dm water system ydtd qj facs 02

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Commissioning Measures Form for Approval

No.YDTD-TS02

Project

name

Phase I of 2330MW Project of Tengda

Coal-fired Power Plant in India

Contract

No.

To: Tengda Project Department of Sichuan Machinery & Equipment Import & Export Corporation

Now it is submitted for the examination and approval with the closed circulating water system commissioning

technical measure of phase I of 2330MW project of Tengda Coal -fi red power pla nt in Ind ia

Document No: QJCS-02.

Appendix: Closed circulating water system commissioning technical measure

Contractor: Sichuan Tongneng Power Technology Co. Ltd.

Project principal Date

Examination and approval opinions of the project supervision department:

Project supervision department (seal)

Supervision engineer: Date

Chief supervision engineer: Date


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Phase I of 2330MW Project of Tengda Coal-fired Power Plant in India

Closed circulating water system commissioning technical measure

2 21

Examination and approval opinions of the owner

Legal person of the project (seal):

Owner representative Date

Contractor: Sichuan Tongneng Power Technology Co. Ltd Mar. 2008


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Phase I of 2330MW Project of Tengda Coal-fired

Power Plant in India

Closed circulatingwater system

commissioningtechnical measure

Sichuan Power Industry Commissioning Test InstituteSichuan Tongneng Power Technology Co., Ltd

Mar. 2008


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Examination and Approval Record for

Documents

D o c u m e n t

n a m e


D o c u m e n t

N o .YDTD-QJCS-02

The 1st

version

Date of

publication

The

2nd

version

Date of

publication

Main revised content

E d i t i o n n o .

The 3rd

version

Date of

publication

Main revised content

M a n a g e r s

a p p r o v a l o f

t h e

c o m m i s s i o n i

n g p r o j e c t

D a t e :


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R e v i e w o f t h e

p r i n c i p a l o f

p r o f e s s i o n a l

g r o u p o f

c o m m i s s i o n i

n g p r o j e c t

D a t e :

C o m p i l e r o f

t h e t e c h n i c a l

d o c u m e n t D a t e

ontent

1. Compi l ati on purpose . . . . . . . . . . . . . . . . . . 2. Compi l ati on reference . . . . . . . . . . . . . . . . 3. Commi ssi oni ng qual i ty standard and obj ect 4. Responsi bi l i ty di vi si on . . . . . . . . . . . . . . 5. Systembri ef i ntroducti on . . . . . . . . . . . . 6. Condi t i ons pri or to commi ssi oni ng . . . .


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7. Commi ssi oni ng work procedure . . . . . . . . . 8. Commi ssi oni ng step . . . . . . . . . . . . . . . . . . . 9.

Safety measure . . . . . . . . . . . . . . . . . . . . . . .

10. Appendi x . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Compilation purpose1.1 To instruct and standardize the commissioning work of system and equipment, and

guarantee safety and normal operation thereof, this regulation is hereby compiled.1.2 Inspect the closed circulating water system electric and thermal work protection interlock

and signal unit, and determine the reliability of the action.

1.3 Inspect the system and equipment operation status, check the system performance, find outand eliminate the possible defects.

2. Compilation reference2.1 Thermal Power Plant Basic Construction Engineering Startup and Completion Acceptance

Code(1996version) power construction [1996]159#

2.2 Power Construction and Acceptance Technical Specification (SteamTurbine )DL5011-1992

2.3 Power Construction and Acceptance Technical Specification(Pipe )DL5031-19942.4 Standard for Quality Inspection and Evaluation of the Adjustment and Commissioning in

Thermal Power Project, Construction Quality [1996]111#

2.5 Regulations for the Startup and Commissioning of the thermal Power Projects,Construction Quality [1996]40#

2.6 Manufactory drawings, installation and operation instructions, quality assurance book andex-factory certifications

2.7 Design documents, drawings, specifications, and commissioning documents as well asconference summary, etc.

2.8 Equipments supply contract, and the international and national standards stated therein


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3. Commissioning quality standard and object3.1 The industrial water system commissioning result conforms to the quality standard of

related closed circulating water systems of Standards for the Inspection and Assessment of

the Adjustment and Commissioning Quality for Thermal Power Projects (1996 version),

and quality requirements of commissioning contract, as well as satisfy with turbine

complete set startup requirements.

3.2 The sub-plant trial operation, attestation and acceptance are qualified, and meet thecomplete set startup requirements.

4. Responsibility divisionAccording to the statements of the administry newly issued Startup Regulation, and the

Commissioning Contract, the responsibilities of each party are as following:

4.1 Installation unit:4.1.1 Responsible for individual equipment commissioning and trial operation work.4.1.2 Responsible for isolation work of the system.4.1.3 Responsible for repair, maintenance and defect elimination of the trial operation

equipments.

4.1.4 Prepare the necessary repair tools and materials.4.1.5 Cooperate with the commissioning unit for subsystem commissioning.4.1.6 Responsible for attestation work after trial operation of system sub-section.4.2 Manufacturing unit:4.2.1 Responsible for startup/closedown, operation regulation and accident treatment of system

trial operation.

4.2.2 Responsible for hanging the formal brand mark of the related systems and equipments.4.2.3 Prepare the regulations, tools, and record reports, etc.for operation;4.2.4 Responsible for patrol inspection and normal maintenance during trial opereation.4.3 Responsibility of commissioning unit:4.3.1 Responsible for compiling trial operation scheme together with technical clarification.4.3.2 Prepare the apparatuses, instruments and tools for the related tests.4.3.3 Responsible for command and control work of subsystem commissioning.4.3.4 Responsible for test data record and sorting.4.3.5 Fill in trial operation quality evaluation table.


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4.3.6 Responsible for attestation work after trial operation of the system and subsystem.4.3.7 Compile the commissioning report.4.4 Individual commissioning of pump group will be responsibility of the installation unit,

with parcitipation of commissioning unit. The sub-system commissioning of pump group

will be responsibility of commissioning unit, with participation and cooperation of the

installation unit and other units. The circulating water pump system commissioning will be

carried out with uniform instruction of trial operation team, it will be implemented by

circulating water system commissioning professional team, the steam turbine discipline

will take the lead, with cooperation of electric, thermal control and other disciplines.

5. System brief introduction5.1 General description

1# and 2# machine sets of phase I of 2330MW newly built up project of Tengda

Coal-fired power plant in India are respectively set by three sets of rated capacity 50%

closed circulating water pumps, and three sets of capacity 50% closed circulating

cooling water heat exchanges, and one 10m3 expansion water tank, the makeup water of

the expansion water tank will be provided by the condensate system and desalt water

system. During normal operation, the closed circulating water pump and the closedcirculating water heat exchange are all respectively two sets operation and one set

standby.

Closed circulating water cooling water system will provide the generator stator

cooler, generator hydrogen cooler, exciter air cooler, electric feed pump motor cooler,

electric feed pump lubricating oil cooler, work oil cooler, anti-flammable oil cooler,

condense pump motor cooler, low pressure drainage pump, hydrogen drier, boiler water

supply pump bearing cooler, condense transfer pump bearing cooler, electric group

mechanical sealing (and cooling chamber) cooling water, and it can also makeup water

for the mechanical vacuum pump. In addition, it will also provide boiler side blower,

draught fan, primary blower lubricating oil station and bearing cooling water, air

preheater bearing cooler, sealing blower cooler, coal grinding machine motor cooler,

high pressure oil pump station, and thin oil station cooler cooling water.

5.2 Equipment specification5.2.1 Closed circulating water pump

Model500S-59B


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Mode double suction horizontal centrifugal pump

flow1300 m3h

lift58 m

efficiency79.4

necessary net positive suction head4 m

shaft power273 KW

rotating speed970r/min

5.2.2 closed circulating pump auxiliary motormodel310KW-6

rated power310KW

rated voltage6KV

rated current39 A

synchronous speed988 r/min

6. Conditions prior to commissioning6.1 The circulating water system, circulating water makeup system, opening

circulating water system can be operated.

6.2 All pipelines and equipments installation of closed water system is completed, andmeet design requirements, together with complete installation technical record;

6.3 It has reliable operation power supply and dynamic power supply, and each AC andDC distribution panel has been electrified;

6.4 Each manual gate and automatic gate of the system has been one by onecommissioned and inspected, the action is proper and flexible, together with

indication of name and switch direction, and it is in the standby status;

6.5 Each instrument, switch and signal has been fully installed, and calibrated properly,they are cleaned up with marking of name, and are ready for use.

6.6 The closed circulating water pump inlet strainer, pump inlet channel and pumpoutlet pressure pipe will be cleaned up;

6.7 The other pipeline system with relation to the closed circulating water pipeline willbe isolated as per requirements;

6.8 The motor and pump bearing will be filled by lubricating oil till the stated oil


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level.

6.9 The expansion water tank has the qualified desalt water, and it can guarantee thesufficient water supply for flushing, and the drainage system is smooth;

6.10 The trial operation site environemnt is clean, the site hole and channel cover plateare complete, and the temporary hole is mounted by guardrail or cover plate, the

platform has normal staircase, channel, bridge walk, handrail and bottom

protection board;

6.11 The operation suspended door and important monitoring instruments and meterswill be mounted by platform or staircase;

6.12 The firefighting system is in the reliable and standby status;6.13 The drainage systems and facilities are normal for use.6.14 The site has formal lighting, accident lighting system, which are complete, reliable

and ready for use.

6.15 The communication equipments as telephone, etc. are installed and can be puttedinto use.

7. Commissioning work procedureThe closed circulating water system commissioning work can be carried out as per

following flow chart:


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Commissioning technical scheme clarification

Commisioning conditions determination;

Interlock protectionand alarming test

Closed circulating water pump group trial operation

Pipeline flushing

System putting into operation and dynamic regulation

Main equipment installation and individual commissioning are completed

Instrument constrol installation and related commissioning are completed;

Electric installation and related commissioning are completed;

Pipe valve installation and commissioning

Safety condition is satisfied

Interlock protection test

Alarming test

8. Commissioning step8.1 Prior to system operation, the electric and thermal work professional staffs will carry ou

the thermal work and electric interlock protection test (the detailed content please refer to the


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annexed table).

8.2 Motor individual trial operationThe motor individual trial operation work will be carried out by the installation

unit,and this content item is only for reference;

8.1.1 Separate the matching wheel between motor and pump;7.1.1 The motor insulation is qualified;8.1.2 The motor spot-drive rotation direction is proper;8.1.3 The motor is operated 2 hours continuously after normal operation;8.1.4 The trial operation will record the bearing vibration, bearing temperature, motor

temperature, motor startup/operation current, and cooling water pressure;

8.3 Trial operation of closed circulating water pump;8.3.1 Preparation prior to trial operation:

a) Wheel connection between the motor and pump is completed;b) The water of expansion water tank is filled to the work level.

8.3.2 Closed circulating water pump startup;a) Open the closed cooling water system air valve, and open the closed heat

exchange water side air valve.

b) The closed circulating water pump is started up at the field.c) Inspect the pump outlet gate and pump operation statuses;d) After the pump capacity is normal, inspect the closed water system pipe, each

air valve of the system will be closed when meeting with water, and inspect the

leakage status;

e) In the trial operation, record the bearing vibration, bearing temperature, motortemperature, motor startup/operation current, pump outlet pressure;

f) Pump group trial operation is 8 hours.8.3.3 Stop operation of closed circulating water pump;

a) The field or remote DCS will stop the operation of closed circulating waterpump;

b) The pump will not be of reverse rotation.8.4 According to the trial operation site status, it may carry out closed circulating water pump

dynamic linkage test.

8.5 Closed circulating water system flushing8.5.1 The pipe will be separated before each system entering the equipment, and the


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inlet and outlet gate of the equipment will be short connected;

8.5.2 Start up the closed circulating water pump, maintain the outlet pressure of pump,and continuously flush the system. To maintain the outlet pressure of the pump,

each sub-system will be flushed in alternation;

8.5.3 Flush scope:a) Machine side: generator stator cooler, generator hydrogen cooler, exciter air

coler, electric feed pump motor cooler, electric feed pump lubricating oil cooler

and work oil cooler, electric group mechanical sealing (and cooling room)

cooling water inlet, anti-flammable oil cooler, condense pump motor cooler, low

pressure heater drainage valve, hydrogen drier, boiler water supply pump

bearing cooler, and condense water transfer pump bearing cooler;

b) Boiler side: boiler sampling water, coal grinding machine motor cooler, coalgrinding machine high pressure oil pump station, seal blower cooler, primary

blower lubricating oil cooler, primary blower bearing cooler, draught fan and

blower lubricating oil cooler and bearing cooler, air preheater top bearing cooler,

etc;

8.5.4 The wate quality is clean and transparent without foreign substances, after theinspection is qualified, the system will be recovered. The water quality will be

periodically inspected, if it is not consistent with the requirements, the water will

be replaced;

8.5.5 When the system water quality reaches certain extent, the thermal workinstrument will be flushed and inputted.

9. Safety measures9.1 When the closed circulating water pump outlet butterfly is closed, the closed

circulating water pump will not be operated;

9.2 Inspect the current and voltage of the closed circulating water pump, and the actualoperation work condition of the pump will be in the stated scope, without

power-exceeding and motor reverse rotation.

9.3 Avoid low flow operation of the closed circulating water pump;9.4 Prior to startup of closed circulating water pump, it will not have abnormal

vibration sound, otherwise the pump will be immediately stopped for inspection

and treatment;


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9.5 The normal operation and accident treatment will be rigidly carried out by poewrplant operat ion regulation.

10.Appendicesa)Condition inspection table

Closed circulating water system trial operation condition inspection table

System description: closed circulating water system

Determination and signature

No. Condition descriptionInstallation

party

Commissioning

party

Supervison

party Owner

1

All equipments and pipe installation of the closedcooling water system has been completed,

accepted and attested.

2

The thermal work instrument and electric

equipment installation and calibration have beencompleted, together with provision of calibrationlist of the instruments, and pressure, temperature

and vibration switches, etc. The instruments and

meters are calibrated and installed.

3

The valve individual commissioning is

completed, the switch action is proper, the limit

switch location and CRT status display is proper.

4

The closed circulating water pump inlet

strainer, pump inlet channel and pump

outlet pressure pipe will be cleaned up;

5

The closed pump motor insulation test isqualified, and the pump and motor bearing have

been filled by qualified lubricating grease.

6

The expansion water tank has the

qualified desalt water, and it can

guarantee the sufficient water supply

for flushing, and the drainage system is

smooth;

7

The trial operation site environemnt is

clean, the site hole and channel cover

plate are complete, and the temporary

hole is mounted by guardrail or cover

plate, the platform has normal staircase,

channel, bridge walk, handrail and

bottom protection board;

8

The operation suspended door and

important monitoring instruments and

meters will be mounted by platform orstaircase;


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9

The closed water system flushing temproary pipe

has been installed as per requirements. The otherpipeline system with relation to the closed

circulating water pipe will be isolated.

10

The site has formal lighting, accident

lighting system, which are complete,reliable and ready for use.

11The firefighting system is in the reliable

and standby status;

Sichuan Tongneng Power Technology Co. Ltd

Date day month 2008

b) Logic inspection tableClosed circulating water system interlock logic inspection table

No. Item Set value Interlock protection action

I. Start up conditions

Expansion water tank level is higher, low I value

outlet valve of closed water pump turnoff

II. Interlock protection conditions

Expansion water tank level is lower, III value closed water pump tripping

CRT startup closed water pumpLinkage opening outlet electric

gate

CRT stop the closed water pumpLinkage closeing outlet electricgate

A pump accident tripping, B pump is inputted for

interlock.B pump interlock startup

A pump accident tripping, B pump is inputted for

interlock, the outlet main pipe pressure is low.

A pump accident tripping, C pump is inputted forinterlock.

A pump is operated, C pump is inputted intointerlock, the outlet main pipe pressure is low.

B pump accident tripping, C pump is inputted forinterlock.

B pump is operated, C pump is inputted intointerlock, the outlet main pipe pressure is low.

B pump accident tripping, A pump is inputted for

interlock.


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B pump is operated, A pump is inputted into


C pump accident tripping, B pump is inputted forinterlock.

C pump is operated, B pump is inputted into


C pump accident tripping, A pump is inputted for

interlock.

C pump is operated, A pump is inputted intointerlock, the outlet main pipe pressure is low.