction Pump (CEP)
② CPP
③ Low Pressure Heater
8

22
Chemical Cleaning
1) Objective
 Alkali Cleaning objective is to remove organic matter in condensate and feed
water system
 Acid Cleaning objective is to remove inorganic matter in boiler water wall.
After condensate commissioning and auxiliary steam system
① Temporary Circulating Water Pump for Chemical Cleaning
② Temporary Heat Exchanger for Chemical Cleaning
③ Temporary Chemical Cleaning Water Mixing Tank
④ Temporary Chemical Injection Pump and Tank
9

23
Feed Water System
1) Objective
Feed Water System is storage feed water, deaerating in feed water, warming
feed water, heat feed water and water feeding to boiler
After condensate system and after Chemical Cleaning
① Deaerator
② Feed Water Storage Tank
③ Motor Driven Boiler Feed Water Pump (MDBFP)
④ Turbine Drive Boiler Feed Water Pump (TDBFP)
⑤ High Pressure Heater
10

24
Chemical Injection System
1) Objective
Chemical Injection System is to control feed water and condensate pH and
dissolve oxygen
 All Volatile Treatment Method
 pH control chemical : Ammonia or equivalent chemical
 Oxygen Scavenger : Hydrazine or equivalent chemical
 Boiler compound : Phosphate or equivalent chemical (Drum type boiler)
 Combined Water Treatment System
 Startup : AVT Method
 During Stable Operation : O2 Treatment Method
After Condensate and Feed water System Commissioning
① Chemical Storage Tank
② Chemical Injection Pump
11

25
Fuel Oil Supply System
1) Objective
Fuel Oil Supply System is to supply fuel for boiler startup, normally boiler startup
fuel is used Light Oil.
After refection completed
① Fuel Oil Storage Tank
② Fuel Oil Transfer Pump
12

26
Contents

27
Draft System
1) Objective
Draft system is to supply combustion air to boiler furnace and remove flue gas
to ambient.
After CCW, Compressed Air system commissioning and duct leak test are
completed.
① Induced Draft Fan (IDF)
② Forced Draft Fan (FDF)
③ Gas Air Heater (GAH) or Air-preheater
④ Steam Coil Air Heater (SCAH)
1

28
Boiler Startup System
1) Objective
One Through Boiler is necessary boiler startup system for sub critical operation
during boiler startup. separator is separate water in the steam at the boiler water
wall out let and then separated water is strafing in the Separator Storage Vessel
(SSV) and then separated water return to the economizer inlet by Boiler
Recirculation Pump.
After Feed Water System and Chemical Cleaning are Commissioning
Completed
① Boiler Recirculation Pump (BRP)
② Separator
③ Separator Storage Vessel (SSV)
④ Boiler Blow Down System
2

29
Oil Burner
1) Objective
Burner is to combust fuel and then fossil fuel convert the thermal energy.
After Compressed Air System Commissioning
① Oil burner
② Atomizing Air System
③ Flame Scanner
④ Ignitor
3

30
Contents

31
Turbine Lube Oil System
1) Objective
Turbine Lube Oil System is providing lubricant to turbine bearing and generator
bearing
After CCW System is completed and Turbine rotor alignment completed
① Lube Oil Tank
② Lube Oil Tank Exhaust Fan
③ Lube Oil Pump (AC)
④ Lube Oil Pump (DC)
⑤ Oil Purifier
1

32
Turbine Turning Gear
1) Objective
Turbine Turning Gear is rotate the turbine rotor from standstill condition and
stretch bent turbine rotor due to rotor weight during standstill condition.
Turning Gear must operate to prevent excess vent after turbine stop and then
turning gear stop after completed cooling down turbine rotor temperature
After turbine lube oil system completed
① Turning Gear
2

33
Contents
 Initial Firing, Steam Blowing & Turbine Bypass Operation
 Turbine Rolling and Synchronizing
 Overall Generating Unit Test

34
Initial Firing
1) Objective
Initial firing objective is integrated boiler system test such as condensate and
feed water system, draft system, fuel oil supply system and burner etc. related
system of boiler by burner ignition.
After cold commissioning completed
① Condensate and Feed Water System
② Fuel Oil Supply System
③ Drafty System
④ Burner
1

35
Steam Blowing
1) Objective
Steam Blowing Objective is to protect turbine due to foreign matter from the
boiler and main steam and reheat steam line.
After Initial Firing
① Condensate and Feed Water System
② Fuel Oil Supply System
③ Drafty System
④ Burner
⑤ Main steam, reheat steam and HP/LP bypass station
⑥ Temporary Piping and Silencer for Steam Blowing
2

36
Turbine Seal Steam System
1) Objective
The section, where the steam turbine rotor exits through the casing is called
gland, and labyrinth fins are installed there. Seal steam is supplied to seal the
section. Also, a gland steam condenser is installed to drain steam leaking from
the gland. Seal steam should always be provided to the turbine, when vacuum
condition is maintained in the condenser. If seal steam is not provided, the
vacuum in the condenser will pull ambient air from the atmosphere through the
gland. The ambient air, which is at a low temperature, will cool the gland rapidly
and as a result the gland casing may deform. This would cause contact between
rotating surface and stationary surface resulting in damage to the rotor.
After turbine turning gear commissioning and complete turbine seal steam line
steam blowing completed
① Turbine Seal Steam Supply and Drain Header and Piping
② Gland Steam Condenser
③ Gland Steam Condenser Exhaust Fan
3
Note : This activity is possible before initial firing if seal
steam line blowing is completed by auxiliary steam

37
Condenser Vacuum Pump
1) Objective
Condenser Vacuum Pump is to remove non-condensable gas in the
condenser when turbine operating and make condenser vacuum condition
for turbine operating before the boiler ignition.
After CW System Commissioning
① Condenser Vacuum Pump
4
Note : This activity is possible before initial firing

38
Condenser Vacuum Pulling
1) Objective
This test is in order to the verifying that the Condenser vacuum pressure is
achieved as Turbine bypass operation starting permissive.
After turbine seal steam system and condenser vacuum pump commissioning
① Condenser
② Turbine Seal Steam System
③ Condenser Vacuum Pump
5

39
Turbine Bypass Operation
1) Objective
Turbine bypass operation is integrated generating unit operation test exclude
turbine system. Main steam and reheat steam are bypassing HP, IP and LP
turbine by HP/LP turbine bypass station.
Generating unit is make turbine steam admission condition such as steam
pressure, steam temperature and steam purity by turbine bypass operation after
boiler firing
After steam blowing and condenser vacuum pulling completed.
① Boiler and Auxiliary System
② BOP and Common System
③ Turbine bypass station
6

40
Coal Firing Test
1) Objective
Coal firing test objective is actual coal combustion test for rerated system such
as coal silo, coal feeder and pulverizer.
① Coal Handling System
② Coal Silo
③ Coal Feeder
④ Pulverize
⑤ Coal Burner
7

41
SCR Test
1) Objective
Selective catalytic reduction (SCR) is a means of converting nitrogen oxides,
also referred to as NOx with the aid of a catalyst into diatomic nitrogen (N2) ,
and water (H 2O). A gaseous reductant, typically anhydrous ammonia, aqueous
ammonia or urea, is added to a stream of flue or exhaust gas and is
adsorbed[citation needed] onto a catalyst. Carbon dioxide, CO2 is a reaction
product when urea is used as the reductant.
① Catalyst
② Ammonia Unloading and Storage Tank
③ Ammonia Vaporizer
④ Ammonia Dilution Blower
8

42
ESP
1) Objective
Electrostatic Precipitation is a physical process by which particulate suspended
in a gas stream is electrically charged in a corona filed and under the influence
of the electric field, is driven to a collecting surface, separating it from the gas.
Before coal firing starting
① EP Casing
② Transformer Rectifier
③ Seal Air Blower
④ Ash Hopper
9
Note : This activity is possible before initial firing as per local requlation

43
FGD
1) Objective
FGD is conducted removing SOx in the flue gas. The SOx-Absorption is
achieved by natural alkalinity present in seawater in a absorber, where the raw
flue gas comes into an intensive contact to the sprayed seawater. Thus the SOx
is absorbed with optimal removal efficiency.
CaCO3 + SO2→ CaSO3 + CO2 (gas)
Conduct with Coal Firing Test
3) Major equipment's (Sea Water type FGD)
① Absorber
② Sea Water Spray Pump
③ Aeration Basin
④ GGH
10

44
Safety Valve Popping Test
1) Objective
Safety Valve is to prevent due to overpressure of boiler system
During Turbine bypass operation
① Safety Valve of Super Heater and Reheater
11

45
Contents

46
Stator Cooling Water System
1) Objective
The stator winding liquid cooling system supplied deionized water to the stator
for cooling the stator winding.
After erection and demin. water treatment system completed
① Stator Winding Cooling Water Tank
② Stator Cooling Pump
③ Stator Water Cooler
④ Stator Leakage Monitoring System
⑤ De-ionizer
1

47
Generator Seal Oil System
1) Objective
Generator Seal Oil System is to prevent of H2 gas leakage from generator
inside through generator rotor between casing surface.
Turbine Lube Oil System Completed
① Vacuum tank
② Main Seal Oil Pump
③ Emergency Seal Oil Pump
④ Recirculation Seal Oil Pump
⑤ Seal Oil Vacuum Pump
⑥ Liquid Detector
2

48
H2 / CO2 Control System
1) Objective
H2 Gas is heat transfer ratio batter then air so cooling effective is high and
friction loss is low because specific gravity is less then air.
Hydrogen gas is an explosive substance when exposed to air so rirst fill the
generator with carbon dioxide and change the carbon dioxide to hydrogen.
Generator Seal Oil system is completed
① H2 Generation System and storage vessel (if applicable)
② CO2 Storage Vessel
③ H2 and CO2 Control System and Alanlizer
3

49
Turbine Steam Admission
1) Objective
Make the steam admission condition by turbine bypass operation and then
steam admission to turbine and then turbine speed accelerate to rated speed as
per turbine acceleration curve.
Check the turbine condition during turbine acceleration such as vibration,
bearing temperature.
Turbine bypass operation is completed
Generator auxiliary system commissioning are completed
Turbine auxiliary system commissioning are completed
① Overall Generating Unit
4

50
Synchronizing
1) Objective
Synchronizing objective is Generating Unit synchronized with electrical grid and
then generating unit is parallel operation with electrical grid.
After Steam Admission
① Exciter / AVR
② Synchronizer (if applicable)
③ Generator Circuit Breaker
5

51
Contents

52
Plant Initial Load Test
1) Objective
Plant is conducted progressively increased to full load operation after
synchronizing and then find different of operating parameter with design
parameter that data is base on combustion and plant tuning.
After Synchronizing
① Overall generating unit
1

53
Turbine Temporary Strainer Removal
1) Objective
Generally temporary strainer is installed as turbine main steam and reheat
steam valve for turbine protection due to foreign matter.
Temporary strainer remove after turbine shutdown if archive the appointed full
load operation time.
After initial load test
① Turbine Temporary Strainer
2

54
Combustion Tuning
1) Objective
Adjust in put parameter such as fuel, feed water, air flow and bias damper and
then optimizer boiler efficiency and boiler combustion parameter such as boiler
outlet O2, unburned carbon, Main steam and Reheat Steam temperature and
pressure as per boiler design data
3

55
Auto Plant Control Tuning / Unit Master Control Tuning
1) Objective
Generating unit is operated according to operated Load Demand from LDC or
Operator.
Generating unit follow the changed load demand and then unit master is
dispatch the unit load demand current target to boiler master and turbine
master.
Boiler master is dispatched which is received demand from the unit master to
boiler sub group master such as fuel master, air master and feed water master.
Sub group master control are follow the boiler master dispatch demand and
then automatically controlled air flow, fuel flow, feed water flow.
Turbine master is dispatched which is received demand for the unit master to
turbine governor controller. Turbine governor controller is adjusted Generator
Output.
Auto Plant Control Tuning and Unit Master Control Tuning means overall
generating unit is automatically controlled according to operator’s generator
output control.
4

56
Unit Startup Test (Cold, Warm, Hot)
1) Objective
Generating units Startup Test is in order to verifying that the startup procedure
and then optimize startup parameter and method.
5

57
Load Rejection Test
1) Objective
A load rejection test is to verify turbine governor’s response when generator
load is suddenly disappeared Incase of GCB is opened.
Turbine control valve is quickly closed, and then turbine speed maintains at
rated speed. Turbine speed is increased at first time, but instantly decreased
and maintained rated speed by turbine governor.
HP and LP bypass valve are quickly open when load rejection occurred.
Boiler is initiated runback at same time and then boiler load is quickly decreased
to around half load.
6

58
House Load Operation
1) Objective
In case of any electrical grid problem, the operating unit will be immediately
isolated from the electrical grid and thus, it will be cutting back to house load, in
parallel with HP-LP bypass operation, till the time connection with the grid is
restored back.
7

59
Run Back
1) Objective
if any major equipment is trip, generating unit is process is unbalanced with
control parameter at this time run back is occurred for prevent of plant trip
In case of runback is occurred, the Generating Unit load will reduce to operable
load and then runback resets later preset time.
Run Back Item (for example)
 Induced Draft Fan (50% x2)
 Forced Draft Fan (50% x2)
 Primary Air Fan (50% x2) – if applicable
 Fuel flow (oil or coal) : Actual Flow and Demand Flow are different over
20%
 Boiler Feed Water Pump (50% x2)
 Turbine Trip
8

60
Load Change Test
1) Objective
Load Change Test is Objective is verifying that the load change capability and
tune and optimize operation parameter according to ramping ramp rate.
This test is normally conducted with Unit master control tuning.
9

61
Emission Test
1) Objective
Emission Test is verifying that the generating unit’s emissions is compliant
environmental regulation or guarantee value such as SOx, NOx and dust during
generating unit operating.
10

62
Reliability Test
1) Objective
Reliability test is conducted in order to verifying that the generating unit operable
reliability for commercial operation.
Normally reliability test condition is decided as per contract. Reliability test
period is normally 10 ~ 30 day and generating unit load is maintained full load or
load dispatch center’s dispatching load.
10

63
Performance Test
1) Objective
Performance test is conducted in order to verifying that the plant efficiency and
capability such as below.
 Net Heat Rate
𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺 𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂 − 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶
𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸
 Net Capacity
Generating Unit’s transmission power that is from generator to electrical grid.
Generating Output – Auxiliary Power Consumption
11

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