OIL FLUSHING ,COMMISSIOINING OF LDO ,HFO SYATEM OF BOILER PART -IV -ABC OF THERMAL POWER PLANT

OIL FLUSHING

After steam blowing is completed, Fuel oil system is normalised for commissioning the LFO

and HFO pumps.

LFO and HFO Pumps are commissioned with pump re-circulation and ready for oil flushing.

LFO pumps of auxiliary boiler are commissioned and available for regular operation.

 

LFO Lines

Fuel lines are lined up for LFO flushing through LFO return line from Boiler.

LFO Pump started and line flushed for 24 hours. Pump suction filter is taken out and

cleaned.

Again flushing continued for 8 hours. If condition of the filter remains clean, flushing can be

terminated.

LFO lines are subsequently normalized and released for regular operation.

HFO LINE FLUSHING:

HFO pump started and first section of the line flushed for 24 hours. In between from time to

time, filter is cleaned.

Again flushing continued for 8 hours. After every 8 hour or as per requirement, filter is

cleaned. Depending on the condition of the filter remains clean, flushing can be terminated.

HFO lines are normalized and released for regular operation.

Oil flushing can be declared completed after minimum of 24 hrs flushing or  minimum of

8 hours running without filter chocking.

HFO /LDO COMMISSIONING INCLUDING OIL GUNS AND CORNER STATIONS

Following equipment  and system will be under commissioning.

Air cooled Oil Gun Assembly :- 

No. of burners  :  20 nos. per boiler arranged in 5 elevations. All Burners will be suitable for

firing heavy oil/LSHS/HPS and bottom most elevation  will be suitable for firing light oil also.

 

LDO Supply & Return Trip Valves

Corner Trip nozzle (Air, Oil & Steam) Valves

High energy arc ignitors assembly

Discriminating Scanner Assembly

Fuel Oil Heaters

Fuel oil lines from HFO/LDO Pump to Burners

Atomizing steam line from Aux. PRDS to burners

HFO Steam Tracing Lines

Pressure Filters are provided before HFO Heating Station and HFO Trip Valves

Plant Completion List to be prepared at site prior to commissioning of oil firing system for

mechanical, electrical and C&I areas.

All manpower ( operation) is in position .Necessary safety precaution is taken oil will be

charged and possibility of fire increases.

As per the normal starting/  operating procedure initially LFO firing is taken up for warming

up the boiler before firing HFO fuel.

Hydraulic Test, Steam blown and oil flushing of LDO/HFO and atomising steam line

completed.

The Fuel Oil Burner Assembly with Scanners and Ignitors are erected as per required

drawing. (Oil Gun ‘dimension, scanner orientation etc are checked from outside and inside

the furnace  & Igniior Advance / Retract mechanisation checked).We termed as Burner

alignment i.e to check the fireball position. It is major and important activity to be completed

before light up.

Steam tracing lines are erected and terminated to suitable outlet point.

Power supply system to scanner, ignitor and trip and corner nozzle valve solenoids are

commissioned and available for operation

Require local/remote I&C input are made available. (List to be prepared at site).

Filter elements in the system are erected in position

 

Corner station are steam blown and corner nozzle valves and burner flexible hoses are

fitted

Trial run of LDO/HFO Pumps through pump RC completed.

 

Steam blowing of LDO, HFO, Atomising Steam Line from Pump House to Ring Header

completed.

Steam Tracing lines are completed with steam traps station.

24 V DC, 220 V Dc supply with UPS are in charged condition

Dry simulation of FSSS System for LDO/HFO oil elevation (AB-LDO & CD-HFO) completed

with required permissive and interlocks (List to be prepared at site)

Scanners and ignitors are mounted as per drawing.

Trial run of ID/FD Fans System and Scanner Air fans completed and released for normal

operation of plant.

Trial run of SAPH and availability of ESP to be ensured.

Boiler cleared for light up (Refer to Boiler O&M for other preparatory checks to be made

prior to light up)

Boiler expansion constraints are removed and ensured for free expansion. Expansion Trans

erected at pre-determined locations.

Availability of instruments and service air to be ensured

Boiler filled up to normal operating level.

Ash handling system erected and provides required sealing at all required locations / areas.

Method

 Start ID/FD/APH Systems as per normal start up procedure. (Respective Testing

Schedules or O&M to be referred) and establish required furnace draft (Around –5 to –10

mmwc).

Depending on the availability of SCAPH, it can be charged (SCAPH charging is optional

during trial light up of LFO burner, which is done to prove the burners)

Start the LDO Pump and ensure charging up to fireman’s floor

Adjust the boiler airflow and wind box DP to the required level

Put the RC valve operation of LFO Pump on ‘auto’

Give command for “start” of LFO burners and watch for flame establishment

Once the flame is established, ensure

a.   Oil combustion is proper and

b.      Flame scanner pick up the flame.

 
After few minutes of operation, trip the burner and observe and ensure that shutdown

sequence take place as envisaged. 

Repeat the above procedure for other LFO Oil Guns

HFO Firing

Start ID/FD/APH Systems as per normal start up procedure. (Respective Testing Schedules

or O&M to be referred) and establish required furnace draft (Around –5 to –10 mmwc)

Charge SCAPH and raise the air temperature to around 60⁰C.

Adjust the boiler airflow and windbox DP to the required level

Charge    a.     Atomising Steam System and

                b.     Steam Tracing System

Start any one of the HFO Pump and after charging HFO Heater, charge HFO line up to

boiler and put under short recirculation first and then long recirculation for raising HFO

temperature.

After attaining HFO firing temperature (around 115⁰C -- 120⁰C), give command for HFO

burner “start”. Watch the flame establishment.

Once the flame is established, ensure

a.   Oil combustion is proper and

b.      Flame scanner pick up the flame.

After few minutes of operation, trip the burner and observe and ensure that shutdown

sequence take place as envisaged.

Repeat the above procedure for other HFO Oil Gun, in that elevation.

Oil Gun, in other elevations are commissioned on similar lines as explained above.

 With the Commissioning of LFO/HFO System, boiler is ready to commence all pre-

commissioning activities, such as alkali boil-out, steam blowing, safety valve floating, steam

dumping etc.

LFO/HFO - Light diesel oil /Heavy fuel oil

mmwc- mili meter of water column

SCAPH - steam coil air preheater.

SAPH - Secondary Air pre heater.

FSSS- Furnace Safeguard Supervisory System ( Burner Management System.

typical PID of LDO/HFO SYSTEM

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