0097循环水系统调试措施CW system procedure.doc

RevDateCompiled byReviewApproval 循环水系统调试方案循环水系统调试方案 CW system commissioning procedure DOCUMENT NO ILPI O SEPC COM WI 0097REV A PREJECT 印尼占碑工厂自备电站扩建项目 LPPPI JAMBI MILL PWP UPGRADED MB 24 TG 27 OWNER 印尼金光集团伦达纸浆与造纸公司 PT PABRIK KERTAS TJIWI KIMIA TBK CONTRACTOR PT SEPCO INDO 目录目录 Catalogue 1系统概况系统概况 1 SYSTEM OVERVIEW 1 2编制依据编制依据 4 COMPILING BASIS 4 3调试前应具备的条件和准备调试前应具备的条件和准备 4 CONDITION AND PREPARATION BEFORE THE COMMISSIONING 4 4调试程序和方法调试程序和方法 7 COMMISSIONING PROCEDURE AND METHOD 7 5质量 职业健康安全和环境管理体系实施措施质量 职业健康安全和环境管理体系实施措施 12 MEASURES OF QUALITY PROFESSION HEALTH AND SAFETY AND ENVIRONMENT MANAGEMENT SYSTEM 12 6附录附录 15 ATTECHMENT 15 0 1系统概况系统概况 System overview 1 1设备系统概述设备系统概述 Equipment system overview 循环水系统的功能是将冷却水送至凝汽器以冷却汽轮机低压缸排汽 维持凝汽器的真空 使汽水循环得以继续 同时还为射水池 主机冷油器 发电机空冷器 EH 油控制装置 凝 结水泵轴承提供冷却水 系统基本流程为 机力通风冷却塔水池 冷却塔集水池 吸水前池 循环水泵 供水管路 凝汽器 辅机冷却水系统 回水管路 机力通风冷却塔 本工程循 环水系统采用机力冷却塔的再循环供水系统 共配 4 座机力通风塔 5 25 台卧式循环水泵 正常 4 台运行 1 台备用 循环水补水来自老厂工业水补水管网 The function of circulating water system is to supply cooling water to condenser to cool down the exhaust steam of the turbine low pressure cylinder and maintain the condenser vacuum to make steam water circulation working continuously and supply cooling water to the water jet pond the main engine oil cooler the generator air cooler EH oil control device and the condensate pump bearing The basic procedure of the system is mechanical draft cooling tower basin cooling tower collecting basin water absorption front basin condensate pump water supply pipe condenser auxiliary engine cooling water system return line and mechanical draft cooling tower The circulating water system of the project adopts mechanical cooling tower recycling water system matched with four mechanical draft cooling towers 5 25 sets of horizontal type circulating water pumps in which four sets are in working condition with one as standby The feed water for circulating water is from industrial water supply pipe line of the former plant 1 2主要技术规范 主要技术规范 Main technical regulation 序号 No 设备参数名称 Parameter item 单位 Unit 参数 Parameter 备注 Remark 1 型式 Type 单级 双吸卧式离心泵 Single stage double absorption horizontal centrifugal pump 2 型号 Mode 700S25 3 循环泵流量 Flow M3 h4200 4 循 环 泵 Circulating water pump 扬 程 Lift m27 5 1 5 功率 Power kW450 6 转 速 Rotate speed rpm742 7 泵的效率 Efficiency 88 8 制造厂 Manufacturer 长沙利欧天鹅工业泵 有限公司 Changsha Swan Industrial Pump Co Ltd 9 型号 Mode YKK500 8TH 10 电压 Voltage KV3 3 11 功率 Power KW450 12 转速 Rotating speed rpm740 13 防护等级 Protection grade IP55W 14 绝缘等级 Insulation grade F 15 电流 Current A99 9 16 循 环 泵 电 机 Circulating pump motor 制造厂 Manufacturer 上海电气集团上海电 机厂 Shanghai Electric Group Shanghai Motor Factory 17 型号 Mode CNTC 4500 2 1 3 调试目的调试目的 Commissioning purpose 18 风机直径 Air fan diameter mm 9140 19 电机型号 Motor mode Y2D 355L 4 6 W 20 电机功率 Motor power KW185 70 21 额定电流 Rated current A332 122 22 转速 Rotate speed r min1485 985 23 减速机型号 Reducer mode LF92 24 输出转速 Output rotating speed r min127 25 填料材料 Filling material PVC 26 标准水量 Standard water flow t h4500 27 总水量 Total water flow t h18000 28 力 通 风 塔 Mechanical draft cooling tower 厂家 Manufacturer 常州西城减速机有限 公司 Changzhou Xicheng Reducer Co Ltd 3 进行循环水系统的通水检查 循环水泵的启停试验 SCS 功能组的试验 电动蝶阀的传 动试验 循环水泵出口液控蝶阀的传动及调整试验 检查循环水泵及系统的试运情况 Check the flow of the circulating water system carry out start stop test for the circulating pump carry out test for SGS function group carry out transmission test for motor butterfly valve carry out transmission and regulating test for outlet hydraulic control butterfly valve of circulating pump and check commissioning condition of circulating pump and the system 2编制依据编制依据 Compiling basis 火力发电建设工程启动试运及验收规定 DL T5437 2009 Code for fossil power construction project from the unit commissioning to completed acceptance DL T5437 2009 火力发电建设工程机组调试技术规范 DL T5294 2013 The unit commissioning technical code for fossil power construction project DL T5294 2013 火力发电建设工程机组调试质量验收及评价规程 DL T5295 2013 Code for the unit commissioning quality acceptance and evaluation of fossil power construction projects DL T5295 2013 火电工程达标投产验收规程 DL T 5277 2012 Specification for acceptance of thermal power engineering reached the standard and put into production DL T 5277 2012 电业安全工作规程 第 1 部分 热力和机械 GB 26164 1 Safety code of electric power industry Part one thermal and mechanical GB 26164 1 电力建设安全工作规程 第 1 部分 火力发电厂 DL 5099 1 Regulation of safety operation in power engineering construction Part one power plant DL 5099 1 火力发电厂水汽化学监督导则 DL T 561 Guide for Chemical Supervision of Water and Steam in Thermal Power Plants DL T 561 设计院提供的工程系统图纸 设计说明书等技术资料 Project system drawings design introduction and technique material provided by the design institute 4 设备制造厂图纸 质量保证书 安装和使用说明书及有关试验文件等 Drawings quality guarantee erection and utilization introduction and related test documents 3调试前应具备的条件和准备调试前应具备的条件和准备 Condition and preparation before the commissioning 3 1组织分工组织分工 Division and organization 1 在分系统试运组的组织领导下 由调试负责实施系统的调试工作 并编写该系统的 调试措施 2 调试人员负责系统内的有关阀门 热工信号及联锁传动工作 并指导有关运行操作 进行试运前的技术和安全交底 测量记录必要数据 3 运行人员负责试运中的操作和运行监视 做好试运设备的安全隔离措施 4 施工单位负责完成系统中有关单体试运 在系统试运中负责维护和消缺工作 组织 协调试运现场的安全消防和保卫工作 5 设计单位配合处理试运中发生设计问题和缺陷 及时提出设计修改或处理意见 做 好现场服务工作 1 Carry out the system commissioning and compile related commissioning measures organized and leaded by sub system commissioning group 2 The commissioning staff shall be in charge of related valves thermal signals and interlock transmission for the system guide the related operation handover the technique and safety before the commissioning and measure and record necessary data 3 Operators shall be in charge of operation and supervision during the commissioning and make safety isolation for the commissioning equipments 4 The construction unit shall be in charge of sub system commissioning and maintenance and defect elimination during the commissioning and organize and negotiate fire fighting and security 5 The design unit shall be in charge of design defect during the commissioning and proposing modification or treatment suggestion and related on site service 3 2调试前应具备的条件调试前应具备的条件 Conditions before the commissioning 3 2 1环境条件 Environment condition 1 场地基本平整 消防 交通及人行道路畅通 试运现场有明显的标志和分界 危险 5 区设有围栏和警告标志 2 试运区的施工脚手架已全部拆除 环境已清理干净 3 现场的沟道及孔洞盖板齐全 试运区的梯子 平台 走道栏杆等已按设计安装完毕 正式投入使用 4 厂内 外排水设施能正常投运 沟道畅通 沟道及孔洞盖板齐全 5 消防系统能正常投入 现场有足够的消防器材 6 试运现场具有足够的正式照明 事故照明能及时自动投入 通风设施良好 7 通讯系统完善 8 设备 管道 阀门等已有命名和标志 1 The site shall be flat with unblocked fire fighting transportation and passageway and obviously mark and boundary shall be set on the commissioning site and the dangerous area shall be isolated with warning mark 2 All construction scaffolds on the commissioning site shall be removed and the site shall be cleaned up 3 The covers for on site ditches and holes shall be complete and the erection of ladders platforms and handrails in the commissioning area shall be completed and into working condition by the design 4 Inside and outside water discharge facilities of the plant shall be completed and into working condition with unblocked ditches and the covers for related ditches and holes shall be complete 5 Fire fighting system is in good condition with enough fire fighting facilities 6 Sufficient illumination shall be provided on the commissioning site and emergency illumination can be put into operation timely The ventilation facilities are in good condition 7 The communication facilities shall be complete 8 Equipments pipes valves etc shall be named and marked 3 2 2设备系统具备的条件 Condition of equipment system 1 设备及系统按要求安装完毕 并经检验合格 安装记录齐全 有关设备的单体试运 工作完成 2 基础混凝土及二次浇灌达到设计强度 3 具有可靠的操作和动力电源 电机绝缘良好 4 各电动 液动阀门经热工调试完毕 动作灵活可靠 5 各指示仪表经校验合格 报警及显示正确 6 SCS 功能试验工作完成 并符合要求 1 The erection for equipments and systems has been completed according to requirements which has been checked and approved with complete erection record and single unit commissioning for related equipments has been completed 2 Foundation concrete and secondary casting meet the design strength 3 Operation and driving power shall be reliable and the motor insulation shall be qualified 4 All motor and hydraulic valves shall be tested by the thermal staff which shall be smart and reliable 5 All indication instruments shall be checked and qualified with correct warning and display 6 SCS function test shall be completed meeting requirements 6 3 3仪器 仪表仪器 仪表 Apparatus and instrument 序 号 No 名称 Name 规格 Specification 精度等级 Accuracy grade 数量 Quantity 备注 Remark 1 振动表 Vibrometer 1 2 红外测温仪 Infrared thermometer 1 注 以上仪器均计量检验合格 精度满足要求 Note all above instruments have been checked and qualified which can meet accuracy grade requirements 4调试程序和方法调试程序和方法 Commissioning procedure and measurements 4 1静态调试静态调试 Static commissioning 4 1 1静态调试条件 Condition of static commissioning 1 循环水系统所有设备 管道安装结束 管道水压试验合格 所有土建 水工施工结 束 循环水管清理干净 检修孔已封闭 上述工作已完成验收签证 2 热工仪表及电气设备安装 接线完毕 仪表校验合格 指示正确 3 循环水管与其它水管间联络管已可靠隔离 4 凝汽器具备通水条件 水压试验合格 5 排水泵 排污泵 循泵电机 液控蝶阀单体调试合格 动作正确 参数正常 CRT 状态显示正确 运行状况良好 6 凝汽器进 出口电动蝶阀单体调试结束 就地及远方开 关动作正常 CRT 状态显 示正确 1 The erection for all equipments and pipes of the circulating water system has been completed with qualified water pressure test all construction and hydraulic construction have been completed with cleaned circulating pipes and sealed repairing holes and all above works have been checked and accepted 2 The erection and wire connection for thermal instruments and electric equipments have been completed with checked and verified instruments that indicate correctly 7 3 The joint pipe from circulating water pipe to other water pipe has been isolated reliably 4 The condenser is provided with working condition which the water pressure test is qualified 5 Single unit commissioning for drainage pump blowdown pump circulating motor and hydraulic control butterfly valve shall be qualified with correct action normal parameter correct CRT condition display and good working condition 6 The single unit commissioning for inlet and outlet motor butterfly valves of the condenser shall be completed with correct action of local and remote start stop control and correct CRT condition display 7 循泵电机绝缘测试合格 8 流道 吸水池内所有杂物 如木块 砖头 纤维制品 金属丝等已清除 9 水池内的水位正常 10 电机轴承已注入合格的润滑油 11 系统调试组织已成立 并已有序地开展工作 12 调试资料 工具 仪表 记录表格已准备好 13 试运现场已清理干净 安全 照明和通讯措施已落实 14 仪控 电气专业有关调试结束 参与调试人员到场 7 The insulation of the circulating motor shall be checked and qualified 8 All sundries in channel and absorption basin shall be cleaned up such as wood blocks bricks fiber wire etc 9 The basin water level shall be normal 10 Qualified lubrication oil shall be filled into the motor bearing 11 System commissioning team has been established and into working orderly 12 Material tools instruments and recording sheet shall be prepared well 13 Commissioning site shall be cleaned up with complete security illumination and communication measures 14 The commissioning for instruments control and electrical shall be completed and related staff shall be on site 4 1 2阀门检查 Valves check 1 当循环水泵及其系统内的阀门安装并单体调试完毕后 即可进行阀门检查 检查的 要求是可以在 DCS 上正确操作 阀门的反馈和实际开度相符合 2 检查时 一人在控制室操作 一人在现场检查阀门实际动作情况 3 阀门检查完毕后 测试阀门全开全关所需要的时间 方便进行的试运工作 4 阀门检查的内容如下 记录表格见调试文件包附表 1 1 电动门检查 2 液控蝶阀的检查与开关时间整定 1 The check for valves of circulating water pump and its system shall be carried out after valve erection and single unit commissioning The check requirement is that the operation on DCS shall be correct and the openness of valve response and actual condition shall be matched 2 During the check one person shall operate in control room and another person shall 8 observe actual action on site 3 After valves check record the time of complete close open in order to carry out the commissioning 4 The valve check items are as following recording sheet see in commissioning file package sheet 1 1 Motor valve check 2 Check and open close time setting for hydraulic butterfly valve 4 1 3逻辑功能检查 Logic function check 1 检查时 一人在控制室操作 一人在现场检查设备的实际动作情况 运行 安装等 单位签字人员共同在旁边见证 检查完毕后 及时在检查项目后签字 During the check one person shall operate in control room and another person shall observe actual action on site witnessed by signature personnel of operation unit and erection unit Complete the signatures on checking items timely after the check 2 检查要求各设备动作正常 逻辑功能满足安全运行要求 如不满足要求 需要提出 逻辑修改建议 提请相关部门同意后 由热工人员负责联系修改 并在记录表格 后注明 All equipments action shall be normal and the logic function shall meet the requirement of safety operation If the logic is fail to meet the requirement the modification advice shall be proposed which shall be carried out by thermal staff after approval by related departments and noted on recording sheet 逻辑功能检查的内容如下 记录表格见调试文件包附表 2 The checking items for logic function are as following recording sheet see in commissioning file package sheet 2 1 循环水泵启动允许条件 2 循环水泵启停试验 3 循环水泵跳闸试验 4 循环水泵联锁启动试验 5 循环水系统阀门联锁试验 1 Start permissive condition of the circulating water pump 2 Start stop test of the circulating water pump 3 Trip test of the circulating water pump 4 Interlock start test of the circulating water pump 5 Valves interlock test of the circulating system 4 1 4保护功能检查 9 Protection function check 1 通过在现场对每个测点加模拟信号的方式进行检查 要求测点通道正确 数据 显示正常 2 循环水泵保护功能检查的内容如下 记录表格见调试文件包附表 3 1 温度保护功能检查 2 防循环水泵闷泵保护功能检查 出口液控蝶阀关或凝汽器左右侧进出口 门关 等 1 Carry out the check by inputting analogue signal to every measuring point on site which the measuring point channel shall be correct with normal data display 2 The checking items for circulating water pump protection function are as following recording sheet see in commissioning file package sheet 3 1 Check for temperature protection function 2 Check for anti blind protection function of the circulating water pump outlet hydraulic control butterfly is closed or inlet and outlet valves of the condenser are closed etc 4 2系统试运系统试运 System commissioning 4 2 1启动前检查 操作 Check and operation before the starting 1 检查水池水位正常 2 检查循环水泵出口蝶阀油站油位 油压正常 各表记指示正确 均已投入 检查 循泵电机轴承润滑油室油位正常 3 检查与其它机组循环水管联络电动门已关闭 关闭冷却水供水管阀门 4 开启循泵出水管线上所有排气阀 5 送上凝汽器进 出口电动蝶阀电源 全开凝汽器进 出口电动蝶阀 6 开启凝汽器循环水水室放空气门 7 将其他循环冷却水用户从循环水系统中隔离 8 送上液控蝶阀控制柜电源 就地 远方各开 关液控蝶阀一次 检查液控蝶阀动 作及反馈正常 9 循环水系统管道注水 10 循泵出水管线上所有排气阀出水后关闭排气阀 11 凝汽器循环水水室放空气管见水排出后 关闭放空气门 12 整个管系已经充满水并排除空气后 可以停止注水 13 检查循泵电机绝缘合格 14 检查热控表计投入 1 Check the basin water level which shall be normal 2 oil level and pressure of outlet butterfly valve s oil station of circulating water pump shall be normal with correct instruments indication which are in working condition 10 lubrication oil level of motor bearing oil box of the circulating water pump shall be normal 3 The joint motor valves to other units shall be closed and feed pipe valve of cooling water shall be closed 4 All air vent valves on outlet pipe of the circulating water pump shall be opened 5 Transmit power to inlet and outlet motor butterfly valves of the condenser which shall be completely opened 6 Air vent valve of the condenser s circulating water room shall be opened 7 The other cooling water users shall be isolated from the circulating water system 8 Transmit power to control cabinet of hydraulic control butterfly valve open and close the valve from local and remote one time to check its action and response which shall be normal 9 Fill water to the pipe of the circulating water system 10 Close all air vent valves on the circulating water pump s outlet pipe when water is effluent from the valves 11 Close the air vent valves on the condenser circulating water room s air vent pipe when the water is effluent 12 Stop filling water when the system is overflowed without air 13 The circulating water pump s motor shall be checked and qualified 14 The thermal control instruments shall be checked 4 2 2循泵试运行 Circulating water pump commissioning 1 远方启动循泵 检查泵旋转方向正确 无异常声音 电流正常 管路系统无泄漏 2 泵启动后 检查液控蝶阀 45s 内逐步全开 3 检查循泵电流 出口压力 振动 轴承温度 电机线圈温度 水池水位等参数正 常 4 设备稳定运行后 检查循泵电流 出口压力 振动 轴承温度 电机线圈温度 水池水位参数正常 定时记录运行数据 试运行时间为 8h 1 Start the pump from remote and the rotation direction shall be correct without abnormal sound and system leakage and the current is normal 2 After starting check the hydraulic control butterfly valves that shall be opened gradually in 45s 3 Check the pump current outlet pressure vibration bearing temperature motor winding temperature basin water level and other parameters which shall be normal 4 When the equipments is in stable working condition check the pump current outlet pressure vibration bearing temperature motor winding temperature basin water level and other parameters which shall be normal Record the operation data regularly in 8 hours 4 2 3循泵停运 Stop the circulating water pump 停运循泵 检查出口蝶阀先快速关闭 快关时间为 6s 快关角度为 75 然后慢关 18s 慢关角度 25 此时蝶阀完全关闭 11 Stop the pump firstly check the outlet butterfly valve and close it rapidly in 6s with rapid closing angle of 75 and then slowly close it in 18s with slow closing angle of 25 till the valve is completely closed 4 2 4注意事项 Attention items 1 循环水泵试运前 检查并确认各项连锁保护投入正常 2 排污泵能正常运行 泄漏水能正常排除 保证地面不积水 防止水淹电缆和油 站 3 泵在出口阀关闭状态下不能运行 反转时间不能超过 5 分钟 4 试运后或试运中设备或系统检修均应办理工作票 5 试运中如需检修设备 系统不准带压进行 如系统泄露严重应停止循环水泵运 行 6 注意检查电机电流应小于额定电流 7 监视循环水泵电机线圈温度小于 125 8 当电动机停止运行时 可以通电加热 以防止凝露 9 电机轴承和轴瓦温度达到稳定时 分别不应超过 85 10 运行时如有甩油现象 可适当降低润滑油位 但需注意轴瓦的温度是否过高 1 Before the pump commissioning check and confirm that all interlock protection are in normal condition 2 The blowdown pump can works well to discharge the leakage water normally to avoid excess water on the ground to drown cables and oil station 3 The pump can not work when the outlet valve is closed with the reverse time in 5 minutes 4 Working permission system shall be necessary during or after the commissioning 5 When the system is running with pressure the repairing is not permitted If heavy leakage appears stop the pump operation at once 6 Check the motor current that shall be less than the rated current 7 Monitor the motor winding temperature of the pump that shall be less than 125 8 The motor can be heated by energization to avoid dew when in outage stage 9 The temperature of motor bearing and bush shall be less than 85 when the temperature is stable 10 If oil throwing appears during the operation the lubrication oil level can be decreased properly and the bush temperature shall be normal 5质量 职业健康安全和环境管理体系实施措施质量 职业健