Commissioning is crucial in the start-up of a steam generator as it ensures its proper functioning, safety, and performance. During this process, comprehensive tests are conducted to verify the correct operation of all components and systems. Adjustments and optimizations are made to maximize efficiency, and safety tests are performed to ensure compliance with standards. Additionally, commissioning provides training to personnel and generates important documentation for future reference and maintenance. In summary, commissioning in the start- up of a steam generator is essential to ensure its long-term successful and reliable operation, while significantly reducing risks for both the equipment and the personnel operating it.
Key stages:
Operator requirements and preparation before initial commissioning operations:
1. Thorough Training: Every operator must be comprehensively trained on the equipment, their designs, purposes, limitations, and relationships to other components. This includes studying the instructions, drawings, and thoroughly inspecting the equipment.
2. Familiarity with Distributed Control Systems (DCS): Operators should understand how DCS integrates individual process controllers into a coordinated, interactive system. This enables them to manage the whole system and control the interrelationship of various subsystems.
3. Simulator Training: Modern DCS can provide operating personnel with advanced simulations of equipment behavior. Simulator training, typically conducted in real-time, ensures operators gain a working understanding of the various systems, including the reaction time and rate of the equipment.
4. Avoiding Inexperience: Preliminary operation should not be entrusted to inexperienced personnel. Improper preparation of equipment or its misuse during preliminary checkout can result in considerable equipment damage and potential safety events.
5. On-going Learning during Initial Operating Period: Operator training is particularly important during the initial operating period when adjustments and tests are being made. Experienced operators are valuable during this period.
Preparation for startup:
1. Inspection: Inspection of the boiler and auxiliary equipment is essential. This helps familiarize the operator with the equipment and verifies the condition of the equipment. The provision for expansion should not be overlooked during the inspection.
2. Cleaning: It is necessary to remove debris and foreign material that accumulate during shipment, storage, erection, or repairs. Particular attention should be paid to fuel lines, with steam cleaning recommended for all oil and gas lines.
3. Hydro-static Testing: Hydro-static testing is performed after the pressure parts are assembled but before the refractory and casing are installed. A hydro-static test at 1.5 times the boiler design pressure is applied to all new boilers and maintained for a sufficient time to detect any leaks.
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