Commissioning Methodology For

Boiler----------After reaching project site

1. Verification for the Readiness of
Pre Commissioning Activities
We need to verify the availability of the followings in order to ensure smooth
& safe pre commissioning
Mechanical Tools-(Prior to this one should understand scope of work )
a. Various type of spanners,Plier ,screw drivers cotton waste, cleaning substance,diesel,grease
etc
b. Safety devices such as Helmet, safety shoes, Boiler Apron, Hand Gloves ,Eye protective
glass and safety belts etc.
c. Introduction of work permit system
d. Required drawings to check the installation/erection readiness.
e. Standard specific check list for proper field inspection.
f. Standard manual for all the auxiliaries from Feed Pump to Hanger supports etc.
g. Protocol format for duct inspection,auxiliaries checking and commissioning mile stone
achievement
h. Boiler operational manual ,should be containing the curves of anticipated fuel flow vs. steam
flow, anticipated Water and steam parameters on various steam flow, anticipated flue gas
temp & pressure parameters on various steam flow, Excess Air vs. oxygen %,fuel &DM water
analysis, steam quality etc.
 1. Verification for the Readiness of Pre
Commissioning Activities
Mechanical Tools (continues)
i. Design flow data sheet for Air ,Feed Water and Steam Flow etc.
j. Safety Interlock logic data sheet.
K Portable display meter including pitot tube to measure Air Head
(static& Kinetic)
l. Standard manometer.
m.Lubrication data sheet & schedule
n. Checking for the availability of required & recommended lubrication
o.Checking for Commissioning spares & outstanding material
p.Checking of DCS operational graphics for operational suitability.
q. Approaches for the field inspection to be checked as well.
r. Checking for the commissioning spares & verification of outstanding items.( if any)
1. Verification for the Readiness of Pre
Commissioning Activities
E & I Tools –(Prior to this one should understand scope of work )
a. Continuity Tester ,Multimeter,On line communicator, Tong tester, Energy meter,Meggaring
device etc.
b. Cable schedule
c. MCC & PCC detail drawing
d. Field wire diagram detail along with junction box.
e. Panel connection detail between DCS end. & field/MCC
f. Standard E & I check list
g. Loop Checking schedule, commissioning spares list and outstanding items (if any)
verification.
h. Civil & Mechanical readiness for DCS,MCC/PCC installation
i. Power requirement for charging each & every panel
j. Approaches for the inspection to be checked as well.
k. Checking for the availability of Instrument & service air.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Mechanical
a. Field inspection of Air & Gas ducts both internal and external including duct supports as
per standard check list. Issuing rectification list (if required). Finally inspection to be
carried out after proper rectification and protocol for inspection to be signed. All the
supports related to this system to be commissioned before fan trial and Boiler Light up.
Support commissioning protocol to be signed as well.
b. Field inspection of all the auxiliaries including fans and pumps as per standard check list.
Issuing rectification list (if required). Finally inspection to be carried out after proper
readiness for trial run of those and protocol for inspection to be signed. Supports related
to the auxiliaries tom be checked & commissioned before trial run, protocol for the same
to be signed
c. Field inspection of Boiler Pressure parts including Boiler Drum, Feed Water Pipe and MS
pipe lines as per standard check list. Issuing rectification list (if required). Finally
inspection to be carried out after proper rectification and protocol for inspection to be
signed.
All the supports related to the entire pressure parts to be commissioned before Boiler
Light up. Support commissioning protocol to be signed as well.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Mechanical
d. Field inspection for Air Compressor readiness (Which will ensure the availability of instrument & service air) as
per standard check list. Issuing rectification list (if required). Finally inspection to be carried out after proper
rectification and protocol for inspection to be signed. Air Compressor to be commissioned at first, as without
this other activities can not be completed.
After trial run of the same, protocol to be signed.

e. Field inspection of entire fuel injection system including burner,atomiser,Ignitor etc. as per standard check list.
Issuing rectification list (if required). Finally inspection to be carried out after proper rectification and protocol
for inspection to be signed. Cleaning of the entire system followed by leak test, Burner &Igniter setting to be
checked and rectified if required. Cleaning & leak test protocol to be made & signed.

f. Checking for the availability of the specified fuel for Boiler/Burner operation. Check the fuel property data
sheet for operational suitability.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Mechanical
g Field inspection of all the dampers as per standard check list. Issuing rectification
list (if required) all the dampers to be made free for trial operation of the same.
Finally inspection to be carried out after proper rectification and protocol for
inspection to be signed
h. Checking for all the valves including drain valves as per standard check list & to
be made mechanically free for DCS trial. Issuing rectification list (if required).
Finally ,inspection to be carried out after proper rectification and protocol for
inspection to be signed. All the valves to be checked for leaking/passing during
Hydro Pressure test, after rectify the problem (if any) protocol to be made &
signed.
i. Checking for the proper restoration of all the Safety Valves after Hydro Test of the
entire pressure parts. Issuing rectification list (if required )Finally ,inspection to be
carried out after proper rectification & readiness for floating test, protocol for
readiness to be signed.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Mechanical
d. Field checking of Air Flow Measurement device as per standard check list. Issuing
rectification list (if required) of the same. Finally inspection to be carried out after
proper rectification and protocol for inspection to be signed. Air Flow measurement
test to be conducted during fan trial & protocol to be signed after test calculation
result incorporation in DCS & field flow transmitter.
e. Boiler Feed pump along with De aerator & storage tank to be properly inspected &
thoroughly cleaned. Protocol of the same to be signed.
f. BFP to be commissioned on recirculation mode along with all the supports. Prior to
the commissioning of BFP Feed Water availability & quality to be ensured.
Protocol of the same to be signed.
g. Final pipe connections of Boiler Feed Water system & spray water for temperature
control system to be made hold. After thorough cleaning of these two system by
running BFP,final connection to be completed. Protocol to be signed for this.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Mechanical
d. Field checking of Feed Water Flow, spray water flow (for temperature control)
measurement devices as per standard check list. Issuing rectification list (if
required) of the same. Finally ,inspection to be carried out after proper rectification
and protocol for inspection to be signed.
e. After steam blowing/purging steam flow and ejector steam flow measurement
devices to be installed and field checking of those to be carried out as per
standard check list. Protocol to be signed for this.
f. Instrument air piping system & service air piping system to be inspected,
thoroughly cleaned & to be made ready for commissioning along with
commissioning of all the supports. Protocol for this to be signed.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
E&I
a. Thorough loop checking to be carried out as per standard loop checking
schedule. Issuing rectification list (if required) of the same. Finally ,loop
checking to be carried out after proper rectification and protocol for the
same to be signed.
b. Field checking of all the instruments including transmitters, pneumatic
valves and motorised valves & dampers to be carried out as per standard
check list. Protocol to be signed for this.
c. Calibration of all the instruments including pneumatic dampers & valves
transmitters etc.
2.Pre Commissioning
Of Boiler Plant along with
auxiliaries.
Activities to be carried out
E&I
d. Auxiliary power incorporation by charging necessary transformer
and PCC etc.and protocol for the same to be signed.
e. All the motors (LT & HT) to be made ready for trial operation in all
respect. as per standard check list. Protocol to be signed for this.
f. MCC and HT breakers to be made ready for all the auxiliaries and
valves and dampers, prior to this electrical safety interlocks to be
checked as well. Protocol to be signed for this.
2.Pre Commissioning
Of Boiler Plant along with
auxiliaries.
Activities to be carried out
E&I
g. Loop checking also to be carried out between MCC and DCS as
per standard schedule and protocol for the same to be signed.
h. DCS to be made ready and operational as per standard check list.
Protocol to be signed for this.
i. Finally check all the Boiler Operational safety interlock (including
Burners etc.) are properly incorporated in DCS or not.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Common (Mechanical ,C & I and Process)
Prior to this Air Compressor, BFP and other important auxiliary like initial water filling
pump to be successfully commissioned.
a Trial run of all the motors of auxiliaries to be carried out as per standard motor
characteristic curves and important parameters to be recorded such as Motor starting
current, normal no load current, Motor winding temp.Motor bearing temp. for
abnormality/future reference and protocol for the same to be signed.
b. Trial operation of all the motorised and pneumatic valves and dampers to be carried
out from DCS. Protocol to be signed for this.
c. Trial run of all the auxiliaries (including fans, pumps etc.) to be carried out from DCS
keeping their individual safety interlock in line .
Protocol to be signed for this.
d. Chemical dozing system to be commissioned and protocol to be signed for this.
2.Pre Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Common (Mechanical ,C & I and Process)
e. Flue gas analyzing system to be installed and commissioned including oxygen analyser and CO
analyser. How ever same to be kept under observation for a prolonged Boiler actual operational
period. Finally protocol for the same to be signed.
f. Carry out dry trial operation of oil burners from DCS. Protocol to be signed for this.
g. Carry out checking of entire safety interlock from DCS i.e Blank Functional Test .Protocol to be
signed for this.
h.. Carry out pressure test of entire draught system including furnace. Protocol to be signed for this.
i. Carry out Air Flow Measurement test. Incorporate the final calculated values in DCS and field
transmitters as well. Protocol to be signed for this.
j. Hydro test of Boiler including boiler feed pipe, MS pipe etc to be carried out once again.
k. Carry out test light up of Boiler.
l. No load trial of Main Fuel (Mainly coal for CFBC & PF fired boiler) Firing system including Coal
Mill,PA fans, Seal Air fans for PF fired only) Coal Bunker, CoalFeeder(For PF & FBC both) to be
carried out & commissioning of the same to be conducted as well.
.
3.Commissioning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
As per standard procedure and commissioning curves followings to be carried
out.
a. Refractory Dry Out (where ever applicable). Protocol to be signed for this.
b. Alkali Boil Out of water circuit. Protocol to be signed for this.
c. Acid cleaning of the water circuit. Protocol to be signed for this
c. Steam Blowing of Steam circuit and MS pipe up to turbine along with
auxiliary steam pipe lines. Protocol to be signed for this.
Prior to this *temporary blowing pipe lines to be installed and supports to
commissioned for this.** Disturbance factor along with blow off pressure to be
Discussed and settled before commencement of actual lowing, *** Target
Plates and target plate holder to be arranged for the blowing.****Start Up vent valve to be
commissioned.
d. Floating test of all the safety valves to carried out. Protocol to be signed for this.
e. EMSV to be commissioned. Protocol to be signed for this.
f. SWAS to be commissioned. Protocol to be signed for this.
4.Start Up
Of Boiler Plant along with auxiliaries.
Activities to be carried out
Start up to be carried out as per standard
Procedure supplied by manufacturer such as
time Vs. pressure curves etc.
After achieving all the
desired parameters like MS pressure and temp.
etc, put the Boiler on Load.
5.Stabilisation & fine tuning
Of Boiler Plant along with auxiliaries.
Activities to be carried out
a. Carry out fuel property analysis
b. Carry out steam and water analysis.
c. Finally Boiler anticipated parameters (along with steam
load) to be established properly by fine tuning air and
fuel in accordance with Oxygen analyser reading.
The above will ensure use of proper excess air in
turn ensure the proper combustion.
Boiler full load operation to be conducted as per contract.
5.Performance Guarantee (PG) Test
Of Boiler Plant along with auxiliaries.
After attaining Boiler smooth and safe full
load operation activities to be carried out
a. Preparation for PG test like ash collection and
analysis,
b. Making of gas temp. and orsat analysis
tapping points.
c. Carry out trial PG test.
d. Finally do the actual PG test.