Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

Page 2 of 15

Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh
Commissioning Department

Project

OPJSTPP (4X600 MW), Tamnar

Procedure

Air Pre Heater

Purpose of Document

For Execution/Information

Document No.

JPL Reference No: Boiler/Comm./004

Rev No. 00

Prepared By

Reviewed By

Approved By

Name
Sign

Signatures
JPL

BHEL

Date

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

List of Contents

1.0

Plant Details

2.0

Objectives

3.0

Proposals

4.0

Services Required

5.0

Safety Precautions

6.0

Emergency Procedures

7.0

State of the Plant

8.0

Method

9.0

Completion Criteria

10.0

Appendices
a) Log Sheets

Signatures
JPL

BHEL

Page 3 of 15

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

1.0

Page 4 of 15

PLANT DETAILS
Rotary Air Preheaters supplied are of Tri-Sector type .

Rotary Air- Preheater generally comprises the following.

1.1

A.C Driven Motor 1 No

1.2

Air Motor 1 No

1.3

Drive Gear Box.

1.4

Rotating elements with support and guide bearing

arrangement with forced lubrication system.

1.5

Soot blower system.

1.6

Fire Sensing device.

1.7

Deluge system

1.8

Water wash system

1.9

Observation ports and light arrangement

1.10

Rotor stoppage alarm

1.11

Plant item completion list for Mechanical, Electrical and C & I

are to be prepared at site.

2.0

OBJECTIVE
To commission the rotary air preheater and make it available
for commissioning and operation of the main plant.

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

3.0

Page 5 of 15

PROPOSAL:
Commissioning of the rotary air preheater is proposed in the
following steps.

3.1

Acid cleaning & oil flushing of Lub-oil system of support &

Guide bearings.

3.2

Trial Run of Main Drive Motors for 8 Hrs.

3.3

Trial run of APH through main motor for 4 Hrs.

3.4

Commissioning of Air Motor and APH operation for 10

minutes through Air Motor.

3.5

Commissioning of Soot Blower system

3.6

Flushing of Deluge and Water Wash System.

4.0

SERVICES REQUIRED:

4.1

Availability of manpower with required Tools for attending to

any leak, cleaning of filters.

4.2

Availability of operating personnel to co-ordinate the

activities.

4.3

Availability of lighting arrangements and communication in

the operating floors.

4.4

Availability of portable fire fighting equipments near test area.

4.5

Availability service water

4.6

Availability of L.T supply

4.7

Availability of Equipment cooling water.

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

Page 6 of 15

5.0

SAFETY PRECAUTIONS:

5.1

Debris in and around APH shall be removed

5.2

Approach / stair case / platform wherever required are made

available.

5.3

Man hole doors kept open for inspection should be clearly

guarded from any unauthorised persons entering in to APH.
(Test team leader to ensure this)

5.4

First aid test available near test area.

5.5

Operations of local start / stop PB are ensured for perfect

operation to facilitate stopping of APH in case of necessity.

6.0

EMERGENCY PROCEDUES:

6.1

The test team should be aware of the procedure to be adopted

in case of damage to machinery of injury or any personnel
connected to the activity.

6.2

The test team should be well aware of procedures to be

adopted in case any abnormality in the activity.

7.0

STATE OF THE PLANT:

7.1

APH and its associated system are erected as per

recommended drawing.

7.2

Acid cleaning of support and guide bearing Lub-oil line

completed.

7.3

All local instrumentation of Lub-oil system completed.

7.4

Power supply systems for the pumps are commissioned and

available for operation.

7.5

Instrument and service Air is available upto APH.

7.6

Cooling water for support and guide bearing lub oil pumps is
available for operation. (Equipment Cooling water System)

7.7

Required local / remote I & C inputs for APH are made

available. (List to be mutually prepared at site).

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

7.8

Deluge and water wash lines are erected upto APH and
drainage facility is ensured.

7.9

APH fire sensing device commissioned and kept ready for

operation.

Page 7 of 15

7.10

Soot blower and its connected piping are erected and kept
ready for operation. Ensure either steam or air (temporary
source) is made available for commissioning APH during APH
start up till main steam source is made available.

7.11

Oil in support and Guide bearings and fluid coupling are filled
up with recommended oil up to correct level. (Refer O & M
Manual).

7.12

All erection log sheets are filled and signed by concerned

agencies

7.13

Flue gas ducts and Air ducts (Primary, Secondary)

connections to APH are completed and ducts are cleared for
any loose material or debris. Expansion bellows connected to
APH should be checked for removal of all temporary braces.

7.14

Dampers at inlet and outlet of APH (Primary of Secondary and

flue gas ) are made free and connected to its drive. All loose
materials / debris lying on the dampers are cleared.

7.15

Main motors are kept decoupled from fluid coupling.

7.16

Service air line connection to Air Motor is complete with

lubricator cum Regulator.

7.17

Fillers in the lub-oil system cleaned and put in position.

7.18

Oil level in the main gear drive ensured up to its normal level.
Local instrumentation of the gear drive completed.

7.19

Insulation of APH should be completed in all respect before

boiler light up with special attention given to Guide bearing
area.

7.20

Platforms, Ladders and other structures around APH are

inspected and thermal expansion of APH casing in all
direction ensured.

7.21

Aluminium finger tabs sets installed after seals are set to the
specification.

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

Page 8 of 15

7.22

Air Seal cover and water shield of support bearing and air seal
cover of guide bearing are erected as per drawing.

7.23

Hot end tracking arrangements are mounted properly and the

system is free to move.

7.24

Breathers of bearing are checked for clean condition.

7.25

Light assembly and observation ports are in position and

wired.

7.26

Adjuster nuts of sector plates are fully tightened and locked to

specification

7.27

Lock nuts of axial seal plate adjusters are fully tightened.

7.28

Entire APH plant inspected and ensured that all loose

material are removed and all personnel are away from rotating
equipment.

7.29

All man hole doors are closed except one or two as decided by
the test team leader.

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

8.0

METHOD:

8.1

Acid cleaning and Oil Flushing of lub-oil system of

support and Guide Bearing system.

Page 9 of 15

8.1.1

After completing the erection of the lub-oil system, oil lines

are dismantled and acid cleaning is done.

8.1.2

Motors of Lub-oil system are decoupled from pump and after

ensuring Insulation resistance at satisfactory level, motor
started, direction of rotation checked and put on 4 Hrs trial
run. No local current measured during this trial run.

8.1.3

After completion of motor trial run, both pump and motor are
coupled.

8.1.4

Pump primed sufficiently and then started and ensured that

the entire system is filled and oil circulation established. (In
the case of lub-oil system of both guide and support beaning,
the bearing itself is the oil reservoir and oil circulated back to
Bearings through filler and cooler) Leaks attended if noticed
during oil circulation.

8.1.5

Initially, the filters in the System are closely observed in terms

increase in pump discharge pressure and filters are cleaned.
Normally, the pump discharge pressure will be around 2.0
KSC to 3.0 KSC and if an increase of around 1 KSC is
observed, it indicates chocking of the filter and requires
cleaning.

8.1.6

Continue oil flushing till the pump discharge pressures

stabilises for a period of 4-6 Hrs.

8.1.7

After completing the oil flushing, the filters are cleaned again
and put back in to the system.

8.1.8

Relief valve in the pump (or mounted in the discharge line) are
set at 2.0 KSC above the normal operating pressure of the
lub-oil system.

8.1.9

For safety reasons, the oil flushing activity to be performed

during day time.

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

8.2

Page 10 of 15

Air pre Heater

8.2.1

After ensuring the insulation resistance of the motor at

satisfactory level, motor bumped and direction of rotation
observed. After correcting the direction of rotation, if found
necessary, the motor put on 4 Hrs trial run. Motor no load
current and vibration are noted once during the trial run.

8.2.3

After completion of motor trial run, motors are coupled to APH

main gear drive through fluid coupling.

8.2.4

Start the lub oil system of guide and support bearing

assembly and establish circulation.

8.2.5

Start the main motor and stop it after about 10-20 secs to
observe for its normal running. Any abnormal sound noticed
to be brought to the notice of the team leader.

8.2.6

Start the main motor again and allow APH to continonsly run.

8.2.7

Observe of
a) Load current (To be logged)
b) Vibration of motor and gear unit (To be logged)
c) Rubbing of Seals / Aluminium finger taps.
(Rubbing of Seals do take place in cold condition and the
team leader to ensure that such rubbings are normal /
abnormal)

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

8.3

Page 11 of 15

Air Preheater (With Air Motor)

8.3.1

a.

Required air pressure (Around 5.0 KSC) at the

supply header to Air motor

b.

Lubricator filled with oil.

c.

Operation of solenoid valve

d.

Pressure gauge in the Air supply line to Air

motor.

8.3.2

Open the bypass valve manually and slowly operate air motor
vis--vis the APH

8.3.3

Operation of air motor vis--vis APH carried out for about 10

minutes. The same operation carried out by operating the
solenoid valve in the main line and APH operated for 10
minutes.

8.3.4

Interlock operation of APH running through Air motor

checked by creating the condition of electrical motors tripping
Note: Normally, the air motor is commissioned during
erection of APH to facilitate erection process.

8.4

APH Soot Blower

8.4.1

After ensuring the insulation value of the motor winding at

salisfactory level, the SB motor started and put on 4 Hrs trial
run. No load current logged once during the trial run.

8.4.2

Ensure
a.
b.
c.
d.
e.
f.
g.

Coupling of motor with speed reducer

Coupling of Speed reducer & gear box
Erection completion of swivel link arrangement with
gear box and swivel arm.
Limit switches for sweep limit with its electrical
connections.
Recommended lubrication of speed reducer & gear
box.
Cleanliness of the nozzles.
Air line connection to APH SB

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

Page 12 of 15

8.4.3

Start the SB motor and observe for the entire operation of

steam nozzle movement from in board location to out board
location and back to in board location (Parking location).
(Refer O & M manual & enclosed drawing)

8.4.4

Set the limit switches for

a) Operating steam valve and
b) Stopping the SB at its parking location.

8.4.5

Charge the air line slowly and blow the SB arm and nozzle
sufficiently.

8.4.6

Ensure the operation of APH SB from remote along with

steam valve opening.

8.5

Flushing of Deluge & Water wash system

8.5.1

Deluge and water wash system are similar in lay-out.

8.5.2

The line is charged up to system inlet isolating valve and

flushed sufficiently through its drain line to plant drain till
clear water observed at drain outlet.

8.5.3

Flushing the system into the APH to be carefully done after

ensuring proper draining facility at the bottom of APH
(Through APH hoppers. At no time, water allowed to get
collected in APH Hoppers)

8.5.4

Flushing through both deluge system and water wash system

carried out one by one sufficiently till clear water observed at
drain outlet.

8.5.5

After completion of flushing, deluge and water wash systems

are isolated and APH allowed for drying (Either by natural or
by running FD Fan and APH)

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

8.6
8.6.1

Page 13 of 15

General
Other miscellaneous system
a) Rotor stoppage alarm
a) Oil carry over unit
b) Light assembly for observation port
c)

9.0

Interlocks with other systems of the boiler. All these

systems are commissioned separately through
respective sections in the O & M manual.

COMPLETION CRITERIA
Air Preheater commissioning completed by carrying all the
proposals given in section 3.0 (Section 3.1 to 3.6)

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

Page 14 of 15

10.0

Date :

LOG SHEET - I

PROJECT

UNIT NO.1

ACTIVITY

: Lub-oil flushing (Guide Bearing / Support Bearing)

Sl.No

TIME

PUMP IN SERVICE
A
B

DISCHARGE
PRESSURE

REMARKS

Signatures
JPL

BHEL

Station: JPL, Tamnar

BHEL/TSX/JPL/BLR-CP/05
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure of Air Pre Heater

Page 15 of 15

10.0

Date :

LOG SHEET - II

PROJECT

UNIT NO.

ACTIVITY

: Trial run of APH Motor (No load) / APH.

Sl.
NO

TIME

MAIN MOTOR IN
SERVICE

VIBRATION
MOTOR

APH GEAR
BOX

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REMARKS