印度BALCO调试大纲修正稿2201105

1、BALCO EXPANSION PROJECT -1200 MW THERMAL POWER PLANTCOMMISSIONING PROCEDURE印度BALCO扩建4 x300 MW燃煤电站工程调试大纲 Aug. 2010 2011年5月Item No.: BALCO-COMM-GCP01Compiled by:编写： 芦正阳 Revised by:审核： 丁联合 Approved by:批准： 目 录1 前言PREFACE32工程概况PROJECT PROFILE33调试范围及主要项目COMMISSIONING SCOPE AND ACTIVITIES43.1调试一般工作原则Princi

2、ples of commissioning43.2调试分阶段任务简述 Description of activities in each stage of commissioning53.3分系统调试项目 Subsystem commissioning items73.4 整套启动试运前应具备条件Prerequisites to unit integrated trial run143.5整套启动试运阶段的调试项目Commissioning activities during integrated unit start-up and trial run stage214 启动调试组织机构及职责

3、分工26COMMISSIONING ORGANIZATION AND ITS RESPONSIBILITIES264.1组织与职责organization and functional responsibility284.2 调试各方主要职责Functional responsibility of commissioning groups305 机组整套试运行的程序和内容33PROCEDURES FOR INITIAL TRIAL OPERATION OF THE OVERALL UNIT335.1 空负荷阶段（此阶段为纯烧油）No-load operation phase (all-oil

4、firing)335.2带负荷试运行阶段On-load trial operation phase365.3 14天可靠性运行 14-day Reliability Operation406 调试进度管理MANAGEMENT OF COMMISSIONING PROGRESS406.1调试进度控制指标Commissioning progress control indexes406.2调试工期的确定Schedule of commissioning activities416.3调试计划Commissioning programme427调试安全管理SAFETY MANAGEMENT IN C

5、OMMISSIONING439 附录 APPENDICES45附录1：组织机构及人员配置 Appendix 1: Organization of BALCO Project45附录2：技术措施清单 Appendix2:List of technical procedures.49附录3：调试流程图 Appendix 3: commissioning sequence diagram.511 前言Preface调试大纲是机组启动调试阶段纲领性文件，编制调试大纲的目的是为了在启动调试的各个阶段把好安全质量关，移交给业主一个可靠、稳定、经济满发的投产机组，确保机组每一个试运阶段和主要调试项目均能达到

6、规定的优良标准的要求，消除不合格项，实现机组高水平投产。As a guide documentary for all stages of unit startup and commissioning, the procedure is focused on insurance of safety and quality in different commissioning stages, in which major commissioning items shall meet the requirements with defects eliminated, and thus handing

7、 over a unit to the Owner that is able to operate stably, efficiently and reliably.启动调试是火电基本建设工程的一个关键阶段，设计、设备、安装等方面可能存在的问题将在此阶段暴露出来并获得解决；同时，启动调试又是一个多单位协作的系统工程。因此，各参建单位应当在启动验收委员会（试运指挥部）的统一领导和协调指挥下，团结协作，安全、优质、高效地完成机组启动调试工作。本调试大纲是针对工程总体而编制的，适用于BALCO扩建4300MW电站工程四台机组的启动调试过程，调试单位及各参建单位必须遵守本调试大纲，若实施中需作必要的修

8、改时，需经试运指挥部总指挥批准。Unit startup and commissioning is a critical phase of coal-fired unit project. Latent and potential defects in design, manufacturing, and installation will be discovered and rectified in commissioning. Moreover, commissioning is also a system engineering involving multiple working pa

9、rties. Therefore, close cooperation between all the parties under the unified direction of the Commissioning Headquarters (CH) is essential for the unit to be commissioned on schedule, in good condition. The master guidelines is drafted based on the specific conditions of BALCO Expansion Project 430

10、0MW Thermal Power Plant. Commissioning team and other participating parties shall follow this master plan. Modifications or amendments if necessary shall be subject to the approval of the Commissioning Headquarters. 本调试大纲由试运指挥部组织审查、批准后生效。The master plan is subject to the review of the Commissioning

11、Headquarters before put into force. 2工程概况Project profile印度铝业有限公司（以下简称“BALCO”）计划在Chattisgarh邦Korba镇建设一座燃煤发电厂。Bharat Aluminum Company Limited（hereinafter refer to “BALCO”） planned to develop an Thermal Power Plant using pulverized coal as the main fuel in korba town in the state of Chattisgarh, India.

12、印度铝业有限公司已建成4 台135MW 机组作为自备电厂，本期建设4 台300MW 亚临界燃煤机组。Four units with 135MW capacity have been built as the Captive Power Plant and four coal fired subcritical units with 300MW capacity will be built at this phase.山东电力基本建设总公司(以下简称“承包商”)于2007年8月20日获得了项目EPC总承包合同，并将以EPC方式完成电站设计、采购、供货、运输、安装、调试和性能验收试验工作。SEPC

13、O （hereinafter refer to “contractor”） got the contract at August,2007 and will be responsible for the design, procurement, supply, delivery, erection, commissioning and performance testing on EPC basis.3调试范围及主要项目Commissioning scope and activities3.1调试一般工作原则Principles of commissioning3.1.1 主体调试单位的调总负

14、责本工程的调试总体协调，调试进度计划编制,调试安全、质量、进度控制。The manager of Commissioning Team shall take the responsibility of overall coordination, preparation of test and trial run schedules, and supervision of commissioning quality and progress, and safety.3.1.2 自分部试运开始，任何辅机试运必须在DCS上操作且相关保护系统投入，以确保辅机试运的安全。From system tria

15、l operation, each auxiliary plant shall be operated on DCS with associated protections in service to ensure safety operation.3.1.3 机组调试过程中，所有保护、联锁完成试验后，必须进行验收。On completion of testing of each protection/interlock item, all working parties shall confirm and accept the results. 3.1.4 每个系统试运前必须进行安全、质量的

16、检查验收，单机试运不合格不得进入分系统调试，分系统试运不合格不得进入整套调试，以确保机组调试质量达到设计要求。Safety and quality inspection shall be conducted before each system is put into trial run. System trial run cannot be started if any component in the system has not passed individual testing. Similarly, overall unit startup cannot be commenced i

17、f any auxiliary system fails to pass trial operation. Only in this manner the unit can be commissioned successfully, fulfilling overall design requirements.3.1.5 分系统或整套试验前，各项基本条件必须满足。All requirements specified in procedures shall be satisfied before trial operation of all subsystems and startup of o

18、verall unit.3.2调试分阶段任务简述 Description of activities in each stage of commissioning3.2.1分系统调试任务 Tasks in subsystem trial run分部试运是电力建设施工的一个重要环节，是对电力设备制造、设计、安装质量的动态考核和检验，是机组能否顺利进行整套启动试运和顺利投产并迅速形成生产能力的关键工序。分系统调试工作作为分部试运工作的组成部分，在本工程中的主要任务是：完成机组全部系统的试运、DCS软件恢复、厂用系统带电、锅炉冷态通风试验、机组化学清洗、锅炉点火吹管等工作。Subsystem tri

19、al operation are a crucial phase to power plant construction. They are intended to dynamically check and test all the pieces of equipment in the aspects of manufacturing, design and installation, thus ensuring the success of overall unit startup and commissioning. Individual system trial operation i

20、s part of the construction tests, and is intended to perform tasks such as trial operation of all systems, DCS software installation, auxiliary power system energizing, boiler cold draft test, chemical-cleaning, boiler light up and steam blowing. 3.2.2机组整套启动试运前准备工作 Preparations prior to integral uni

21、t startup本阶段的主要任务是组织机组分系统调试后的缺陷封闭检查、机组整套启动试运计划制定、机组整套启动试运前质量监督检查、机组整套启动试运应具备条件检查确认、召开启动验收委员会会议、审议试运指挥部有关机组整套启动准备工作报告、协调整套启动的外部条件、决定机组整套启动的时间和相关事宜。Major tasks covered in this stage are:1) organizing to check all defects have been eliminated after subsystems trial run2) drafting of unit integral start

22、up commissioning schedule3) supervising of quality checking all preconditions are met for the unit to startup4) conference of the Overall Start-up Commissioning Committee is to be convened5) examination (scrutinizing) reports on preparations for overall unit startup 6) coordinating external conditio

23、ns for unit integral startup7) determining when the integral unit startup commences and other issues. 3.2.3机组空负荷试运调试任务 Commissioning tasks in no-load trial operation of the unit机组整套启动调试是机、电、炉、热、化各专业联合运作的一个过程，也是对设计、制造、安装、调试质量的最终检验。Integral unit startup and trial operation is a process of joint effort

24、 of turbine, boiler, electrical, chemical and I&C teams. It is a final comprehensive test the quality for design, manufacturing, erection and commissioning.机组空负荷调试阶段的主要任务是完成锅炉冷、热态冲洗，机组初次冷态启动与试验、机组并网前电气试验、汽轮机超速试验、锅炉蒸汽严密性试验及安全门校验、汽机主汽门、调门严密性试验等。Major tasks to be completed in this stage are:1) cold and

25、 hot flushing of boiler;2) initial cold unit startup and tests;3) electrical tests prior to generator synchronization;4) turbine overspeed tests,5) boiler steam tightness test and safety valves setting;6) turbine MSVs and CVs tightness test.3.2.4机组带负荷试运调试任务 Tasks in on-load trial run of unit 机组带负荷试验

26、的目的，在于通过各项试验，考验机组额定工况下，稳定运行的能力，并通过优化组合运行参数和燃烧初调整等各项调整试验，使机组具备一个较经济、稳定的运行工况。In this stage, various tests are performed to examine whether the unit is able to run stably under the rated conditions, and through optimization of operational parameters and adjustment, to determine a stable and efficient o

27、perational condition for the unit.机组带负荷调试的主要任务是发现和解决设备和系统动态运转过程中的问题，消除由于各种原因造成的设备和系统缺陷，使所有设备、系统达到设计的额定工况和出力，进行制粉系统调整试验、锅炉燃烧初调整试验、低负荷断油试验、SCS设备及程控投用试验、MCS 热控自动装置投用试验、MCS 协调控制负荷变动试验、厂用电切换试验、真空严密性试验、甩负荷试验、RUNBACK试验等。The purpose of on-load testing and adjustment of the unit is to discover and solve any

28、potential defects and/or difficulties and to make the systems and equipment to attain design conditions and output. In this stage, some testing and adjustment shall be conducted as follows: 1) adjustment for coal pulverizing system;2) initial adjustment for boiler combustion;3) oil cut-off on low lo

29、ad4) SCS initial operation5) MCS initial operation6) load change test in CCS mode7) changeover of auxiliary power source8) vacuum tightness test9) load rejection test10) Runback of unit3.2.5机组满负荷试运调试任务Full-load trial run of unit机组满负荷整套试运主要任务是机组再次启动并网后逐渐投入所有系统、热工仪表、保护、自动等。当锅炉投电除尘、断油、吹灰系统投用正常，汽机投高加，热控

30、仪表正常投入、汽水品质合格、机组负荷300MW 时，进入14天可靠性运行。In full-load trial operation, the unit is restarted and brought into parallel operation with the power grid, with all the systems, I&C, protections, automatic controllers and others put into operation in succession. When ESP and soot-blowers are working steadily,

31、 oil cut-off succeeds, HP feed heaters were put in and most I&C are working normally, water and steam measure up to the standards, and the unit is running at 300MW steadily, the 14-day reliability operation will begin.3.2.6机组14天可靠性运行14-day Reliability Operation完成机组带负荷试运后，如果需要停机检修，则停机检修完成后。再次启动机组使机组负

32、荷达到300MW ； 投入机组的连锁保护和仪表；投入机组的自动控制系统。使机组完成14天的可靠性运行。After completion of unit on-load trial operation, the unit will be shut down for defects repair if necessary, then restarted and loaded up to 300MW, with the protections, interlocks, instruments, and automatic control systems put in service. The uni

33、t should stand the 14-day on-load operation for reliability. 3.3分系统调试项目 Subsystem commissioning items机组分系统调试项目的内容依据本工程调试合同而定。All activities shall be carried out in accordance with the Project Commissioning Contract.3.3.1锅炉专业调试工作 Boiler commissioning activities3.3.1.1 对机组锅炉范围内的主要设备及系统进行检查。Inspection

34、of boiler plants and its auxiliary systems 3.3.1.2 组织检查各汽水电动门、烟风调节档板及隔绝门档板。Joint checkup of steam/water MOVs, regulating and isolating dampers on flue gas ducts.3.3.1.3 辅机联锁、保护检查试验。Testing of interlocks and protections of each auxiliary plant.3.3.1.4 空压机系统调试Trial run of air compressor system.3.3.1.5

35、 风机系统调试。Testing of air draft fans.3.3.1.6 空预器系统调试。Trial run of air preheater system.3.3.1.7 锅炉冷态通风试验。Cold draft testing of furnace.3.3.1.8 燃烧器动作试验和同步性检查试验。Burners actions test and their simultaneity checkout.3.3.1.9 燃油系统、炉前点火油系统调试及燃油泄漏试验。Trial run of fuel oil system, light up oil system and fuel oil

36、 leakage test.3.3.1.10 制粉系统调试。Trial run of coal pulverizing system.3.3.1.11 FSSS系统联锁保护模拟试验。Simulation test of interlocks and protections of FSSS system.3.3.1.12 密封风、冷却风系统调试。Trial run of sealing and cooling air system.3.3.1.13 辅助蒸汽供汽系统调试。Trial run of auxiliary steam supply system.3.3.1.14 锅炉汽、水系统检查。I

37、nspection of boiler water and steam system.3.3.1.15 锅炉疏水排污系统调试。Trial run of boiler drain and blowdown system.3.3.1.16 锅炉膨胀系统检查。Inspection of boiler thermal expansion.3.3.1.17 吹灰系统调试。Trial run of soot blowing.3.3.1.18 除灰除渣系统调试。Trial run of ash and slag handling system.3.3.1.19 输煤系统调试。Initial operatio

38、n of coal handling System3.3.1.20 锅炉化学清洗和冲洗工作。Carrying out chemical cleaning and water flushing for boiler.3.3.1.21 锅炉减温水管道系统冲洗。Completing pipes blowing and flushing for boiler desuperheating water system.3.3.1.22 锅炉蒸汽管路吹管调试。Completing boiler steam blowing.3.3.1.23 锅炉安全门校验,包含PCV阀试验。Associating manuf

39、acturer in setting of safety valves，including pressure control valves (PCV)。3.3.1.24 锅炉工作压力水压试验。Completing hydrostatic testing for boiler at rated pressure.3.3.1.25 配合冷却水系统、取样加药及排污等系统的试运工作。Associating in trial run of cooling water system, dosing and sampling system and blowdown system etc.3.3.1.26 配

40、合除尘器试验。Associating in ESP testing.3.3.1.27 机、炉、电大联锁试验。BTG testing.3.3.2汽机专业调试工作 Responsibility of Turbine Team3.3.2.1 对机组汽机范围内的主要设备及系统进行检查。Inspection of major plants and systems in turbine house3.3.2.2 组织安全门校验及检查调节门、抽汽逆止门、电动门。Organizing to check all CVs, steam extraction check valves and MOVs and ca

41、librate safety valves3.3.2.3 辅机联锁、保护检查试验。Inspection of interlocks and protections of auxiliary plants3.3.2.4 循环水系统试运行。Initial operation of C.W. system3.3.2.5 开式循环冷却水系统调试。Trial run of OCCW system3.3.2.6 闭式循环冷却水系统调试。Trial run of CCCW system3.3.2.7 真空系统调试。Trial run of condenser air evacuation system3.3

42、.2.8 辅助蒸汽系统调试。Trial run of auxiliary steam system3.3.2.9 辅助蒸汽管路吹扫。Steam blowing of auxiliary steam pipelines3.3.2.10 凝结水及凝结水补给水系统调试。Trial run of condensate and water makeup system3.3.2.11 除氧器及高压给水系统调试。Trial run of deaerator and HP feed heater system3.3.2.12 电动、汽动给水泵调试。Trial run of MBFP and steam-dri

43、ven BFPs3.3.2.13 低压给水系统调试。Trial run of LP feed heater system3.3.2.14 抽汽加热器及疏水系统调试。Trial run of steam extraction heater and drain system3.3.2.15 轴封供汽系统调试。Trial run of gland steam system3.3.2.16 汽轮机润滑油及盘车、顶轴油系统调试。Trial run of turbine lube oil, TG and jacking oil system3.3.2.17 汽轮机油净化装置调试。Trial run of

44、turbine lube oil purification system3.3.2.18 发电机冷却水、氢及密封油系统调试。Trial run of generator stator cooling water, hydrogen and sealing oil systems3.3.2.19 汽轮机调节系统静态调试。Static test of turbine governing system3.3.2.20 DEH系统静态调试。Static test of DEH (digital electro-hydraulic control system)3.3.2.21 汽轮机汽门关闭时间测试。

45、Testing of duration of turbine MSVs and CVs closing3.3.2.22 汽机旁路系统调试。Commissioning of BPS3.3.2.23 低压缸喷水冷却系统调试。Test of spraying cooling system of low pressure cylinder3.3.2.24 胶球清洗设备系统调试。Test of rubber ball cleaning plant3.3.2.25 配合化学清洗。Associating in chemical cleaning3.3.2.26 配合锅炉蒸汽管路吹管调试。Associatin

46、g in boiler blowing3.3.2.27 机、炉、电大联锁试验。BTG testing3.3.3电气专业调试工作 Responsibility of Electric Team3.3.3.1 220KV升压站及厂用电源系统带电。Energizing of 220 kV switchyard and station auxiliary power systems3.3.3.2 发电机变压器组的保护系统调试。Trial run of protection system of generator-transformer unit3.3.3.3 主变压器冷却控制系统调试。Trial ru

47、n of cooling control system of generator transformer.3.3.3.4 发电机、变压器、厂用变压器的控制信号、保护的传动试验。Testing of transmission for control singles and protections of generator-transformer unit and unit auxiliary transformer.3.3.3.5 发电机励磁系统的调试。Testing of generator excitation system3.3.3.6 发电机同期系统调试。Testing of gener

48、ator synchronization system3.3.3.7 直流系统调试。Testing of DC power supply system3.3.3.8 保安电源系统调试及试运。(包括柴油发电机)Trial run and operation of emergency power supply (DG)3.3.3.9 厂用电切换系统调试。Testing of changeover of auxiliary power supply3.3.3.10 不停电电源系统调试。Trial run of uninterrupted power supply (UPS) system3.3.3.

49、11 故障录波系统调试。Trial run of fault waveform recording system3.3.3.12 微机监控系统(ECS)调试。Testing of ECS3.3.3.13 机、炉、电大联锁试验。Testing of BTG interlocks3.3.4 热控专业调试工作 Responsibility of I&C Team3.3.4.1 检查测量元件、取样装置的安装情况、仪表管路严密性试验记录以 及变送器、逻辑开关等校验记录。Inspection of measuring and sampling devices, examination of instrum

50、ent tube tightness test data and transmitter/switch calibration data.3.3.4.2 检查执行机构的安装情况及远方遥控操作试验。Inspection of actuator installation and testing of remote operation of each actuator.3.3.4.3 分散控制系统（DCS）的受电和软件调试。Energizing of DCS (distributed control system) and software debugging3.3.4.4 计算机系统硬件检查和I/

51、O通道检查。Inspection of hardware, including and I/O channels, of the computer system3.3.4.5 辅网系统（BOP）调试。Trial run of Balance Of Plant(BOP)3.3.4.6 锅炉炉膛安全监控系统（FSSS）调试。Trial run of furnace safeguard supervisory system (FSSS)3.3.4.7 机组数据采集系统(DAS)调试。Trial run of data acquisition system (DAS)3.3.4.8 机组事故记录系统（

52、SOE）调试。Trial run of sequence of events record system (SOE)3.3.4.9 机组模拟量调节系统(MCS)调试。Trial run of modulating control system（MCS）3.3.4.10 协调控制系统调试(CCS)Test of coordinated control system (CCS)3.3.4.11 顺序控制系统(SCS)调试。Trial run of sequence control systems (SCS)3.3.4.12 汽机数字电液控制系统(DEH)调试。Trial run of turbin

53、e digital electro-hydraulic control system (DEH)3.3.4.13 汽机旁路控制系统(BPC)调试。Trial run of turbine bypassing control system (BPS)3.3.4.14 汽机监视(TSI)、保护系统（ETS）调试。Trial run of turbine supervisory instrument (TSI) and emergency trip system (ETS)3.3.4.15 汽动给水泵控制系统调试。Testing of steam-driven BFP control system3

54、.3.4.16 给煤机控制系统调试。Testing of coal feeder control system3.3.4.17 锅炉保护联锁系统调试。Testing of boiler interlocks and protections3.3.4.18 汽机保护联锁系统调试。Testing of turbine interlocks and protections3.3.4.19 锅炉吹灰顺控系统调试。Trial run of SCS of boiler soot blowing system3.3.4.20 空预器控制系统调试。Trial run of APH control system

55、3.3.4.21 除灰顺控系统调试。Trial run of ash handling system3.3.4.22 除渣顺控系统调试。Trial run of slag handling system3.3.4.23 凝结水精处理顺控系统调试。Trial run of sequence control system for condensate polishing plant3.3.4.24 给水、炉水加药控制系统调试。Trial run of dosing control system of feedwater and boiler water 3.3.4.25 发电机氢油水控制系统调试。

56、Generator hydrogen-oil-water control system commissioning3.3.4.26 配合辅机试转及热力系统调试。Assist in trial run of auxiliary equipment and thermal systems3.3.4.27 其它辅助车间控制系统调试。Commissioning of other auxiliary plant control systems3.3.4.28 机、电、炉大联锁试验。BTG interlock testing3.3.5化学专业调试工作Commissioning of chemical sp

57、ecialty3.3.5.1 循环水加药系统调试Trial run of C.W.chemical dosing system3.3.5.2 化学水处理系统调试 Trial run of chemical water treatment system3.3.5.3 凝结水精处理系统调试。Trial run of condensate water polishing system3.3.5.4 锅炉补给水系统调试。Trial run of boiler make-up water system3.3.5.5 发电机冷却水处理系统调试。Trial run of generator cooling water treating system3.3.5.6 加药系统调试