DOCUMENT

: PJ-WI05a : 1 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TABLE OF CONTENTS
TITLE STEP 1 : BOILER PRESSURE PARTS Checking boiler external mountings Checking boiler internals Checking safety valves STEP 2 : DRAUGHT PAGE

2 3 4 5

Checking draught system, gas passes and ducting

STEP 3 : ELECTRICALS Checking of all wiring and panels 6

STEP 4 : FEEDWATER Checking feed pumps and feedline Commissioning feedwater system STEP 5 : COMBUSTION Inspection of burner Checking of ignition system Commissioning fuel oil pipework Commissioning gas pipework Commissioning of burners Firing on oil Firing on gas Boiling out STEP 6 : UNIT COMMISSIONING Floating safety valves Setting combustion Checking automatic control Change of fuels (if applicable) STEP 7 : UNIT OPERATION

7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Starting boiler from cold Putting boiler into service Taking boiler out of service Putting boiler back into service from warm / hot conditions

NOTE : The information contained in this set of Work Instructions is for general application only. For final burner settings, refer to manufacturer details. This information is not self-updating and is subject to change without prior notice .

DOCUMENT

: PJ-WI05a : 2 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Checking boiler external mountings STEP ACTION Testing and commissioning is carried out after the boiler and all its mountings and fittings have being installed at site. Before commissioning or testing the boiler, the following steps must be thoroughly checked :

SYSTEM : Boiler pressure parts REMARKS SIGN.

Check feedwater controller, and leave valve open to boiler. Check water level controls and alarms mechanically. Leave valves open to boiler. Check water level control valves. Check water level gauge glasses. Leave cocks in operating position. Check that all pressure flanges on boiler shell are to the correct pressure rating. Check all pressure doors on boiler shell. Check that all boiler auxiliary valves are to specification. Check feedwater valves on boiler. Check feedwater strainer. Check that blowdown valves are fitted & operate freely. Leave valves closed and leave handle in locked position. Check that boiler pressure gauges are fitted. Syphon pipes should be inspected. Check that all gaskets are correctly fitted and are of correct rating.

DOCUMENT

PJ-WI05a 3 OF 27

REVISION DA1E DISK FILE

2 19-Aug-1999 PJ- a PAGE

()
TESTING, PRE-COMlVllSSIONING
& COMlVllSSIONING-

PACKAGED

BO ILER

WORK INSTRUCTIONS
DOCUMENT PAGE REVISION : PJ-WI05a : 4 OF 27 : 2 : 19-Aug-1999

DISK FILE

: PJ-WI05a

TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

TESTING / COMMISSIONING ACTIVITY : Checking safety valves SYSTEM : Boiler pressure parts TESTI STEP ACTION REMARKS SIGN. STEP 1 2 3 4 5 6 7 8 Check that valves are fitted properly to boiler crown.

Check that main steam pipework is fitted properly and supported. Check silencer is securely mounted. Check that drain connections are free.

Check that safety valve is correctly sized and to specification. Check that safety valve seat / discs are not scoring. Check that escape pipework is fitted properly and supported. Check that safety valve silencer is securely mounted.

If fitted.

Re-lap if necessary.

If fitted.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Checking draught system, gas passes and ducting STEP 1 2 3 4 5 6 ACTION Check that forced draught fan and motor is properly secured. Remove inlet grill & check that fan impeller is free and that no foreign matter is present in fan casing. Check clearance between fan, runner & inlet eye. Refit fan gaiter on to fan casing. Check that fan discharge dampers are free and properly secured.

SYSTEM : Draught REMARKS SIGN.

Remove rear access doors and inspect furnace and gas passes for any foreign NOTE : this operation is matter which may be present. also required for inspection of transfer chamber rear end and front end. Check exit flue gas duct for obstruction. Check exit flue gas chamber for ease of operation. Leave in closed position. Check micro-switch and set to correct operational mode.

7 8

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Checking of all wiring and panels STEP 1 2 3 4 ACTION Check control panel fixing and mountings. Check incoming supply cable. Check fuse ratings. Check all control panel connections.

SYSTEM : Electricals REMARKS SIGN.

NOTE : main control to be functionally tested by supplier. If possible, boiler-electrical maintenance personnel to be present.

5 6 7 8 9 10 11

Check that all external wiring are to relevant connections. Check that contactor, overload and relay are working. Check flame monitoring controls. Check control panel earthings. Check terminal numbering. Check feedwater control system wiring. Check chemical pump control sequence with feedwater pump. NOTE : some pumps have control. Check flow instrument wiring, numbering and earthing, and that they are to relevant connections. chemical separate

12

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Checking feed pumps and feedlines STEP 1 2 3 4 5 Check that chemical line to feed pipe is correctly fitted. 6 Check that feed pump discharge orifice is in position. 7 ACTION Check that feed pump is fitted properly and securely bolted down. Check that pump coupling is fitted correctly. Check that pipework to and from feed pump is secure and tightly jointed. Check that direction of non-return valve complies with system. Check that gauges are properly fitted.

SYSTEM : Feedwater REMARKS SIGN.

is any difficulty.

DOCUMENT

: PJ-WI05a : 8 OF 27 : 2 : 19-Aug -1999 : PJ-WI05a

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAG E REVISION DATE DISK FILE

TESTING / COMMISSIONING ACTIVITY : Commissioning feedwater system STE P ACTION

SYSTEM : Feedwater

REMARK S NOTE : this is only applicable for a boiler fitted with a modulating control system.

SIGN.

This section covers the preparation of the feedwater system, including the commissioning of the feedwater pumps and filling the boiler to working level. It is assumed that treated water is available at the feed tank. 1 Open the following valves: i) Main feedwater isolating valve; ii) Boiler feedwater isolating valve. Check that feedwater discharge valve is closed. Check system is properly fitted with correct type of gasket. Turn pump shaft by hand - it should rotate freely. Check pump and motor alignment. Check that feed pump filters are cleaned. Prime feed pump by opening vent valve and turning pump by hand.

2 3 4 5 6 7

NOTE : check gland if there

NOTE : some fitted with vent plug only.

8 9

Shut vent valve when all air is expelled. Check following valves prior to starting pump. Ensure these valves are CLOSED: i) Feedwater controller isolating valve; ii) Feedwater controller discharge valve; iii) Feedwater controller bypass valve. Turn control panel isolator ON. Check feed motor direction by switching Feed Pump Control ON and then quickly OFF. If direction is wrong change phase wires. Note pump static pressure.

10

11

12 If direction is correct switch pump ON and leave it running. 13 Check that delivery pressure rises as speed of pump increases. 14 15 16 17 Slowly open feed pump discharge valve. Slowly open feedwater controller bypass valve. Crack open and shut boiler feedwater check valve, to vent feedwater line. Shut feedwater controller bypass valve.

18

Open feedwater controller isolating valves.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Commissioning feedwater system (continued) STEP 19 ACTION Check that following valves are CLOSED: i) Boiler water sampling cock; ii) Chemical dozing discharge to boiler valve. Open feedwater controller bypass valve and shut controller discharge valve. Slowly open boiler feed isolating valve.

SYSTEM : Feedwater REMARKS SIGN.

20 21

Check that motor amps do not rise above maximum rating.

22 23 24

As water rises in gauge glass check and set Low Water Lock-Out and Low Water Alarm switches. Shut feedwater controller bypass valve and open controller discharge valve. Shut feedwater pump when level setting has been completed.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Inspection of burner STEP 1* 2 ACTION Check that gas ignitor is properly assembled and securely fitted to wind box. Check only one of the following : * a) oil atomiser is correctly assembled and correct sprayer plate fitted; b) rotary cup shroud protrusion; c) oil nozzle on pressure jet electrode position and spark gap.

SYSTEM : Combustion REMARKS SIGN.

NOTE: depending on model or Manufacturer Standard if fitted if fitted if fitted

3*

For furnace side inspection of burners, check that stabiliser or flame baffle is NOTE : rear door must be off for transfer chamber fitted centrally in guard. inspection. Check that gas spouts are correctly aligned. Check that flame scanner tubes are fitted. if fitted if fitted

4* 5*

NOTE:
If the feedwater system is provided with automatic switch-in to spare feedwater pump; and in case the pump in operation fails: There are three operation modes for the pump system, namely, automatic, manual and off. Automatic mode Pump 1 will be the primary pump in operation and Pump 2 will be a standby. Should Pump 1 fail and cause the feedwater to fall below 8 barg, Pump 2 will switch on to operate while Pump 1 will automatically shut off. In order to enable Pump 1 to work again, the operator will have to switch the selector to the off mode followed by the automatic mode.

Manual mode Pump 1 and Pump 2 cam be started / stopped separately with the push-button provided in the local panel.

Off mode Pump 1 and Pump 2 will not operate in this mode.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Checking ignition system STEP 1 2 3 4 ACTION Check that all lines are complete and that solenoid valve is fitted. Check that wiring is satisfactory. Check that ignitor is positioned. Adjust pressure regulator to give controlled pressure at inlet of solenoid valve

SYSTEM : Combustion REMARKS SIGN.

NOTE : check burner manufacturers instruction manual for required pressure.

* Delete if not applicable

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY pipework STEP ACTION

Commissioning fuel oil

SYSTEM : Combustion REMARKS SIGN.

The following procedures cover supply of fuel oil up to fuel pump located on boiler and priming of system.

Check that fire valve is open and that Fire Protection system is fitted correctly. Open the following valves: i) Oil outlet valve on tank; ii) Oil pump suction valve; iii) Oil re-circulating valve; iv) Oil pump discharge valve; v) Oil meter bypass valve (if fitted); vi) Fuel oil return valve. Close oil meter isolating valve. Clean oil filters and vent oil lines.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Commissioning gas pipework STEP 1 2 ACTION Check that all valves are fitted and tightly jointed. Open gas to governors on boiler. Check for leaks after venting. 3

SYSTEM : Combustion REMARKS Refer to flow diagram. NOTE : for gas-fired boiler. SIGN.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Commissioning of burners STEP ACTION Commissioning of burners is carried out after checks have been completed on burner equipment and electricals. The choice of fuel for initial commissioning depends on availability. Note that performance and satisfactory operation of gas ignitor must be proven before oil or gas is introduced to furnace. Commissioning of feedwater system need not necessarily be carried out prior to commissioning the burners as long as the boiler can be filled to the normal operating level with appropriate chemicals for boiling out.

SYSTEM : Combustion REMARKS SIGN.

Open following valves: Ignition gas isolating valve. Check that isolating valves at burners are closed. Open other valves in circuit. Check main steam stop valve is closed. Open vent valve on boiler shell. Check that following valves are CLOSED: i) Boiler blowdown valves; ii) Water gauge blowdown valves; iii) Bypass valve on feed control valve; iv) Gas inlet valves; v) Ignition gas valves; vi) Atomising steam valve; vii) Atomising steam pressure regulator bypass valve. Check that following valves are OPEN: ii) Steam valve to water level control transmitter;

ii)

Sequencing valves to water level switches; iii) Steam valve to water level switches; iv) Valve to pressure transmitter on boiler crown; v) Valves to high steam pressure switches; vi) Valve to boiler pressure gauge; vii) Valves and gauge cocks to all oil, gas, atomising steam, ignition, gas line gauges and pressure switches; viii) Valves to economiser bypass.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Firing on oil STEP FIRING ON OIL 1 2 3 4 5 6 7 8 9 Check that water level is satisfactory. Check that Fuel Selector switch is selected to OFF position. Check that Fuel Change-Over switch is in NORMAL position. Check that Low Fire Hold switch is selected to HOLD position. Switch on 240V isolator to instrument chassis A and B burner. Check Power On lamp. Press Lock-Out Reset push button. Cancel alarms and fault memory units. Open the following valves: i) Oil inlet and return valves; ii) Ignition gas valves; iii) Steam valves to oil heater. Select OIL on Fuel Selector switch. ACTION

SYSTEM : Combustion REMARKS SIGN.

If twin burner. If fitted.

If fitted.

10

Oil will circulate until correct temperature and pressure is reached. Burner management sequence will start. When low fire is established, keep this firing rate for at least one hour NOTE : refer to burner manufacturers instruction to dry out refractory . manual. NOTE : if oil is fuel for boiling out proceed now to Section : Boiling Out (Page 17).

11

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Firing on gas STEP FIRING ON GAS 1 2 3 4 5 6 7 8 Check that water level is satisfactory. Check that Fuel Selector switch is selected to OFF position. Check that Fuel Change-Over switch is in NORMAL position. Check that Low Fire Hold switch is selected to HOLD position. Switch ON and check Power On lamp. Press Lock-Out Reset push button. Cancel alarms and fault memory units. Open following valves: i) Ignition gas valves; ii) Main gas isolating valve. Check that gas pressure is correct. Select 9 10 GAS on Fuel Selector switch. ACTION

SYSTEM : Combustion REMARKS SIGN.

If fitted.

If fitted.

NOTE : burner management sequence will start. Refer to burner manufacturers When low fire is established keep this firing rate for at least one hour to instruction manual. dry out refractory. Check that combustion conditions are reasonable and record CO2 level. NOTE : if gas is the fuel for boiling out proceed now to Section : Boiling Out (Page 17).

11

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Boiling out STEP Water capacity of boiler : ACTION m
3

SYSTEM : Unit commissioning REMARKS SIGN.

Chemicals required for boiling out : NALCO NALCO NALCO Check that chemicals have been added. Fire burner and maintain low fire setting. Maintain firing rate for one hour and then raise to approximately 50% firing rate. Check combustion & adjust. Raise pressure to 7 barg, closing air vent at approximately 1 barg.

Open air vent. Drain and flush out boiler. Refill with treated water.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Floating safety valves STEP ACTION It is essential that inspector for Regulating Authority (Department of Occupational Health & Safety - D.O.S.H. / J.K.K.P.) witnesses lifting of safety valves before boiler is used to export steam to range. Fire burners on either gas or oil and raise pressure at firing rate at low firing. Adjust excess pressure control to prevent burners cutting out switch to low fire.

SYSTEM : Unit commissioning REMARKS SIGN.

Adjust shell safety valve spring, if necessary, to lift at Re-adjust excess pressure control to normal setting.

barg.

Check that water level settings trip burner operation in presence of inspector.

DOCUMENT

: PJ-WI05a : 19 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Setting combustion STEP ACTION Although some adjustments have been made to combustion, it is necessary to carry out final checks to ensure that combustion conditions are acceptable over the complete modulation range. This can be preferably done by exporting steam to line with facility to vary load to allow reasonable time at each setting to check combustion.

SYSTEM : Unit commissioning REMARKS SIGN.

Set firing rate to low fire i.e., minimum firing rate. Check flue gas at boiler exit. CO2 or O2 values should be in accordance with specifications. Increase firing rate to maximum over a period. Adjust at intervals. On conclusion of tests put boiler on automatic control and check performance. Repeat 1- 4 for second fuel.

DOCUMENT

: PJ-WI05a : 20 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Checking automatic control STEP ACTION With boiler on line it is necessary to check that all controls are working properly and responding as designed.

SYSTEM : Unit commissioning REMARKS SIGN.

Check that boiler cuts out on high pressure if load is taken off. Check that burner re-starts as pressure falls. Check that boiler performs over modulating load range satisfactorily. Check that feedwater control is satisfactory during above checks Repeat with second fuel.

DOCUMENT

: PJ-WI05a : 21 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Change of fuels (if applicable) STEP ACTION The burner and control equipment has been designed to give semi-automatic fuel change-over. With this dual fuel burner type it is usually required to have the stabiliser further retracted when fired on gas. Therefore, a check is required to determine whether it is possible to eliminate the need for this adjustment. To check, the stabiliser will be set for gas firing and then fired on oil to see if there is any impingement on throat or gas speeds. If there is a problem then stabiliser adjustment will have to be made. A detailed account of the change-over mechanism is given in the burner manufacturers instruction manual.

SYSTEM : Unit commissioning REMARKS SIGN.

NOT APPLICABLE TO SAACKE BURNER. FOR SAACKE BURNER REFER TO MANUFACTURER STANDARD.

DOCUMENT

: PJ-WI05a : 22 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Starting boiler from cold STEP 1 ACTION Check that following valves are CLOSED: i) Boiler blowdown valve; ii) Steam outlet valve; iii) Water gauge blowdown valve; iv) Feed pump discharge valve. Check that following valves are OPEN: i) All feedline valves except pump discharge valve; ii) Air release valve on boiler crown; iii) Steam and water valves to both gauges; iv) Steam valve to water level controls; v) Water (sequencing) valves to water level controls; vi) Fuel oil valves. Check that switches on burner panel are selected to OFF position, and that Low Fire switch is in LOW FIRE position. Switch ON panel and RE-SET Lock-Out Control push button.

SYSTEM : Unit operation REMARKS SIGN.

If fitted.

4 5

Check water level in boiler. If water is required : i) Switch ON feed pump; ii) Open pump discharge valve slowly to maintain back pressure on NOTE : when there is no pump; steam pressure on boiler, there is a possibility of overloading the pump motor unless back pressure is maintained. iii) iv) v) Allow water level to rise until it reaches 1/2 level gauge glass; Switch OFF feedwater pump; Close pump discharge valve.

Check that oil is available in ring-main and that it is at correct pressure and Refer to burner manufacturers instruction temperature. manual on oil pressure and temperature. Switch ON burner. Start up sequence will commence and, after a pre-purge Refer to burner manufacturers instruction period, burner will light up. manual on sequence controlling. Allow boiler to warm through on low fire only. NOTE : failure to do this will result in burner going to HIGH FIRE position, and this will impose undue stress on boiler.

When steam vapour issues freely from air release valve on boiler crown, valve may be fully closed. If necessary, blowdown water to maintain correct water level.

10

DOCUMENT

: PJ-WI05a : 23 OF 27 : 2 : 19-Aug -1999 : PJ-WI05a

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAG E REVISION DATE DISK FILE

TESTING / COMMISSIONING ACTIVITY : Putting boiler into service STE P

SYSTEM : Unit operation

ACTION

REMARK S

SIGN.

The boiler may be put into service at full pressure or at a lower pressure if Assume boiler pressurising is desired. Before doing so : carried out from COLD starting. 1 2 Switch ON feed pump. Fully open feedwater suction valve. If water level is low, raise water level to 1/2 level gauge glass. NOTE : if main line is COLD allow steam to pass slowly into it, ensuring all steam traps have been warmed through. Steam stop valve can then be progressively opened. During this steam raising period and before blowing down to maintain water level, it is convenient to allow water level to rise so that high level alarm can be checked. It is also good practice to operate sequence blowdown valves on water level controllers so that alarm circuits are tested. Excess steam pressure switch can also be tested by allowing steam pressure to rise above normal working level. Switch will shut down burner at a pressure just below setting level of safety valve Burner cut-out : barg Allow steam pressure to drop and check for burner re-start, noting its pressure on re-start -

3 Check water level is at nominal working level.

4 Slowly crack open main steam stop valve.

Burner cut-in :

barg

DOCUMENT

: PJ-WI05a : 24 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Taking boiler out of service STEP ACTION

SYSTEM : Unit operation REMARKS SIGN.

Taking boiler out of service for a period up to 48 hours.

Close main steam valve. Switch OFF burner. Switch OFF water feed pump when level is at nominal working level.

STANDBY : If boiler is being retained on standby, it is recommended that it is flashed up at intervals. This will reduce thermal stresses on boiler and pipework. Alternatively, burner could be left with switch ON and set to LOW FLAME position, allowing excess steam pressure to stop and start burner to maintain steam pressure.

COMPLETE SHUT DOWN : As with (1), (2) & (3), but also close all isolating valves on fuel supply line. Close all water feedline valves. If boiler is to be out of service for any length of time, usual precautions must be taken to prevent corrosion of internal and gas-side surfaces.

DOCUMENT

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WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

TESTING / COMMISSIONING ACTIVITY : Putting boiler back into service from warm / hot condition STEP ACTION For starting boiler from warm / hot condition, follow instructions for Section : Starting boiler from cold (Page 22), but :

SYSTEM : Unit operation REMARKS SIGN.

Do not open air release valve on boiler crown. Burner may be selected to AUTO (i.e., allowed to modulate).

DOCUMENT

PJ-WI05a

26 OF 27
REVISION DA1E DISK FILE

2
19-Aug-1999 PJ- a PAGE

()
TESTING, PRE-COMlVllSSIONING
& COMlVllSSIONING-

PACKAGED

BO ILER

DOCUMENT

: PJ-WI05a : 27 OF 27 : 2 : 19-Aug-1999

WORK INSTRUCTIONS
TESTING, PRE-COMMISSIONIN G & COMMISSIONING - PACKAGED BOILER

PAGE REVISION DATE

NOTE:

All actions as stated in this set of Work Instructions are subject to change by VHM authorized personnel to suit boiler applications.

2nd PORT

1st PORT

FORM PAGE

: PJ-FMBTD : 1 : 0 : 09-Apr-1998 : PJ-FMBTD OF 4

BOILER TESTING DATA

NAME : CHECK ITEM
1. BOILER WATER LEVEL SETTING

REVISION DATE DISK FILE

DATE : RESULT OK NOT OK

HIGH WATER

LOW WATER EXTRA LOW WATER

NOTE :

2.

SAFETY VALVE SETTING

NOTE :

PRESSURE

VENT BLOWDOWN BLOWDOWN %

FORM PAGE

: PJ-FMBTD : 2 : 0 : 09-Apr-1998 : PJ-FMBTD OF 4

BOILER TESTING DATA

CHECK ITEM
3. HEAVY OIL SERVICE TANK HEATER CONTROL

REVISION DATE DISK FILE

RESULT OK NOT OK

CONTROL LIMIT

C C

4.

BOILER FUEL PUMP HEATER CONTROL

BURNER FAN ON IGNITION ON HEATER OFF

C C o C
o o

5.

PHOTO ELECTRICAL CELL

DARK LIGHT

LIGHT DARK

BURNER ON BURNER OFF

6.

BOILER PRESSURE SETTING : CUT - OUT : CUT - IN : MODULATING : HIGH/LOW/HIGH

REMARKS:

FORM PAGE

: PJ-FMBTD : 3 : 0 : 09-Apr-1998 : PJ-FMBTD OF 4

BOILER TESTING DATA

CHECK ITEM

REVISION DATE DISK FILE

RESULT OK NOT OK

DOOR SWITCH INSTRUMENT TESTING DE-AERATOR TESTING : STEAM SUPPLY - STEAM PRESSURE - SAFETY VALVE

: WATER SUPPLY - LEVEL - PUMP OPERATION - WATER TEMPERATURE TIGHTEN ALL VALVES AT 7 BAR OIL SERVICE TANK LEVEL ADJUSTMENT

WATER SOFTENER : PRESSURE SETTING : WATER HARDNESS

FORM PAGE

: PJ-FMBTD : 4 : 0 : 09-Apr-1998 : PJ-FMBTD OF 4

BOILER TESTING DATA

REVISION DATE DISK FILE

SAFETY INTERLOCK ELEMENT OF THE FIRING SYSTEM

OPERATION
1. 2. 3. 4. 5. 6. 7. 8. 9.

CHECK O.K. / NOT O.K.

Door Switch Oil Temp. Stat. Control System Oil Valve/s Photocell Pilot Gas, Ignition Valve Oil Pump Low Fire Switch High Fire Switch

10. Low Fire Hold Switch 11. High Water 12. Low Water 13. Extra Low Water 14. Limit Switch

- High Pressure - Modulation

15. Gas Pressure 16. Air Pressure

- Pilot

- Primary - Secondary
17. Oil Pressure 18. Stack Temperature 19. Steam Temperature 20. Smoke Monitor (Flue Gas) 21. Automatic Blowdown 22. Chemical Feeding 23. Lockout 24. Hand Control Potentiometer 25. Furnace Temperature

DOCUMENT

: PJ-WIBST : 1 : 4 : 12-Jun-2002 OF 4

WORK INSTRUCTIONS
BOILER STEAM TEST - SITE

PAGE REVISION DATE

BOILER STEAM TEST

This work instruction applies to all range of boiler produced by Vickers Hoskins. The purpose of the steam test is to demonstrate the setting and proper function of the safety feature installed on the boiler. The test shall be conducted immediately after the boiler has been commissioned and preferably before supplying steam for downstream application. Representative from boiler end user shall be invited to witness the test and the test results shall be recorded. In the case that it is a statutory requirement, the test shall be witnessed and approved by the inspection authority. The following tests shall be conducted where applicable:

Lifting of Safety Valve(s)

While firing the boiler at maximum firing rate, observe the lifting of the safety valves and the rise in pressure in the boiler. The safety valve(s) should be set at a pre-determined blow-off pressure so as not to cause the pressure inside the boiler to rise by more than 10% of the approved maximum allowable working pressure or the boiler design pressure, whichever is applicable.

Hi/Lo Water Level Alarm

The audible alarm system for high and low water level inside the boiler drum shall be tested to make sure the alarm comes on when the water level rises or falls to the set level.

Flame Failure Check

This is applicable to boiler fired by burner(s) using liquid or gaseous fuel. The flame detecting device (photocell) is to be removed temporarily while the burner(s) is running. This is to test the lock out of the burner(s) in case of flame failure.

Extra Low Water Level

Extra low water level alarm or control (if fitted) shall be tested for its intended function of providing a second audible alarm only and/ or disable the firing equipment of the boiler.

10

Burner Cut Off at Boiler High Pressure

The burner shall be tested to cut at pre-set high boiler pressure automatically. This is to prevent boiler overpressure and unnecessary lifting of safety valves.

11

Burner Safety Interlock

This interlock shall be tested for its function when the burner locks out. The purpose is to test whether the burner can be re-started if the extra low water level and/or the flame failure is active.

12

Level Gauge Indications

The above tests shall be conducted with both the steam stop valve and water inlet valve closed. During the test, the water level inside the boiler shall not be allowed to disappear from the water level gauge. If this happens, switch on the feed water pump and pump in water. The test can be continued after the water level inside the boiler has been re-established. In the case of boiler installed with superheater, care must be taken to ensure that the superheater always has steam flowing throughout the whole duration of the test. This is done by venting the superheater during the firing process so as to prevent overheating of the superheater tubes.

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WORK INSTRUCTIONS
BOILER STEAM TEST - SITE

PAGE REVISION DATE

Project : Item
1.

Client :

Date : Remarks

Work Description
Lifting of Safety Valve(s)

Fill boiler with water to the normal working level (NWL). Close the water inlet and steam outlet valves. Fire up the boiler with low fire until the boiler pressure rises to about 50% of the operating pressure. Re-set the burner high pressure cut off switch at a higher pressure than the safety valve set point. Slowly increase the firing rate and go to high fire until both the safety valves blow. Record the blow off pressure. Continue firing the boiler at maximum firing rate for 10 minutes. Observe and record the rise in boiler pressure. Decrease the firing until the safety valves re-seat. Observe and record the safety valve re-seat pressure.

Results : Blow Re-seat

1st valve :
(superheater )

KPa psig ) KPa psig ) KPa

KPa psig ) KPa psig ) KPa

2nd valve :
(boiler drum)

3rd valve :
(boiler drum)

psig )

psig ) KPa

Boiler over pressure : (

psig )

2.

Burner Cut-Off at Boiler High Pressure

Set the burner high pressure switch to cut off the burner between operating pressure and safety valve blow-off pressure. Fire the boiler until the boiler pressure reaches the set pressure of switch. Observe the boiler pressure when the burner is cut off. Release the boiler pressure after Cut-Off at high pressure and observe the auto re-start of the burner.

Result : High pressure burner cut off : ( Kpa. psig)

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WORK INSTRUCTIONS
BOILER STEAM TEST - SITE Item
3.

PAGE REVISION DATE

Work Description
Flame Failure Check

Remarks

Remove the photocell flame detecting device located at the burner. Observe the cut-off of the burner.

4.

Low and Extra-low Water Level (Oil/ Gas Fired Boiler only)

Open the blowdown valve and drain out the boiler water while the burner is operating. Observe the drop in water level inside the boiler until the low level alarm comes on to stop burner firing. Continue to drain out the water and allow the water level to drop to extra-low water level. Observe the burner lock-out and the interlock to ensure all fan systems become inactive. The burner or fans cannot be restarted until the trip relay has been manually reset.

Result : Low level alarm : Burner lock out at extra-low level : mm below N.W.L. mm below N.W.L.

5.

Burner Safety Interlock

Try and re-start the burner or fan system with the extra low water level active.

Result : The system can / cannot start without lock-out being reset.

6.

High Level Alarm

Start the feed water pump and pump in water to reach high water level. Observe the water level when the alarm comes on.

Result : High level alarm : mm above N.W.L.

DOCUMENT

: PJ-WIBST : 4 : 4 : 12-Jun-2002 OF 4

WORK INSTRUCTIONS
BOILER STEAM TEST - SITE Item
7.

PAGE REVISION DATE

Work Description
Level Gauge Indications Gauge Cock mm

Remarks

Extra High Level

High Level

Normal level

Low level

Extra Low level

Gauge cock

Date of Test

Conducted by : Witnessed by : (DOSH Inspector) Witnessed by : (End User Representative)