SHORTFALL IN COMMISSIONING OF BOILER

As a Commissioning professional, lot of unexpected things are experienced during the Commissioning of Boiler, which are never recorded but leave behind a great impact in terms of performance, money and failures.

Commissioning takes own time without bypassing the events, but there is always shortage of time from both end i.e. SELLER & PURCHASER. This shortage of time is always beneficial to SELLER as anyhow activity is completed.

Commissioning of Boiler require a systematic approach in a planned & recorded way to start plant in a perfect manner. Actually, there is a normal tendency to neglect the systematic & sequential approach during commissioning on behalf of urgency.

Defects Noticed during & after Commissioning of Boiler:-

  1. Piping Supports misalignment & uneven loading in hot condition
  2. Shifting of Piping / Piping Support from its original position
  3. Water carryover in PRDS piping after de-superheating section
  4. High Spray water flow to control Main Steam temperature
  5. Uneven Thermal Expansion of Pressure Parts / Casing
  6. Abnormal Vibration in Pressure Parts / Casing / Ducting
  7. Heavy Fluctuation in Drum level, Furnace Draft
  8. High back end temperature (Flue Gas Temperature at APH Outlet)
  9. Maximum Loading of Fans & Blowers
  10. High Emission/SPM from ESP / Bag Filter
  11. High Un-burnt Carbon in Fly Ash / Bottom Ash
  12. Inadequate drain piping of PRDS, Soot Blowers, Control Stations
  13. Secondary Combustion in Superheater Zone
  14. Bed Material slippage in Wind box / Bed material shifting on grid floor
  15. Water carryover from Deaerator Air/Gas Vents
  16. Water ingress in Insulation
  17. Improper fixing of Insulation & Cladding
  18. High insulation cladding surface temperature w.r.t. design
  19. High sound decibel form equipments / silencer
  20. High Auxiliary Power Consumption w.r.t. individual equipment
  21. Less Difference of Pressure in-between Steam Drum & Boiler Feed pump discharge to adjust power consumption
  22. No Approach for Valves, Dampers, Instruments, O&M Work
  23. Non availability of Inter-connecting platform, Safe working platform

Mandatory steps for commissioning of Boiler are described in details in attachment (Under mentioned steps are bypassed / clubbed with each other to reduce time span/unavailability of resources and inputs/incompetent personnel/low priority client)

  1. Pre Commissioning
  2. Cold commissioning
  3. Hot Commissioning

Read details in attachment