Detailed Introduction to Thermal Oil Furnace Commissioning Steps

Commissioning is an important task to further verify installation quality, system performance, and familiarize operators with procedures, ensuring normal operation. It should be jointly participated by management, technical personnel, and operators. During the initial startup and operation of the equipment, the equipment's working conditions should be measured and recorded to ensure the normal operation of the system in the future.

1. Commissioning Purpose:

Check whether each unit equipment operates normally.

Check whether the system operates normally under cold conditions.

Enable operators to become familiar with and master operating procedures.

2. Commissioning Requirements:

All motor rotations are correct, equipment loads are normal, and actions are correct, running continuously for more than 2 hours.

The circulating oil pump should undergo cold commissioning before the water pressure test.

Keep records of commissioning operations, promptly eliminate possible faults. Make all preparations before commissioning.

Commissioning is carried out in two steps: cold state and hot state.

I. Cold Commissioning:

After the boiler installation inspection is completed, cold commissioning of each part is required. Cold commissioning must be performed by boiler operators.

1. Air Leakage Test:

(1). Air Side Test: During the test, close the last damper, start the blower, open the inlet regulating door to maximize system air pressure, check all flange connections, welds, and other leak-prone areas, mark them, and handle after shutdown.

(2). Flue Gas Side Test: During the test, first close all dampers, doors, and openings in the furnace flue. For positive pressure test, start the blower to pressurize the flue gas side, adjust the damper to maintain a positive pressure of 200-400MPa in the furnace, fully open the grate air doors, close the ash discharge doors, fully open all dampers along the flue gas flow, close all ash discharge doors, slag discharge doors, furnace doors, observation holes, and seal the dust collector with water. Check leak locations, mark them, and handle after shutdown.

Leakage is prone to occur at furnace wall expansion joints, pipe penetration points, flue connection flanges, and welds.

Test Method: Add white powder or ignite a combustible that produces smoke at the blower inlet, so that white powder traces or smoke escape at leak locations.

Leak Elimination Method: For furnace wall expansion joints, fill with asbestos rope; for door and opening leaks, scrape the contact surfaces flat; for flue connection flanges, add asbestos rope and tighten bolts; for welds, perform repair welding.

3. Cold Commissioning of Piping and Circulation System

Commissioning Steps:

Check whether all equipment and piping installation meets drawing requirements.

Check whether system pressure test and flushing meet requirements.

Check whether the electrical system and control instruments are properly installed.

Inject lubricating oil or grease into the hot oil pump bearing housing and other transmission mechanisms as required.

Run each moving mechanism individually to check if the rotation direction is correct and the sound is normal.

Adjust each valve of the system to prepare for oil injection and test run.

Use the oil injection pump to inject oil into the high-level expansion tank.

Start the hot oil circulation pump.

Observe whether the inlet and outlet pressure of the hot oil circulation pump, pressure drop of the furnace body, inlet and outlet oil temperature, exhaust gas temperature, and other instrument readings are normal.

If no abnormalities occur after continuous cold operation for more than four hours, hot commissioning can proceed.

II. Organic Heat Transfer Heater Installation Inspection and Acceptance:

After the organic heat transfer heater is fully installed, the main unit and auxiliary equipment should be carefully inspected and accepted item by item to meet the requirements for ignition operation. A comprehensive inspection should at least include the following items:

1. External Inspection of the Furnace Body: Mainly check whether there are deposits or blockages inside the furnace and flue, whether the furnace inner wall is intact, with no cracks, protruding bricks, or falling off. Check whether the insulation layer is intact, all flue doors, inspection doors, etc., are intact, operate flexibly, and seal tightly.

2. Grate Inspection: Mainly check the necessary clearance between the moving and fixed parts of the grate, and check whether the handle of the moving grate can be pushed and pulled freely and reach the specified position.

3. Fan Inspection:

For fan inspection, first manually rotate the coupling or transmission V-belt to check for any abnormal conditions such as friction, collision, or jamming between moving and stationary parts. The fan inlet regulating plate should open and close flexibly and tightly. Check the fan rotation direction, and ensure the impeller rotates smoothly without friction or collision.

4. Other Inspections:

Check all pipes and valves of the organic heat transfer circulation system (including the oil injection pump and hot oil circulation pump).

Check all pipes and valves of the blowdown system.

Check all pipes, valves, and insulation of the steam supply system.

Check the sealing of the dust collector outlet.

Check the electrical control instruments and protective devices in the control room.

III. Pressure Test:

1. Test Preparation:

After the entire heating system is fully installed according to standards, perform a pressure test. The liquid-phase heat transfer heater is tested at 1.5 times the working pressure. The test medium should not be water (use a special cleaning solution YDJ prepared with 0.5-0.7% sodium hydroxide added to the furnace for pressure testing; after passing the test, rinse clean and then use compressed air to dry the moisture inside the boiler pipes), because water pressure testing makes it difficult to drain water completely, creating a safety hazard. The temperature during the test should be above 5°C. Maintain the test pressure for 20 minutes, then reduce to working pressure and check for leaks at all connection points. If leaks are found, repair them promptly and repeat the pressure test.

2. Acceptance Criteria:

The pressure test is considered qualified if it meets the following requirements:

(1). No traces of leakage on the metal walls and welds of pressure parts.

(2). No visible residual deformation after the hydraulic test.

3. Safety Measures and Precautions:

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