Boiler Operation Manual QN1 SEC G 04 TP 003(239)

QUANG QUANG NINH THERM AL POWER J OINT STOCK STOCK COMPANY COMPANY 2×300 300 MW MW

SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL

QUANG NINH THERMAL POWER JOINT STOCK STOCK COMPANY COMPANY

2 × 300 M W – A nthra nthracite Coal F ired Po Power Stati tatio on

Boiler & Auxiliaries

Operation Manual

Date: Date: 2008-09-15 -09-15

No.:QN1-SE No.:Q N1-SEC C-G-04 -G -04-T -TP P-003 -003

Rev. : A


SEC


Index 1 SCOPE ...................................... ................................................................................... ............................................................................................................ .................................................................. ... 4 2 SPECIFI SPECI FIC C QUOTI QUOT I NG DOCUM DOCUMENTS ENT S....................................... ..................................................................................... ............................................................. ............... 4 3 BOIL BOI L ER TECHNI TE CHNIQUE QUE SPECIFI SPECI FICATI CATION......... ON............... ........... .......... .......... ........... ........... .......... .......... ........... ........... .......... ........... ........... .......... ........... ........... ..... 5 3.1

NTRODUCTI ON OF OF BOILER .......................................... INTRODUCTION ........................................................................................ ........................................................................ .......................... 5

3.2

BOILER NAMEPLATE ......................................... ........................................................................................... ................................................................................... .................................7

3.3

BOILER DESIGN INFORMATION .................................................... ...................................................................................................... ........................................................ ...... 8

3.4

REQUIREMENT FOR QUALITY OF BOILER S TEAM ..................................... ............................................................................... ..........................................16

3.5

BOILER AUXI LIA RY EQUIPMENT ............................................................ ................... 19 EQUIPMENT TECHNICAL TECHNICAL SPECIFICA SPECIFICATIONS TIONS .........................................

4 BOIL ER AND AN D INTERL IN TERLOCK OCK PROTECT PROTECTION ION VALUE VAL UE AUX AU X IL I ARY EQUIPMENT..... EQUI PMENT........ ...... ...... ...... ...... ...... ...... ..... 34 4.1

BOILER PROTECTING L IMIT VALUE .............................................. ................................................................................................ ...................................................... .... 34

4.2

INTERLOCK PROTE PROTECTION CTION VALUE VALUE AUX ILI ARY EQUIPMENT EQUIPMENT.................................... 35 BOILER AUXILI ARY INTERLOCK

5 START-UP................................................. START-UP ............................................................................................... ............................................................................................. ............................................... 44 5.1

BASIC REGULAR ....................................... ....................................................................................... ......................................................................................... ......................................... 44

5.2

REPAI ...................................................................................... ...........................................44 EPAI R TEST AND ACCEPTANCE INSPECTION I NSPECTION ...........................................

5.3

CHECK A ND PREPARATI ..................................................................................... .............................................70 PREPARATION ON BEFORE START-UP........................................

5.4

COLD START-UP SEQUENCE ................................................. ............................................................................................... ............................................................... ................. 74

5.5

HOT START-UP .............................................. ................................................................................................. ...................................................................................... ................................... 83

5.6

PARA METER CONTROL ............................................................. ............... 87 CONTROL VAL VAL UE I N THE PROCESS OF START START-UP ..............................................

6 MONITORI ONI TORING NG A ND A DJUSTM DJ USTMENT ENT IN BOIL BOI L ER OPERATI OPERATION ON ...... ........... .......... .......... .......... .......... .......... ........... ........... ........... ........ 88 6.1

TASK AND A ND OBJ OBJECTIV ECTIVES ES OF OF OPERA OPERATION TION ADJUSTMENT ADJ USTMENT ................................................ THE MAI N TASK ......................................................... ......... 88

6.2

OPERATION TION CONTROL CONTROL ............................................. MAIN PARAM ETER AND LI MIT OF OPERA .................................................................... ....................... 88

6.3

OPERATION ............................................ CHECKING, MONITORING AND MA INTENANCE I N BOILER OPERATION ................................................ .... 91

Date: Date: 2008-09-15

No.:QN1-SEC-G-04-TP-003

Page 1

Rev. : A


SEC 6.4


BOILER OPERATION MEASURE CONTROL ......................................... ................................................................................... ................................................. ....... 100

7 SHUT-DOWN SHUT-DOWN OF BOIL BOI L ER................................................................................... ER................................................................................................................. .............................. 100 7.1

BASIC REGULAR (GENERALS ) .................................................. .................................................................................................... ........................................................ ...... 100

7.2

PREPA ................................................................................ ...................................101 REPA RATION BEFORE SHUT-DOWN OF OF BOIL ER .............................................

7.3

SHUT-DOWN .............................................................. ................ 102 DOWN WITH SLI DING PARA PARA METER (NEED COOLING ) ..............................................

7.4

NORMAL SHUT .......................................................................................... ..............................................104 104 SHUT-DOWN (HOT STAND-BY ) ............................................

7.5

EMERGENCY SHUT ........................................................................................... ....................................................................... ..................... 105 SHUT-DOWN .........................................

7.6

DOWN MAI NTENANCE ........................................... SHUT-DOWN ......................................................................................... ................................................................. ................... 105

8 BOIL BOI L ER AUX A UXIIL IARY EQUIPM EQUI PMENT ENT ........ ............. ........... ........... ........... ............ ........... ........... ............ ........... ........... ........... .......... ........... ........... .......... ........... ........1 ..11 13 8.1

IA RY EQUIPMENT OPERA OPERATION TION................................................... BASIC REGULAR OF AUXIL IARY .................................................................. ............... 113

8.2

MOTOR OPERATION ............................................... ............................................................................................. ........................................................................... ............................. 117

8.3

TART-UP, STOP STOP AND OPERATIONAL OPERATIONAL MA INTENANCE OF AUXI LIARY LI ARY EQUIPMENT AND S SY Y STEM .......... S TART .......... 117

9 PERIODIC WORK WORK , TEST AND SHIFT SHIFTING ING OF OF THE BOIL BOIL ER AND RELEVANT AUXIL AUX IL IARY IA RY EQUIPMENT............................................................................................................................................. 171 10 A CCIDENT CCI DENTS S PROCESSIN PROCESSING G OF BOIL BOI L ER........................................... ER......................................................................................... .............................................. 172 10.1

BASIC PRINCIPIA OF ACCIDENTS PROCESSING ......................................... ................................................................................. ........................................172

10.2

BOILER EMERGENCY SHUTDOWN........................................... ......................................................................................... ......................................................... ........... 174

10.3

SHUTDOWN APPLICATION OF BOILER ................................................ .............................................................................................. ..............................................178

10.4

BOILER ABNORMAL OPERATION PARAMETER ......................................... ................................................................................. ........................................178

10.5

EJ ECTION OF OF UNIT ............................................ L OAD REJECTION .......................................................................................... ................................................................... ..................... 183

10.6

AUXILIARY POWER SUPPLY INTERRUPTION........................................... ..................................................................................... ..........................................184

10.7

NSTRUMENT A ND A PPARATUS POWER SUPPLY I NTERRUPTION ....................................185 CONTROL &INSTRUMENT

10.8

FIRE A CCIDENT .......................................... .......................................................................................... ...................................................................................... ...................................... 186

10.9

PROCESSING INFERIOR QUALITY OF WATER AND S TEAM ................................................... ................................................................ ............. 188

10.10

BOILER HEATING SURFACE SLAGGING SERIOUSLY ............................................ ...................................................................... .......................... 190

Date: Date: 2008-09-15


Page 2

Rev. : A


SEC


10.11

GAS DUCT REBURNING................................................ .............................................................................................. ................................................................ .................. 191

10.12

UNIT TRIP .............................................. ................................................................................................ ...................................................................................... .................................... 192

10.13

S TEAM DRUM FULL FEEDED............................................. ............................................................................................. ........................................................... ........... 194

10.14

S TEAM DRUM SHORT FEEDED ........................................... .............................................................................................. .......................................................... ....... 195

10.15

PRIMING................................................. ................................................................................................... ...................................................................................... .................................... 197

10.16

HIGH FURNACE PRESSURE ........................................... ............................................................................................. ................................................................ .............. 197

10.17

LOW FURNACE PRESSURE................................................ ................................................................................................ ............................................................ ............ 198

10.18

BOILER BURNING OUT............................................. ............................................................................................... .................................................................... .................. 199

10.19

FUEL TRIP .............................................. ................................................................................................ ...................................................................................... .................................... 200

10.20

WATER WALL TUBES TXPLOSION............................................... ............................................................................................. .................................................. .... 201

10.21

ECONOMIZER TUBES EXPLOSION............................................... ............................................................................................. .................................................. .... 202

10.22

SUPERHEATER TUBES EXPLOSION .............................................. ............................................................................................ ................................................. ... 203

10.23

REHEATER TUBES EXPLOSION ................................................ .................................................................................................. ..................................................... ... 204

10.24

THE BREAK OF S TEAM PIPES OR FEEDWATER PIPES OUTSIDE THE BOILER .................................205

10.25

HIGH S TEAM DRUM PRESSURE ......................................... ............................................................................................ ........................................................... ........ 206

10.26

AUXILIARY FAILURE ......................................... ........................................................................................... ........................................................................... ......................... 208

11 A PPENDI PPEN DIX X ................................................. ............................................................................................. ......................................................................................... ............................................. 232 11.1

CONTRASTI VE L IST OF THE ABSO AB SOLU LUTE TE PRESSURE PRESSURE AND TEMPERATURE IN I N SATURATED SATURATED STATES STATES .. 232 THE CONTRASTIVE 232

11.2

BOILER COLD START-UP CURVE ......................................... ....................................................................................... .............................................................. ................ 233

11.3

TUP CURVE.................................................. BOILER HOT STAR- TUP ................................................................................................ ....................................................... ......... 234

11.4

DRUME LEVEL V S LOAD CURVE .......................................... BOILER DRUME .................................................................................... ................................................. ....... 237

11.5

BOILER O2IN FLUE GAS VS LOAD CURVE ........................................... ........................................................................................ .............................................238

Date: Date: 2008-09-15


Page 3

Rev. : A


SEC 1


Scope This

operating

&

maintenance

manual

provides

the

principle,

methods

and

steps of the start-up, shut-down, operating & maintenance, control and adjustment of the boiler for Vietnam Quang Ninh 2×300MW Project. All the staff engaged in operating equipment

maintenance

and

management

of

manufacture

and

production

technology

management in Quang Ninh power plant should be familiar with all or relevant parts of the manual and execute extremely strictly. strictly. 2

Specific Quoting Documents The items included in the following Chinese standards are made of the items of this manual

by citing it. When this manual was promulgated, all the standards in it are valid and of

will

be revised

.The

parties

using

the

manual

should

explore

the

possibility

the latest version of following standard which will be decided whether to apply to this

standard. Besides the following standards, when the equipment manufacturer has the special requirement which meets the safety operation the

equipment

manufacturer

should

standards,

the

special

requirement

from

be complied with.

No.

Standard Code

Standard Name

01

DL/T 607-1996

300MW turbine operation guidelines

02

DL/T 611－1996

300MW boiler operation guidelines

03

DL/T 612－1996

Monitoring regular of power industry boiler and pressure vessel

04

DAS(1994)277

Working regulation of power safety (Thermal mechanical parts) Working regulation of power safety

05

DL408-91 (power plants and substations parts)

06

DL558-94

Investigation of production accidents in power industry

07

DL435-91

Explosion-proof of furnace regular for thermal Power Plant pulverized coal-fired boiler

08

DL/T 561－95

09

GB/T 12145-1999

Vapor and chemical monitoring guidelines of thermal power plant The quality of vapor

of thermal power generating units and

steam power equipment

Date: Date: 2008-09-15

No.: QN1-SEC-G-04-TP-003

Page 4

Rev. : A


SEC 10

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL Anti-corrosion guidelines of stand-thermal power plant

SD223-87

equipment 11

GB7596-87

Oil quality standards in turbine in the operation of power plant

12

GDF(2000)589

25 pieces of key requirement to prevent accidents in power production

13 3

major

Design information and equipment information of manufacturer

Boiler Techni Techni que Specification

3.1 3.1

Introdu ction of Boil er 

This boiler is designed by Alstom who provides performance-test technique supp ort .It is manufactured by Shanghai Boiler Works Ltd. This form of boiler is doublearched, W-flame with single furnace, then one middle reheat, control circulation and sub-critical steam drum furnace. Two units are equipped with one start-up boiler for steam source.

Design coal for boiler is anthracite which is from Vietnam CAM PHA and HON GAI 

mining areas. 

Combustion system: the system adopts hot air feeding, each boiler with 16 duplex-type feeders, 32 pulverized coal burner. The capacity of pulverized coal combustions is 100%

BMCR

with

design-coal.

heavy

oil according to TCVN 6239-2002 standards. This boiler adopts two-

stage ignition. The high-energy the

heavy-oil

burner

Start-up

igniter

and

ignites

stable

the

HPO

combustion

burner

adopt

and

then

ignites pulverized coal. Fuel oil burners will be steam

atomized. This project set 2×5000 tons tank and 2 unloading fuel pumps, two 100% capacity AC, DC supply pump, 1 dirty oil pump and 1 sewage pump. Oil burning system arranges oil supply pipe and oil return pipe to boiler burners according to oil supply and return single piping circulation. 

Oil burners: Each arch nose has 8 HFO burners, namely each boiler has 16 burners. The auxiliary steam which pressure is constantly 5.25 bar (g) makes HFO atomization and

also

cleans

the

burners.HFO

will

be

ignited

by

high-energy

igniter.

Each HFO burner will be equipped with specialized specialized flame detector. detector. Cooling wind will be provided through two separate specialized circuit burner and the flame detector .When oil burner is stopped, it will exit from burner quarrel by about 330 mm to avoid impact of radiation (prevent the burners from damaged). Low heat value (LHV value) is fuel heat input at 30% BMCR by adopting 12 burners to achieve the burning burning capacity at 30% BMCR BMCR (two


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL burners in each arch nose are stopped operation).The adjustment ratio of burner is 1:5

Date: Date: 2008-09-15


Page 5

Rev. : A


SEC


using J11 burner. 

Flue and air system, pulverized coal system: flue and air system adopts balance draft, the

flue

then

gas

FGD,

Force

will

be

discharged

or directly

draft-fan

and

to

the

to

induced draft-fan

single

way

BBI

globe

is

passing

passing

axial

flow

the fan.

ESP

FGD FDF

and

bypass.

is

moving

blade adjustable. Milling system bin and

flue gas drying milling system with 2

atmosphere

atmosphere

blade adjustable and IDF is static

with

the

balance draft. Each

mill.

Primary

air

boiler

fan

is

equipped

adopts centrifugal

fan .The vent will be filtrated pulverized coal through cloth dust collector and then discharged to atmosphere through vent fan. 

Ash As h s lag la g remo re mova va l a nd as h y ard: ar d: Ad opti op ti ng dry dr y ash as h extr ex trac ac ti on as h a t th e bo tt om is discharged fly ash

to

slag

pool

through

slag

crusher

and

hydro

ejector

.The

coll ect ed fro m AP. AP. econ omiz er and ESP is sen t to the large ash silo(total silo(total 2 ash silo ,each has 2500 m3 volume), the dry ash is further dealt with through the ashwater mixture

and

silo

ash emulsion pump (the method for retaining and comprehensive

through

transported

to

ash

pool

and

then t hen

transported

to

ash

utilization of dry ash) ； Desulphurization and dust removal system: Choose 4 ESP. This project sets up one 

200m-high two-steel

cylindrical

chimney

and

also sets

up 100%

capacity

scrubber adopting Limestone - gypsum wet desulphurization process and GGH； 

Compressed considering



air

system:

total

three

50%

capacity

compressors

little lubrication oil.

Safety valve: This boiler is equipped with 8 spring safety valves supplied by Crosby America ,who are located in the following places: 3 valves at the drum, 1 valve at SH outlet RH

outlet

piping,

piping,

2

valves

at

RH

one electromagnetic

outlet

relief relief

piping,

valve

is

2

valves

mounted mounted

on

at SH

outlet piping. The valve is VTI brand supplied by Crosby America. BMCR is 995t/h, the total discharging capacity of drum safety amounting

to

88.62

percent

of

BMCR.

The

valves

is

881.796,

discharging capacity of SH

safety valves is 153.86t/h, amounting to 15.46 percent of BMCR. The discharging capacity

of

SH

and

drum

safety

valves

is

1035.656t

/h,

amounting

to

104.09% percent of BMCR. Max RH steam flow is 848.6t/h. The discharging capacity of safety valves at RH inlet is 512.94t/h, amounting to 60.45 percent of Max RH steam flow. The discharging capacity of safety valves at RH outlet is 379.157t/h, amounting to 44.68 percent of Max RH steam flow, The aggregate of discharge capacity at RH outlet and


SEC inlet

is

892.097t/h,

flow.

The

Date: Date: 2008-09-15

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL amounting to 105.13 percent of the Max RH


Page 6

Rev. : A

steam


SEC


discharging capacity of electromagnetic Relief Valve is 166t/h, amounting to 16.68% percent of BMCR, It is not included in Safety Valve capacity whatsoever. 3.2

Boi ler Nameplate

Type of boiler

Unit

SG-995/17.5-M728

Manufacturer

SBWL

Fabrication no.

728-1-8069 Double-arched,

Boiler form

furnace,

W-flame

then

a

with

middle

single reheat,

control circulation and sub-critical steam Boiler maximum rating(B －

continues

t/h

995

MCR Continues rating(RO)

t/h

889.1

Rated temp. of main steam(B-MCR／RO)

℃

541／541

M Pa·g

17.29／17.13

Reheater steam flow(B-MCR／RO)

t/h

882.498/736.407

Temp of reheater inlet／outlet(B-MCR)

℃

320/540

Temp of reheater inlet／outlet(RO)

℃

309/540

Pressure of reheater inlet／outlet(B-MCR)

MPa·g

3.53/3.34

Pressure of reheater inlet／outlet(RO)

MPa·g

3.14/2.98

℃

281/273

Rated pressure of main steam B-MCR ／ RO)

Temp of feed water (B-MCR／RO) Date of starting erection Date of starting manufacture

Date: Date: 2008-09-15


Page 7

Rev. : A


SEC 3.3


Boiler Design Design Information

3.3.1

Water Bulk of Boiler Pressure Parts

No.

System

Pressure

Units

1

Drum

m

2

Water wall

m

Date

3

40

3

82

Total

Superheater

Primary system

273

economizer and

3

3

151

m

3

48

m3

24

m

header and other connecting pipe

4

Reheater Secondary system

5

Header and connecting pipe

3.3.2

72

Boiler Safety Valve Valve Setting Pressure and Discharge Desi

Blow Set Set pressur e Specificat N o.

Location

Type of valve

io n (inch)

Openi ng MPa

Bl o w dow do w n MPa 19.8

gn

down

Dischargi

Different

ng

ial

capacity t/h

℃

3

291.697

369

4

293.924

369

5

296.175

369

3

153.860

557

pressur

temp

e%

1

DRUM

HE-96W

3 M2 6

20.50

2

DRUM

HE-96W

3 M2 6

20.60

3

DRUM

HE-96W

3 M2 6

20.70

HCI-98W

3 L2 6

18.70

HCI-46W

6 RR10

4.50

4.37

3

253.574

313

HCI-46W

6 RR10

4.60

4.46

3

259.366

313

HCI-48W

6 RR10

4.10

3.98

3

187.347

554

4

5

6

7

Reaheate r outlet Reaheate r outlet Reaheate r outlet Reaheate r outlet

Date: Date: 2008-09-15


9 19.7 8 19.6 7 18.1 4

Page 8

Rev. : A


SEC


Reaheate

8

HCI-48W

r outlet

6 RR10

4.20

4.07

2..5″ 2..5″×4″

18.50

3

191.810

554

2

166

557

Superhea 9

ter

E0L121N7BWR

outlet(ER

A5P1

18.1 3

V) 3.3.3

Thermal Performance Calculation for Boiler Operation Coal combustion(loads) Items

Unit

1. Total Total output of Generator

MW

2. Steam flow

kg/H

BMCR

75%

60%

RO

RO

300

225

210

RO

(a)

Reheater outlet

995

882.7

639.4

518.9

(b)

High-pressure turbin inlet

995

882.7

639.4

518.9

(c)

High-pressure

822.5

735.3

543.0

443.8

849.4

756.5

555.0

443.8

turbin

Exhaust (d)

Mid-pressure turbin inlet

*60% RO

kg/cm g

(a)

Drum

190.4

186.5

156

127.5

(b)

Superheater outlet

176.3

174.7

149

121.9

(c)


169

169

145.5

119.1

(d)

High-pressure

37.6

33.6

24.7

20.0

33.7

30.1

22.1

18.0

turbin

Exhaust (e) Mid-pressure turbin inlet 4. Steam temp.

℃

(a)

Drum

362

360

347

333

(b)

Superheater outlet

541

540

539

539

(c)


538

538

538

538

(d)

High-pressure

323

312

301

304

538

538

538

538

turbin

Exhaust (e) Mid-pressure turbin inlet

(a)

loads

2

3. Steam pressure

5. Feedwater pressure

Minmum

2

kg/cm g

BFP outlet

Date: Date: 2008-09-15


Page 9

Rev. : A


SEC (b)


High-pressure

heaters

outlet (c)

Economizer inlet

193.9

189.4

158.7

129.9

(d)

Economizer outlet

193.4

189.0

158.5

129.8

6. Temp. of feedwater

℃

(a)

Feedwater pump outlet

(b)

Economizer inlet

281

273

254

243

(c)

Economizer outlet

299

291

275

267

4.19

3.88

1.13

1.12

2.36

2.34

0.11

0.12

3.00

3.00

' (g) Heat loss due to radiation

0.20

0.26

(h)

Other((L8)

0.25

0.25

(i)

Manufacturing

0.50

0.50

11.75

11.48

7. Heat heating (a) gas (b)

loss

Heat

'

in in

(high

the

dry

% flue flue

Moisture in fuel (L2')

(c)

The water generated

from the

hydrogen

combustion (d)

in

The moisture

in

the

air((L4') (e)

Un-burned carbon ((L5')

(f) The carbon

formation

of

allowance

((L9) Total(Σ Total(ΣL) (j)

Ambient air temperature

℃

24

24

24

24

(k)

Relative Humidity

%

80

80

80

80

(l)

Atmospheric pressure

kg/cm2

1.0332

1.033

1.0332

1.033

1.0332

%

88.25

88.52

kg/H

129500

99100

4815

4815

4815

4815

8. Total heat efficiency 9. Fuel consumption (coal) 10.

Heat

(a)

LHV of coal

Date: Date: 2008-09-15

kcal/kg 4815


Page 10

Rev. : A


SEC (b)


HHV of coal

4980

4980

4980

4980

86.9

78.5

59.3

49.9

2.9

2.6

1.95

1.65

163.1

147.4

111.2

93.7

4980

11. Furnace heat absorption (total heat release) 3

(a)

x 10

Per Effective volume

(b)

Per Flat area

(c)

Per effective

3

kcal/m H x 106 2

kcal/m H protruding

x 103 kcal/m2H

radiation surface 12.

Air temp.

(a)

Steam heater inlet

29

29

29

29

(b)

Steam heater outlet

29

29

29

29

31

31

31

31

29

29

29

29

356

352

324

308

333

333

311 311

297

(c) Air primary (d)

℃

preheter

Air

inlet

preheter

inlet

secondary air (e)

Air preheter outlet primary

air (f)

Air

preheter

outlet

secondary air (g)

Mill entrance

580

580

580

580

(h)

Mill export

110

110

110

110

13.

Gas Temperature

(a)

Furnace outlet

1015

990

910

860

(b)

Superheater inlet

825

800

730

700

(c)

Superheater outlet

670

650

610

580

(d)

Air preheter inlet

400

392

358

340

(e)

Air preheter outlet

(Un-corrected)

131

127

118

109

(Corrected)

124

121

111

102

76

TBA

TBA

TBA

80

77

72

69

14. Dew-point preheter

of

℃

air

15. Temp of cold end metal of AP. AP.

Date: Date: 2008-09-15


Page 11

TBA

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL 3

16. Flue gas volume

10 kg/H

(a)

Economizer outlet

1332

1205

936

827

(b)

air preheater outlet

1422

1291

1020

910

103 kg/H

1216

1101

864

765

M/s

11.2

9.8

7.2

6.2

103 kg/H

41.7

37.8

28.7

24.1

(a) Furnace outlet

24

24

28

35

(b)

Economizer outlet

25

25

29.5

37

(c)

Air preheater outlet

34.4

34.9

42

52

(d)

ESP outlet

21.

O2

(a) Furnace outlet

3.8

3.8

4.3

5.2

(b)

Economizer outlet

4.0

4.0

4.5

5.4

(c)


5.1

5.1

5.9

6.8

(d)

ESP outlet

22.

CO2

(a) Furnace outlet

14.4

14.4

14.0

13.3

(b)

Economizer outlet

14.3

14.3

13.8

13.1

(c)


13.4

13.3

12.7

11.9

(d)

ESP outlet

17. Combustion air volume 18. Maximum speed of flue gas flow in convection section 19. Ash content of economizer outlet 20. Excess air

% Vol

% Vol

% Vol

x 106

23. Heat absorption

kcal/H

(a)

Furnace

264.7

249.2

202.4

172

(b)

Superheater

225.0

195.2

139.9

116.8

116.5

106.1

77.8

64.3

(d) Economizer

28.5

24.6

19.3

17.1

Total

634.3

575.1

439.4

370.2

(c)

Reheater

(e)

Air preheater

TBA

TBA

TBA

TBA

(f)

Steam air heater

0.0

0.0

0.0

0.0

24.

The heat

intensity

heating surface

Date: Date: 2008-09-15

of

x103 kcal/m2H


Page 12

Rev. : A


SEC


(a)

Furnace

TBA

TBA

TBA

TBA

(b)

Superheater

TBA

TBA

TBA

TBA

TBA

TBA

TBA

TBA

(d) Economizer

TBA

TBA

TBA

TBA

(e)

TBA

TBA

TBA

TBA

(c)

Reheater

Air preheater

3.3.4

Characteristics of Fuel(coal)

No. I

Symbol

Unit

Range

Date

Heat value High heat value

HHV

Kcal/kg

4680-5300

4980

Low heat value

LHV

Kcal/kg

4490-5157

4790

II

Analysis

1

Total Moisture(as received)

War

%

5.55-12.0

9.00

2

Free moisture

Ws

%

4.81-9.88

7.63

3

Inherent Moisture

Win

%

0.78-2.35

1.48

4

Moisture in the air dried sample

Wad

%

0.80-2.41

1.39

5

Fixed carbon (as received)

Cfar

%

49.54-63.15

53.68

6

Volatile matter(as received)

Var

%

5.82-8.61

6.83

7

Ash content(air dried basis)

Ad

%

28.0-37.36

33.5

8

Ash content(as received)

Aar

%

25.48-34.0

30.49

Total

100.00

III

Element analysis

1

C(ADB)

Car

%

46.83-63.75

54.62

2

H(ADB)

Har

%

2.56-2.97

2.62

3

O(ADB)

Oar

%

1.66-2.68

2.09

4

N(ADB)

Nar

%

0.73-0.86

0.77

5

S(ADB)

Saror

%

0.27-0.66

0.41

6

A(ADB)

Aar

%

25.48-34.0

30.49

7

M(ADB)

War

%

5.55-12.0

9.00

Total

100

IV

Physical characteristics

1

Hardness, grindability index

-

-

45-70

47

2

Pulverized coal particle size

-

-

-

100

%

6.16-17.5

10.53

(0-15 mm) +10mm

Date: Date: 2008-09-15


Page 13

Rev. : A


SEC


5-10mm

%

9.89-18.3

14.22

2.5-5mm

%

15.60-21.71

18.62

1.25-2.5mm

%

8.73-13.76

0.63-1.25mm

%

12.36-18.13

14.89

0.315-0.63mm

%

6.80-14.45

10.02

-0.315mm

%

11.47-31.47

20.77

3

Density

-

0.92-1.10

1.00

4

static angle

°

33-39

37

3.3.5

Characteristics of Burning(ash)

No.

Components

Symbol

Unit

Range

Design Design date

Ash components 1

SiO2

%

57.60-64.10

62.83

2

Al2O3

%

23.3-28.64

24.76

3

Fe2O3

%

4.26-6.16

5.41

4

V2O5

%

0.018-0.028

0.026

5

TiO2

%

0.50-0.91

0.68

6

CaO

%

0.30-0.77

0.44

7

MgO

%

0.67-1.42

1.11

8

K2O

%

3.35-4.70

3.64

9

Na2O

%

0.15-0.55

0.48

10

P2O5

%

0.19-0.30

0.24

11

SO3

%

0.251-0.481

0.341

12

MnO

%

0.006-0.050

0.043

13

Other

%

0.00

0.00

Total

100.00

Ash physical characteristic 1

Ash density

2

FYI

g/cm R



3

cm

0.224 - 0.370

0.291

301x102 - 603x102

525x102

Solubility of ash 1

2 3

Initial

deformation

temperature Hemispherical temp. Fluid temp.

Date: Date: 2008-09-15

softening

T1

0

C

1210 - 1280

1250

T2

0

C

1430 - 1600

1570

T3

0

C


0

C

Page 14

1530 - 1600

Rev. : A


SEC 3.3.6


Characteristics of Fuel(heavy-oil)

3.3.6.1

Characteristics of heavy-oil

Characteristics

Test method

Date No.1

3

Density at 15℃ mt/m

=<

=< 0.991

No.2B

No.3

=< 0.991

=< 0.991

=<180

=<380

=<2.0% =<2.0%

=<3.0%

=<3.5%

=<+12

=<+24

=<+24

0.965

Viscosity at 50℃

No.2A

=<87

=<180

TCVN

6594:200

(ASTMD1298) ASTM D445

cSt cSt Sulphur

content,

by

weight Pour point ℃ Ash content

%

TCVN67O1:200O

=<+24

=<0.15 =<0.15

=<0.15

=<0.35

(ASTM TCVN3753:1995

ASTM

D97 TCVN2690:1995/ASTM D482

Water

content,

by

volume Purity, by weight

=<1% =< 66

Flash point℃

=<1%

=<1%

=<1%

=< 0.15%

=< 0.15%

66

66

D95

=< 0.15% ASTM D 473 66

TCVN 66O8: 20O0/ ASTM ASTM

>=

HHV, kcal/kg

>= 10,000

>= 10,000

>=10,O00

10 000 LHV, kj/kg 3.3.6.2

TCVN2692:1995/ASTM

ASTM ASTM

D382S/ASTM D240/ 240/

ASTM ASTM

D480

40,800(usual)

The corresponding value of temp. of fuel burner entrance and viscosity viscosity of heavy oil (for detail information refer to viscosity - temperature curve) Item

HFO No.1

HFO HFO No.2A & 2B

HFO No.3

2.5 °E

2.5 °E

2.5°E

95

110℃

130℃

0.917

0.934

0.922

viscosity of fuel required in the entrance of burner Required Required Matching temp. Required Required Matching density 3.3.6.3

J11 J11 oil burner design parameter HFO HFO flow o f each each bu rner

Date: Date: 2008-09-15

HFO

At om izat io n

pressure of steam flow of


Page 15

Steam pressure of

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL each each burne burnerr each each burne burner r

Maximum 30% BMCR, running 12 burners Standard values 30% BMCR, running 16 burners Minimum 3.3.6.4

each each bu rner

l/h

bar(g)

kg/h

bar(g)

1935

20

110

5.25

1450

14

115

5.25

390

2

165

5.25

Requirement for oil and steam steam parameters parameters in burners operation Fuel oil

parameter 2.5°E

Steam Steam parameter(dry parameter(dry steam as r equired)

(make

the

corresponding Viscosity at the burners

adjustment temp,

of

the

Burner pressure

5.25 bar(g)

Temp.

about 200℃

Estimated

at Burner pressure

2 ~ 20 bar (g) Maximum BMCR

30%

heat

input,

namely 21280 kg/h.

Flow

Max flow

The constant flow

2.6 t/h, flow

Peak

flow

is

t/h (atomization

in return line is

cleaning

10% of 3.4

continuous

Requirement for Date of Quality of Boiler Steam in Normal Normal Operation Item

Unit

Normal range

1. Feed water Conductivity (after cationic resin exchanger) at 25°C Expected values :

µS/cm (microSiemens/cm)

Total hardness detectable by

:

i.

e.

not

Nil

Dissolved oxygen at degasser outlet

mg/kg (O2)

Hydroxide content at economizer inlet

mg/kg (N2H4)

Date: Date: 2008-09-15

< 0. 3～0. 2 9. 2～9. 4

pH obtained by ammonia injection


≤ 0. 01 > 0. 010～0. 020

Page 16

and are

Requir Requir ement for Quality of Boiler Steam

3.4.1

3.9

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL Item

Unit

Normal range

Total iron (Fe),

mg/kg

< 0. 010

Total copper (Cu)

mg/kg

< 0. 003

mg/kg (SiO2)

< 0. 020

Silica content, 2, Boiler water

µS/cm

Conductivity (at 25℃)

< 20 9. 2～9. 5

pH (at 25℃ ) mg/kg (PO43-)

Phosphate content Free caustic

Nil

Silica content, recommended 3.4.2

2～3

mg/kg (SiO2)

0. 010～0. 300

Status

Date

Alert date for abnormal quality of boiler steam

Steam sample

Condensate

Feedwater

at

Degasser

outlet

Feedwater

at

economizer inlet

Item pH value

In the regular scope

9. 1 to 9. 5

dissolved oxygen

More than or equal to

20 ppb

Cation conductivity

More than or equal to

0. 5 µS/cm

dissolved oxygen

More than or equal t

10 ppb

pH value


9. 1 to 9. 5

Cation conductivity

More than

0. 5 µS/cm

Dissolved oxygen

Less than

10 ppb

Hydrazine


10 to 20 ppb

Conductivity pH value Boiler

Silicic acid F Na

Saturated steam

Cation conductivity

Na Silicic acid

Superheated

Cation conductivity

More than In

the

50 µS/cm

regular

9. 0 to 10. 0

scope

100 ppb

More than

1ppm

More than

-

More than More to

than

or

equa 0. 5 µS/cm

20 ppb

More than More to

steam

Na

Date: Date: 2008-09-15


than

50 ppb or

equa 0. 5 µS/cm

20 ppb

Page 17

Rev. : A


SEC Steam sample

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL Item Silicic acid

Date: Date: 2008-09-15

Status More than


Date 50 ppb

Page 18

Rev. : A


SEC 3.5 3.5


Boiler auxiliary equipment technical specific ations

3.5.1

High-pressure bypass

1

Basic date

2

Parameters

Use

3

High-pressure bypass valve

Quantity

4

Equipped with 2 units Fluid characteristics

5

Type of fluid

steam

6

Maximum control flow(max CV)

750 t/h (75%BMCR)

7

Min differential pressure at max CV

130 bar

8

Minimum inlet pressure at max CV

179. 3 bar

9

Max temp. at max CV

543 ℃

10

Minimum control flow(min. CV)

8 t/h

11

Max differential pressure at min CV

205 bar

12

Max inlet pressure a t Min CV.

205 bar

13

Min temp. at Min CV.

420 ℃

14

Quick-opening set pressure

182. 8 bar

15

Slow –opening set pressure

179. 3 bar

16

17

18

Characteristics and specifications of executive executive bo dy Differential pressure after the valve is shut off Type Type of executive bod y (electric, pneumatic and hydraulic)

205 bar

hydraulic

19

Fault location indicator

20

Solenoid operated control valve (SOV) yes or

21

Manual control

yes

22

Stroke Period (fast& control)

3& 20 sec(from 0％to100％)

23

Limit switch

close

24

Pressure switch for air pressure difference

no

25

Location transmitter

yes

26 27

Gas

source

pressure

open

reducer

with

instrument

no

Characteristics

Date: Date: 2008-09-15


Page 19

Rev. : A


SEC


28

Design pressure

205 bar is effective

29

Design temp.

543+5 ℃

Tightness

30 3.5.2

rank(selon

/

acc.

to

ANSI

B16-104)

rank V

Air preheater Item

Unit

Design Design date

Form

A. P( trisector, trisector, rotating the heating surface )

Type

2-29VI(T)-86”SMRC

Rotor diameter

mm

10318

Rotor height

mm

2185

Height of heating surface

mm

Hot section 880,cold

Quality

set

2

Manufacturer

1000,

middle

layer

of

hot

section

SBWL Main Motor

Motor Type

Auxiliary Motor

Y180M-4B3

Y160L-8B3(Double-axis )

Power

kw

18. 5

7. 5

Voltage

V

380

380

Rated Current

A

Rotating speed

r/min

1470

720

Reducer Type

SGW100D

Reducing rate of speed

128. 3

Axis rotating speed(main

r/min

11. 46

Axis rotating speed(axial

r/min

5. 61

N. m

12300

Rated Torque output Support bearing Guild bearing

Thrust spherical roller bearing Type: Type: 90394/750 Double-out centripetal roller bearing Type: 3153172

Oil circulation system Oil station Type

Date: Date: 2008-09-15

Guidance bearing

dilute-Oil

Support bearing dilute-Oil

station

station

OCS-D2A

OCS-D2A


Page 20

Rev. : A


SEC


Item

Unit

Type Type of Motor Moto r

Design Design date Y802-4B3

Motor power

kw

Motor speed

r/min

Type Type of oil o il pump

0. 75(2 set) 1390 3GR25×4 tri-screw pump

Flow

m3/h

0. 8

Rated pressure

MPa

1. 0

Working temp. of Cooler

℃

60～70

Temp of cooling water

℃

＜30

Consumption cooling

of

Pressure of cooling water

3

0. 8

MPa

0. 2

m /h

Type Type of oil filter

SPL25C-2 net

Type Type of oil cooler

GLC1-0. 8 Tubular

3.5.3

Induced draft fan Item

Unit

Design Design d ate

Remarks

Form

Axial

Type

G158/273

Manufacturer

Shanghai Blower works Ltd.

Quality

set

3.5.4

2 Anti-clockwise

Rotation direction Motor Power

adjustable static-blade

Kw

At the direction of air flow

1500

Forced draft fan Item

Unit

Design Design date

Form

Axial(hydraulic, adjustable moving-blade)

Type

FAF20. 4-10-1

Manufacturer

Shanghai Blower works Ltd.

Date: Date: 2008-09-15


Page 21

Rev. : A


SEC


Quality

set

2

Air fan total pressure

Pa

5267(T. B) 3660(BMCR)

Speed

r/min

Shaft output Efficiency

kw

％

Range of moving-blade

1470 T. B:621,BMCR:405 84.08(BMCR

operating 83.21(BMCR

condition:86. 50)

condition:86. 72)

Anti-clockwise(at the direction of end of Motor shaft )

Rotation power

kw

1250

Rotation speed

r/min

1482

Primary air fan Item

Unit

Form

Design Design date Single-suction centrifugal

Quality

set

2

Type

1788AB/940

Manufacturer

Shanghai Blower Works Ltd.

Speed

r/min

1480

Outlet total pressure

Pa

TB:14850 Pa BMCR:11000 Pa

Inlet temperature

℃

TB:39 BMCR:24

Power

kw

400

Direction 3.5.6

operating

degrees 45

Rotation direction

3.5.5

T. B:650,BMCR:418

Inlet:90o outlet:0o(from Motor side )

Mill fan

Type: M25452 Type: Type: Centrifugal: Media of mill fan: air

Date: Date: 2008-09-15


Page 22

Rev. : A


SEC


Item

Unit 3

BMCR operating

TB operating operating con dition

condition

Standard Flow

Nm /h

151650

144430

Inlet Temp.

℃

120

110

Inlet Gross Pressure

Pa

-8500

-8000

Outlet static Pressure

Pa

-700

-1200

Total Pressure of Air fan

Pa

7800

6800

Selection point efficiency

％

83. 1

76. 8

0. 9735

0. 9767

543. 8

Compression

correction

factor Axial power

kw

622. 5

Rotation direction

r/min

980

Rotation power

kw

710

Rotation speed

r/min

980

Motor voltage

kv

6. 6

Manufacturer 3.5.7

China ChengDu Electrical power machinery factory

Milling Item

Unit

Design Design date

Remarks

Manufacturer

Shanghai Heavy machinery Works Co. Ltd.

Mill cylinder type

BBI4796

Mill cylinder effective diameter Mill cylinder effective length

Milling method

Date: Date: 2008-09-15

mm

4650

mm

9740 Ball mill with drying and purging by hot air


Page 23

Rev. : A


SEC


Item

Unit

Design Design date

Remarks

Main Motor Manufacturer

Shanghai Motor Works

Type

YTM900-6

Power

kW

3500

Voltage

V

6600

Speed

r/min

986

V

230

Electric

heater

Single-phase voltage

Power 1200x2 W(used when shut-down)

Main Motor lubrication dilute-oil station (XYZ-20) Nominal pressure

MPa

0. 5

Nominal flow

L/min

20

Primary

Lubrication

Volume

L

Lubrication Speciation

450

46 turbine oil L-TSA m /h

3

2. 5

Power

kW

1. 5

Voltage

V

400

Speed

r/min

1400

Cooling water volume

Main Reducer Type Speed rate Lubrication Type

ML2PSF150 i

9. 275 Reducer

with

compulsory

lubricating

of

independent dilute-oil station

Date: Date: 2008-09-15


Page 24

Rev. : A


SEC


Item

Unit

Design Design date

Power

kW

Voltage

V

400

L

1500

Primary

Lubrication

Volume Lubrication Speciation

Remarks

11

ISO VG320 3

Cooling water volume

m /h

8

Low speed driving set [plant reducer(An auxiliary motor)] Type

NMCD560-125

Speed rate

i

Motor Type

125 YEJ280S-6(B35)

Motor Power

kW

45

Motor Speed

r/min

970

Motor Voltage

V

400

Revolving speed of disk Primary

r/min

lubrication

volume

L


0. 105

180

Mid-extreme pressure industry gear oil N220(GB5903-86)

Main bearing HP and LP lubrication dilute-oil station Type Lubrication Speciation

GDR-60/10/170 L

Cooling water volume Cooling water volume Electric heater

Date: Date: 2008-09-15

2800 ISO VG460

m3/h

18 Total 6 (400VAC/3kw x 6)


Page 25

Rev. : A


SEC


Item

Unit

Design Design date

Remarks

LP pump(1 set) Nominal pressure

L/min

170

Nominal flow

MPa

1

LP Pump Motor(1 set) Power

Kw

7. 5

Voltage

V

400

Speed

r/min

1440

Nominal pressure

L/min

4X15

Nominal flow

MPa

20

Injecting HP oil pump (1 set)

Injecting HP oil pump motor(1 set)

Power

Kw

30

Voltage

V

400

Speed

r/min

1470

Electric wire heater

VAC/kW 230/

HP lubrication pump(1set) Nominal Pressure

L/min

2X5

Nominal Flow

MPa

10

HP lubrication pump motor(1set) Nominal Pressure

Nominal Flow Speed

Date: Date: 2008-09-15

Kw

3

V

400

r/min

1440


Page 26

Rev. : A


SEC


Item

Unit

Design Design date

Remarks

The girth gear grease circuit lubricating equipment Type

GSPZ-Z-8

Operation Pressure

MPa

0. 4~0. 6

Max Pressure

MPa

0. 8

Max volume of oil supply

g/min

1500

Required

gas

supply

capacity

Working oil pressure

0. 6MPa

3

m /min 0. 42

MPa

20

Quantity

8


NLG100-0

Gear sealing air equipment Air fan type

CQ3-J m3/h

800

Pressure

pa

590

Power

kw

0. 37

Voltage

V

400

Speed

r/min

2900

Flow

Spring coupling equipment Primary grease volume

kg

Grease speciation

about 4 NLGI

02

Lithium

Grease

lubricants

Gear coupling equipment Primary grease volume

Date: Date: 2008-09-15

kg

About 13


Page 27

Rev. : A


SEC Item

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL Unit

Grease speciation

Design Design date

Remarks

E. P. Lithium Grease lubricants

Small gear equipment rolling bearing Grease speciation

3.5.8

SKF ALFALUB ALFALUB LGEP 2

Cold feeder Item

Specification

Manufacturer China's Hubei YiDu Electrical and Machinery

Main body

MSD100

Motor

YVP160L-6

China Xi An Motor Works

Reducer

ZSY250-80

China's JiangYin, JiangSu gear box Works

Output

30～110 Tons／hour

3.5.9

Engineering Co., Ltd.

Pulverized Coal feeder Item

Unit

Design Design d ate

Remarks

Manufacturer

China ShenYang Power Plant Engineering Ltd.

Type

SGF－13

Output 3.5.10

t/h

3～13

Pulverized Coal Feeder Item

Unit

Design Design date

Remarks

Manufacturer

China ShenYang Power Machinery Works

Type

LSG－500

Transmission distance Motor Power

Date: Date: 2008-09-15

m KW

32. 2 7. 5


2

Page 28

Rev. : A


SEC 3.5.11


classifier Item

Unit

Design Design date

Remarks

Manufacturer

Chian Wuxi Liangxing power equipment Ltd.

Speciation

Φ6800mm

3.5.12

Thin pulverized coal separator Item

Unit

Remarks

China WuXi Joint Venture Power Equipment Co., Ltd.

Manufacturer

Φ3500mm

Speciation 3.5.13

Design Design date

Vent fan Item

Unit

Design Design date China's Shenyang Blower Factory

Manufacturer Type

SFY15F-C5A

Form

Single inhalation double support centrifugal

Direction of air intake

90° left rotation(right rotation)

Direction of air outtake

45° left rotation(right rotation )

Impeller diameter

mm 1500

Rotor critical rotation speed

r/min 1930

Inlet flow volume

m3/s 28. 36

Air fan total pressure

KPa 5. 7

Inlet temperature Air fantotal pressure effciency

℃

120

%

84

Air fan axial power

kW 200

Motor effciency

kW 250

Date: Date: 2008-09-15

Remarks


Blade outlet

Page 29

Rev. : A


SEC


Motor voltage 3.5.14

kv

6. 6

Boiler water circulation pump Item

Unit

Design Design d ate

Form

LP head with no seal

Type

LUVc250×2-410/1

Manufacturer

England

Heyward

Remarks

Tyler

company Medium

water

HAYWARD TYLER

Single

inhalation

double support centrifugal Quantity

set

3

Design pressure

bar

210

Hydraulic test pressure

bar

315

Absorbed pressure

bar

198

Medium density

S·g

0. 554

Design temperature

℃

Max differential pressure of pump shell and boiler water

℃

2 operation meet BMCR

369 lower than 56

Higher than 56℃ trip

2182

Single

Pump flow

m3/h

Efficiency

％

83

Cold/hot

kw

222. 7

Hot:130. 0

Absorbed efficiency Pump inlet and outlet differential pressure

Lower than 0. 11 alarm MPa

about 0. 3(31. 1mH2O ) Lower than 0. 055 trip

Motor Form

Date: Date: 2008-09-15

Three-phase


squirrel-cage

Page 30

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL induction

Type

LUV55/4FQ20-605

Rated power

kw

200

Rated voltage

KV

6

Rated speed Rotation speed

r/min

1450

Rated current

A

27. 5

Start-up current

A

135

Motor efficiency

％

88. 0/87. 0

cold/hot

0. 805/0. 72

cold/hot

Power factor Input power

kw

252. 8/140. 5

cold/hot

Total efficiency of pump

％

73/72. 2

cold/hot

Water cooler of HP filling water and cleaning water HP side design pressure HP

side

hydraulic

MPa test

pressure LP side design pressure LP

side

hydraulic

MPa

MPa test

pressure Design temperature

MPa

℃

21 31. 5

1 1. 5

180

Motor heat exchanger HP side design pressure

MPa

22

LP side design pressure

MPa

3

LP side required pressure

MPa

0. 65

HP side design temperature

Date: Date: 2008-09-15

℃

343


Page 31

Rev. : A


SEC


LP side inlet temperature

℃

38

max

LP side outlet temperature

℃

44

max

3

11

HP side motor circulation water volume HP side motor circulation

m /h

℃

32～49

normal operation

water temp. 3

LP side required flow

m /h

8. 5

Lower than 6. 5alarm

Heat exchanging efficiency

kJ/s

34. 2

Cold,2 pump operation

2

Lower than 1. 5alarm

Required

flow

forLP

m3/h

cooling water hot panel hot

panel

outlet

allowable highest temperature LP

cooling

water

hot

flow

2

m3/h,

panel pressure drop 3.5.15

0. 2

MPa

panel required pressure At

50

℃

hot

0. 05～0. 08

KPa

Flame scanner cooling air fan Item

Unit

Design Design d ate

Manufacturer

SBWL

Type

VC 710 N/2

Air flow Total pressure 3.5.16

m3/h

1153

Pa

9480

Remarks

Intermittent and continuous blowdown flash tank Item

Manufacturer

Date: Date: 2008-09-15

Unit

Design Design date

Remarks

China Jinan pressure vessel plant


Page 32

Rev. : A


SEC


Continuous blowdown flash tank Form

Vertical

Type

LP-3. 5

Volume

m

Design pressure Design temperature

3

3. 5

MPa

1. 5

℃

360

Intermittent blowdown flash tank Form

Horizontal

Type

DP-20

Volume

m

Design pressure Design temperature 3.5.17

3

20

MPa

1. 0

℃

250

Steam air preheater Item

Unit

Manufacturer

Design Design date

Remarks

China Hankou power equipment plant

Primary air A. P Type Volume Design pressure Design temperature

NFZ3. 2-1-2. 645FBZ m3

185

MPa

1. 6

℃

360

Secondary air A. P Type Volume

Date: Date: 2008-09-15

NFZ3. 2-1-2. 690FBZ m

3

607. 5


Page 33

Rev. : A


SEC


Design pressure Design temperature Steam

air

MPa

1. 6

℃

360

preheater

drain box Type

NSL-16-0. 5 m3

Volume

4

0. 5

Boil er and interlock prot ection value auxiliary equipment.

4.1 4.1

Boiler protecti ng Limit Value

Name

Units

LL

L

N

H

HH

Remarks Drum

water

level

under the center Drum water level

100％Load:0 mm

-425

-240

+100

+200

line of drum － 175mm;

50％Load -115

L, H: alarm;

Furnace pressure

L, H: alarm, Pa

-2500

-2000

-100

+1000

+4000 LL/HH: Boiler MFT N:HPO isolating valve allowable L: alarm

Burning oil pressure

Mpa

0. 5

1

2. 5

LL: Burning oil trip H:HPO pressure high alarm

Burning oil pressure

Mpa

Date: Date: 2008-09-15

1. 85


N:HPO

1. 9

leaking

test pressure proper

Page 34

Rev. : A


SEC Name

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL Units

LL

L

N

H

HH

Remarks H:

HPO

leaking

test pressure low N:HPO

temperature

allowable Burning oil

90

℃

temperature

95

100

135

L:HPO

low

temperature alarm LL/H:HPO trip L: low pressure alarm

Atomization steam

LL: Mpa

0. 4

0. 5

0. 9

low

pressure

Burning oil trip

pressure

H:

high

pressure

alarm L: Atomization steam

low

temperature

alarm 180

℃

230 H:

temperature

high

temperature alarm 4.2 4.2

Boiler auxiliary interlo ck prot ection value auxiliary equipment. Name

1.

Units

LL

L

N

H

HH

Remarks

Air

preheater N: open allowable; Bearing temperature

<70

℃

70

85

H:

alarm

profit

Preheater

Air

open;

HH: Air Preheater trip 1）

L: alarm, delay 10Sjum r/min

0. 5

0. 8

1

to Motor, then after 3 s

Rotation

open

Date: Date: 2008-09-15


Page 35

stand-by

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL LL: air preheater trip L: after lower than L

2） Inlet flue gas

150

℃

419

allow stop Air Preheater

temperature 3） Temp. of primary

378

℃

478

H: fire alarm

and 4） Soot blowing

℃

If L: higher than L allow

130

soot blowing

Steam temp. 5） Soot

L: Mpa

1. 04

1. 2

blowing

soot

blower

allow soot

blowing

Working pressure

steam 6） 2． ID Fan Lubrication flow Lubrication pressure

L/min

3

Mpa

0. 12

>3

4

ID

0. 4～

L:

alarm;

pressure

0. 86

LL:

alarm, delay 30S trip

0. 6

Mpa

open

allow;<3alarm

LL: Hydraulic oil

Fan

stand-by

pump

automatic;

2. 5

L:ID Fan open allow Oil filter differential

Mpa

0. 35

H: alarm

pressure Oil position of oil bank

Bearing

blanking ID Fan open, mm

150 alarm

℃

Date: Date: 2008-09-15

60～70


90

110

Page 36

H: alarm;

Rev. : A


SEC


temperature Temp. of Oil

HH: ID Fan trip L: open heater ℃

in Oil Bank

30

30-40

40 H: close heater

Oil cooler outlet

＞45℃,alarm

45

℃

temperature

Surge

+100

Kpa

delay

on site

85

95

130

135

℃

80

90

℃

90

100

℃

130

140

mm/s

8

11

℃

temperature Stator coil temperature

90

℃

ID

Fan trips

Motor bearing

15S

H:

alarm,

prohibit

open; HH: trip

H:

alarm,

prohibit

open; HH : trip

3．FD Fan Bearing temperature Motor bearing temperature Motor coil temperature Vibration Lubrication pressure

L: alarm; Mpa

0. 35 LL: alarm, trip

FD fan lubrication

L/MIN

>3FD

3

allow;<3alarm

flow

Date: Date: 2008-09-15


Fan

Page 37

Rev. : A

open


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL L: stand-by pump open

FD fan hydraulic oil

Mpa

0. 86

automatic

2. 5

pressure

H:FD Fan open allow

FD fan differential

Mpa

0. 35

H: alarm

pressure FD fan oil location of oil

mm

150

L: alarm

tank FD fan temp. of oil in oil

L: open electric heater 30

℃

30-40

40 H: close electric heater

tank FD Fan oil cooler outlet

＞45℃alarm

45

℃

temperature FD fan

delay 15S and FD Fan

KPa

On site

℃

80

90

℃

90

100

℃

130

140

mm/s

8

11

trips

surge 4． Primary air fan Bearing temperature Motor bearing temperature Motor Motor coil co il temperature Vibration Outlet air pressure

Pa

Date: Date: 2008-09-15

2400

L:

3000

alarm,

Pulverized coal


Page 38

Rev. : A

LL:


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL trip, N: adjustment

5．Pulverized coal exhauster Bearing temperature Motor bearing

℃

80

90

℃

90

100

℃

130

140

mm/s

8

11

℃

80

90

℃

90

100

℃

130

140

mm/s

8

11

temperature Motor Coil temperature Vibration 6．Vent air fan Vent fan bearing temperature Vent fan motor bearing temperature Vent fan motor Coil temperature Vibration Vent temperature

L, H: alarm; ℃

90

110

120

130 HH: Stop Vent fan

High temp. for produce

℃

300

700

800

L, H: alarm

pulverized Bag type filter

150

℃

Date: Date: 2008-09-15


Page 39

Rev. : A


SEC


temperature 7．Mill Mill Lubrication pump outlet

Mpa

H: Open safety valve

1. 035

at lube oil pump outlet

main pipe pressure HP oil pressure

Mpa

0. 02

1. 8～23 Mill open Jacking oil pressure

Mpa

allowable ; HH: Open

1. 5

Safety valve at jacking oil pump outlet

Bearing rotation oil

Mpa

3

pressure N: Mill open allowable; Bearing temperature

℃

45

<85

65

70

H: alarm HH: Mill trips

Mill small

N: Mill open allowable

gear ℃

<77

77

88

H: alarm

Bearing HH: Mill trips

temperature Temperature of reduction

℃

<85

85

90

gearbox Motor bearing temperature

N: Mill open allowable H: alarm HH: Mill trip

H: alarm ℃

Date: Date: 2008-09-15

<80

80

90 HH: Mill trips


Page 40

Rev. : A


SEC Motor coil temperature

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL H: alarm <120

℃

130

140 HH: Mill trips

＞ Lubrication temp

LL:

opening ℃

24

27

32

46

49

allow Lubrication

pump; electric

L:

put

heater;

N:

stop electric heater; H: Lubrication filter differential

MPa

0. 15

L/min

30

L/min

60

0. 25

L: alarm;

pressure Lubrication flow Reducer oil supply flow Cooling water flow

m3/h

L: alarm

＞

15

Mill

open

Mill

open

Mill

open

allowable

Temperature of

L:

mill

＜

250

allowable

inlet primary

＞

Mill inlet Primary air

Kpa

3

L:

allowable

11

pressure

＞H: Mill trips

Classifier outlet primary

H:

L: Mill open allowable; ℃

100

150

175

air temp.

H: delay 3min Mill trips

Differential

＜ N:

pressure of

Kpa

3. 5

feeder

4. 5

non-drive Inlet

≥H:

and classifier

15M

Date: Date: 2008-09-15


Page 41

open

coal

allowable; alarm, delay and

Rev. : A

Mill


SEC


outlet primary air Differential pressure of drive Inlet and classifier

＜N: open coal Kpa

3. 5

4. 5

feeder allow;≥ allow;≥H: alarm, delay

outlet primary

15M Mill trips

air Mill

＞H: Require changing

Lubrication station strainer

Kpa

207

242

differential

the strainer;

＞HH: go bypass

pressure 8． Boiler water circulation pump pump inlet

L:

outlet

pressure alarm

differential

Mpa

0. 10

differential

0. 14 LL: Low differential

pressure

pressure trip H:

Motor room

Low

high

temperature

alarm 55

℃

temperature

60 HH: high temperature trip

9． Air compressor Compressed air main pipe

Mpa

0. 4

0. 55

0. 75

pressure Air

L/LL:

alarm,

open

stand-by

shunt

compressor Mpa

Date: Date: 2008-09-15

0. 7


0. 8

L: load, unload

Page 42

Rev. : A

Air


SEC


compressor vent pressure Air compressor cooling water

50

℃

outlet temperature 10．Soot blower Soot blowing steam supply

Mpa

3. 0

3. 5

LL: alarm

pressure Drain

H: close drain valve

280

℃

temperature

and allow soot blowing

Steam air preheater Water level of drain tank

mm

Date: Date: 2008-09-15

200

300

550


800

900

Page 43

Rev. : A


SEC 5


Start-up

5.1

Basic Regular

5.1.1

Before the start-up of the new erected or overhauled boiler, boiler, the trial operation, test and

equipment acceptance of main equipment and auxiliary equipment should be finished. Before start-up of the boiler having minor repairs, the trial operation and test and equipment acceptance of the repaired equipment should be finished. 5.1.2

After major or minor repairs, the shift supervisor supervisor should have the final report about

improved items of equipment and instruments after finishing system change. 5.1.3

Choose the right method of start-up

5.1.4

If the following arbitrary arbitrary conditions occur, occur, the start-up boiler should should be prohibited:

5.1.4.1

If the repair work of the system or equipment affecting the boiler start-up is not finished or work sheet is not canceled, inspection test and trial operation is not acceptable.

5.1.4.2 5.1.4.3

Interlock, protection and trip test are not performed. DCS system is not in service service affecting the operation and monitoring of the units.

5.1.4.4 Thermal control main instrument. For e.g., main main steam temperature, main steam steam pressure, reheat steam temperature, reheat steam pressure, drum water level, furnace pressure, feed water flow and steam flow can’t be put in service. 5.1.4.5 5.1.4.6

Quality of boiler water can’t reach the requirement. FFCS can’t be put in service.

5.1.4.7

Thermal control signal system can’t be put in service.

5.1.4.8

The safety valve system for main boiler auxiliary system (e.g. Safety valve, ERV valve, drum emergency drain valve, burning oil Electromagnetic valve) are not in service.

5.2

Repair Repair test and acceptance inspecti on

5.2.1

Requirement of acceptance inspection refers to acceptance inspection procedures in

instructions of boiler professional overhaul 5.2.2

Acceptance inspection inspection after repair should be executed acc. to scattered scattered trial operation

acceptance inspection and system trial operation acceptance inspection and whole start-up acceptance inspection. 5.2.3

All acceptance inspections of thermal control interlock test are confirmed by static test

method.

Date: Date: 2008-09-15


Page 44

Rev. : A


SEC 5.2.4


All auxiliary scattered trial operation acceptance inspection is is through acceptance

inspection of motor empty operation and the method with auxiliary equipment operation. 5.2.5 5.2.5.1

Classification of repair test First type of test: A.

Hydraulic test of boiler body. body.

B.

Furnace cold air dynamic field test.

C.

Procedure control test for soot blower and blowdown.

D.

FSSS, CCS cold position simulation test.

E.

Safety valve setting test.

F.

Each rotation machine Single logic test.

G. 5.2.5.2

Air leaking test of boiler body. body.

Second type of test: A. Interlock test of Boiler rotation machine (including milling system). B. Accidents button Test Test of Boiler rotation machine. C.

5.2.5.3

5.2.5.4

Single protection trip test of Boiler rotation machine.

Third type of test: A.

Main valve, duct damper single test.

B.

Each intermittent work, intermittent test.

Test requirement: A.

All tests should be done after overhaul.

B.

Before starting the units, minor repair repair,, sudden inspection inspection and the the second and and third type of test should be done. If necessary, the first type of test is also required.

C.

Make the associated test when when the equipment is abnormal.

D.

HP motor is usually done the static test

E.

The responsible department should write a detailed testing procedure. They shall report it to higher authorities for approval and the test result with signature the

Date: Date: 2008-09-15


Page 45

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL relevant departments authorized is also required.

F.

Make the detailed record record for the test. Any issues should be reported to the relevant depart and dealt with till acceptable.

G.

Each intermittent work and intermittent switching test is required acc. to the relevant requirement.

5.2.6

Boiler Hydraulic test

5.2.6.1

The over-pressure test should should be performed if any of the following situation occurs(Working pressure test first):

1） After major repairs or replacement of the heating surface (replacement of water wall tubes is more than 50%, replacement of any components of superheater, reheater, economizer and major repairs of drum). 2） Resume operation after shut-down for more than 1 year. 3） Boiler pressure is seriously more than 1.25 times of working pressure. 4） Large deformation of heating surface occurs after serious shortage of water. 5） Acc. to the operation status, the reliability of safety equipment is suspected. 6） After major and minor repair or repair of local heating surface of boiler, working pressure test should be done. 5.2.6.2

Boiler Hydraulic test pressure value is as following: Primary system

Secondary system

Working pressure(MPa)

20. 5

4. 5

Overpressure test(MPa)

30. 75(1. 5 times)

6. 75(1. 5 times)

5.2.6.3

Boiler Hydraulic test scope :

1） Primary system includes all the pipes, heating surface and header from non-return flap at feedwater pump outlet to HT superheat er outlet (i.e. including feedwater pipe, economizer, drum, water wall, LT superheater, HT superheater, connecting pipes and header). 2） Secondary system includes all the pipes, heating surface and header from reheater inlet to

HT

pipes

reheater

outlet

and header).

(i.e. including

LT reheater, HT reheater

connecting


SEC

Date: Date: 2008-09-15



Page 46

Rev. : A


SEC


3） At working pressure, the following valve should be check secondary damper firstly and then primary damper(Acc. to the te st procedure): A.

Lower furnace drum drain valve.

B.

Drum Air damper.

C.

Economizer outlet pipe Air damper

D.

Superheater Air damper.

E.

Reheater Air damper.

F.

Superheater drain valve.

G. Reheater drain valve. H.

Thermal control instrument pipe valve (If there is not any secondary damper only do

pressure test for primary damper). 4） At working pressure, pressure test will be only done for primary damper of the following pipe valves: A.

Soot blowing steam primary damper. damper.

B.

Primary attemperator drain primary damper.

C.

Secondary attemperator drain primary damper.

D.

Reheater attemperating water primary damper.

E.

Chemical sample primary damper.

F.

Intermittent blowdown primary damper.

G. Blowdown primary damper. 5 ） For

blowdown

firstly. firstly.

system

Open completely

at

the

furnace

bottom,

close

motorized

valve

the former manual valve to do pressure test. If the test is

acceptable, close manual valve to do pressure test. 6 ） Working pressure test with remote and local water level instruments, i.e. close the remote water drain

valve

level

instrument

drain

valve

and

local

water

level

instrument

and completely open other damper, test water water level instrument drain

valve; then close water level instrument and try water side and steam side primary damper.

Date: Date: 2008-09-15


Page 47

Rev. : A


SEC


7） At working pressure, perform pressure test with drum safety valve, check seal conditions but the valve stem should be jammed by the feed screw to prevent trip. Other superheate r and reheater safety valve should be jammed and isolated. 8） Open economizer re-circulation damper when it is fed water. if it is finished close the damper. 9 ） Perform

the

instrument pump

overpressure

and isolate

motor

and

or

Boiler

test, jam

withdraw

each e ach

remote

safety

valve.

and

local

Boiler

water

water

level

circulation

is thoroughly isolated. Boiler water circulation pump

plugging plate for overpressure test should be installed. 5.2.6.4

Conditions for Boiler Hydraulic test :

1） All

steam

should should 2 ） After should

pipe

valve

be acceptable; be check,

in

pressure

Motorized

test, valve,

after

heating

pneumatic

surface valve,

repair control

work, valve

finished adjustment. And acceptance inspection is acceptable. installation

and

reset

of

steam

system

pressure

instrument

be finished. Primary system pressure pressure test is confirmed confirmed by drum local pressure

instrument on roof. Secondary system pressure test is confirmed reheater inlet local pressure. Pressure instrument accuracy is 0.5. The span should meet the test requirements(span shall be 1.5 to 2.0 times of overpressure test pressure). 3） Each system Suspenders, springs and hangers have been adjusted and forced smoothly. 4） Each valve, Setscrew, Suspenders (Hanger) shouldn’t be fixed too tightly before hydraulic test. 5） Expansion indicator correction is finished, and direction is correct. 6） Boiler platform, stairs path is Unobstructed , remove all impeding scaffolding 7） Drum wall temperature measurement points is corrected and can be put in service. 8） The scaffoldings of each checking parts are safe and firm with adequate light. 9） Feedwater pump trial operation is acceptable. 10） Pressure test provisional pipes are installed and checked acceptable. 11） HP bypass “quick open ” condition is compulsive. 12） Producing water by Chemical water system is in service. Chemical feed system and


SEC Date: Date: 2008-09-15



Page 48

Rev. : A


SEC


chemical is prepared. Water quality and chemical is checked acceptable. Water used by primary

system

Water

used

is

about

550t

by secondary

dematerialized

water.

Test

(about

system s ystem

water

2

times

water

is

of

water

about

is dematerialized

water

Volume

180t

).

adopting

with

200

ppm

ammonia+ hydrazine treatment and PH value is higher than 10. 5. 13） Emergency pressure drop method must be prepared. Intermittent blowdown valve and motorized and

pipes

drain

valve

at

lower

furnace

drum

are

well

stand-by

are unobstructed to do quick pressure drop if overpressure.

14） Set up local pressure instrument of drum and reheater and make control room with well communication. 15） When hydraulic test, circumstance temperature is usually higher than 5℃,otherwise make the anti-freeze measures. Water temp. from 30 to 70 ℃ is suitable (not lower than 20℃). 16 ） At

working

(installation)

pressure

hydraulic

test

shall

be

chaired

by

repair

tech. responsible staff. Overpressure test shall be chaired Chief

Engineer and designated person in charge. 17） All test staff should follow a clear division of labor, subject to a unified command and insist on jobs. 5.2.6.5

Introduction of hydraulic test method: Open motorized feedwater pump and fill the water through economizer from main feedwater system. One side of superheater secondary attemperator water or main feedwater bypass pipes raise pressure, but these two methods can’t be performed at the same time. Only one can be selected. Reheating system feeds water to Reheating system through attemperating water pipes. Close main feedwater pipes valve and then do pressure test. Test should be performed in order of high to low, i.e. Hydraulic test of steam system, then hydraulic test of reheater system. If for

5.2.6.6

all

tests

are

finished,

do

pressure

drop

and

drain.

some secondary damper and primary damper.

Hydraulic test steps

1） Open all air damper of Drum, Superheater and reheater system 2） Close all drain valve of Superheater and reheater system.

Do

pressure

test


SEC

Date: Date: 2008-09-15



Page 49

Rev. : A


SEC


3） Besides cold

drain

primary

damper

of

intermittent

blowdown,

continuous

blowdown,

reheater, close all drain primary damper an d secondary damper. 4） Close boiler main steam valve and main steam bypass valve, close primary drain valve, secondary drain valve in front of main steam damper. 5 ） Before hydraulic test, 3 boiler water circulation pumps should be fed water to exhaust steam acc. to t o the manual, (Notice: Hydrazine can only be

fed to

deaerator, not to condenser). After filling water and exhausting air, air, open outlet nonnonreturn flap of 3 boiler water circulation pump. 6）

Acc. to normal filling procedure fill the boiler to the visible drum water level. Stop filling through feedwater pipe and change to filing through superheater water spray secondary attemperator till air dampers of drum and superheater is continuously overflowing the water. Close air dampers of superheater and drum and stop filling.

7）

Forbid filling the boiler through feedwater control system and superheater water spray attemperating at the same time.

8） Check HP

bypass

damper

at

“closed

”

condition

and

quick

open

condition

is been compulsory. compulsory. 9） Check reheater system pressure zero. 10 ） Completely some

side

open

motorized

pump

recirculation

damper

and

valve

of

of secondary superheater attemperator water and motorized isolation

damper. Micro-open motorized control valve. Make use of the open position of the motorized control valve and feedwater pump rotation speed to control pressure rising speed ≯0. 3Mpa/min. 11） Before filling, after filling water is full and when working pressure is reached, the record of indicators of expansion system shall be checked. 12） If whole pressure rising reaches 1～2Mpa, 10M Pa and 75％ of working pressure, suspend system.

if

it

pressure is

rising

and

do

primary

check

for

Primary

normal, continue raising pressure. if working pressure is

approached, decrease pressure rising s peed ≯0. 2Mpa/min to prevent overpressure. 13 ） If

primary

monitor 5min valves.

system

local pressure pressure

drop

pressure

reaches

instrument

of

20.

5Mpa,

drum,

stop

record

pressure the

rising,

status

of

and comprehensively check each heating surface and pipe





Page 50

Rev. : A


SEC


14） Acc. to the scope of pressure test, switch the primary valve and secondary valve of primary system. Raise pressure again to 20. 5 Mpa, record the status of 5 min pressure drop and check each first valve etc. 15） If overpressure test is required, after above check result is normal, confirm boiler water circulation pump motor and boiler water are isolated and boiler water circulation pump plugging plate for overpressure test is installed. Drum water level instrument trips. After the

staffs

withdraw

the

scene,

with

pressure

rising

speed

≯ 0.

1Mpa/min raise the pressure to 30. 75Mpa .Keep 10～20min and then open final superheater air valve at roof or cold superheater drain valve to do the pressure drop. Pay attention to pressure drop speed ≯0. 1Mpa/min. After pressure is dropped to 20. 5Mpa, close pressure drop air valve or drain valve, record the status of 20 min pressure drop, and comprehensively check. 16）

If pressure test is acceptable or check abnormal, open superheater drain valve, drop the pressure to zero and pay attention to controlling pressure drop speed≯0. 3～0. 5Mpa/min.

17） When hydraulic test of primary system is finished, do hydraulic test of reheater system. 18 ） Use

reheater

attemperating

water

pipe

to

fill

the

reheater,

after

water

overflows at reheater outlet air damper, close all reheater reheater system air dampers, open open the first reheater exhaust steam valve and stop filling water. 19 ） Control feedwater pump rotation speed. Through reheater attemperating water control valve

with

≯ 0.3Mpa/min

pressure

rising

speed

and

pressure

raise

the

to

1

MPa. Comprehensively check reheater system. 20） If the t he check result is normal, raise pressure to 4. 5Mpa, stop pressure rising, isolate reheating system, monitor local provisional pressure instrument 5min, record the status of pressure drop and comprehensively check reheating system. 21 ） Acc. to scope of pressure test, switch the primary valve or secondary valve of primary system, do pressure rising again to 4. 5 Mpa and record the status of 5 min pressure drop. 22）

If the overpressure test is required, after above check result is normal and the staffs


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL withdraw the scene. With pressure rising speed ≯0. 1Mpa/min raise the pressure to 6, 75Mpa. Isolate reheating system, keep 10～20min and observe changes in pressure.

Date: Date: 2008-09-15


Page 51

Rev. : A


SEC


23） Micro-open final reheater air valve at the roof to drop pressure, monitor provisional pressure instrument and pay attention to pressure drop speed ≯0.1Mpa/min when pressure reaches working pressure in the overpressure test. When pressure drop to 4. 5Mpa, close pressure drop air valve, record the status of 5 min pressure drop and comprehensively check 24） When reheating system pressure test is acceptable, open final reheater air valve at roof or

reheater

drain valve

to drop

the

pressure

to

zero,

monitor provisional

pressure instrument and pay attention to pressure Drop speed ≯0. 3~0. 5Mpa/min. 25） When pressure test of reheating system is acceptable, drop pressure to zero and open superheater and reheater drain valve to drain. For e.g., if Boiler needs draining, open lower furnace drum blowdown valve to comprehensively drain for drum and water wall. 5.2.6.7

The key position for hydraulic test check:

1） Whether the valve of each system after repair is leaking. 2） Whether joint of safety valve is leaking. 3） Whether and

each

heating

surface,

especially

the

position

having

repair

work

the position requiring requiring strict strict check check is leaking and deformation.

4） Whether each expansion indicator, pipes hanger has abnormal expansion. 5.2.6.8

Hydraulic test acceptable acceptable standard(Hydraulic test meet the following following requirements, requirements, i.e. acceptable ):

1） There are no leaking traces of water on pressure parts, metal wall and welding sea m. 2） At primary system working pressure, when stop raising pressure., pressure drop in 5min is

<0.

5Mpa.

At

secondary

system

working

pressure,

when

stop

raising

pressure, pressure drop in 5min is ≯0. 25MPa. 3） No obvious deformation of pressure parts. 5.2.6.9

Boiler hydraulic test attentions :

1） When boiler is fully filled water, before pressure rising, jam drum and superheater safety valve; When doing hydraulic test for secondary system, jam reheater safety valve; when do overpressure test, jam each safety valve. 2） If reheating system has provisional pipes, the pipes should be purged before installation,





Page 52

Rev. : A


SEC


each welding seam should be check acceptable and welded by acceptable welder. 3） Feedwater pump reach the top pressure, completely open recirculation valve and strictly monitor operation conditions to ensure feedwater pump operation safe. 4） Each drain valve of main steam valve outlet drain, cold reheater and hot reheater should be opened. Immediately check whether there is any water is drained to prevent cylinder from water. 5） Each drain valve at main feed water equipment side should be checked whether the valve is strict leaking and pay attention to the water entering into HP heater at pressure rising. 6）

When raising pressure, monitor attemperating water flow. If flow is big and pressure rise is slow, system leaking may be serious. Check the t he cause intermediately.

7） Boiler filling shall be performed acc. to filling requirement. 8） Monitor drum wall temp.>20℃ in the test and differential temp.≤ temp.≤50℃. When drum is checked, heating surface wall temp. should be ≤49℃. 9 ） After test, open drain valve and air damper firstly to drain. If drain is finished, dismantle plugging plate valve. Because there is no drain pipe in front of the plugging plate valve, most of the water can’t be drained. When dismantle plugging plate valve, firstly ease the plugging plate, let the water leak slowly form plugging plate valve to prevent steam pipes from full water and then open drain valve of steam pipes to prevent cylinder from water. 10 ） When do the hydraulic test, specified staff should monitor pressure instrument. Drum local Emergency

and

remote

pressure drop

pressure pipes pip es

instrument

valves

shall

should be

be

often

unobstructed.

checked.

The

valves

should be operated by specified person to prevent overpressure. 11） When do the pressure test, stop all welding work on boiler body, prohibit opening valve and striking on the pressure parts arbitrarily. arbitrarily. 12） Scaffoldings of each checking parts are complete. The path is unobstructed and full of light. 13 ） Specified strictly

person

should

be

responsible

for

pressure

rising

to

prevent overpressure acc. to to local pressure. When pressure reach10% of test

pressure, correct local pressure instrument and control pressure instrument. When the differential pressure is large, contact with the relevant person to deal with it.





Page 53

Rev. : A


SEC


14） When do hydraulic test, the relevant person should follow a clear division of labor, subject to a unified command and set a clear and reliable communications. 15） Only test staff can be permitted in to the scene. 5.2.7

Boiler safety valve check

5.2.7.1

Conditions and requirement for safety valve check.

1） After major repair of boiler and repair or replacement of the valve, the hot check must be performed for safety valve to maintain the reliability. reliability. 2）

Safety valve set value is performed as following:

Setting Setting pressure No.

Location

Type of valve

Specification (inch)

Design Blow down

Opening reseating Differential MPa MPa pressure%

Discharging

temp

capacity t/h

℃

1

DRUM

HE-96W

3 M2 6

20. 50

19. 89

3

291. 697

369

2

DRUM

HE-96W

3 M2 6

20. 60

19. 78

4

293. 924

369

3

DRUM

HE-96W

3 M2 6

20. 70

19. 67

5

296. 175

369

HCI-98W

3 L2 6

18. 70

18. 14

3

153. 860

557

HCI-46W

6 RR10

4. 50

4. 37

3

253. 574

313

HCI-46W

6 RR10

4. 60

4. 46

3

259. 366

313

HCI-48W

6 RR10

4. 10

3. 98

3

187. 347

554

HCI-48W

6 RR10

4. 20

4. 07

3

191. 810

554

2..5″ 2..5″×4″

18. 50

18. 13

2

166

557

4

5

6

7

8

Reheater outlet Reheater outlet Reheater outlet Reheater outlet Reheater outlet Superheate

9

r outlet(ERV) 3）

E0L121N7BWR A5P1

Before igniting the boiler, the safety measures to prevent the turbine from the steam must be done.

4） The leader from tech. dept. and safety dept. should be on site when checking the valve.

Date: Date: 2008-09-15


Page 54

Rev. : A


SEC


It is conducted operators

by

chief

engineer,

chaired

by

repair

staff

in

charge

and

participate in it. When test, the relevant person should follow a clear division of labor, subject to a unified command to prevent overpressure. 5） Set a convenient, clear, clear, reliable communication. 6） Strictly close boiler main steam valve, turbine main steam valve, IP main steam valve and

HP

drain

valve

non-return

flap

etc.

Open

turbine

main

steam

drain valve, cold reheater drain valve and hot reheater steam drain valve. 7） Turbine turning shall be put in service before the unit gets any load. 8） Drum water level high signal is compulsory (Drum water level protection releases ). 9） HP bypass quick open condition is compulsory. 10） When check safety valve, pressure indicator of local pressure instrument and before operating control panel of drum, superheater, reheater and turbine main reheater steam must be corrected. The local data and the date on the control panel shall be

same. When

instrument

of

there

local

are

errors

between

attention

to

data

on

pressure

pressure instrument and control room CRT, CRT, local pressure

instrument should be followed. In the process paid

the

correcting

local

and

of

pressure

rise

and

checking,

before operating the panel. Specified

person monitor the pressure and contact relevant staff. 11）

Checking safety valve shall be performed when boiler is started only or the load of

unit is only 10%—20% ECR load. 12） Pressure rise of boiler shall be performed acc. to pressure rising curve. In the process of pressure rise, strictly monitor tube temperature of heating surface in the allowable value. 13） When shall

check,

monitoring

and

adjustment

for

the

burning

and

water

level

be strengthened strengthened to prevent full water, water, inadequate water and overpressure.

14） When safety valve is being checked, if the valve is opened, the staff shouldn’t approach safety valve. 15） When

accidents

occur,

stop

checking

and

acc.

to

relevant

accidents

treatment requirement perform treatment. 16） When check, strengthen the contact and strictly finish each work acc. to each division of labor.





Page 55

Rev. : A


SEC


17） Check for safety valve is performed in the order of high action pressure to low. Unchecked safety valve should be isolated. 18） When check safety valve, firstly check by the opening aid checking equipment. If it is acceptable, actual opening check can be performed. 19） When check ERV valve, actual opening check after control return circuit check is acceptable. 5.2.7.2

Drum and superheater safety valve check :

1） Trip water level protection. 2） Open HP bypass and put HP bypass in automatic service to ensure cooling the reheater system. Open steam exhaust valve at reheater outlet. 3） Control boiler combustion rate, put 4 to 8 oil burners in service. 4） When main steam pressure reach 10bar,stop pressure rising, inform the repair staff of hot fixing screws and comprehensively checking welding, valve, man hole and hot expansion conditions of pressure parts. If

check is finished, after repair staff

Informing of raising pressure, continue raising pressure. 5） When turbine condenser vacuum reach 300mbar, put LP bypass in service. 6 ） When and

pressure stability

reaches

75 ～ 85 ％

of

safety

valve

test

pressure

is maintained, repair staff check safety valve by hydraulic check

implement, record opening pressure and reseating pressure till it is checked acceptable. 7） If informed of continuing pressure rise, put bypass control valve in “manual“ control. Manual

control

close),slowly

the

position

raise pressure to

of safety

indicator valve

of

HP

design opening

bypass value

(mustn’t and then

keep it. Repair person shall adjust it. 8） After safety

opening

safety

valve,

major

open

HP

bypass

manually

and

let

valve reseating.

9） Record opening pressure and reseating pressure of safety valve. 10） If the action of safety valve is incorrect and adjustment is required, repair staff shall requires pressure drop or drop pressure to 75～85%of rated pressure. And then adjust the safety valve acc. to manufacturer requirement.





Page 56

Rev. : A


SEC


11） If adjustment is required for more than 3 times, the adjustment should be performed after safety valve is cooled. In cooling period, the staff can check other safety valves, but need locking the cooled safety valve. 12） When check safety valve, if safety valve has no action, keep pressure stable. 13）

Raise pressure to safety valve opening pressure, pop safety valve. When safety valve

has action, record the data of opening and reseating pressure. 14） Using the same method to check each safety valve of drum and each safety valve, ERV valve of superheater in the t he order of high open pressure into low. 15）

If safety valve check is finished, all safety valve lock shall b e dismantled and the safety

valve should be in service. 5.2.7.3

Reheater safety valve check:

1） If safety valve of drum and superheater check is finished, resume water level, control the combustion and control boiler pressure drop speed. If pressure drops to 6～8MPa, use HP, LP bypass or units load to control the setting pressure of safety valves of reheating steam to reheater inlet. Stabilize the combustion and maintain stable stable pressure. Repair staff should check reheater safety valve. 2） Adjust opening and reseating pressure of safety valve to 75～85%of test pressure. Other operation and record refer to drum and superheater safety valve. 3） Using same method, check each reheater inlet safety valve and outlet safety valve in the order of high opening pressure to low. 4）

If safety valve check is finished, all safety valve lock shall be dismantled, put safety valve in service.

5.2.7.4

If safety valve check is finished, finished, acc. to the shift supervisor’s supervisor’s order shut-down the boiler or raise temperature and pressure t o start up the boiler.

5.2.7.5

If safety valve check is finished, inform thermal control staff of releasing signal of compulsory.

5.2.7.6 1）

Attention for safety valve check: When check safety valve, HP bypass can’t be closed completely to prevent reheater “burning”. Also LP bypass can’t be closed completely; otherwise reheater outlet steam exhaust valve should be opened.





Page 57

Rev. : A


SEC


2） In order safety valve,

to

decrease

safety

valve

center

erosion,

after

the

action

of

Pressure Drop should be performed to let safety valve reseating. 3） When

check

Prevent 4）

full

safety

valve,

fluctuation

of

drum

water

level

is

large.

or inadequate water accidents lead by false water level.

When safety valve takes action, it may lead differential pressure and current fluctuation of boiler water circulation pump. One boiler water circulation pump can be closed acc. to the situation (pay attention to it and fill the water in time).

5） Each Superheater metal temperature shall be controlled in allowable scope. When main steam flow ＜ 150T/H, profit using attemperating water. When air steam flow≥ flow≥150T/H, if attemperating water is required, control the speed not too fast. Control attemperating water in min. scope to prevent temperature from sudden drop and too much stress to damage the equipment. 6）

Checking jobs.

monitoring

Prepare necessary

Subject 5.2.8

and

to

a

instrument

repair

implement

staff and

follow

a

implement

clear to

division prevent

of

noise.

unified command and insist on jobs.

Main valve and flue gas damper test

5.2.8.1

Test attention:

1） All motorized valve, Electromagnetic valve, control valve, pneumatic valve and flue gas damper should be done the reliability test before start-up of boiler. boiler. 2） Before test, confirm that there will be not any corresponding movement of the medium and any repair work etc . Safety of equipment, pipes and duct, and personal security can’t be affected. 3） Before test, do the manual test to confirm machinery part normal. 4） 5.2.8.2 1）

Specified staff is responsible for monitoring. Acceptable standard for test. When doing local manual operation, opening and closing operation is flexible, accurate and reliable.

2）

Opening and closing operation is flexible and limit switch action is accurate when doing local electric operation.


SEC

Date: Date: 2008-09-15



Page 58

Rev. : A


SEC


3） When DCS operator does the test, opening and closing operation is flexible and limit switch action is accurate. The data on the instrument indicator is consistent with local actual location. 4） For motorized intercept valve which can be interrupted do the interruption test. 5.2.8.3

Test method and steps:

5.2.8.3.1

Motorized valve check :

1） Confirm that test valve don’t affect operation system. After repair work, contact with thermal control staff staff and repair staff staff should be on site. 2） Valve Valve power has bee n in service .Signal and indicator is correct. 3） Confirm valve at close position showing the corresponding CRT screen. 4） Put

valve manual control at a suitable suitable position of indicator. indicator. (keep travel

from the closing closing direction or opening direction) 5） Motorized test switch is correct. If the valve has “stop” button, test stop function in service. Limit

switch contact

and automatic/manual au tomatic/manual switch

also

should be tested in service. 6 ） Close motorized valve completely and keep remaining travel manually. Thermal control staff determines break contact for closing direction. Correct local instrument and CRT screen in the same indicator, and in closed position. 7） Open

motorized

valve

completely.

With

same

method

adjust

completely

opening remaining travel. Thermal control staff determines breaking signal at opening direction. Correct local instrument and CRT screen in the same indicator, and in opened position. 8） Record completely opening period and completely closing period of motorized valve, travel and remaining travel at opening direction and closing direction. 9） Electric completely open and completely close valve once. Check mechanical dial of position of

indicator, light, signal

right. Opening

and closing

is flexible.

Motor shall automatic trip at the set point, otherwise readjust it again. 10）

If test is finished, put valve in position before test.

11）

Motorized valve check attention: A、 When travel limit switch has faults or valve limit body don’t cooperate with travel





Page 59

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL limit switch well, pay attention to preventing travel limit switch from out of control to damage motor and valve. If necessary replace it.

B、 For non-rising stem valve or rising stem valve whose valve stem is difficult to see, in the adjustment before travel limit switch is set, don’t depend on motor moment protection action or method of hearing motor surplus air sound to confirm valve completely

opened,

completely

closed

position.

Must

manually

perform adjustment. C 、 Confirming direction

principle

of

valve

remaining

travel

:At

closing

after completely closing valve manual open about 0. 5～1 circle(HP

valve low value, LP valve high value ) or acc. to actual conditions confirm that open about 90% of full travel at opening direction and max open position of indicator is 95% of full travel. D、 In valve switch test opening and closing button can’t be put at the same time or the to

switch

can’t

be

turned

from

opening(closing)direction

directly

closing (opening) direction to prevent damaging Motor.

E、 If the valve is moment limit valve, never manually operate it after test. F、 For motorized valve with local, remote control perform full travel test for local an d remote control switch once and the result shall be normal. G、 Motorized valve with interlock will be performed interlock test to make it normal after check is finished. 5.2.8.3.2

Control valve test :

1） Confirm that test valve don’t affect o peration system. After repair work, contact with Thermal control staff and repair staff. 2） Gas source and valve power is sent. Confirm that air pressure direction is normal and opening and closing direction are right. 3）

When

perform

local test,

put control

valve

“manual/automatic”

switch

handle in manual position. With rotation rotation hand wheel open and close the full travel of control valve. travel indicator

The

actual

conditions

must

be

consistent

with

in check process. Change the handle to automatic position.

4） Show the corresponding CRT screen. Manually operate corresponding switch of control valve to separately intermittent and continuous open and close full travel


SEC

Date: Date: 2008-09-15



Page 60

Rev. : A


SEC


test once. Check signal, mechanical dial of position Indicator is consistent with the actual data and control is flexible. 5） Cutting off air test: Cut off air source of control valve, check AO valve automatic closed after cutting off air source. Check AC valve automatic opened after cutting off air source. In air cut-off te st, prevent system operation from affecting. 5.2.8.3.3

Damper test :

1） Before test, carefully check equipment. If repair work is finished, keep the site clean. 2） Confirm that test valve don’t affect o peration system. After repair work, contact with thermal control staff and repair staff should be on site. 3） Send relevant air valve, then power of damper, air source, and put relevant

air pressure

temperature

instrument

instrument,

negative

pressure

instrument,

in service.

4） Signal and mechanical dial of position Indicator are normal. Each damper rotation is good and transmission equipment is also good. 5） Each piece of auxiliary equipment of the system has opening condition. 6）

Operate

corresponding

CRT

separately perform intermittent travel once. Check signal position

indicator

and

screen,

manually

and continuous

direction

consistent

response

opening with

damper

and

and closing

mechanical

dial

full of

the direction correct.

7） There is not any leaking and other abnormal phenomenon in operating pneumatic equipment with flexible action and right direction. 5.2.8.3.4

Air fan moving-blade test :

1） Before test, carefully check equipment. If repair work is finished, keep the site clean. 2） Before test put corresponding hydraulic control oil system in service, control oil pressure pressure normal and then send control power. 3） Rod and pin of executive body are not loose, bended and exfoliated. 4） Local and main control switch control the moving blade. The direction is right and

Date: Date: 2008-09-15


Page 61

Rev. : A


SEC


the action is flexible. Whe n the position of indicator on the CRT screen is from 0~100%, local position should be consistent with it. 5） Record period and angle of opening and closing full travel in the test. 6） In the process of test, when abnormal conditions occur, stop test, check for the cause and solve it and then test again till it is acceptable. 5.2.9 5.2.9.1

Opening, closing and accident accident button test for auxiliary equipment : Test condition and requirement :

1） After auxiliary motorized equipment and control circuit is repaired, must perform test for auxiliary equipment switch and accident button. 2 ） Acc. to repair work requirement, learn the detail in equipment repair content, abnormal situation,

test

that

of mechanical and motorized parts on site is all finished, work-

repair

work

requirement

and

scope.

Check

and

confirm

sheet is recovered and the test condition is had. Then resume relevant system. 3） If empty trial operate the motor, confirm that motor wiring and earthling cables

are complete, backrest wheel disengages and oil quality of bearing

Lubrication position is normal. After check it normal, contact to send the power. In trial rotation pay attention to the correctness of rotation direction of motor. 4） Before trial operation of auxiliary equipment, when motor power is cut off, rotor is without collision collision and blocking, oil position oil quality is normal, cooling water valve, seal water valve

is opened,

outlet

and Inlet instruments of

primary

damper are opened, pump is filling filling water to exhaust air is finished, Inlet valve of centrifugal pump is confirm ed opened, outlet valve of volume pump is confirmed opened, inlet and outlet valve of axial pump is confirmed opened. After all the conditions are normal ,do the test. 5） Auxiliary equipment which can be operated on CRT screen and local operation board should be operated op erated separately. 5.2.9.2

Test method :

1 ） Contact with electric staff to put 6KV rotation machine switch into test position. Before test

check che ck

the

correctness

of

electric,

thermal

control

instrument,

sound and light signal. Confirm operation button and interlock switch is at stopped position.


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL 2） Before trial-operation of coal feeder, coal feeder inlet and outlet valve should be closed

Date: Date: 2008-09-15


Page 62

Rev. : A


SEC


and coal feeder has no remaining coal. 3 ） Switch

on

each

rotation

machine

acc.

to

normal

procedure

(A.

P,

ID

fan, FD fan, primary air fan, seal air fan, mi and coal feeder) once. Each rotation machine status color should be changed from green to red. 4） In the order of the contrary of above sequence on the CRT screen gradually stop each rotation machine. Each rotation machine status color should be changed from red to green. 5） Gradually switch on air preheater, ID fan, FD fan, Primary air fan, and mill and coal feeder. In the contrary sequence locally put accident button of each rotation machine. On color

become

the

CRT

screen

corresponding

rotation

machine

status

yellow, yellow, accident speaker sound alarms. If test is finished reset each

switch. 5.2.9.3

Auxiliary equipment protection test :

1） Test condition and requirement : A.

After units are major repaired or minor repaired and auxiliary electric equipment and control circuit are repaired, must perform auxiliary equipment protection test.

B.

Auxiliary equipment protection test must be performed after auxiliary equipment starting and stopping test and accident button test is acceptable and meet relevant requirement for starting auxiliary equipment and accident button.

C. In the test, 6kV can be only operation power. power. If switch is at test position, 380V auxiliary auxiliary equipment is sent as dynamic power. 2） Test method : A. Stand-by auxiliary auxiliary equipment shunt opening test te st : a)

Acc. to normal normal opening operation, open one piece of auxiliary auxiliary equipment and check stand-by auxiliary equipment having opening condition.

b)

Put auxiliary equipment interlock switch in service.

c)

Turn on accident button to let operation auxiliary equipment trip and send sound and light alarm signal and stand-by auxiliary equipment is automatic opened.

d)

By Using the same method separately test other auxiliary equipment. If test is finished, resume auxiliary equipment to the original.





Page 63

Rev. : A


SEC B.


Low oil pressure shunt shunt opening protection test for auxiliary equipment oil pump : a)

Acc.

to

normal

opening

operation,

open

one

piece

of

oil

pump

and

auxiliary equipment and check stand-by auxiliary equipment having having opening

condition. b)

Put oil pressure pressure protection in service. Thermal control control staff make low oil pressure signal. When oil pressure is lower than primarily value, stand-by oil pump will be automatic secondary

value,

started.

when

oil

pressure

is

lower

than

auxiliary equipment trip and oil pressure data is recorded. If

it doesn’t match the set value, thermal control staff adjust it to match c)

By using using same method separately separately test other auxiliary equipment. If test is finished, resume auxiliary equipment to original condition.

C.

Low water (oil, (oil, Air)pressure shunt opening protection test : a)

Acc. to normal normal operation, open auxiliary equipment and check stand-by auxiliary equipment having opening condition.

b)

When do the low water (oil, (oil, Air) pressure protection, Thermal Thermal control staff made low water (oil, Air)pressure signal. When water (oil, Air)pressure is lower than set value, stand-by and

water

auxiliary

equipment

should

be

automatic

opened

(oil, Air)pressure data is recorded. If it doesn’t match the set value,

thermal control staff adjusts it to match. c)


D.

High temperature protection test for auxiliary equipment bearing a) b)

Acc. to normal opening operation, open one piece of auxiliary equipment. Put temperature temperature protection in service. Thermal control staff staff made high temperature signal.

When

signal

should

sent. When

value,

auxiliary

be

equipment

temperature

is

temperature

high is

primarily higher

value,

than

alarm

secondary

trips. Record oil temperature data. If it doesn’t

match the set value, thermal control staff adjusts it to match. c)


E.

Water level of protection test

Date: Date: 2008-09-15


Page 64

Rev. : A


SEC


a)

Acc. to normal opening operation, open auxiliary equipment.

b)

Put water level protection in service. Thermal control staff makes water water level low analog signal. When water level level drops to some value, alarm signal should be sent. If water level is lower than second value, auxiliary equipment trips. Record water level. If it doesn’t match the set value, thermal control staff adjusts it to match.

c)


F.

Air preheater oil circulation test a)

Thermal control staff staff make guild bearing oil high temp, analog signal, guild bearing oil pump should be automatically open and then make guild bearing oil low temp. analog signal, guild bearing oil pump should be automatically stopped, record oil temp. data, if it doesn’t match the set value, Thermal control staff adjust it to match.

b) 5.2.9.4

Sing same method to support bearing test.

Auxiliary equipment power test :

5.2.9.4.1

Test condition and requirement :

1） If auxiliary equipment is repaired, trial operation must be performed. If trial operation is good and acceptance inspection is acceptable, it can be put in service or stand-by. stand-by. 2） Relevant system is confirmed trip or adopts reliable safety measures. 3） Power

test

of

auxiliary

equipment

should

be

performed

after

auxiliary

equipment opening and closing test, accident button test and auxiliary equipment protection test are acceptable and should meet relevant condition and requirement in auxiliary equipment protection test. 4） Relevant protection around opening auxiliary equipment should be put in service. 5） Operation and dynamic power of auxiliary equipment should be sent. 6） Before trial operation of FD fan and primary air fan, ID fan should be opened to prevent furnace from producing positive pressure. 7） Continuous operation period after repair of air preheater, primary air fan, seal air fan, ID Fan, FD fan is 2—4hour. Empty time of mill should not be more than 10min. Operation period of other rotation machine should be not less than 30min.


SEC

Date: Date: 2008-09-15



Page 65

Rev. : A


SEC


8） When trial operation, relevant mechanical, electric repair staff should be on site. 9） Before trial operation comprehensively check auxiliary equipment. 5.2.9.4.2

Test method and steps:

1） Open Each piece of auxiliary equipment at boiler side in the order of Air preheater, ID fan, Primary air fan, seal air fan, f an, mill and coal feeder. 2） If equipment in trial operation is abnormal, immediately stop checking the cause and solve it and then trial operation can be performed performed again. 5.2.9.4.3

Test acceptance inspection standard :

1） Rotation direction is correct. 2） No abnormal sound, friction and percussive sounds. 3） Bearing temperature and vibration meet in the scope equipment regular value. 4） Equipment system has leaking phenomenon. 5） Equipment output reach nameplate output and motor current shouldn’t be more than rated current. 5.2.10

Boiler rotation mechanical interlock test

5.2.10.1 Interlock action specification: 1） When main motors of 2 air preheaters are stopped, shunt open air preheater auxiliary motor, 2 ID Fans trip and boiler MFT trips. 2） When 2 ID Fans are stopped, 2 FD Fan, 2 primary air fans, seal air fan and milling plant system are shunt tripping. 3） When 2 FD Fans is stopped, 1 ID Fan is shunt tripping, Boiler MFT trips. 4） When 1 Primary air fan is stopped, milling plant system is shunt tripping. 5） When 1 ID Fan is stopped, corresponding side FD Fan is shunt tripping. 6） When 1 FD Fan is stopped, corresponding side ID Fan is shunt tripping. If only one ID and FD Fan is in service, ID Fan can’t be shunt tripping. 7） Mill is stopped, corresponding mill is shunt tripping, hot air valve is automatically closed and cold air valve is automatically opened.

Date: Date: 2008-09-15


Page 66

Rev. : A


SEC


5.2.10.2 interlock test method : 1） Put boiler flue gas system master interlock, air fan interlock and each pulverizing system interlock, air preheater main and auxiliary motor interlock in service 2） Continuously switch on each air preheater p reheater main motor, ID fan, FD fan, p rimary air fan, seal air fan, mill and coal feeder. 3） Close 1 Air preheater and its auxiliary Motor should be shunt and the other rotation machines are normal. switch off 2 Air preheaters, MFT should be performed. Primary air

fan

and

pulverizing

system

shall

shunt

trip.

Trip

rotation

machine

CRT screen status color becomes yellow. Accidents speaker alarms, alarm window lights and reset each trip switch. 4）

Continuously switch on each rotation machine switch. Stop 1 ID fan,

corresponding side FD Fan shunt trip and the other rotation machine is normal. Switch off 2 ID Fan, MFT should be performed. FD Fan and the following each rotation machine should shunt trip. Each trip rotation machine status color on CRT screen become yellow, yellow, accidents speaker alarms, alarm window lights and reset trip switch. 5） Continuously switch on 2 ID Fan and the following each rotation machine. Switch off 1 FD fan, its corresponding side ID Fan shunt trips, the other rotation machine is normal. Switch off 2 FD Fan, MFT should be performed, one side ID Fan, 2 Primary air fan, each rotation machine of pulverizing system shunt trip. Tip rotation machine status on CRT

screen

becomes

yellow.

Accidents

speaker

alarms,

alarm

window

lights and reset each trip switch. 6） Continuously switch on 2 ID Fan and the following each rotation machine switch. Switch off 1 Primary air fan, the other rotation machine is normal. Switch off 2 Primary air fans, MFT should be performed. Each rotation machine of pulverizing system shunt trips. Trip rotation machine status on CRT screen becomes yellow. Accidents speaker alarms, alarm window lights and reset trip switch. 5.2.10.3 Requirement and preparation for rotation mechanical test: 1） Rotation machine with major repair should be performed interlock test and should be not less than 2 hour trial operation. Before trial operation, confirm rotation machine and electric equipment and relevant system has no repair work. 2） Shut valve of 6KV rotation machine, accident button and interlock test will only be static test. Before test contact with thermal control staff, electric staff sends relevant





Page 67

Rev. : A


SEC


operation on test

power

and

instrument

control

power

and

dynamic

switch

is

put

position. 3） When in trial op eration contact with electric staff send dyn amic power. power. 5.2.11

Boiler MFT test

5.2.11.1 Boiler MFT test, thermal machine and electric support test should be chaired by thermal control staff. 5.2.11.2 MFT test items are listed as follows: If meet any following following condition, MFT trips. 1） Control system power can’t be put in service or air pressure for control is not correct (3 get 2 pressure), delay 3s and then trips. 2） No ID fan is in service. 3） No FD fan is in service. 4） No air preheater is in service. 5） Total air flow is lower than the lowest( delay 2s and then th en trips). 6） If water temperature is high and steam exhaust doesn’t exist for more than 6s or water temperature is not high, furnace gas-temperature probe exits or furnace temperature is high (delay 6s). 7） No steam exhaust condition (delay 6s and then trips ) 8） Drum water level is too low (delay 2s then trips) 9） Boiler water higher than

level

is

too

high

(delay

60s),

and

Steam

flow

is

112%MCR. 10） No circulation pump is in service, delay 2s and then trips. 11） Furnace pressure is high or low. 12） Flame scanner cooling air pressure is too low (delay 600s and then trips) 13） Furnace surge is reset, or all flame scanners fail. If they fail, delay 15s, finally burners flame scanners fail. 14） Superheating steam pressure is too high (pressure switch), delay 6s and then trips.





Page 68

Rev. : A


SEC


15） ESP Inlet flue gas temperature is too high, delay 2s and then trips. 16） In load-dump, after delaying T1, steam flow is still higher than x1% of initial flow before load-dump and only 1 circulation pump is in service. 17） In load-dump , after delaying ts(T1 + T2) , steam flow is still higher than x2% of initial flow before load-dump and only 1 circulation pump is in service. 18） Any accident button is put. 19） In load-dump, at least 1 coal feeder control circuit is at manual position and steam flow flow is higher than y%. Notice: above x1, x2, y value is per the data on site or is confirmed by thermal control logical value.

Date: Date: 2008-09-15


Page 69

Rev. : A


SEC 5.2.12


Drum water level test

5.2.12.1 When Drum water level is higher than first value (+100mm) ,send alarm signal. 5.2.12.2 When Drum water level is raised to protecting value value (+200), trigger trigger MFT. MFT. 5.2.12.3 When Drum water level is lower than the first value (-240mm) ,send alarm signal. 5.2.12.4 When Drum water level is as low as the protecting value (-425), trigger trigger MFT. MFT. 5.3

Check and preparation preparation before start-up

5.3.1 5.3.1.1

Mechanical Mechanical ch eck before start-up Before start-up of boiler, boiler, must confirm that installation and repair work has been finished, acceptance inspection is acceptable and all repair work is finished.

5.3.1.2

Each platform, stairs, unobstructed path, railings is firm and integrity, integrity, ground is clean, full of light and fire prevention is complete.

5.3.1.3

No one works in check furnace and duct. Confirm that there is is not any implement left, scaffolding is dismantled., heating surface is cleaned, and refractory belt is complete and not exfoliated. Switches observation hole and checking hole are flexible and closed strictly after checking.

5.3.1.4

Insulation of each system (pipes, vessel etc.) is well, hanger is complete, and instrument is complete and not leaking. Each erosion-proof valve is complete and obstacle is unobstructed.

5.3.1.5

Air valve, damper and valve are complete. Marks are complete and switch is right right and flexible, direction is clear, remote control equipments is firm.

5.3.1.6

Each expansion indicator is complete with right location and pilot graduate is clear and correct. Pointer is without jam and record defaults.

5.3.1.7

Burners have good heat insulation. Duct and blast box has no dash, oil and debris to obstruct expansion of blast box.

5.3.1.8

Burning oil system and steam to purge, oil burners, igniter and control system are complete and can be put in service.

5.3.1.9

The ash handling equipment is available for service, service, soot blower transmission transmission is is flexible, the location is showed correctly, correctly, and at exit position.

5.3.1.10 Furnace gas-temperature probe retracts flexibly and is put in service. service. Furnace flame monitor and cooling system is complete.

Date: Date: 2008-09-15


Page 70

Rev. : A


SEC 5.3.1.11


Local water level is clear and in service, opening and closing steam valve is flexible and not leaking. It is full of light and camera system is complete and can be put in service.

5.3.1.12 Safety valve and ERV are complete, steam exhaust is unobstructed and fixed. 5.3.1.13 Inform dash, chemical, combustion operation staff of comprehensively checking checking each system, preparing for start-up and having the start-up condition. 5.3.1.14 Check for each auxiliary equipment, rotation machinery and auxiliary equipment equipment is acceptable. Mechanical parts is with no jam, Lubrication quality is acceptable and oil is full. Cooling water, seal water and etc. are normal. 5.3.1.15 Check each valve, valve, air valve is in in open position. 5.3.1.16 Raw coal and pulverized coal bunkers are filled and available. 5.3.1.17 HFO is available. The The associated heat tracing and pretreatment system have been checked and are available for service. 5.3.1.18 The ESP is available and ready for service. The rapping and the insulator heating systems are in service. Low temperature or low level alarms are cleared. 5.3.2

Thermal Thermal contr ol and electric check before start-up:

5.3.2.1

In center-control room, there there is full of light and accident lighting lighting is reliable.

5.3.2.2

Each instrument is sent the power, power, operation switch and change-over switch, Light of indicator are complete.

5.3.2.3

Open all transmission and sample valve for signal pipe of measuring instrument instrument and close blow down valve.

5.3.2.4

Alarm equipment, protection panel, control control panel panel and each monitor instrument, record record instrument and printer are normal and put in service.

5.3.2.5

DCS station is normal. The data on CRT CRT screen screen and instrument is consistent with equipment actual status.

5.3.2.6

Check all safety interlock equipment in service. Confirm interlock protection for CCS, CCS, FSSS, PLC, DAS etc. correct.

5.3.2.7 5.3.3 5.3.3.1

Each piece of auxiliary equipment Motor Motor has good insulation. insulation. Test and prepare before stat-up : All the main test before start-up of boiler: 1.

Opening, closing position test for valve and damper

Date: Date: 2008-09-15


Page 71

Rev. : A


SEC 2.


Static opening, interlock

closing,

change-over

and

accidents

button

test

and

logical test. 3.

Gang test for auxiliary equipment.

4.

Gang test for auxiliary equipment lubrication pump.

5.

Air preheater drive equipment test.

6.

Boiler interlock protection test i.e. MFT condition test.

7.

Turbine, boiler and generator big interlock logical protection test.

8.

Other test acc. to repair conditions.

5.3.3.2

Confirm that each valve, air valve, damper meet the requirement.

5.3.3.3

Each auxiliary auxiliary equipment power and operation power are sent. Each instrument get power and control power.

5.3.3.4

Put industry water system in service, check operation normal. normal.

5.3.3.5

Open air compressor system, check system operation normal, and keep compressed compressed air pressure above 0. 65Mpa.

5.3.3.6

Contact with neighbor unit or start start up boiler boiler to supply auxiliary steam header with with air, air, and keep pressure about 0. 525Mpa.

5.3.3.7

Check and put oil circulation of burning oil system in service. Put purging steam in service to heat the pipe and drain to clean.

5.3.3.8

Put water seal at boiler bottom and fully fill water.

5.3.3.9

According to oil temp conditions, put electric heater in service. If oil temperature is consistent with the regular, regular, open oil equipment of each mill and air peheater, peheater, FD fan oil station. Acc. to temp. of Oil in Oil tank, put cooling air fan of ID fan in service.

5.3.3.10 At the 12th hour before igniting the boiler, boiler, put ESP ash box heating automatic. At 2nd hour before igniting the boiler put ESP rapping in service 5.3.4 5.3.4.1

Initial Initial firing precautions: precautions: To insure a maximum safety margin during start-up, start-up, an air flow flow of at least 30% of full load air must be maintained in order to produce the following conditions: 1） An air-rich furnace atmosphere

Date: Date: 2008-09-15


Page 72

Rev. : A


SEC


2） To avoid the possibility of accumulation or stagnation of explosive mixtures in the event of poor or delayed ignition after fuel is introduced to the Furnace. 5.3.4.2

As the boiler load is increased, the operators shall check that the air flow is increased to maintain the design operating ope rating excess air. A periodical verification should be made. Refer to the curve “Design excess air versus boiler load” at the end of this section.

5.3.4.3

Never attempt to light a burner without its associated igniter or without atomizing /scavenging medium available.

5.3.4.4

If combustion hasn’t started within 15 seconds after the fuel is fed to burner nozzle the fuel should be cut off and a furnace purge during 5mn should be performed again.

5.3.4.5

During start-up, start-up, the boiler firing is done preferably with the oil burners located at the center of the arch. The required firing rate shall be adjusted to operate without exceeding the maximum allowable furnace exit gas temperature of 550 °C.

5.3.4.6

As an addition, in order to maintain the Furnace exit gas temperature below 550℃,the necessary fire rates to obtain the required pressure rise gradient are approximately the following(airflow% refers to the airflow MCR): 1） 6 % of the BMCR firing rate with an airflow o f about 30% during the first stage of the pressure rise. 2） When increased

5.3.4.7

the

pressure

rise

slows

down,

the

firing

rate

can

be

by approximately 12 % of the BMCR with airflow of about 40%.

When the boiler is being warmed up, the saturated steam temperature rise rise gradient must be limited to 100 °C/hour during du ring the first hour and to 110°C/hour during the second hour. Note: It is recommended to follow the shower rate of temp. increases during the initial start-up of a new unit or after repair works in Furnace This will allow sufficient time for drying the refractory, checking the expansion movements and to allow the operators to become familiar with the characteristics of the steam generator and its auxiliaries.

Date: Date: 2008-09-15


Page 73

Rev. : A


SEC 5.3.4.8


The boiler limits shall not be exceeded. Consult the start-up start-up curves curves and diagrams given at the end of this section.

5.3.5

Superheater Superheater and reheater reheater protectio n durin g cold start-up :

5.3.5.1

This is especially important important when there is no demand for steam such as when starting up and shutting down. During the periods when there is no steam flow through the turbine, an adequate steam path shall be ensured.

5.3.5.2

During start-up, start-up, the superheater is protected by the steam flow passing passing through the HP bypass and the reheater is protected by the steam flow passing through the start-up vent or through the LP by-pass. It is considered that the minimum steam flow required for a proper protection is 10% of BMCR (approx. 100t/h).

5.3.5.3

During the first phase of the boiler start-up, start-up, the generated steam flow flow is insufficient to cool down and protect the superheater and reheater elements from high flue gas temperature. Therefore, particular care must be taken not to overheat the exchangers.

5.3.5.4

In order to protect the superheater and reheater until a sufficient sufficient and continuous steam, the firing rate must be controlled to keep the maximum Furnace exit gas temperature from exceeding 550

5.3.5.5

When the steam flow is established above the minimum required (steam flow approx 100t/h), the thermocouple probe may be retracted and the firing rate increased. However, care must be taken to ensure that the totality of the steam flow crosses the reheater, i. e., that there is not any auxiliary steam from cold reheater pipes.

5.3.5.6

When steam is taken taken from cold reheat to feed the auxiliary auxiliary steam header, never take more than 20% of the steam flow through HP by-pass during start-up phases.

5.4 5.4

Cold start-up sequence If the period after shut-down is more than 40 hour or remnant drum pressure is lower than 20

bars, it is called cold shut-down. At Design condition estimated period of cold start-up to full load is 6. 5hour. 5.4.1 5.4.1.1

Boiler filling If checking work work before igniting the boiler is finished, after getting boiler of filling water, water, Boiler can be filled and the requirement for boiler filling is as following : 1） Confirm all valves of steam system in right position. 2） Clean the assayed

Date: Date: 2008-09-15

system before

filling


the

boiler.

Water quality

Page 74

should be

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL acceptable. temp. Try

Water

temperature

is

decided

acc.

to

drum

wall

decreasing differential temp. If it is large, the speed of filling shall be slow to prevent drum, header and etc. from from producing too big hot stress. 3） 3 boiler water circulation pumps are filled water. Air exhaust is finished. Motor cooling water system are put in service and the cooling water is adequate. 4） Economizer recirculation valve has been opened. 5） Open feedwater bypass motorized valve. 6） Locally open 3 boiler water circulation pump outlet valve. 7） Boiler filling period should be controlled in: Sumer ≥２hour, Winter ≥ Winter ≥4 hour. 5.4.1.2

Condensate of boiler filling filling or dematerialized dematerialized water quality should meet requirement requirement :

Condensate water

dematerialized water

Form

colorless

hardness

0mmol/L

hardness

≤0umol

Conductivity

≤0. 5us/cm

Fe

≤1000ug/kg

SiO2

≤20ug/L

Cu

≤200ug/kg

pH

9

Date: Date: 2008-09-15


Page 75

Rev. : A


SEC 5.4.1.3


Temperature of filled water is higher than 20℃ and approach drum wall temp as possible as it can. The differential temperature of water temperature and drum wall temperature shall not be over about 28℃.In the process of filling, the differential temperature of drum upper and lower wall temp can’t be higher than 40℃.

5.4.1.4

Acc. to requirement of filled water temperature required by drum wall temp, open condensate water pump or steam booster pump (or motorized pump) through feedwater bypass to fill boiler till economizer air da mper overflow water and then close valve economizer air damper.

5.4.1.5

Open feedwater bypass valve valve and adjust water pump rotation speed to fill the the water smoothly. smoothly. Control filling water speed. If water temp approaches drum wall temp, add the th e speed suitably. But Drum wall differential temp. can’t be over set value.

5.4.1.6

When water level rise to lowest water level level on the drum local water level instrument, turn down feedwater control valve, control filling speed to let water level rise to high water level slowly. slowly. If perform superheater hydraulic test, continue filling till ea ch air damper of superheater continuous overflow water and then close each air damper.

5.4.1.7

If filling is finished, close each water intake intake valve, stop water pump, and monitor drum water level should be kept constant, otherwise it is required that checking for the cause and reporting to the shift supervisor. supervisor.

5.4.1.8

When filling boiler, 3 boiler water circulation circulation pump Motor Motor room continues keeping filling water till boiler water circulation pump finishes air exhaust, boiler is ignited and pressure rise to 2. 07MPa and then the n stop filling water.

5.4.2 5.4.2.1

Boiler cold igniting pressure rising Start 2 boiler circulating pumps, pumps, and readjust drum level to approach the low level if necessary. necessary. Select the third pump in hot stand by.

5.4.2.2

Open the air and gas path, that means: 1） Start both air heaters 2）

In the sequence open the breaking damper at burning air outlet.

3） Put the flame scanner cooling air system and the fuel-oil burner sealing air system service. 4） Start one I. D fan and put the furnace pressure in automatic. CAUTION: The ID fans are able of developing excessive drafts that may damage

Date: Date: 2008-09-15


Page 76

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL part of the air/gas circuits. Care shall be taken to establish and maintain an open air/gas path through the unit prior to starting an ID fan. Ensure that: 

Air dampers to HFO burners are in open position;



The balancing dampers of secondary air compartments are not closed;



The shut off damper and the control valves of at least one FD

fan are opened. 5） Start one F. D fan. 6） Take care, during starting the first FD fan to maintain opened ope ned the shut-off damper and control valves of the other FD fan. 7） Increase the secondary air flow at the minimum required, i. e. 30% of full load airflow. 8） Successively start the second ID fan and the second FD fan. 9） Put in automatic control all the fans and combustion airflow command. 10） Put in automatic control the air dampers on secondary and tertiary air circuits FCA/B PCV 11A, 11B, 11B, 11C, 21A, 21B, 21C, 14, 15, 1 5, 24, Check the following recommended positions FCA/B PCV 11C 11C and 21C are opened 100% FCA/B PCV 11B 11B and 21B are opened 20% FCA/B PCV 11A and 21A are closed FCA/B PCV 14, 15, 24 and 25 are closed

Date: Date: 2008-09-15


Page 77

Rev. : A


SEC 5.4.2.3


Start the steam air preheaters (if auxiliary steam is available) and verify that the temperature set point is in automatic.

5.4.2.4

Start both primary air fans and put PA pressure control in automatic control.

5.4.2.5

Put in service the retractable probe.

5.4.2.6

Open the reheater start-up vent FRS UV 01.

5.4.2.7

Open the economizer re-circulating valve FSR UV 002.

5.4.2.8

Open the rear pass pass and ITS drain valves FSR UV 003 and 005.

5.4.2.9

Verify that the cold reheat drain valve FRS UV 002 is in automatic

5.4.2.10 With airflow of 30 % of nominal flow, perform a Furnace purge during 5 minutes. “ Soot blowing allowable allowable ” condition : 1)

Whole security of the units is established. I.e. control system power is in service, air pressure of instrument is normal.

2)

At least one ID fan is in service.

3)

At least one FD Fan is in service.

4)

Close all oil burners.

5)

Pulverized coal feeder is in service.

6)

All ESP system is shut down.

7)

All flame scanners don’t scan flame.

8)

Close burning oil main closure valve.

9)

Close all pulverized coal burners, i.e. primary air damper is closed.

10) Burning improving air valve of burners is at purge position (open specified air valve, close other valve ). 11) Total air flow (primary air and secondary air) is from 25% to 40% BMCR flow. flow. Furnace purge is correct, and then ignite burning oil burners. In furnace purge time if any condition can’t be reached, purge will be stopped; 5 min timer must be reset.

Date: Date: 2008-09-15


Page 78

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL In furnace purge time, finish burning oil circuit leaking test. If “ leaking test is not

finished ” or “leaking test is abnormal” , need reset furnace purge end storage. Check the cause for failure, re-perform a furnace purge. 5.4.2.11 Check the boiler safeties setting conditions. 5.4.2.12 Open the boiler isolating valve and the HP by pass. pass. Place the HP by-pass by-pass in auto auto with the HP pressure set point at 60 bars. This will position the HP by pass at a constant opening (minimum start-up opening, around 20%). 5.4.2.13 Start one after the other, other, 2 oil burners at the centre of the arch (FBI+FBN or FBH+FBF), FBH+FBF), and check locally the correct operation of the burners and the quality of the combustion. “ Furnace Furnace igniting allowable” allowable” condition : 1） Boiler purge is finished and “Purge end storage” is set up. 2） Control system power can be put in service and air pressure for control is correct. 3） At least one ID Fan is in service. 4） At least one FD Fan is in service. 5） At least one air preheater is in service. 6） Total air flow is higher than min value. 7） Boiler drum water level is not at high position. 8） Drum water level is correct, i.e. above too low water level. 9） At least one circulation pump is in service, i.e. pump works (Motor contactor auxiliary switch) and relevant differential pressure is higher than min value. 10） Furnace pressure is correct, i.e. between the highest and lowest (pressure switch 3 get 2). 11） Flame scanner cooling air equipment is in service, i.e. cooling air is higher than min value. 12） Superheater outlet steam pressure is not too high (3 get 2). 13） ESP Inlet Flue gas temperature is not too high.

Date: Date: 2008-09-15


Page 79

Rev. : A


SEC


14） Accidents button is not put. 15） If water temp is high and steam exhaust exists or if water temp is not high, Furnace gas-temperature probe is in service and furnace temperature is not high. Notice: required condition for steam exhaust: Open HP cylinder steam intake valve (Open emergency closure valve and close



turbine control valve) and open ope n boiler outlet closure valve (close limit switch). HP bypass in not close :

 

LP bypass valve is not closed.



IP steam intake valve is opened (close limit switch) and HP control valve is not closed.



Open reheater outlet air draft valve (no closure, limit switch is switched on, no action). If all conditions are met, boiler total safety storage can be automatically set up,

and then the burners can be put in service. “ Oil supply to oil burners allowable allowable”” condition: 1）

Oil pressure is normal.

2）

Meet conditions for furnace igniting allowable or any burners is ignited.

3）

No MFT condition.

4）

No OFT condition.

5）

Oil burner’s secondary air damper is at igniting position.

6）

Oil a burner steam purge valve and oil valve is closed, oil burner and igniting burner exit, oil burner power is normal.

Date: Date: 2008-09-15


Page 80

Rev. : A


SEC


5.4.2.14 If necessary adjust the firing firing rate. During During pressure rise rise control the firing rate to keep the maximum furnace exit gas temperature below 550 °C. The rising rate of saturated steam temperature is about 100 °C/hour during the first hour and to 110°C/hour during the second hour. The pressure rise of the boiler meets relevant requirement. (see start-up curve). 5.4.2.15 When the drum pressure pressure increases above 2 bar, bar, close the ITS ITS and motorized motorized drain valve of the rear pass. 5.4.2.16 As the water in the boiler is warmed up and expands, the level in the drum will increase. If it is required, open the intermittent blow down valve at the circulating pumps outlet to decrease and maintain normal water level in the drum. 5.4.2.17 Increase the firing firing rate. Start Start more oil burners if it is required. Continue surveying the furnace exit temperature (<550°C) and the gradient of the saturated steam temperature (<110 (<110 °C/hour). 5.4.2.18 Put feed water water control valves in automatic as soon as possible. At this stage, the drum level is controlled by the start-up valve FSR-LCV-52D. FSR-LCV-52D. 5.4.2.19 Close the economizer re-circulation re-circulation valve, as soon as a permanent feed water flow above 100t/h is established. 5.4.2.20 When the steam flow rate is above 100 t/h, stop the retractable retractable probe. 5.4.2.21 When vacuum is established in the condenser, condenser, put in service the LP bypass with with and set the reheater pressure set point to 8 bar. Close the reheater start-up vent when the LP by-pass starts opening. 5.4.2.22 Check that spray water valves are in automatic and that temperature set points are in accordance with turbine rolling requirements. 5.4.2.23 As soon as the reheated steam conditions are within the required value, start turbine rolling 5.4.2.24 When HP pressure reaches 60 bar, bar, the HP HP by-pass switches from minimum opening position to automatic pressure control mode. The by pass opens to control the HP pressure at 60 bar. 5.4.2.25 The Boiler pressure control is in automatic, manually continue increasing the firing rate by adjusting oil pressure and/or adding burners to obtain a steam flow of 200 t/h. For information, at this stage 10 to 12 oil burners are expected to be in service. 5.4.2.26 Start the electrostatic precipitator. precipitator.

Date: Date: 2008-09-15


Page 81

Rev. : A


SEC


5.4.2.27 When steam flow is >200 t/h, prepare to put pulverized coal burners in service if the coal silo has pulverized coal. One rotary coal feeder can be started when the permissive conditions are met. 5.4.2.28 Continue monitoring monitoring superheating/reheating steam conditions and prepare for turbo and generator synchronization. 5.4.2.29 When feed water flow is above 200 t/h open feed regulating valve and differential pressure is lower than 5 bar . The main feed valve LCV52 takes over drum level control. 5.4.3 5.4.3.1

Rolling of the turbine and synchronization When the boiler load is around around 20% (steam flow 200 t/h), the HP steam pressure is 60 bar, the LP pressure 8 bar. As soon as HP/LP steam temperature conditions are satisfactory, satisfactory, the turbine ca n be rolled up.

5.4.3.2

During speeding up of the turbine, the boiler is maintained at constant steam steam flow 200 t/h. Maintain steam temperature at 400 °C on HP side and at 390 °C on IP side.

5.4.3.3

When the turbo-generator warm-up is completed completed and permissive conditions are are met steam is introduced to the turbine.

5.4.3.4

The HP by-pass is closed gradually to let the turbine HP cylinder take over the superheated steam flow.

5.4.3.5

The LP by-pass closes gradually to let the turbine IP and LP cylinders take over the reheating steam flow to the turbine and generator are synchronization.

5.4.4

Load rise

5.4.4.1

The maximum maximum boiler load that can be achieved with oil burners can reach 30% at most

5.4.4.2

When steam flow is higher than 200t/h, start one rotary coal feeder and after stabilization start a second one on the opposite side of the Arch nose. The associated oil burners should be in service to ensure ignition of the pulverized coal.

5.4.4.3

diving of the flames

Adjust the secondary air distribution in the arch compartments, in order to obtain diving of the flames (the control stations of dampers FCA/B PCV 11A/B/C and 21A/B/C are operational as soon as a rotary feeder is in service)

5.4.4.4

When steam flow is is higher than 250t/h start the milling milling plant if require. require.

5.4.4.5

Start more coal burners according to load and pressure rise. The total coal demand can be put in automatic and the firing rate can be then controlled by the boiler load demand set point.

Date: Date: 2008-09-15


Page 82

Rev. : A


SEC 5.4.4.6


When the HP by-pass is closed, raise the pressure gradually by controlling the firing rate. The saturated steam temperature gradient shall remain below the Design limits (see start-up curve).

5.4.4.7

Keep the fuel-oil burners in service service as long as required and until the expected numbers of coal burners are operating. Furthermore, it is recommended to keep in service 4 oil burners after reaching full load to obtain a stabilized temperature on the refractory. refractory.

5.4.4.8

Transfer the turbine control and the boiler load demand to automatic. Under this mode the unit is in the coordinated mode selected by the operator (boiler or turbine following). Normally the boiler following mode is used: the opening of the turbine valves controls the load and the firing rate controls the steam pressure.

5.4.4.9

Put the steam temperature control in automatic. Verify Verify that correct set points have been reached.

5.4.4.10 Check the total airflow which has to be sufficient sufficient at all times times for the actual firing rate. 5.4.4.11 When the target load is reached, verify that boiler-operating conditions are in conformance with design data. Refer to expected values and to the sliding pressure and excess air curves. 5.5

Hot start-up Hot status boiler is classified as the following types: • Moderate: Shut-down for 10 to 40 hour, boiler pressure is from 2. 0 to 6. 5 MPa. •hot: shut-down for 1 to 10 hour, boiler pressure is from 6. 5 to 14. 0 Mpa. • Extremely hot: shut-down for less than 1 hour, boiler pressure is higher than 14. 0 Mpa.

5.5.1

Check and preparation preparation before hot s tart-up:

5.5.1.1

Control air source, power is reliable, reliable, and control air source pressure pressure normal.

5.5.1.2

Fire scanner and fire-proof system is normal, Air preheater fire extinction equipment is reliable.

5.5.1.3

Put water seal at boiler bottom in service. service. Filling Filling water, water, each piece of equipment of ash handling system is at stand-by status.

5.5.1.4

Burning oil oil system system and atomization steam system system is normal.

5.5.1.5

The following equipment operation is normal, If it is stopped, open it again : 1） 2 Air Preheater. Preheat er.

Date: Date: 2008-09-15


Page 83

Rev. : A


SEC


2） AC flame scanner cooling air fan, DC air fan are at “interlock”. 3） 2 boiler water circulation pump, and stand-by pump is at “interlock”. 5.5.1.6

The following auxiliary equipment is at stand-by status 1） A, BID Fan 2） A, BFD Fan 3） A, BPrimary air fan 4） A, Bpulverizing system 5） All pulverized coal feeder and oil burner 6） A, BSteam air preheater 7） A, B ESP

5.5.1.7

All soot blowing burners position are correct and at “exit” position.

5.5.1.8

A, B Furnace outlet flue gas temperature probe probe has been put in service. service.

5.5.1.9

A, B Furnace Furnace flame flame TV has been put in service.

5.5.1.10 Steam system check is finished and its valve position meets the requirement before igniting the boiler: 1） Close all air damper of superheater an d drum. 2） Open economizer recirculation valve. 3） Open atmospheric relief valve at reheater outlet. 4） Automatic drain valve at cold reheater main pipe is reliable. 5） Each manual valve of attemperating water system is opened, each motorized valve, control valve are closed. 6） Main steam valve and bypass valve are closed

Date: Date: 2008-09-15


Page 84

Rev. : A


SEC


5.5.1.11 Close the left drain valve of superheater. superheater. 5.5.1.12 Check that drum drum local or TV water level instrument has been put in service and drum water level is normal. 5.5.1.13 Each valve valve position of soot blowing system is right. right. 5.5.2

Boiler hot start-up steps ：

5.5.2.1

Open opening vent valve FRS UV 001 of the reheater.

5.5.2.2

Make sure that there is no drain opened in in reheat pipe and automatic drain valve FRS UV 002 is available and ready for service.

5.5.2.3

Open during a sufficient time (see (see table) the automatic drain valves on superheater: 1） Drain valve of steam walls of rear pass FSR UV 003. 2） Drain valve of LTS inlet FSR UV 005. 3） Drain valve of superheater outlet steam pipe FSR UV 004. 4） The drains have to be opened before firing the boiler during a time long enough to eliminate all the water out off the superheate r. The time is function of the duration of the shut down a nd the pressure in boiler. Follow the indications here below

Residual drum pressure (bar)

150

80

50

10

- FSR UV 003

2

5

10

65

- FSR UV 004

2

5

10

60

- FSR UV 005

2

5

10

60

duration of opening (mn) before firing:

Date: Date: 2008-09-15


Page 85

Rev. : A


SEC 5.5.2.4


Open drains and conditioning devices of the main steam lines lines according according to the instructions of the turbine manufacturer. manufacturer.

5.5.2.5

Start, one side after the other, the ID and FD fans.

5.5.2.6

Start the steam air preheaters.

5.5.2.7

Start one after the other both PA PA fans and put PA pressure control in automatic.

5.5.2.8

Adjust the airflow to 30 % of nominal flow and perform Furnace Furnace purge during 5 minutes. minutes.

5.5.2.9

Open the HP by-pass by-pass gradually by adjusting pressure set point below the actual remaining pressure.

5.5.2.10 Start 2 diagonals of oil burners as soon as possible. 5.5.2.11 According to turbine conditions, maintain or raise boiler pressure by adjusting HP by-pass set point and increasing firing rate. 5.5.2.12 Close the economizer recirculation valve, as soon as a permanent permanent feed water flow is established and put in automatic the drum level control. 5.5.2.13 When the vacuum is established established in the condenser, put in service service the LP by-pass and close the reheater start-up vent. 5.5.2.14 Steam flow and steam temperatures will will rise rapidly in relation relation with the firing rate. 5.5.2.15 Open main steam steam line warm-up lines and boiler stop valve according to turbine turbine manufacturer. When turbine start-up conditions are reached, start rolling the turbine. 5.5.2.16 Start the Electrostatic precipitator. 5.5.2.17 After synchronization, synchronization, raise the load by putting in service service additional burners. Check proper airflow. airflow. 5.5.2.18 Control firing rate to obtain obtain the load acc. to raise startup curve gradient (110°C/hour). (110°C/hour). 5.5.2.19 Put the steam temperature and load controls in in automatic. 5.5.2.20 Check that firing conditions are stable. Check that pressure and temperature set points are reached. 5.5.3 5.5.3.1

Boiler star-up attentions : Metal wall wall initial temperature and other relevant parameter parameter of turbine HP and MP cylinder and boiler status decide the start-up status of the unit.

5.5.3.2

In strict accordance with with start-up curve of each status, raise temperature temperature and pressure.

Date: Date: 2008-09-15


Page 86

Rev. : A


SEC 5.5.3.3


When raise the pressure, pay attention to the changes of steam and water quality. quality.

5.5.3.4

When oil is burning, burning, close monitor the changes of temperature temperature of air preheater outlet flue gas.

5.5.3.5

In the process of start-up, pay attention to burning conditions, especially oil burning. When each oil burner is put in service, out of service and normal operation, strengthen the check for oil burner. If oil burner has oil leaking, bad atomization, when oil is leaking, immediately take measures to solve. When oil burner is stopped, close burning oil input manual valve, if the defects can’t be solved, “prohibit opening” marks should be put on it.

5.5.3.6

Check the reliable operation of flame flame scanner scanner equipment at any time.

5.5.3.7

Check economizer protection, i.e. the using condition of economizer recirculation valve.

5.5.3.8

Check protection for superheater superheater and reheater and can’t allow operation of steam with no path. Pay attention to monitoring metal wall temp. in the allowable scope.

5.5.3.9

For the oil with primary start-up start-up or with major repair, repair, confirm boiler hot expansion of each parts, especially the low hot expansion. Record each data of boiler expansion indicator for reference of start-up.

5.6 5.6

Paramete Parameterr cont rol value value In the process of start-up

5.6.1

Parameter which should be controlled in boiler cold start-up Time(min )

Parameter

Units 0

60

144

255

390

60

60

167

Main steam pressure

bar

0

6

Main steam temperature

℃

／

260 400

400

541

Reheat steam temperature

℃

／

240 390

390

539

Main steam flow

t/h

0

0

200

200

995

unit load

MW

0

0

0

15

300

turbine impulse starting

synchronization

full load

specification

5.6.2

boiler igniting

Parameter which should be controlled in boiler hot start-up

Parameter

Date: Date: 2008-09-15

Units


Time(min )

Page 87

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL 0

20

50

60

110 110

Main steam pressure

bar

0

78

100

100

167

Main steam temperature

℃

／

400 480

480

541


℃

／

380 460

460

539

Main steam flow

t/h

0

120 300

300

995

Unit load

MW

0

0

0

15

300

turbine impulse starting

synchronization

full load

specification

6

Boiler igniting

Monitoring and adjustment in boiler operation operation

6.1 6.1

The main task and objectiv es of operation adjus adjus tment

6.1.1

Keep evaporative capacity of boiler is in the rated value and meet the requirement of unit

load. 6.1.2

Maintain normal and stable steam pressure, pressure, steam temperature temperature and drum water water level.

6.1.3

Maintain water and steam quality acceptable.

6.1.4

Keep good combustion, raise raise boiler efficiency and keep the furnace clean.

6.1.5

Ensure that boiler boiler and subsidiary equipment should be opened, stopped safely and

operated economically and safely. safely. 6.2

Main Main Paramete Parameterr and limit of operation cont rol

6.2.1

Different load operation control main Parameter value: Coal burning(load )

Item

Units BMCR

1.

Generator

total

output power 2. Steam flow (a)

Superheat steam

Date: Date: 2008-09-15

MW

75%

60%

Min

RO

RO

*60% RO

300

225

210

882. 7

639. 4

518. 9

RO

kg/H 995


Page 88

Rev. : A

load


SEC (b)


Reheat steam

3. Steam pressure

849. 4

756. 5

555. 0

443. 8

2

kg/cm g

(a)

Drum

190. 4

186. 5

156

127. 5

(b)

Superheat steam

176. 3

174. 7

149

121. 9

33. 7

30. 1

22. 1

18. 0

(c) Reheat steam 4. Steam temperature

℃

(a)

Superheat steam

541

540

539

539

(b)

Reheat steam

538

538

538

538

193. 9

189. 4

158. 7

129. 9

281

273

254

243

129500

99100

29

29

29

29

356

352

324

308

333

333

311 311

297

110

110

110

110

5. Feedwater pressure (a)

Economizer Inlet

6. Feedwater temperature (a)

2

kg/cm g

℃

Economizer Inlet

7.Fuel consumption (coal)

kg/H

8. Air temperature

℃

(a)

Steam air

preheater

Inlet (b)

A. P outlet Primary air

(c)

A. P outlet

Secondary air (d)

Mill outlet

9. Flue gas temperature

℃

(a)

Superheater outlet

670

650

610

580

(b)

A. P Inlet

400

392

358

340

(c)

A. P outlet

124

121

111

102

Date: Date: 2008-09-15


Page 89

Rev. : A


SEC


10.

O2 content in Flue gas % Vol

(a)

Economizer outlet

4. 0

4. 0

4. 5

5. 4

(b)

A. P outlet

5. 1

5. 1

5. 9

6. 8

6.2.2

Limited value of boiler operation main Parameter control :

Parameter Name

Units

Setting value

range

Superheat steam pressure

bar

175±5

±2

Superheat steam temperature

℃

541±5

±2


℃

538±5

±2

Drum water level

Date: Date: 2008-09-15

mm


Page 90

Rev. : A


SEC 6.3


Checking, monit oring and maintenance in boil er operation

6.3.1 6.3.1.1

Checking in boiler operation : Intermittently check check each operation parameter parameter and equipment operation conditions in DCS screen in boiler normal operation. If there are abnormal parameters or abnormal conditions of equipment, immediately analyze and take corresponding control measures.

6.3.1.2

Intermittently check equipment operation conditions in boiler normal operation. If there is abnormal vibration, abnormal sound or coal leaking, pulverized coal leaking, air leaking, steam leaking or oil leaking etc. in equipment operation, immediately take isolation measures.

6.3.1.3

Often analyze each operation parameter, parameter, comparative comparative analysis analysis of each data of indicator indicator of equipment on site and each parameter from DCS. If there is any doubt or big errors, the cause must be checked carefully and solved.

6.3.2

Combustion control of boiler:

6.3.2.1

In boiler operation immediately control coal quality condition fed to the furnace and per coal quality condition, adjusts mill outlet temperature and differential pressure between inlet and outlet.

6.3.2.2

In operation close close monitor change of air flow and oxygen content of flue flue gas. At any time air flow should be more than lower than 30% BMCR operating condition, keep Flue gas oxygen content in suitable scope.

6.3.2.3

Often check burning condition in the furnace and observe fire condition pulverized coal .

6.3.2.4

When furnace burning is not stable, immediately put oil burner in service for stable burning. When Boiler load is lower than 60% BMCR, input oil for stable burning.

6.3.2.5

When raise load, crease air flow and then crease crease fuel. When drop load, decrease fuel and then decrease air flow

6.3.2.6

Intermittently check total air air flow for boiler burning, adjust to keep appropriate rate of air /coal to reach good burning operating condition.

6.3.2.7

Acc. to coal quality and burning condition, adjust the position of air valve of air adjustment and axial blade, keep reasonable pressure drop of burners and alternate secondary air rotating speed to confirm degree of disturbance of mixture of air and pulverized coal.

Date: Date: 2008-09-15


Page 91

Rev. : A


SEC 6.3.2.8


Acc. to boiler combustion system each parameter parameter and steam temperature change trend immediately adjust the position of indicator of secondary air dampers at front, rear arch A, B, C row, and minor adjust the position of indicator of each upper and lower tertiary air valve of front and rear wall to change the length of W flame.

6.3.2.9

Good burning operating condition is that “fuel －air” mixtures is burning in furnace lower parts, i.e., the mixtures stay longer in the furnace with full of flame which is golden yellow. If oil is burning, flame is white and light. And don’t impact water wall and plate superheater. Ignition point of fuel can’t be approached which can cause burners burned and damaged by around coking easily. And incompletely burned fuel content in ash and fly ash is low.

6.3.2.10 Turn up external secondary Air damper. damper. Flame ignition point of pulverized coal becomes remote; Otherwise, turn down external secondary Air damper, damper, ignition point of fuel become near. Add external secondary air flow and carbon content in the fly ash is obviously decreased but maintain burning safety at the same time. The final setting value for the position of indicator of external secondary air shall be a little smaller than critical position of indicator. indicator. 6.3.2.11 Internal secondary air damper should be decreased decreased to make flame flame closer and make critical position of indicator of external secondary air become large and make burners air flow’s direction to external secondary air to make it economical. 6.3.2.12 If burning flame is instable, check primary primary air flow. flow. Big air flow and thick pulverized pulverized coal will cause flame instability. instability. Otherwise, too low primary air flow may cause pulverized coal uneven distributed in burner tips to lead burning disturbance. 6.3.2.13 In normal operation, keep furnace negative pressure pressure -100Pa. -100Pa. 6.3.2.14 Furnace outlet oxygen content is decided by different fuel characteristic and load. When oxygen content is at manual position, control it acc. to oxygen content control setting value. If oxygen content control is automatic, through “automatic” or “manual” method change oxygen content setting value to perform automatic control. When oxygen content in flue gas is at “automatic” measure, acc. to the range in the following table to perform adjustment. Boiler load (T/H)

400

500

600

700

800

900

995

Flue gas oxygen content

6. 8

5. 5

4. 7

4. 35

4. 15

3. 95

3. 95

Date: Date: 2008-09-15


Page 92

Rev. : A


SEC


6.3.2.15 When oil burner is in service, burning oil fire condition should be monitored by flame scanner. If there is not any oil burne r, the corresponding pulverized pu lverized coal feeder can’t be put in service. 6.3.2.16 The best operation measure of pulverized coal feeder is that same same burning burning tip is on two arches to maintain the burning stability. In big load, try to put all pulverized coal feeder in service and rotation speed should be controlled under 10rpm and can’t be more than 11rpm to prevent pulverized coal feeding pipe of re ar wall blockage. When control rotation speed pulverized coal feeder, the rate of increase or decrease should not be large to reduce the interference of burning. 6.3.2.17 In operation, try to make rate rate of air /coal(PA/PC) /coal(PA/PC) meet the following requirement requirement Boiler load (%)

BMCR

100% 100%EC ECR R 75EC 75ECR R

50%ECR

40%ECR

PA/PC(air PA/PC(air /coal) rate

1. 03

0. 98

1. 17

1. 13

Date: Date: 2008-09-15


0. 98

Page 93

Rev. : A


SEC


6.3.2.18 When do combustion adjustment or increase load of the boiler, boiler, besides keep steam temperature and steam pressure normal, keep water wall outlet operating conditions temperature in normal scope. After burners are put in service, immediately check whether fire condition is good and immediately adjust air flow to prevent smoke emission form the chimney. 6.3.2.19 In boiler normal operation, often check air leaking conditions of the body and duct. Check Check seal of each section good, each valve and hole are closed strictly and ash handling equipment seal good. 6.3.2.20 In boiler normal operation, operation conditions of burners and heating surface should be checked. Strengthen analysis and comparison. If there is phenomenon of slag building, clogging and fire extinction, immediately adopt adjustment measures. 6.3.3 6.3.3.1

Steam pressure control: When unit are in the operation with “turbine and boiler coordinating” measure, through inner control circuit, compare actual measured value of main steam pressure setting value and actual measured value of boiler outlet main steam pressure to change boiler load in order to let boiler combustion obtain adjustment and finally reach the objective of controlling steam pressure to meet requirement of unit load.

6.3.3.2

In the period of starting-up the unit, minimum minimum start-up start-up pressure is controlled by HP bypass at 60bar and unit is operated at “setting pressure” operation measure.

6.3.3.3 In the process of increasing increasing unit load, gradually close HP bypass till till it is completely closed. HP bypass is changed to operation with “variety gradient” control measure. Unit control measure is changed to “sliding pressure” operation. 6.3.3.4

Put boiler main load load requirement and oxygen content control into “automatic”. “automatic”. The unit gradually increase load through increasing steam pressure setting value.

6.3.3.5

When the following following condition occurs, HP HP bypass shall be quick opened to control boiler outlet pressure: 1)

Turbine trips.

2)

Operate with auxiliary power.

3)

Main steam pressure is over 18. 5MPa.

Date: Date: 2008-09-15


Page 94

Rev. : A


SEC 6.3.3.6


Main steam pressure normal adjustment is controlled in±0. 2 MPa and not more than ±0. 5Mpa. If main steam pressure＞18MPa, it is regarded as “Main steam high pressure”.

6.3.4 6.3.4.1

Steam temperature control In boiler normal operation, main main steam steam temperature is controlled at 541±5℃, two side differential temperature is lower than 10℃ and at the same time operation medium temperature in each section and wall temperature doesn’t exceed regular.

6.3.4.2

Main steam temperature is controlled mainly by water water spray attemperator. Superheater primarily attemperator will perform “rough adjustment” for steam temperature and its water spray volume is decided temperature before using attemperator. Keep wall temperature of mid-temperature superheater from exceed the allowable value. By using secondary attemperator of superheater performs “micro-adjust” to main steam temperature to keep instability of boiler outlet steam temperature, high sensitivity of controlling steam temperature by secondary water spray attemperator, and small delay. Through changing flame center position, main steam temperature can be auxiliary controlled.

6.3.4.3

Control of reheater steam temperature is mainly performed through combining combining attemperating water and burning adjustment, i.e. through changing the position of indicator of upper and lower third air control damper of front and rear arch to change flame center position to reach the objective of decreasing or increasing reheat steam temperature. Adopt water spray attemperating to control reheat steam temperature.

6.3.4.4

Use and attention for attemperating water : 1)

Superheater, reheater water spray attemperating control can be used at main steam flow＞150T/H. Superheater primary water sprays attemperating is used to

control

wall

temp.

limited

and auxiliary

water

spray

of

mid-temperature

control

main

be

steam

prevent

temperature.

over

Secondary

primary attemperating is the final adjustment for the main steam

temperature. Differential temperature not

superheater,

more

than

10 ℃ ,

of

two

side

of

superheater

should

Strictly control that attemperator outlet steam

temperature must be higher than saturated temperature 15℃ at its operation pressure. 2)

When

control

attemperating

water

and

keep

steam

temperature,

adjustment of attemperating water can’t be quick increase or quick decrease for the operation has a certain lag. 3)

When control attemperating water, water, pay attention to differential pressure relation relation





Page 95

Rev. : A


SEC


between drum feedwater pressure

is

pressure and

changed,

feedwater main

attemperating

water

pipe pressure. control

valve

When

should

be

correspondingly adjusted. Usually keeping feedwater pipe pressure higher than drum pressure 20 bar is better. 6.3.4.5

When the following condition occurs, occurs, especially especially pay attention to monitoring steam temperature to prevent prevent overheating and sharp drop of steam temperature. 1)

Increase or decrease load

2)

Start or stop burners

3)

Start or stop Feedwater pump

4)

Start or stop air fan (single side air fan trip or resume)

5)

Start or stop pulverizing system

6)

Start or stop high temperature heater

7)

Instable steam pressure

8)

Coal quality is changed.

9)

Ash deposit, slag building on heating surface

10)

Bad burning condition or changes of flame length

11)

Pulverized coal is unbalanced. Pulverized coal fineness fineness is changed

12)

Soot blowing occurs.

13)

Large fluctuation of drum water level

14)

Boiler blowdown

15)

When oxygen content in furnace is being changed.

Date: Date: 2008-09-15


Page 96

Rev. : A


SEC 6.3.4.6


In normal operation, each water spray spray attemperator shall be put in automatic service. Pay attention to water spray automatic control in normal service. In changing operating conditions, strengthen monitoring steam temperature to prevent over temperature. For e.g. automatic control can’t follow the changes of steam temperature. Switch to “manual” measure to adjust.

6.3.5 6.3.5.1

Drum water level control Strictly monitor drum water level. Control variety rule of drum water level and feedwater pump characteristic. Be familiar with equipment system and performance. In operation keeping stable normal water level is the chiefly task to maintain boiler safety an d economical operation.

6.3.5.2

The change of water level shows the balance relation between boiler load and Feedwater. Feedwater. When start the boiler and main pipe pressure of feedwater pump＞50 bar, open feedwater pump outlet motorized valve. At this time put feedwater pump rotation speed into “automatic”. On the control console send the opening order to feedwater control isolation valve to automatically trigger the following procedure: For e.g. if feedwater low flow control valve FCV52D is closed (ZSL52), open its isolation motorized valve UV20A, UV20B (ZSH20A ZSH20B), put FCV52D into “automatic” operation. For e.g. If feedwater main flow control valve FCV52 is closed (ZSL52), when Boiler main steam flow ≥380T/H and send main flow control isolation valve UV19 opening order. Open FSRUV19 (ZSH19) and feedwater control is switched from bypass control automatic to main flow control valve FCV52. In boiler normal operation, through FCV52 control drum water level. When load drop to flow≤ flow≤286T/H or feedwater control valve front and rear differential pressure (PT90-PT85=PPS90) ≥60bar, feedwater control is switched from feedwater control automatic to bypass control valve FCV52D. Drum water level is controlled through feedwater control valve and feedwater pump rotation speed. When only through feedwater pump rotation speed controlling Drum water level, it will cause the fluctuation of attemperating water pressure which makes steam temperature difficult to control. Therefore, this measure can’t be adopted. When feedwater has to be controlled through feedwater pump rotation speed, the staff should be more careful and pay attention to change of attemperating water volume to prevent fluctuation of steam temperature.

6.3.5.3

Work scope of drum drum normal water level is -290mm－-175mm. When its water level drop s to -240mm or rises to +100mm, low or high drum water level alarm is sent. When its water level drops to -425mm, rise to +200mm, MFT trips.

Date: Date: 2008-09-15


Page 97

Rev. : A


SEC 6.3.5.4


In normal operation, put feedwater flow control into “automatic”, drum water level is set “automatic” feedwater pump rotation speed and feedwater control valve is put at “automatic” measure. measure. And monitor drum water level in the following scope. Boiler load (％) Drum water level(mm)

6.3.5.5

50

60

70

800

90

100

-290

-265

-245

-220

-200

-175

When boiler operating conditions is changed, e.g. When load, steam pressure, feedwater pressure are changed, change of feedwater pump operation measure and change of burning operating condition occur and boiler blowdown etc., strictly monitor change of water level. If the fluctuation of wate r level is large, immediately switch water level control to manual control to prevent the accidents caused by full water, inadequate water. If emergency occurs, use continuous blowdown and intermittent blowdown valve to cooperate with control.

6.3.5.6

When attemperating water flow is increased increased and water spray spray attemperating control valve opening position is ≥70%, feedwater pump rotation speed should be automatic increased and feedwater control valve should be automatic closed about 10%. (but not completely closed). Keep feedwater main pipe pressure constant to avoid large fluctuation of drum water level.

6.3.5.7

When drum water level level automatic control jumps jumps to “manual” measure, strengthen monitoring and control of drum water level, feedwater flow and feedwater pressure.

6.3.5.8

If the following condition occurs, strengthen monitor and adjustment of water level : 1)

The large fluctuation of feedwater pressure and feedwater flow.

2)

When safety valve is opening or reseating and boiler blowdown.

3)

When load is changed and HT heater exit operation.

4)

When opening or closing feedwater pump, impulse impulse starting, synchronization and etc in the start-up or shut-down of boiler.

5)

When feedwater pump and control equipment fault occurs.

6)

When

switch

over control

valve control

and feedwater

pump rotation

speed control or steam pump and motorized pump. 7)

When pressure parts leaking occurs.

Date: Date: 2008-09-15


Page 98

Rev. : A


SEC 8)


When open or close turbine turbine control valve, bypass bypass valve, superheater and main steam pipe drain valve.

9) 6.3.5.9

When burning is instable or perform fire extinction treatment.

Any data on drum remote water level indicator is abnormal, immediately contact with thermal control staff to deal with If it can’t be resumed, and relieve water level protection.

6.3.6 6.3.6.1

Boiler blowdown To keep steam, water water quality and heating surface internal clean, must perform boiler blowdown. Classify boiler blowdown to continuous blowdown and intermittent blowdown.

6.3.6.2

Continuous blowdown is controlled blowdown blowdown volume acc. to the result of chemical chemical analysis and boiler water quality parameter and through adjusting position of indicator of continuous blowdown valve FSRUV17.

6.3.6.3

Intermittent blowdown is performed acc. to the result of chemical analysis and after receiving the notice from chemical shift sup ervisor, ervisor, through intermittent blowdown valve FSRUV02 or 2 mins blowdown at morning shift every day. Intermittent blowdown shall be performed at low load

6.3.6.4

Intermittent blowdown operation 1） Check

closure

valve

FSRHV034

at

Open

condition,

micro-open

intermittent blowdown valve FSRUV02 to heat pipe. 2） After heating pipe, fully open intermittent blowdown valve FSRUV02, after 2min, close this valve. 3） In the process of intermittent blowdown, pay attention to the change of drum water level and operation conditions of boiler water circulation pump to prevent water circulation from damaged. 4） If blowdown is finished, blowdown valve FSRUV02 should be checked closed strictly. 6.3.6.5

If the following following condition condition occurs, stop intermittent intermittent blowdown blowdown operation : 1)

When drum water level is not normal, normal, feedwater control is no good.

2)

Blowdown system fault or strong vibration of pipe.

3)

Boiler accidents occurs.

Date: Date: 2008-09-15


Page 99

Rev. : A


SEC 6.3.6.6


Prohibit long period blowdown and blowdown valve leaking. In operation to prohibit boiler boiler blowdown by boiler water circulation pump inlet header drain valve.

6.4

Boiler operation measure cont rol

6.4.1

Totally there are 5 types of units’ operation measures: manual, Boiler following mode,

turbine following mode and coordinate control and electricity network control. 6.4.2

Manual measure: it is the most basic measure, boiler main controller controller and turbine main

controller operation measure is at manual measure, i.e. Boiler side, turbine side is manually kept parameter by operation staff and change unit load or keep stable operation acc. to requirement. 6.4.3

Boiler following following mode: Turbine controls load, Boiler controls inlet pressure. pressure. At this time,

turbine main controller is at manual measure, or remote control of DEH system not put in service. At this measure, turbine controls load, and boiler main controller in automatic measure operation, automatic closed loop control inlet pressure. 6.4.4

Turbine following mode: Boiler controls load, Turbine Turbine controls inlet pressure. At this time,

boiler main controller is at manual measure, but turbine main controller is in automatic measure operation. Through changing position of indicator of control valve to stable inlet pressure, at this measured DEH systems put in service. 6.4.5

Coordinate control measure: at this measure, measure, boiler boiler main controller and turbine main

controller is in automatic measure operation. 6.4.6

Electricity network control: at this measure, unit coordinate control is put in service, and

electricity network load dispatch system put in automatic following. Electricity network send Generator unit load order, Generator unit automatic follows load order and boiler and turbine make corresponding automatic control to meet requirement of electricity network load order. 7

Shut-down of Boiler

7.1

basic regul ar (generals )

7.1.1

Boiler normal normal shut-down must strictly be accordance with shut-down curve curve control relevant

parameter. 7.1.2

In boiler abnormal shut-down must prevent shut-down in the process of accidents or

enlargement accidents. 7.1.3

Before shut-down of boiler do corresponding check and preparation.

7.1.4

After shut-down shut-down of boiler, if emergent emergent repair is needed, accelerate boiler cooling i.e.

compulsory cooling and adopt the following operation:

Date: Date: 2008-09-15


Page 100

Rev. : A


SEC 7.1.4.1


Keep Drum high water level+300～+500mm, and strengthen changing water, deaerator water temp. is decided by boiler cooling condition.

7.1.4.2

After shut-down for 6 hour, Boiler is sealed. After shut-down shut-down for 6～18hour, Boiler naturally air draft.

7.1.4.3

At 18 hour after shut-down, open 1 ID, FD Fan, Fan, keep about 30％BMCR air flow Boiler to compulsory air draft.

7.1.4.4

Strictly control Pressure Pressure Drop speed, total temperature drop and pressure Drop In the process of drum upper, lower wall differential temperature≤ temperature≤40℃.

7.1.4.5

Strictly monitor boiler water water circulation circulation pump operation conditions, when Drum Drum pressure pressure

＜15bar, close 1 boiler water circulation pump. If boiler water circulation pump has vaporization Phenomenon, immediately stop boiler water circulation pump operation. 7.1.4.6 7.1.5

When boiler water temperature＜70℃, close boiler water circulation pump, Boiler drain. After shut-down, shut-down, in order to prevent heating surface from internal erosion, erosion, per different

conditions, perform corresponding shut-down maintenance work. 7.1.6

When boiler pressure doesn’t drop to 0 and Motor power isn’t cut off, giving giving up monitoring

boiler unit and auxiliary equipment can be allowed. 7.1.7

In the process of shut-down strictly strictly control control Pressure Drop speed, seriously operation, and

strictly monitor differential temperature of drum upper, lower wall is less than 40 ℃. 7.2 7.2

Preparation Preparation before shut-dow n of boiler

7.2.1

The shut-down of Boiler unit must obtain the superior order, and the measure, measure, reason and

period of shut-down and then prepare for the shut-down, and inform chemical, burning operation, desulphurization staff on duty an d Thermal control staff of shut-down period. 7.2.2

Before shut-down, inform each staff on duty to comprehensively check system managed

by himself to record all detailed defects condition to solve all the defects after shut-down. 7.2.3

If the period for shut-down is more than 3 days, grind all the coal in the bunker grinding.

Pulverized coal in pulverized coal bunker need be burned out. If the period for shut-down is in 3 days, the position of pulverized coal shall be less than 5 meter. 7.2.4

Comprehensively check Burning oil oil and Atomization steam system system has been put in

stand-by. stand-by. Atomization steam pressure is normal; each oil burner is reliable which can be put in service at any time. 7.2.5

Decrease load before shut-down, soot blow boiler body and air preheater. preheater.

Date: Date: 2008-09-15


Page 101

Rev. : A


SEC


7.2.6

Comprehensively check check HP bypass system, confirm Hydraulic plant operation normal.

7.3

Shut-down with slidi ng parameter parameter (need (need cooli ng )

7.3.1

Shut-down adopts sliding parameter shut-down; gradually reduce the boiler combustion

with turbine decreasing load to keep steam pressure, temperature and flow suitable for the requirement for turbine sliding parameter decreasing load. 7.3.2

When decrease fuel, decrease decrease corresponding air flow. flow. Strictly Strictly prohibit prohibit total air flow ＜

30%MCR till the unit are shut-up. 7.3.3

When pulverizing system thoroughly pumped, stop pulverizing system and keeps keeps

lubrication system of tube mill long operation. 7.3.4

Close moisture absorption valve at pulverized coal bunker.

7.3.5

At 75% of boiler load (Steam (Steam flow 750t/h) stop PC burners burners as required and keep the

associated fuel oil burner in service, continue decreasing load and monitor furnace temperature. 7.3.6

Switch from “global flame flame detection” mode to “individual scanning” mode occurs when the

boiler load is below 70% BMCR (618t/h). Stop PC burners as required and keep the associated fuel oil burner in service (at least until the PC pipes have been purged).And from then on the measure is mixture of oil and pulverized coal. Put A. P soot blower, keep continuous soot blowing pattern. 7.3.7

With drop of unit load, slowly slowly decrease main steam steam pressure pressure setting value, monitor monitor

superheat steam temperature and Reheat steam temperature drop rate should be ＜1℃/min., In the process of whole pressure drop, Drum upper and lower wall differential temperature should be lower than 40℃. 7.3.8

When automatic control is not good, switch to manual adjustment.

7.3.9

Gradually close pulverized coal feeder. Firstly close pulverized coal downcoming gate of

pulverized coal feeder .When pulverized pu lverized coal is empty, close pulverized coal feeder. 7.3.10

When Boiler Main steam flow≤ flow≤286T/Hour feedwater control valve front and rear differential

pressure≥ pressure≥60bar, feedwater control is switched form feedwater automatic control to bypass control. 7.3.11

When Main steam flow＜250T/H, all pulverized coal feeder is stopped unconditional.

Inform of stopping ash handling, keep cathode and anode rapping in operation and ash handling equipment in operation.

Date: Date: 2008-09-15


Page 102

Rev. : A


SEC 7.3.12


When Main steam flow＜150T, 150T, stop using attemperating water . When water spray

motorized valve and control valve can’t be closed tightly, stop each water spray manual valve, and make operation record. 7.3.13

When the load is 75MW, 75MW, switch to auxiliary power. When load is 50MW, switch valve of

turbine, quick decrease load to 0. Generator reverse Power trip, perform shunt tripping of turbine. Shut-down the boiler and close all burners. Purge all PC pipes correctly. Close burning oil safety valve and each oil burner input oil manual valve and burning oil control plant inlet oil manual main valve. Confirm all fuel is cut off. 7.3.14

To prevent Atomization steam from entering into furnace in the period of shut-down of

boiler, close atomization steam main valve. 7.3.15

After boiler trips, close the superheater stop valve FSR UV 004 and the HP by-pass. by-pass.

Open rear pass drain FSR UV 003, 005. Open the drains and blow down devices of the main steam piping and main turbine piping, according to the instructions of the turbine manufacturer. 7.3.16

Do not reduce airflow below 30 % of full load airflow. airflow. keep total air flow 30%MCR, after

performing furnace purge for 10 mins, gradually stop Primary air fan, FD Fan, ID Fan, confirm each air fan Inlet and outlet damper closed. 7.3.17

Trip A, B side Steam air preheater

7.3.18

Contact with chemical staff staff on duty, duty, stop chemical feed pump, and close chemical chemical feed

valve, continuous blowdown valve and ach sampling valve. 7.3.19

Keep 2 Air Preheaters operation, 1 flame flame scanner cooling air fan in operation, 1 oil burner

cooling air fan operation. 7.3.20

Keep 2 boiler boiler water circulation pump in operation, When drum pressure＜15bar, per the

conditions stop 1 boiler water circulation pump operat ion. Keep drum high water level +100mm. Open Economizer recirculation valve. 7.3.21

Control boiler cooling cooling rotation rotation and keep the differential temperature measured measured by any two

thermal couple is less than 50 °C. 7.3.22

When Drum pressure≤ pressure≤3bar, Open each Air damper of superheater and rehe ater.

7.3.23

To prevent economizer, economizer, air preheater and etc. from from secondary burning which damages

equipment. After shut-down boiler, boiler, monitor gas te mperature of each section. When air preheater inlet gas temperature ＜120℃, stop A, B air preheater operation, stop flame scanner air fan and oil burner cooling air fan operation.

Date: Date: 2008-09-15


Page 103

Rev. : A


SEC 7.3.24


When boiler water temperature≤ temperature≤70℃, stop boiler water circulation pump. Close outlet

non-return flap and heating pump manual valve, power of 3 boiler water circulation pump should be cut off. Open Drum left, right side interlayer of air damper. 7.3.25

When boiler water temp.≤ temp.≤70℃ and boiler water circulation pump is stopped, if boiler must

be drained, comprehensively check the steam and water system. 7.4

Normal shut-dow n (hot stand-by )

7.4.1

When shut-down, try to keep main steam pressure pressure and Main steam steam temperature. temperature.

7.4.2

Speed of pressure drop when load is dropped is much lower lower than cooling speed of normal

shut-down. 7.4.3 7.4.4

Put soot blowing equipment in service for A.P. A.P. When the turbine is off load, load, the boiler should continue to be fired in order to increase the

pressure above 140 bar before bottling (Per the conditions of hot stand-by equipment). 7.4.5

After boiler fire-off, close main main steam valve and HP bypass bypass valve, close all air valve

damper to bottle-up. 7.4.6

Operation of shutting-down each valve of steam, water water system system for hot stand-by is as

following: 7.4.7

Open Reheater outlet steam exhaust valve, FSRUV001.

7.4.7.1

Open cold Reheater main pipe drain valve FRSUV002.

7.4.7.2

Keep all drain valve and Air damper of drum, Superheater and Reheater closed.

7.4.8

Keep total air flow 30%MCR, after performing furnace purge for 10 mins, stop Primary Primary air

fan, ID Fan, FD Fan. 7.4.9

Steam air preheater trip.

7.4.10

Keep Drum high water level+100mm, completely close Feedwater motorized valve.

7.4.11

If hot stand-by period, keep 2 Air Preheater, Preheater, 1 flame scanner scanner cooling air fan, 1 oil burner

cooling air fan, 2 boiler water circulation pump operation. 7.4.12

Keep lubrication system of tube mill long operation.

7.4.13

After shut-down shut-down for 20 hour, hour, open the following drain drain valve to drain 1 hour for superheater

system. Keep Air damper of Drum and superheater closed. 7.4.13.1 Open front wall enclosure drain valve valve FSR FSR UV003 7.4.14

Open rear wall enclosure drain valve FSR UV005

Date: Date: 2008-09-15


Page 104

Rev. : A


SEC


7.4.14.1 Open Main steam valve front front drain valve FSR FSR UV006 UV006 7.5

Emergency Emergency shut -down

7.5.1

Emergency shut-down is quick shut-down shut-down to prevent from serious accidents or enlarging

accidents needed when serious faults of boiler or other main equipment occur. 7.5.2

Emergency adopts the MFT order which will cut cut off immediately all the fuels to the boiler

furnace (coal and fuel oil). 7.5.3

The sequent operation follows the operation after the boiler fire-off in hot stand-by

shut-down terms 7.6 7.6

Shut-down maintenance

7.6.1 7.6.1.1

Maintenance in short shut-down of boiler (shut-down 3~4 days) : Maintenance in short shut-down of boiler (shut-down 3~4 days), for hot stand-by, stand-by, Boiler can be started arbitrarily. arbitrarily.

7.6.1.2

Treatment after shut-down shut-down refer to “Boiler normal shut-down (hot (hot stand-by)”.

7.6.2

Maintenance in medium-period shut-down of boiler (shut-down 3~4 weeks) :

7.6.2.1

After Boiler Boiler fire-off, fire-off, immediately immediately sub-control closing closing boiler main steam valve FSRUV04A, FSRUV04A, FSRUV04B. When shaft seal of turbine don't use steam, immediately close HP bypass.

7.6.2.2

Open reheater outlet steam exhaust valve valve FRSUV001, FRSUV001, High temp. Reheater inlet, outlet Air damper: FRSHV006, HV007, HV014, HV008, HV009, and cold reheater main pipe drain valve FRSUV002.

7.6.2.3

Open Superheater drain valve: Open front wall enclosure drain drain valve FSRHV019, UV003. UV003. Open rear wall enclosure drain valve FSRHV020, UV005.Open main steam valve front drain valve FSRHV068, UV005.

7.6.2.4

Close continuous blowdown valve, each sampling valve, chemical feeding valve

7.6.2.5

When Drum pressure≤ pressure≤3bar, open superheater air damper, When Air damper doest overflow steam, immediately close Air damper, damper, drain is finished, f inished, close Each drain valve, and completely isolate hot seam pipe and of the atmosphere.

7.6.2.6

When reheater drain is finished, close reheater outlet atmospheric relief relief valve. Each Air damper of high temperature reheater inlet and outlet, and cold reheater main pipe drain valve completely isolate reheater steam pipe and the atmosphere.

Date: Date: 2008-09-15


Page 105

Rev. : A


SEC 7.6.2.7


When boiler water temperature drops below 180℃ and drum water level is at about -290mm, inform chemical staff of adding N2H4 and NH3, keep boiler water circulation pump operation to keep N2H4＝200ppm, PH≥ PH≥10. 5. in boiler water and keep drum water level+100mm.

7.6.2.8

When boiler water N2H4＜50ppm, immediately add N2H4.

7.6.2.9

When boiler water temperature≤ temperature≤120℃, boiler water circulation pump can be stopped.

7.6.2.10 Superheater system filling N process: 1） When 1bar,

Superheater

drain

is

finished,

Boiler

pressure

drops

to

open superheater superheater filling filling N valve FSRHV031, FSRHV031, and HV029, HV029, Open drum inner

layer filling N valve FSRHV007, and HV005. Notice, must fill N in the boiler cooling process. In the process of filling N keep Nitrogen pressure in the scope of 0. 1~0. 3bar to prevent air entering in to furnace. 2） When boiler water circulation pump is stopped, Open drum inter layer filling N valve :FSRHV045 and HV044to fill N to the furnace, and keep Nitrogen pressure 0. 1～0. 3bar. 7.6.2.11 Filling N Process of reheater system: 1） Check before reheater system filling N 2） In the cooling process of Boiler 3） Close HP bypass valve 4） Each valve of reheater water spray at temperating system closed tightly 5） LP bypass valve close 6）

Close

turbine

pressure cylinder

HP

cylinder

steam

steam

intake

exhaust

valve,

and

non-return high

flap,

#section

valve and isolation primary damper on pipe. 7） After cold Reheater main pipe drain is finished, close drain valve.

Medium

air

pump


SEC

Date: Date: 2008-09-15



Page 106

Rev. : A


SEC


7.6.2.12 After reheater air exhaust is finished, close reheater outlet atmospheric relief valve and air damper at high temperature reheater inlet and outlet. 7.6.2.13 Open reheater filling N valve FRSHV012 and HV006, HV014 to fill reheater system N, keep Nitrogen pressure 0. 1~0. 3 bar, to prevent air entering in to reheater system. 7.6.3 7.6.3.1

Maintenance for boiler long shut-down(shut-down 4weeks~3 months):(wet) Maintenance pricinple: 1）

Under

normal

conditions,

after

shut-down

of

boiler

perform

wet

maintenance for superheater system. Only the major or minor minor repair and repair repair on pressure parts occur, occur, dry maintenance (hot boiler drain) shall shall be performed. 2）

When unit are shut-down for more than 2 weeks, change from feedwater pressure maintenance ammonia

or

dry

maintenance

(hot

boiler

drain)

to

superheater

with

-hydrazine maintenance for superheater.

3） Reheater adopts filling N maintenance. 7.6.3.2

Maintenance method key points: Drain the ammonia

remaining

left

water

in

Boiler.

Fill

the

boiler

-hydrazine solution maintenance liquid. Prevent Air from entering. Perform filling N maintenance for reheater. 7.6.3.3

Superheater system maintenance operation method : 1） At cold status of boiler, open air damper, drain valve and water discharge valve of steam, water system. Drain the remaining water in feedwater system, water wall and superheater. When the remaining water in feedwater system, water wall and superheater is drained,(about 2hour ),close all drain manual or motorized valve and water discharge valve and intermittent blowdown manual valve and continuous blowdown manual valve (Open when perform chemical sampling) 2）

Chemical

staff

maintenance

makes

the

maintenance

solution

maintenance chemicals box, When water level of feedwater box is highest after level which can be seen (2800mm). Open pump feed feedwater with chemical (chemical feed is switched to feedwater box) 3） After receiving the notice that chemical staff finishes feeding chemicals, open feedwater pump to circulation feed water 30 min, mix the chemicals and liquid.





Page 107

Rev. : A


SEC


4） Chemical make the sampling analysis of feedwater that the concentration of maintenance liquid:N2H4≥200mg/l,PH 10~10. 5. 5） Open condensate water pump to fill water to boiler water circulation pump motor. 6）

When

filling

finished,

water

for

boiler

water

circulation

pump

motor

is

open feedwater pump, make use of feedwater bypass to fill boiler to

+100mm, run 3 boiler water circulation pump for 3 times, put #2boiler water circulation pump in service. At this time, stop filling water for boiler water circulation pump and stop filling Boiler. 7）

Make

use

system

to

of

superheater

secondary

attemperator

water

fill superheater acceptable maintenance solution, system top

pressure, When Drum pressure reach 0. 3Mpa, close all air damper, boiler filling is finished. 8） Inform of chemical boiler water sampling analysis, water quality standard is: PH 10~10. 5, N2H4 50~200mg/l. 9） In

the

high

period

of

maintenance,

water level+500mm,

superheater

when

open

1

Drum

water

feedwater

level

drop

pump.

to

Through

secondary attemperator fill water to boiler, boiler, top pressure. When

drum pressure reach 1 bar, stop fill water to boiler. 10）

When maintenance solution in feedwater box is not enough, inform chemical

staff of making chemical, feed chemicals feed and water feedwater box. 7.6.3.4

Perform filling filling N maintenance of reheater reheater system, Nitrogen pressure is kept at 0. 3~0. 5 bar and method is as following: 1）

Check before reheater system filling N : a） Boiler has been cooled. b） HP, HP, LP bypass has been closed. c） Motorized B

valve,

control

valve

and

manual

valve

of

reheater

side attemperating water have been closed.

d） Close

turbine

HP

cylinder

vent

non-return

flap

and

bypass

motorized valve ,mid pressure cylinder steam intake valve ,high temperature heater #7 section steam pump motorized valve and drain manual valve (AHP HV087), motorized motorized valve at cold

valve

at

cold

reheater

to

deaerator

and

A,





Page 108

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL reheater to auxiliary steam header, e） Open cold, hot reheater main pipe drain motorized valve (for steam exhaust). f ）

Atmospheric relief valve at reheater outlet is closed.

g） Each Nitrogen bottle at Nitrogen station is full filled with nitrogen. h） Safety

valve

at

Nitrogen

station

air

supply

main

pipe

has

been

checked acceptable. 2） Filling N operation : a）

Micro-open air supply valve at each Nitrogen bottle of Nitrogen station. When the pressure before opening pressure governor valve at air supply main pipe reach 120bar~150bar, stop opening Nitrogen bottle.

b）

Manually control pressure governor valve at Nitrogen station. Keep Nitrogen pressure after opening pressure governor valve at 5 bar. Fill Nitrogen pressure governor station with Nitrogen to exhaust air.

c） Close front ,rear manual valve pressure governor valve at pressure governor station. d）

Manually and

open

pressure

governor

station

bypass

manual

valve

make valve outlet Nitrogen Nitrogen pressure 2 bar and reheater system filled

N to exhaust air. e） After 60min, manual close pressure governor station bypass manual valve. Reheater system filling N to exhaust air is finished. f ）

Manually close bypass manual valve of pressure regulation station and close drain

motorized

valve

of

cold

reheater reheat er

and

hot

reheater reh eater

main pipe. Purge reheater system and exhausting air is finished. g） Open reheater system filling N valve FRS HV012, FRS HV006, FRS HV014. h）

Open front ,rear manual valve pressure governor valve at pressure governor station, manually clockwise control pressure governor valve to make pressure after opening pressure governor valve 0. 3 bar ～0. 5bar.

i）

Reheater system filling N is finished. Record Nitrogen pressure of Nitrogen station and Nitrogen pressure governor station


SEC

Date: Date: 2008-09-15



Page 109

Rev. : A


SEC 7.6.3.5


Monitoring in the period of maintenance: 1） Each shift record boiler drum pressure, reheater Nitrogen pressure twice. 2）

Every

Monday

separately

open

each

boiler

water

circulation

pump

once and each time is 30min. If circulation is finished, inform chemical staff staff of sampling and analyze concentration of maintenance solution. 3） In the period of maintenance, boiler water, open feedwater box sampling valve, and keep flow of 50~200ml/h. 7.6.4

Boiler heating with pressure drain maintenance method:( suitable for mid, long period

shut-down ) 7.6.4.1

When in the mid or long period of boiler shut-up boiler or after shut-up, pressure parts parts need long repair time and can’t be performed wet measure. And when pe rform filling N maintenance, boiler can adopt heating boiler with pressure and drain. When Boiler water is drained out, make use of boiler remaining heat to dry instrument of pressure parts in boiler to reach the objective of maintenance.

7.6.4.2

Operation steps After boiler shut-down, when drum pressure is 10bar: 1） Stop boiler water circulation pu mp, inform electric staff cut off power. power. 2） Close boiler water circulation pump outlet valve and boiler water circulation pump is at isolation condition. 3） Open HP side air exhaust damper of boiler water circulation pump cooler. 4） Boiler drains. Each valve valve position in the system is listed in the following following table : No.

1

2

3

Valve Name

Valve No

Status

FSR HV032

open

FSR HV033

open

FSR HV081

close

HV082

close

UV17

close

FSR HV012

open

Economizer drain valve

Continuous blowdown valve

Drain valve at boiler water

Date: Date: 2008-09-15


Page 110

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL pump Inlet header

4

5

6

Water

wall

circumferential

header drain valve

FSR HV060

open

FSR HV049 HV080 HV062

open

FSR HV071 HV084

open

FSR HV034

open

FSR UV002

open

FSR HV068

open

FSR UV06

open

Intermittent blowdown valve

Main steam valve inlet drain valve

5） If drain is finished, close all drain valve in above table. 6） When Drum pressure reach 3bar, open the following Each valve : 1

Economizer outlet air exhaust valve

FSR HV074 HV073 HV075

open

2

Drum inner-layer air damper

FSR HV005 HV006 HV008 HV009 open

Drum interlayer air damper

FSRHV044 HV046

open

Drum interlayer air damper

FSR SV40 HV047

open

Top outlet header head er air damper

FSR HV063 HV064

open

FSR HV021 HV022

open

FSRHV054 HV055 HV056

open

3

4

5

6

Low

temp.

superheater

outle

air damper Mid temp. superheatier outlet heade air damper

7

High temp. superheater outlet header FSR HV029 HV030 air damper

open

8

High temp. reheater Inlet air damper FSRHV014 HV006 HV007

open

9

Reheater outlet steam exhaust valve FSRHV013 UV001

open

7） When Boiler drain is finished for 2hour, Open each drain valve of steam side: No.

Valve Name

Date: Date: 2008-09-15


Valve No

Status

Page 111

Rev. : A


SEC


1

Drain valve at roof Inlet header

FSRHV050 HV059

open

2

Front wall enclosure drain valve

FSRHV019 UV003

open

3

Rear wall enclosure drain valve

FSRHV020 UV005

open

Drain

valve

superheater

4

from

low

tomedium

temp.

open

temp. FSRHV023 HV024 HV035

superheater 5

Main steam valve front drain valve

FSRHV068 UV006

open

6

Low temp. reheater Inlet drain valve FSRHV015 UV002

open

a)

When above air air damper and drain valve valve is opened for 2hour, 2hour, close all air damper and drain valve.

Date: Date: 2008-09-15


Page 112

Rev. : A


SEC 7.6.5 7.6.5.1


Points for attention of Boiler maintenance: In the period of boiler maintenance, maintenance, chemical staff shall assay boiler water quality acc. to regular, when N2H4 concentration ＜50ppm, it should be added to original content.

7.6.5.2

Before boiler is added hydrazine and ammonia (i.e. (i.e. N2H4 and NH3), only keep 1 boiler water circulation pump in operation, other outlet of 2 boiler water circulation pump shall be closed.

7.6.5.3

Before boiler is filled N after cooling.

7.6.5.4

After filling N maintenance, maintenance, if entering in in to drum to work is needed, perform air draft and then can enter into it.

7.6.5.5

Boiler adopts maintenance of adding Na3PO4. 12H2O(Na3P04)solution, before open boiler, must perform drain and rinsing work. Its drain method is as same as shut-down drain method.

8

Boiler auxiliary equipment

8.1 8.1

Basic regular of auxiliary equipment operation

8.1.1

Check before auxiliary equipment is put in service:

8.1.1.1

Check work-sheet is finished, no staff staff works on the equipment.

8.1.1.2

Full of light light on on site, site, clean ground, no debris obstructing operation. operation.

8.1.1.3

Equipment Appearance is in its integrity integrity with heat good insulation. Each hole valve is strictly closed, connection with the system completely. completely. Instrument is complete and direction is right.

8.1.1.4

Bearing Lubrication position is normal, oil quality is acceptable, acceptable, and Lubrication system at good stand-by status. Grease is added per the regular.

8.1.1.5

Cooling water unobstructed, water flow is adequate and don't overflow. overflow.

8.1.1.6

The Anchor Bolt is complete and firm. Motor wiring wiring and earthling earthling cable is good. Insulation is acceptable.

8.1.1.7

Shields are complete and integrated.

8.1.1.8

The data on DCS of each air valve is consistent with the actual and transmission machine is complete.

8.1.1.9

Control circuit power, interlock, thermal control staff protection test is acceptable and is in service, automatic equipment is put in service or has the start condition.

Date: Date: 2008-09-15


Page 113

Rev. : A


SEC


8.1.2

Auxiliary equipment open principle:

8.1.2.1

Normal open 6KV equipment equipment and 380V equipment. Specified Specified staff staff stands at the position of accidents button to monitor it on site. If any problem is found, fo und, immediately put accident button stop operation.

8.1.2.2

The equipments with the same trunk can’t be operated at the same time before opening 2,6 KV equipment inform the electric operation staff. Without permission, it can’t be opened.

8.1.2.3

In normal condition, squirrel-cage squirrel-cage Motor at cold status can be allowed opened twice. Each interval will not be lower than 5min. At hot status can be allowed opened only once. Only when there is accident treatment and opening time is not more than 2～3 mins, motor can be opened once more. Otherwise, it can be opened after 30min (iron core temperature is hot status when it is above 50℃, below 50℃ it is cold status).

8.1.2.4

Strictly prohibit opening with load.

8.1.2.5

When open auxiliary equipment pay attention to it’s the executing condition of opening procedure, current returning time, current indicator and other Parameter of equipment. Pay attention to t he display on monitor CRT equipment status is correct.

8.1.2.6

After open equipment local check equipment in good operation, without any abnormal sound, vibration,, friction and percussive sounds.

8.1.3

General rule for

Auxiliary equipment operation maintenance:

8.1.3.1

Cooling water is adequate and lubricating system is normal.

8.1.3.2

Equipment operation is stable stable without any abnormal noise and abnormal friction and impact sound. Each parts and inlet or outlet pipes are complete and not loose, non-swing and etc.

8.1.3.3

Operation of Each valve, air valve and primary dampers flexible, action is normal and position direction is correct.

8.1.3.4

Each thermodynamic, thermodynamic, electric instrument for measure and display is normal. Thermodynamic, electric protection and relevant automatic control is put in service and is normal.

8.1.3.5

Control the following parameters according to manufacturer’s requirement. If there is no requirement, control according to the following requirement: 1） Rolling bearing temperature≯80℃,sliding bearing temperature℃≯65.

Date: Date: 2008-09-15


Page 114

Rev. : A


SEC


2） The shell temp. of gear gearbox ≯60℃. 3） Opening Motor shell temperature≯65℃,enclosed motor shell ≯humidity 80℃. 4） Rolling equipment axial shaft displacement displacement is ≯2~4mm. Sliding equipment axial shaft displacement is ≯0. 5mm: 5） Vibration value: Rotation speed(r/min) Vibration value(mm)

≤3000

≤1500

≤1000

≤750

0. 05

0. 085

0. 10

0. 12

6） When any of the following conditions occurs, emergently stop auxiliary equipment operation : a） Bearing temperature abnormal rises or exceed s the regular. b） When strong vibration on the equipment or axial shaft displacement or the danger which may may damage equipment occurs. c） Motor or cable smokes and fires. d） The obvious sound of metal friction in the inner of equipment can be clearly heard. e） Other faults which endangers safety of person and equipment. 8.1.4 8.1.4.1

General rules for rotation equipment fault and treatment When any of the following conditions occurs, emergently stop operation of rotation equipment : 1） Equipment has strong vibration. 2） The obvious sound of metal friction in the inner of equipment can be clearly heard. 3） Motor or cable smokes and fires. 4） Bearing smokes and fires or sliding bearing temperature exceeds 80℃, rolling bearing temperature exceeds 100℃. 5） Equipment leaking endangers safety of person and equipment.

Date: Date: 2008-09-15


Page 115

Rev. : A


SEC 8.1.4.2


When any of the following conditions occurs, firstly firstly open stand-by pump (air fan ),stop fault pump (air fan ): 1） Gland heats, smokes or with overflowing water, oil leaking, and adjustment is not efficient. 2） Sliding bearing temperature reaches 65℃,rolling bearing temperature reaches 80 ℃

and with rising trend.

3） Motor shell temperature rises to 70℃,and continues rising. 4） Motor Current exceeds rating value. 5） Motor cable is serious overheating. The insulation exude a smell of burning 8.1.4.3

Treatment for operation pump (air fan) trip: 1） Confirm operation pump (air fan) trip and stand-by pump (air fan ) shunt good. Reset gang pump (air fan )switch. If stand-by pump (air fan )is not gang ,manual open it. 2） Cut off trip pump (air fan )operation switch. 3） check each section of gang pump (air fan ) normal, check the reason for trip of trip pump (air fan )and solve it for stand-by. 4） If opening stand-by pump (air fan )don’t take effect, immediately check for the cause. For the 380V motor

,start trip trip pump (air fan )again once more . Confirm

6KV power equipment should be checked no obvious fault ,it can be switched on again.

Date: Date: 2008-09-15


Page 116

Rev. : A


SEC 8.1.4.4


For important important plant plant service auxiliary equipment, besides the faults faults which endangers safety of person and equipment must be immediately stopped. Usually open the stand-by auxiliary equipment and then stop fault auxiliary equipment.

8.2

Motor operation

8.2.1

Motor can be operated at the temperature of rated cooling air according to the specified

data on manufacturer’s name plate. 8.2.2

The highest monitoring temperature of motor coil and and iron iron core shall not be exceeded

in any case according to manufacturer’s regulation. If manufacturer has no regulation, the highest temperature of the motor coil and iron core can’t exceed 105℃ and the rise of temperature can’t exceeds 65℃. 8.2.3

Motor can be operated in the scope of 95%~110% 95%~110% of rated voltage, and its rated output is

constant(5. 7～6. 6 KV, 360～420V). In the period of rated output operation the unbalanced value of voltage between phases can’t exceeds 5％. In the period of operation at unbalanced voltage pay attention to over-hot and vibration of the motor. In normal operation , motor current shall not exceed ＋5％ of rated value. If it exceeds ＋

8.2.4

5％ to ＋10％ , in 15 min shift supervisor can’t decrease the current to rated current. If it is caused by the accidents of main motor, the above rule needn’t to be followed. 8.2.5

Temperature of motor bearing is controlled according to the following standard (If the

manufacturer has its own requirement, perform according to manufacturer’s regulation): 8.2.5.1

Sliding bearing :can’t exceeds 80℃(Temperature (Temperature rises by 40℃).

8.2.5.2

Rolling bearing :can’t exceeds 100℃(Temperature rises by 60℃).

8.2.6

Daily check work, maintenance maintenance for motor and the detailed requirement requirement of opening and

stopping operation refer to specific terms in “electric operation manual. 8.3 8.3

Start-up, Start-up, stop and operational maintenance of auxili auxili ary equipment and system

8.3.1 8.3.1.1 1)

High voltage bypass Check-up before the start-up of high voltage bypass. Make sure that every pipeline is perfectly connected with facilities, facilities, valves complete, and test and adjustment fully completed and that movement is flexible and reliable as well.

2)

Make normal

3)

sure

that

the

functioning

of

the

hydraulic

pressure

station

is

without leakage.

Thermal meter and controlling controlling system system should be put into use

Date: Date: 2008-09-15


Page 117

Rev. : A


SEC 4) 8.3.1.2


Open the hand-operated valve of attemperating water HV002. Start-up of high voltage bypass

1)

Make sure that the hydraulic pressure pressure station is normally functioning.

2)

Put into into use the high high voltage bypass on DCS. DCS.

3)

Turn on the pressure-reducing valve controller of the high voltage bypass to 20% by hand.

4)

Set main steam pressure and steam pressure lower limit (the stream pressure is set at 60 bar).

5)

Set steam temperature of the high voltage bypass outlet at 320℃, press the “automatic” button on the attemperating water regulating valve controller of high voltage bypass.

6)

Send out the start-up order, order, the “red” “red” indicator light at the HSN001 operation station will soon be “brightened”.

7)

Operate automatic on the pressure-reducing valve of the high voltage bypass, the high voltage bypass thus enters into operation with a minimum opening of 40% and “the minimum opening” indicator light is is on.

8)

When the steam steam pressure of the boiler outlet is is below the minimum fixed value (60bar) on starting up, set the regulating valve of the high voltage at start-up opening fixed value (40%).

9)

When steam pressure reaches the minimum start-up pressure pressure (60 bar), bar), the “minimum “minimum opening” indicator light is off, while “the minimum pressure” indicator light is on, ensuring the high voltage bypass is controlled in a state of minimum pressure.

10)

Maintain the minimum pressure of start-up when the pressure-reducing valve of the high voltage bypass gradually opens as the burning is intensified.

11)

When the

the

“high-pressure

cylinder”

switch

signal

has

been

sent

out,

“minimum pressure” indicator light is off, while “slip “slip pressure” indicator is on,

bringing the system into an operational state. 12) Close the high voltage valve as turbine valve gradually opens to maintain the fixed pressure values, and during this process, the PI controller will set the changing gradients at the fixed value of 4 bar/min.

Date: Date: 2008-09-15


Page 118

Rev. : A


SEC 13)


As the turbine load increases, increases, the high voltage valve valve will be narrowed till it is fully closed when the “slip pressure” indicator light is off while the “normal functioning” indicator light is on

14)

After that, the high voltage voltage pressure-reducing valve will automatically automatically regulate rate of pressure rise of the boiler. boiler.

8.3.1.3 1)

Functional maintenance and parameter High voltage bypass parameters

Items Steam

temperature

of

Unit

Data

℃

540+5

bar

184

bar

44

℃

337+5(>360℃alarming)

T/H

760

bar

210

℃

257

S

12

S

3

S

3

the high voltage bypass inlet Pressure of the high voltage bypass inlet Pressure of the high voltage bypass outlet Steam

temperature

of

the high voltage bypass Flow of high voltage bypass Pressure

of

attemperating water Temperature

of

attemperating water The start-up controlling time of the high voltage bypass Swift-opening

time

of

the high voltage bypass Opening attemperating

time water

of stop

valve

Date: Date: 2008-09-15


Page 119

Rev. : A


SEC Full-opening

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL time

attemperating

of water

S

8

regulating valve 2)

Conditions for swift opening of pressure reducing reducing valve of the system a)

Reach safety ∆P (adjust safety valve to influence load)

b)

Reach

c)

When turbine is running (high voltage main body of turbine opens), auxiliary power

Pmax safety

operates,

or

(adjust safety valve)

else

steam

turbine

will

trip,

forecasting

the

full

close

down of high voltage main body. body. d)

Operator can open it by hand (press any button), and under any circumstances, circumstances, it can be swifted from the manual-controlled model to the automatic model when the high voltage valve is opened. It is also suitable for desuperheat-regulating ductwork.

8.3.1.4 1)

Operation of high voltage voltage bypass in the the stoppage process of the unit When the set pauses in the phase of “slide pressure”, lower the main main steam pressure pressure setting and ensure high voltage maintains “set” pressure for regulating.

2)

When the set set enters into the phase of “fixing pressure to reduce load”, as the regulating valve of the steam machine gradually narrows, the pressure-reducing valve is opened, maintaining the fixed pressure.

3)

Hydraulic pressure station keeps keeps on operating after the boiler stops working to ensure that the pressure-reducing valve remains in a closed state.

8.3.1.5 1)

2)

Faults and countermeasures of high voltage bypass Causes: a)

Failure of hydraulic pressure station

b)

Failure of 380V power supply and tripping of hydraulic pressure oil pump

c)

Failure of 48V DC power

State

Automatic closing and locking of FCV58, UV59 and TCV59 3)

Countermeasures

Date: Date: 2008-09-15


Page 120

Rev. : A


SEC


Find out the causes and have faults removed immediately 8.3.2

Air preheater

8.3.2.1 1)

Check-up before the start-up of air preheater Make sure that there are no people working and no foreign bodies in the air preheaterhas no, and that man holes are fully closed when the maintenance of work ticket is finished, and that the surrounding of the air preheater has no sundries.

2) Make sure that the smoke and air flues are well connected and that the executive mechanism of sealing device is in a high position. 3)

Make sure that executive mechanisms UV03 and UV04 have sent off electricity. electricity.

4)

Make sure that the speed reducer has been injected with qualified oil, and that hydraulic couplers has also been oiled without leakage.

5)

Make sure that soot-blower is placed in the outlet and that the soot-blowing and steam pipelines are connected.

6)

Make sure that smoke, smoke, air pressure, and temperature and fire-measuring fire-measuring devices and local control switch as well, are in good condition.

7)

Fire protection and check-up of cleaning system: a)

Make sure that pipes are fully connected and equipment complete.

b)

Close fire fire protection and fire-extinguishing nozzle manual manual valveHV001 and HV007, close fire-fighting water-cleaning manual inlet valveHV002 and cleaner manual valve as well.

c)

Open fire protection hose leak-hunting valveHV003, HV005 to ensure they have no water, and prove that HV001, HV007, HV002 and HV004 are sealed.

d)

Close washing water preparation station hand-operated valveHV008

8)

Make sure that position detector and revolution detector have be switched on.

9)

Make sure that main motor, motor, low-speed motor and oil pump pump motor have been switched on

10)

Make sure that smoke and gas inlet baffle UV01D, UV01C, heat primary air outlet baffle UV01B and servo motor heat secondary air outlet baffle UV01A have sent off electricity and is in the closed state.

Date: Date: 2008-09-15


Page 121

Rev. : A


SEC 11)


Put in bearing oil system and cooling water a)

Open force-bearing force-bearing bearing oil-receiving oil-receiving valveHV022 valveHV022 and oil removing valveHV024.

b)

Open the cooling water-receiving water-receiving valveHV020 and removing-valveHV021 removing-valveHV021 of the oil cooler to make sure that the cooling water flows smoothly. smoothly.

c)

Open

the

cooling

water

receiving-valveHV010

and

removing-valveHV011

of

the guiding bearing o il cooler. 12)

Check-up of oil system and duplex strainer a)

Make sure that the filter is complete and that duplex three-way valve valve HV012 (HV023) is normally placed and is flexible in switch, and that differential pressure gauge indication is correct.

b)

Use single control on the DCS DCS to launch bearing lubricating oil pump, check the pressure pressure difference of duplex filter.

c)

Examine the oil system to make sure has no there is no oil leakage and see see to it that the safety valve of pipe is in the re-seating state without leakage.

d) 13)

Stop the oil pump when the check-up is done

Locally try low-speed motor and examine the following following items in initial start-up after the maintenance a)

Make sure sure that the moving direction of air preheater is right right

b)

It should be free of blockage and noises, and is flexible in turning

c)

Make sure that speed reducer sounds normally normally and hydraulic couplers have no oil leakage.

d)

If something abnormal is detected in the trial, the trial can not be resumed until errors have been removed

8.3.2.2

Operation of air preheater

1)

Start-up of sub group level a)

Make sure that that the check-up before start-up start-up is done

b)

Operate the manipulation (HSN001) (HSN001) on the DCS to issue start-up order

Date: Date: 2008-09-15


Page 122

Rev. : A


SEC c)


Low-speed motor should be tripped if itit is in the process of operating, and when it stops validating, main motor will start working with green light off and red light on .

d)

Force-bearing and guiding bearing oil pump pump enter into linkage back-up uses uses

e)

Smoke and gas inlet baffle and heat secondary air outlet baffle automatically automatically open

f)

Heat primary primary air baffle (UV01B) remains closed until corresponding primary primary blower starts

g)

When

the

air

preheater

is

operating

at

a

low

speed,

the

low

speed

motor

will automatically stop when the subgroup starts, and main motor also starts,

which, if 20mins after start-up, still can not reach normal speed will automatically stop, while low speed motor automatically restart. h)

Should the above problems are met met (1.2.4), resume the subgroup. If it also does not work, resume until errors have all been removed.

2)

Single control start-up a)

Confirmation of check-up before start-up

b)

Use the single control start-up order on the DCS and make sure air preheater starts operating

c) 3)

Locally open smoke and gas inlet baffle baffle and heat secondary air baffle baffle

Local start-up a)

Start-up check-up confirmation

b)

Set the “remote or local” button to be “local” “local”

c)

Press the start-up button locally, make sure that air preheater starts slowly and operates normally

d) Open the smoke and gas inlet baffle and heat secondary air outlet baffle when necessary. necessary. 4)

Maintenance and surveillance of air preheater in operation a) Put air preheating sealing devices into operation after boiler gets ignited, (when driven by the main motor), and operate HSN005 by using single control.

Date: Date: 2008-09-15


Page 123

Rev. : A


SEC


b)

The right place of sector board is decided by function generator based on load.

c)

Position fixed value is invariable invariable when load is low (below 40%), it becomes variable when the load is between 40% and 100%, and position limit (above and below) can solely be adjusted by 4 fanning strips.

d)

Prevent the device from being clamped as there is an order of automatic receding receding every 24 hours.

e)

Operator can issue receding order either by operating HSN005 on the DCS, or by pressing button local.

f)

Regularly check up the air preheater to guarantee that it has no noises in in operation and its gearing is normal.

g) Make sure that the force-bearing and guiding bearing system is normal without leakage and that the temperature of oil is at a normal level. h)

Make

sure

temperature i)

the

smooth

circulating

of

cooling

water

and

normal

of backwater.

After the air preheater has been charged (at a normal or lower speed), when the temperature of bearing increases to over 60℃, oil pump will automatically start up, and

it

automatically

stop

when

the

temperature

return

50 ℃

to

(FRA/B,

TSH15,TSH25). Still, check the air duct to guarantee that it is without air leakage when the oil temperature of guiding bearing increases, if the problem exists, notify repair workers to work on it in time. j)

Report to chief and shift chief-operator immediately should there be serious leakage of bearing lubricating oil and cooling water in operation.

k)

In operation, rationalize burning to avoid a second time burning, strictly supervise the temperature regularly be

of

air

preheater

do soot-blowing,

reinforced

as

for

smoke example,

and the

gas job

of

in

and

out,

soot-blowing

and should

the pressure difference between air preheating smoke in and

out increase. l)

During operation, strictly strictly supervise the air preheater outlet and inlet and primary and secondary air temperature. If any abnormal is detected, take measures immediately.

m) n)

Normal functioning Air preheater soot-blowing


SEC

Date: Date: 2008-09-15



Page 124

Rev. : A


SEC o)


Use the flame measure measure the temperature difference between air temperature of air preheater outlet and that of heat-up component outlet. When it exceeds 50℃, the controlling room should give off warning signal.

8.3.2.3 1)

Halt of air preheater Do not halt halt the operation of air preheater until the smoke temperature in outlet is is at a degree of more than 175℃ after stopping burning.

2)

Stop operation, give subgroup stop order(HSN001) through DCS. a)

Main motor ceases to run

b)

Force-bearing and guiding bearing oil pump automatically stops.

c)

Heat secondary air outlet baffle automatically closes

d)

Smoke and gas inlet baffle automatically close

e) If heat alternative stops burning, yet air preheater keeps on functioning, normal check-up maintenance should be done f)

If there be repair work after the burning of boiler, boiler, cut off main motor and low-speed motor power

8.3.3 8.3.3.1

Induced fan Check-up before the start-up of induced fan

1)

Check the basic principles and rules for basic check-ups

2)

Adjustable baffle can give electricity and normally switch

3)

Inlet and outlet baffles can give electricity and completely open and close close as well

4)

Motor has delivered power

5)

Local button is sound

6)

Every circuit circuit measuring measuring and protective protective devices are checked out and put into use

7)

Requirements for start-up of themal regulator are met met

8.3.3.2 1)

Start-up of induced fan Conditions for start-up

Date: Date: 2008-09-15


Page 125

Rev. : A


SEC


a)

Air preheater on the corresponding side is operating.

b)

Vibration of air fan is slight.

c)

At least least inlet and outlet baffles of one force fan are openned.

d)

Corresponding inlet vane is closed.

e)

Corresponding outlet truncated baffle is closed.

f)

Every oil gun air baffle is opened.

g)

Open A, B and C secondary air regulating baffle and tertiary air regulating baffle as well.

2)

Sequential control start-up a)

Using DCS, send out induced fan subgroup control start-up order, order, with the green light off and red light on.

b)

After conditions for start-up start-up are met, confirm and complete complete requirements asked of induced and force fan and inlet and outlet baffles as well.

c) Outlet baffle is

baffle

automatically

opens

30

seconds

later, later,

and

inlet

adjustable

“automatic”. d)

When the induced fan on the other side is is not running, its outlet baffle automatically automatically closes.

e)

When

the

induced

fan

on

the

other

side

has

began

functioning,

start

the second induced fan, when the motor is started , it will automatically automatically open the outlet baffle, the inlet adjustable baffle of these two induced fans should be adjusted correspondingly, and “automatic” should be put in. 3)

Start-up by hand a)

Set “manual” on inlet adjustable baffle

b)

Make sure that requirements for start-up are met

c)

Using DCS, DCS, send out induced fan single control start-up start-up order and make sure that the induced fan starts normally. normally.

d)

Open outlet baffle

Date: Date: 2008-09-15


Page 126

Rev. : A


SEC


e)

Set inlet adjustable baffle to be “automatic”.

f)

When the induced fan on the other side is not operating, close its inlet and outlet baffle.

g)

If the induced fan on the other side has began operating, open the outlet baffle baffle by hand when the motor is started, and put in automatic when the opening of these two inlet adjustable baffles are adjusted consistently. consistently.

8.3.3.3

Maintenance and surveillance

1)

Regularly check the induced fan

2)

Make sure that bearing oil level is at a normal normal level and is good in quality. quality.

3)

Make sure sure that transmission gear is complete and functions normally. normally.

4)

Examine the temperatures of induced fan bearing, motor and bearing, vibration should be normal and be in line with BTG operational inspection value.

5)

Vibration of the air fan should be less less than 120μ 120μm

6)

When bearing temperature reach 90℃, warning signal should be given off, and when it reaches over 105℃, operation should be stopped.

7)

When motor bearing temperature reaches 90℃, a warning signal should be given off, and when it reaches over 105℃, operation should be stopped.

8)

When of coil temperature reach 100℃, a warning signal should be given off, and when it reaches more than 120℃, operation should be stopped.

9) 8.3.3.4 1)

Current of motor should be less than rated rated current current Out-of-operation of induced fan Sequential control stops a)

Outlet baffle is “automatic”

b)

Force fan on the corresponding side has stopped running

c)

Use DCS to issue “stop” order

d)

This induced fan stops operating with red light off and green light on. The current is “zero”

Date: Date: 2008-09-15


Page 127

Rev. : A


SEC e)


When the induced fan on the other side is running, outlet adjustable baffle and inlet baffle of the former fan automatically close.

f)

Stop of the last induced fan:

g)

Corresponding force fan and primary fan have stopped operating, and the inlet and outlet baffles of a force fan automatically start.

2)

h)

Use sequential control to stop the last induced fan

i)

Outlet baffle of the two two induced fan close 15mins after it automatically automatically opens

j)

Set the inlet adjustable baffle to be “manual”, and make it “zero”.

Manual operation suspension a)

Stop the corresponding force fan

b)

Set the inlet adjustable baffle baffle of the suspended fan to be “manual”. “manual”.

c)

Gradually narrow the inlet adjustable baffle and take care to keep the draft of hearth.

d)

Manually execute the “stop” order and wait for the stop of the induced fan.

e)

Close outlet and inlet baffles.

f)

When stopping the last induced fan, open the outlet and inlet baffles baffles of these two induced fan, and appropriately open the inlet adjustable baffle according according to the draft of hearth, and what is more, close all baffles 15mins after draught.

8.3.4 8.3.4.1

8.3.4 Force fan Conditions for start-up

1)

Corresponding air preheater is running

2)

Corresponding induced fan is running

3)

Its inlet and outlet baffles should be closed

8.3.4.2

Sequential control start-up

1)

Make sure that the inlet baffle baffle of the induced fan is set “automatic”

2)

Make sure that the cooling air balanced baffle in in the force fan which waits waits for start-up is closed.

Date: Date: 2008-09-15


Page 128

Rev. : A


SEC


3)

Open the outlet and inlet baffles of another force fan.

4)

After issuing issuing the “start” “start” order for waiting force fan on the DCS, confirm and complete all conditions for start-up.

5)

The force fan then slowly starts, with green light off and red light on.

6)

30 seconds later, inlet baffle will automatically open, manually manually open inlet adjustable baffle to 10% (the inlet adjustable baffle can be directly set “automatic”).

7)

Cooling air balanced baffle automatically opens.

8)

When another force fan is not running, its outlet baffle baffle automatically closes.

9)

If the force fan on the other side is already running, outlet and cooling air balanced baffles will automatically open 30 seconds after the second force fan low-speed motor gets started. Manually adjust the opening of the two force fan inlet

adjustable baffles and make them consistent. The opening degree is decided by total load demand multiply 30%, and the inlet adjustable baffle of the force fan can be set “automatic”. 8.3.4.3

Manual start-up

1)

Set inlet manual adjustable baffle of the start-waiting force fan to be “manual”.

2)

Open the inlet and outlet baffles of another force fan on the other side.

3)

Close cooling cooling air balanced baffle on the waiting side that wait for opening.

4)

Operate single control “start” order.

5)

Force fan now starts slowly. slowly.

6)

Open the outlet baffle 30 seconds later. later.

7)

Open the side cooling fan balanced baffle.

8)

If the force force fan on the other side is not running, make sure that its its inlet baffle baffle is closed.

9)

Gradually open the inlet adjustable baffle, and set “automatic”. “automatic”.

10)

If the force fan on the other side is running, start start the second force fan, and 30mins later, manually open the outlet baffle and cooling balanced baffle, also, adjust the inlet baffle of the two force fans to be consistent and set “automatic”.

Date: Date: 2008-09-15


Page 129

Rev. : A


SEC 8.3.4.4 1)


Maintenance and surveillance When the force fan is running at a high speed, its current should be less than the rated current.

2)

When the hearth blows, the amount of air should be between 25%MCR and 40%MCR.

3)

Amount of air/that of burning burning should be more than 9kg/kg

4)

Vibrating should be less than 120μ 120μm

5)

Temperature of bearing bearing should be more more than 90℃ (warning)

6)

Temperature of motor bearing should be more than 90℃(warning)

7)

Temperature of coil should be more more than 100℃(warning)

8.3.4.5

Operation suspension of force fan

1)

Set the inlet adjustable baffle to be “automatic”

2)

Using DCS, issue the “stop” order.

3)

When the force fan stops stops running, running, green light light turns on while red light goes out.

4)

Automatically close the inlet and outlet baffle if the force force fan on the other side side is running.

5)

Automatically close cooling balanced baffle.

6)

Outlet baffle will automatically automatically open after the two force fans have stopped operating, and it will automatically switched to

close

15mins

later

when

inlet

adjustable

baffle

is

“manual”. Single control operation suspension of force fan 1)

Manually narrow the inlet adjustable baffle until it reaches reaches zero

2)

By solely executing the “stop” order, order, stop the running of force fan.

3)

If another force fan is running, running, make sure that the outlet baffle of the former one one is closed.

4)

Close the suspended side cooling balanced baffle.

5)

After these two force fans stop operating through the single control order, order, using DCS, DCS, manually open their inlet baffles and have them closed 15mins later.

Date: Date: 2008-09-15


Page 130

Rev. : A


SEC 8.3.5 8.3.5.1


Primary air fan Conditions for start-up

1)

Air preheater on the corresponding corresponding side should be in in operation

2)

Induced fan on the corresponding side side should be in operation.

3)

Inlet and outlet baffles of start-waiting start-waiting primary primary air fan should be closed.

4)

Heat primary air valve of the air preheater outlet on the corresponding side should be closed.

5) 8.3.5.2 1)

Vibrating of air fan on the start-waiting start-waiting side should be slight Start up of subgroup control After making sure that conditions conditions for start-up start-up are met, using DCS, issue the subgroup control order orde r.

2)

Primary air fan starts running running with green light off and and red light on.

3)

1min after the primary air fan starts, starts, its outlet baffle will will automatically open, so will will heat primary air valve of the air preheate r.

4)

Gradually open inlet adjustable baffle and set primary air pressure and inlet baffle baffle to be “automatic”.

5)

After the second primary air fan starts operating, using hand, adjust the opening of 2 inlet adjustable baffle to be consistent and set them to be “automatic”.

8.3.5.3

Start-up of single control

1)

Make sure that conditions for start-up are met

2)

Set the inlet adjustable baffle to be “automatic”

3)

Through single control, execute the “start” order

4)

This primary primary air fan then starts starts operating, with with red light light on and green light off.

5)

1min later, open the inlet baffle plate by hand

Gradually open inlet adjustable baffle plate and set it to be “automatic”.

Date: Date: 2008-09-15


Page 131

Rev. : A


SEC 8.3.5.4 1)


Maintenance and surveillance Normal level of primary air pressure should be at 38mbar, 38mbar, when it drops drops to 30mbar 30mbar or less, sound the alarm

2)

Give 10 seconds for coal pulverizer to trip when the primary primary air pressure reaches 24mbar 24mbar or less

3)

Current of air fan should should be less than 59A

4)

Vibration of air fan should be less than 80μ 80μm

5)

When the temperature of bearing reach 85℃, a warning sign should be given off

6)

When temperature of motor bearing reach 90℃, a warning sign should be given off

7)

When temperature of coil reaches 100℃, a warning sign should be given off

8.3.5.5 1)

Out-of-operation of primary air fan Subgroup control suspended operation a)

Issue primary air fan subgroup subgroup control “stop” order through through DCS

b)

Make sure that the air fan stops operating

c)

Inlet adjustable baffle automatically turn to “zero”

d)

Outlet baffle automatically close and heat primary air will will automatically shut down baffle

2)

8.3.6 8.3.6.1 1)

Single control operation suspension a)

Gradually close close the inlet adjustable adjustable baffle by hand until it reaches zero zero

b)

Execute “stop” order

c)

Make sure that the air fan stops operating

d)

Close the inlet baffle by hand

e)

Make sure heat primary air baffle automatically close

Pulverizing system Check-up before start-up Start and check rotating machine (refer to basic requirements)

Date: Date: 2008-09-15


Page 132

Rev. : A


SEC 2)


Make sure that pipelines of the system are air proof, proof, free of power leakage and power accumulation and that they have no fire threat

3)

Make sure that blast-proof blast-proof valve valve of the system system is complete

4)

Make sure that all air lock HV005,012,022 are flexible in movement and strictly closed

5)

Make sure that all thermal signal of control panel and control device are sound and useable

6)

Safety interlock security test is up to standard

7)

Fire-fighting equipment is complete

8)

Check the lubricating oil system a)

Oil level of oil tank tank is normal, normal, when it reach over 450 litre, its height should be 2/3 that of the original.

b)

Temperature of oil tank is is at a normal degree

c)

Quality of oil should be fine

d)

Oil quality of reducer should be fine and oil level level should be at 1/2 height of the original

e)

Strainer of main oil system and reducer oil system system should be clean and flexible in swift

8.3.6.2 1)

f)

Connection of system piping should be sound and free of oil and water water leakage

g)

All valves are rightly placed.

Operate all coolers Operate low pressure oil pipe oil cooler: a)

Open cooling water outlet and water inlet valve of cooler, cooler, close the bypass valve

b)

Make sure sure there is a cooling water flow (20m3 (20m3 /h).

c)

Put in main reducer cooler

d)

Open

cooling

water

outlet

of

oil

cooler

and

front

and

rear

doors

temperature-controlling valve (bypass valves closed), and open water inlet valve

Date: Date: 2008-09-15


Page 133

Rev. : A

of


SEC e) 2)


Make sure that there is a flow of cooling water water

Put into into use the main motor cooler of ball mill mill a)

Open cooling water water outlet valve of water cooler and water inlet valve, cooling water outlet valve of main motor bearing and water inlet valve as well.

b) 8.3.6.3 1)

Make sure that that the cooling water flow is right

Check-up of powder-manufacturing equipment Ensure

that

coal

feeder

has

no

sundries,

scraper

chain

is

complete,

pulverized coal discharging discharging pipes are smooth, all inspection holes are closed, and and coal level of raw coal bunker is sufficient. 2)

Gear wheel seal cover of ball mill should be sealed and seal fan 008ZV is reliable and acts as back up.

3)

Air drive guide baffles of cyclone separator separator UV10, UV20 can rightly operate and are reliable in action.

4)

Exterior of feeder is complete, complete, interior strict without without accumulated powder and mechanical parts test normally.

5)

The

inspection

that

of

of

pulverized

coal

discharging

machine

is

the

same

as

the pulverized coal conveyer.

6)

Pulverized coal bunker is closed tightly, tightly, pulverized coal level measuring device is correct. correct.

7)

All valves valves of the system should be in the following positions: a)

Motor-operated main main valves valves for adding steel ball are closed.

b)

Motor-operated sub-valves for adding steel ball are closed.

c)

Pulverized coal discharging plugboard and hot smoke hand-operated valve of the coal feeder are open and the air-operated valve is closed.

d)

Air cooling valves are closed.

e)

Hot air regulating valve is closed.

f)

Hot smoke smoke bypass bypass valve valve of ball mill mill is is in in a state of opening of commissioning.

g) Air-operated guide baffle of cyclone separator is directed to the pulverized coal

Date: Date: 2008-09-15


Page 134

Rev. : A


SEC


bunker. h)

Air-operated plugboard plugboard UV06 between pulverized coal conveyer and pulverized coal bunker is closed.

i)

Pulverized coal-discharging valve of bunker is closed

j)

Outlet of cyclone separator is closed

k)

Inlet valve of coal pulverizer pulverizer exhauster is closed, recycled air valve in the outlet is in the state of opening of commissioning, air fan bearing cooling outlet is closed and inlet thereof opened.

l) m) n)

Exhaust air fan inlet inlet regulating regulating baffle is closed and outlet valve is closed. Exhaust air pipe cooling air valves are opened Moisture-absorbing pipe valves of coal bunker are opened, and moisture-absorbing pipe communicating valves are opened as well.

o) 8.3.6.4 1)

Controlling power and utility power of various rotating rotating machines are reliable.

Operation of coal pulverizing system Get lubricating oil system started a)

Controlling Power and utility power are prepared, prepared, and lubricating oil system is in normal condition.

b)

Group control start-up (on DCS): execute execute group control order, lubricating oil system group control procedures automatically go on 1) Main speed reducer oil pump is is got started. 2) When oil temperature of main oil tank is not more than 35℃, low pressure oil pump will start operating. 3) When oil temperature reaches 10℃ or more, low pressure oil pump get started 4) When oil temperature reaches 35℃ or more, top tiles and jacking oil pump get started

c)

Single control start-up 1) Get it started in sequence on DCS.

Date: Date: 2008-09-15


Page 135

Rev. : A


SEC


2) Start-up conditions, procedure and group control start-up. d)

Local surveillance of lubricating oil system start-up: Speed-reducing oil pump starts normally, normally, and the oil flow is not less than 60 litre every second. Low pressure oil bump starts normally, and oil pipelines have no vibration and leakage. Bush oil-pumping pressure gauge should be more than 0.2bar, oil-pumping flow (meter) more than 30 litre per second, and jacking oil pump inlet oil pressure (meter) 1.6bar or so. Jacking oil pump starts normally, oil outlet pipelines have no leakage and top bad oil pressure is somewhere between 25bar 25ba r and 50bar. Jacking oil pump starts normally, oil outlet pipeline have no leakage, and jacking pressure is somewhere between 35bar and 60bar

2)

Setting value of lubricating lubricating oil system and their relations

Main oil tank: a)

When oil level is low (less than 450 litre), low pressure oil pump will trip, so will high pressure oil pump and coal pulverizer chain

b)

When oil temperature is less than 10℃, low pressure oil pump will trip

c)

When oil temperature is less than 35℃, jacking (oil) pump will trip

d)

When oil temperature is is less than 35℃, electric heater will automatically put into action

When oil temperature reaches more than 40℃, electric heater will automatically stop. Low pressure oil pump exporting oil temperature is 8bar, when it reaches 12bar or more, safety safety valve should be in place Oil temperature after cooler is 45 ℃, temperature control valve will automatically regulate When pressure difference of filter reaches 1.5bar or more, a warning signal should be given off

Date: Date: 2008-09-15


Page 136

Rev. : A


SEC


When temperature of low pressure pipelines reach 60℃ or more, coal pulverizer will trip When bush oil flow of coal pulverizer is less than 30L per second, the sub-coal pulverizer will trip. When the oil pressure of oil pump inlet of top pad and jacking is 1.6 bar, the constant pressure valve will automatically adjust; when the oil pressure is equal to or more than 1.8 bar, the safety valve will trip while PSL111 PSL111 coal mill trips and the oil pumps of top pad a nd jacking trip when the oil pressure is 0.2 bar. When oil pressure of jacking pump reaches 60bar or more, safety valve trips. When oil pressure of jacking pu mp reaches 110bar or more, safety valve trips. When oil temperature of jacking pump is too low, say 15bar, jacking oil pump will trip (coal pulverizer trips) When oil temperature of jacking is too low, say 30bar, jacking oil pump and coal pulverizer will trip When oil temperature of speed reducer reaches 65℃ or more, a warning signal should be given off 1)

Pressure difference difference of filter is too high, the alarm is given.

2)

Oil flow is too low, say 60 litre per min, oil pump of speed reducer and coal pulverizer pulverizer will trip

Big gear fueling injection equipment: big gear fueling injection air atomizing pressure is less than PSL201, 4ba r, send off warning signal Stop the operation of lubricating oil system in case of the following situations Lubricating oil system needs repair Lubricating oil system lose great amount of oil and stop operating because of accidents 3)

Subgroup control start-up of coal pulverizing system

Requirements for start-up a)

Remote and local button of its transmission should be set at remote

b)

Lubricating oil system functions normally

Date: Date: 2008-09-15


Page 137

Rev. : A


SEC


c)

Its transmission has no vibration and high alarm

d)

When temperature temperature of bush coal mill is less than 70℃, it is at a normal level, as is motor bearing when its temperature is less than 90℃.

e)

Boiler safety protection device should be set set MFT resetting, and control and drive power of all equipment belonging to the coal pulverizing system should be reliable

f)

Flow of steam should be more than 270T/H.

g)

Inlet adjustable baffles of both air-lack air fan and coal pulverizer exhauster should be fully closed.

h)

Temperature of coal pulverizer pulverizer inlet should be less than 128℃.

i)

Gigger braking device “loose”.

j)

At least one of adding steel motor -driven main valve and sub valve should be closed.

k)

Thermal signal should be correct, and noise-measuring device of coal pulverizer pulverizer should be put into use

l) m)

Revolution local controlling tank switch of coal feeder should be set set “on” Star-up Star-up preparation on the DCS

Exhaust air quantity should be set between 30000 Nm3 /h and 40000Nm3 /h Temperature of coal pulverizer outlet should be set at 115℃ Inlet adjustable baffles of air-lack air fan, hot air and cool air should be set “automatic”, rev of coal supply should be set “zero” and “automatic” Start-waiting Start-waiting coal pulverizing system will be repositioned Start the exhaust air circuit (on DCS) a)

Execute subgroup control order 1) Start the exhaust air fan 2) Cooling air baffle of exhaust air fan inlet will be closed while its outlet baffle will be opened 30 seconds after it gets started

b)

Inlet adjustable baffle be set “automatic”, fixed value of exhaust air quantity should be set

Date: Date: 2008-09-15


Page 138

Rev. : A


SEC


Start mill-exhausting circuit Execute subgroup control start-up order 1)

Mill exhauster gets started

2)

Inlet baffle UV02 will open 30 seconds seconds after mill exhauster exhauster gets started

Start hot smoke circuit Execute subgroup control HSN007 start-up order 1)

Get hot smoke smoke air-drive truncated baffle UV05 started

2)

Inlet adjustable baffle of exhaust air fan automatically open, adjust the fixed value of exhaust air quantity

3)

Adjustable baffle of hot air and cool air automatically adjust, temperature of controlling coal pulverizer outlet gradually increase until it reaches its fixed value

4)

Draft of coal pulverizer outlet and mill mill exhauster inlet then gradually increase

Start the coal pulverizer Execute the sub group start-up order when temperature of coal pulverizer inlet reaches more than 90℃ 1)

Start auxiliary motor, motor, have ball mill mill slowly operate, and 2mins later, unplug the auxiliary motor and plug the main motor

2)

Get big gear seal fan started

3)

Put big gear oil blooming system into use

If seal fan does not operate, coal pulverizer (main motor) will trip To restart coal pulverizer, use single control seal fan(on the DCS) when it is normal Start coal feeder Execute subgroup control start-up order 1)

Local controlling controlling tank is electrified electrified 5 seconds after after it gets started

2) Speed-controlling device of coal feeder will be put into a automatical control state 5 seconds after coal feeder and controlling tank are electrified.

Date: Date: 2008-09-15


Page 139

Rev. : A


SEC 3)


After the coal pulverizing system gets started, see to it that temperature of coal pulverizer inlet slowly increase until it reaches its fixed value, and that the adjustable baffles of hot air and cool air are in the automatic position, and that noise-measuring indicator of coal pulverizer chang from high to low until it reaches normal value

4)

Group control of coal pulverizing system

Conditions for start-up Start preparation on the DCS: Start-waiting Start-waiting coal pulverizing system reseats. Exhaust air flow control reture circuit, temperature-controlling circuit and speedcontrolling A/H order of coal feeder are all “automatic”. Sub group start-up conditions are met. Group control start-up Execute HSN001 group control start-up order. order. 1)

Get exhaust air fan circuit circuit started through automatic sequencing.

2)

Get mill exhauster started through automatic sequencing.

3)

Start hot smoke circuit through automatic sequencing.

4)

Inlet baffle baffle of exhaust air fan automatically adjust exhaust air flow. flow.

5)

Adjustable

baffles

pulverizer

inlet temperature until it reaches 90℃.

of

hot

air

and

cool

air

automatically

adjust

coal

a)

If gigger motor is operating, it will trip.

b)

Coal pulverizer automatically starts through automatic sequencing.

c)

Coal feeder automatically starts through automatic sequencing, rev control circuit of coal feeder will automatically adjust coal supply quantity.

6)

Maintenance and parameter during operation

Adjustment of coal pulverizing system in operation a)

Objectives of adjustment

Date: Date: 2008-09-15


Page 140

Rev. : A


SEC 1)


Make sure that the fineness degree of coal powder is up to standard standard and is fine in evenness degree to avoid incomplete burning loss

2)

Guarantee lower

3)

the

best

output

of

coal

pulverizing

system,

and

try

to

power consumption of milling

When boiler functions safely and economically, economically, guarantee coal powder supply and sufficient coal level to suit the change of load, and ensure that there is enough buffering time when when coal pulverizing system system fails

b)

Adjustment and instruction in operation 1)

Coal feeding speed adjustment Coal feeding speed adjustment automatically proceeds according to the signal of noise-measuring device, and it works in the manner of “automatic”. In face of the problem of manually adjusting coal feeding amount, when slowing down or quickening speed, ensure that th at the coal feeding is slow and consistent, starting or closing the coal feeder to adjust coal feeding is is banned

2)

Adjustment of exhaust air amount Inlet adjustable baffle of exhaust air fan should be “automatic” Flow amount of exhaust air can be changed through exhaust air amount enactment, and when humidity of raw coal is high, increase exhaust air amount properly

3)

Adjustment of coal pulverizer inlet temperature Adjustable baffles of hot air and cool air should be “automatic”, the opening of hot air adjustable baffle appropriate, and cool air adjustable baffle closed. With coal pulverizer outlet temperature enactment, hot air and adjustable baffles should be automatically

cool air

adjusted, aimed at adjusting coal

pulverizer outlet temperature. Restriction loop is used to avoid temperature rise at coal pulverizer entrance, the temperature

of

coal

pulverizer

inlet

should

always

be

higher

than

secondary air temperature (minimum temperature difference △T=20℃) If

outlet

temperature

revolution slowly reaches

Date: Date: 2008-09-15

drops

falls by

too

much

connecting

(about10 ℃ revolution

lower), slide

coal

feeding

system

normal


Page 141

Rev. : A

until

it


SEC


temperature value 4)

Noise control of coal pulverizer If coal pulverizer noise drops too much to avoid the blocking of coal pulverizer, coal feeder revolution is automatically shifted to 20% that of its rated revolution

5)

Hot smoke bypass valve HV002 of coal pulverizer Manual baffle HV002 can control coal powder circulation amount from raw powder separator to coal pulverizer (when it is closed, the baffle increases the coal powder circulation amount, and it can only be adjusted once in the test)

6)

Mill exhauster recirculating valve HV003 In debugging, fix its opening which should not be changed in operation Mill

exhauster

through

air

current

raw powder separator

accumulation

of

carries

the

powder

into cyclone

from

coal

pulverizer

separator, separator, and a nd to

avoid the

coal powder in the pipelines, the speed of gas in the pipes

should be as much as that of the fixed minimum value 7)

Adjustable baffle of raw powder separator Its function is to adjust the effect of raw powder separator to ensure the fineness of coal

powder

is

up

to

standard,

and

in

debugging,

fix

its

opening

level which is generally not adjusted in operation When its opening enlarges, draught of the system and coal pulverizer will increase and coal powder become thick When the fineness of coal powder passes 200 in normal operation, objective should be between 92% and 95%. c)

Operational parameters of coal pulverizing system

Temperature monitoring 1)

Normal value of coal pulverizer pulverizer inlet hot smoke air temperature is somewhere between 350 and 700℃, when it reaches upper limit of 800 ℃ and lower limit of 300℃, a warning signal should be given off.

2)

Normal value of coal pulverizer inlet temperature is 115 115℃, when it reaches 120℃ or is

Date: Date: 2008-09-15


Page 142

Rev. : A


SEC


less than 90℃, a warning signal should be given off, when it reaches 130℃, exhaust air and mill exhauster will trip, so will interlocked coal pulverizing system Air pressure monitoring 1)

Normal value value of coal coal pulverizer outlet draft should be somewhere between 20mbar and 30mbar

2)

Inlet draft of mill mill exhauster should be equal to 70mbar of less 3

Exhaust air amount should be 40000Nm /h or less Powder level of coal bunker should be maintained a level higher than 8 meters, when it is 3 meters high or less, a warning signal will sound and pulverized coal feeder will trip. When it is 11 meters high or more, sound the alarm, and when powder level reaches 12.5 meters, stop the coal pulverizing system or remove powder to another coal bunker on the other side Electric current value of rotating machine 1)

Value of exhaust air fan should be less than that of rated electric current

2)

Rated electric current value of mill exhauster should be less than that of rated current

3)

Rated electric current value of coal pulverizer should be less than that of rated electric current

Inspection and maintenance of coal pulverizing system in operation Inspectors status

of

should

regularly

check

all

equipment,

checking

the

functional

all equipment, collating local instrument and control room numerical value, and

immediately reporting and acting to deal with problems when something abnormal happens. Operational parameters of all auxiliary organs should be controlled within the following scope 1)

Coal pulverizer

Normal temperature value of bush should be at 45℃ or so and less than 70℃. Main motor bearing temperature should be less than 90℃ Coil temperature of motor should be less than 100℃ Cooling water flow of main motor cooler should be at a normal level Cooling water flow of main motor bearing should be at a normal level

Date: Date: 2008-09-15


Page 143

Rev. : A


SEC 2)


Mill exhauster

Bearing temperature should be at a degree lower than 90℃ Bearing temperature of motor should be at a degree less than 90℃ Coil temperature of motor should be at a degree less than 100℃ Bearing vibration should be less than 80μ 80μm, when it passes 80μ 80μm, air fan will trip Cooling water amount of motor should be normal 3)

Exhaust air fan

Bearing temperature should be at a degree less than 90℃ Bearing temperature of motor should be at a degree less than 90℃ Coil temperature of motor should be at a degree less than 100℃ Bearing vibration should be less than 80μ 80μm, when it passes 80μ 80μm, air fan will trip Cooling water amount of motor should be normal 4)

Lubricating oil system

Oil temperature of main oil tank should be somewhere between 35℃ and 40℃ Oil level of main oil tank should be 1/2~2/3 of its original height (based on on-site oil level gauge) Bush oil-receiving flow amount of coal pulverizer should be more than 30 litre per second Pressure difference of oil filter should be less than 1.5bar normally, when it reaches 1.5bar or more (PDSH102), rearrange the oil filter and notify workers for maintenance and clean the oil filter that has been blocked. Top pad oil temperature should be somewhere between 25bar and 50bar (normally it is 30bar or so) Jacking oil temperature should be somewhere between 35bar and 60bar (normally it is 40bar or so) Oil system has no vibration and oil leakage 5)

Oil system of speed reducer

Date: Date: 2008-09-15


Page 144

Rev. : A


SEC


Oil system should be free of oil leakage Oil flow should be more than 60 litre every minute When pressure difference of filter is too great, change the filter and notify repair workers for maintenance and clean the one that has been blocked Cooling water flow indictor of cooler should be placed in the protection zone 6)

Big gearwheel grease-blooming system

Oil in the oil barrel should be sufficient, if oil shortage problem is found, notify oil inspectors to refuel in time Motor-driven pump and oil blooming should be normal When electromagnetic valve rear pressure reaches 4bar (PSL201), sound the alarm. 8.3.6.5 1)

Suspended operation of coal pulverizing system Subgroup control stops (on DCS) a)

Set the speed-controlling device of coal feeder to “manual” “manual” status to bring the speed down to zero

b)

Operate the subgroup control stop order order and stop coal feeder

c)

After the coal feeder stops, make sure that coal in the coal pulverizer pulverizer have all been removed and its outlet draft diminish, and when outlet temperature passes 120℃, operate

the

pulverizer motors order),

subgroup

control

stops stops operating, can

and

be 30

stopped minutes

stop

assistant

order.30 motor

by operating later,

seal

fan

seconds

gets the

after

started

local

or or

coal

(assistant emergency

will automatically stop (it can

also be realized by operating the single control stop order on the DCS). d)

Operate the subgroup subgroup control stop order, order, make sure that hot smoke air drive baffle and inlet adjustable baffle of exhaust air fan, and hot air and cool air adjustable baffle plate automatically close

e)

Operate the subgroup control stop order, order, mill exhauster will stop and its inlet baffle baffle plate will automatically close

f)

Operate the subgroup control stop order, order, exhaust air fan will stop operating, and its inlet and outlet adjustable baffles will automatically close, whereas cooling air baffle

Date: Date: 2008-09-15


Page 145

Rev. : A


SEC


in the exhaust air vent will automatically start 2)

Group control stop (on the DCS) a)

Carry out the group control stop order and stop proceeding the procedures.

b)

Coal feeder stops operating, and the opening speed-controlling device drops to zero

c)

15 minutes after coal feeder stops operating, its subgroup control circuits also cease successively

8.3.6.6 1)

Emergency automatic stopping and tripping of the pulverizing pulverizing system The pulverizing system trips trips when when one of the following conditions is met a)

‘Emergency stop’ command is operated

b)

Boiler MFT action is done.

c)

A ball mill trips when when the pulverizing pulverizing system is treated with group control.

d)

If one of the above conditions occurs, occurs, the following steps should be operated at the same time

e)

The coal feeder trips automatically

f)

The main motor of coal mill mill trips trips automatically and the helper motor starts up after 30 seconds.

2)

g)

The hot smoke air circuit trips automatically

h)

The pulverized coal exhaust circuit circuit trips automatically

i)

The exhaust gas circuit trips automatically

The tripping of each subgroup control circuit The exhaust gas circuit trips when one of the following conditions is met a)

Action of the boiler MFT is done

b)

The outlet temperature of the coal mill is equal to or higher than 130 degrees

c)

Steam flow<270T/H with 3 minutes’ delay

d)

Vibration of exhaust gas fan ≥80μ 80μm with 10seconds’ delay

Date: Date: 2008-09-15


Page 146

Rev. : A


SEC e)


After the start-up command command is given two seconds, the exhaust gas fan motor has no electricity.

f)

The group control commands or subgroup control commands are done

The pulverized coal exhaust circuit trips when one of the following conditions is met a)

When the start-up command is given 90 seconds, the entrance truncated baffle is not open

b)

The outlet temperature of the coal mill is equal to or higher than130 degree

c)


d)

The pulverized pulverized coal exhauster vibrates too sharply with 10seconds’ 10seconds’ delay

e)

After the start-up command command is given 2 seconds, the pulverized coal exhauster motor is not switched on. The group control commands or subgroup commands are done

The hot smoke wind circuit trips when one of the following conditions is met a)

The exhaust gas fan motor is powered off

b)

The pulverized coal exhauster motor is powered off

c)

The pulverized coal exhauster entrance baffle is not opened completely

d)

The lubricant circuit of the coal mill is not put into operation

e)

After the start-up command command is given given 30 seconds, the hot smoke baffle is not open

f)

One tripping tripping command command is is given from from the group control or subgroup control

The coal mill trips when one of the following conditions is met a)

The lubricant circuit of coal coal mill mill is not put into operation

b)

Any top bearing oil pressure is equal to or less than 30bar (top watt watt pressure≤ pressure≤15bar)

c)

Any top watt oil blooming flow <30litre/minute with 5 seconds’ delay

d)

The oil temperature temperature in the oil tank is equal to or higher than 60 degree, or less than 35 degrees.

e)

The lubricant circuit of the coal mill is not put into operation.

Date: Date: 2008-09-15


Page 147

Rev. : A


SEC


f)

The lubricant lubricant circuit circuit of the coal mill is not put into operation.

g)

The alarm issues when cooling water water flow is low. low.

h)

The temperature of top watt is equal to or higher than 70 degree.

i)

The locking pole of turning gear leaves the position.

j)

Both of the two steel tubes with electric valves are not closed

k)

After the main motor is started up 2 seconds, the centrifugal intermittent intermittent device of the turning

l) m)

gear is in a closed position

After the main motor is started up 2 seconds, the seal fan is not started up Switch to the operation of the turning gear is required

n)

The time of the oil blooming blooming system’s system’s fault is more more than one hour

o)

The hot smoke air baffle is not open

p)

Action of the boiler MFT is done.

q)

The entrance fuel pressure of the high pressure pressure fuel pumps is equal to or less than 0.2 bar

r)

One group control command or subgroup command is done

s)

After the main main motor of coal mill mill is powered off 30 seconds, the auxiliary auxiliary motor is started up

The coal feeder trips when one of the following conditions is met a)


b)

The pulverized coal level of pulverized coal bunker is too high (LSHH06A/06B) (LSHH06A/06B)

c)

The main main motor motor of coal mill is powered off off

d)

The baffle baffle of hot smoke smoke air is not open.

e)

After the coal feeder is started up 25 seconds, the speed of revolution is too slow slow

f)

After the coal feeder is started up 2 minutes, minutes, the coal is not supplied and with 30 seconds

Date: Date: 2008-09-15


Page 148

Rev. : A


SEC g) 8.3.7 8.3.7.1


One stop command from from the group control command or subgroup command is done

The turning gear of the ball mill Regulations about operation of the turning gear

1)

When the pulverizing system system is stopped while the rotating equipment has no fault

2)

When adopting mechanical mechanical supervision to the coal mill

3)

Before starting up the coal mill after being stopped a long time, the lubricant system must be adjusted in the state of turning gear

4)

When the main motor is started up, the turning gear motor motor should be run for 2 min in low speed.

8.3.7.2

The start-up conditions of turning gear:

1)

The lubricant lubricant circuit of coal mill is put into operation

2)

Speed reducer lubricant circuit is in operation

3)

The temperature of bearing of the coal mil is normal

4)

The main main electromotor electromotor of coal mill mill is powered off

5)

The braking braking device of turning gear is in the “loose” position

8.3.7.3 1)

The start-up of turning gear Start up on the spot a) When the pulverizing system is stopped, but its rotation machine is normal, the persons on duty should start start up the turning gear until the main motor starts up b)

Press the on-the-spot startup button to start up the turning gear when mechanical inspection is

needed,

or

operation

of

coal

mill mill

at

slow

speed

is

needed for adjusting the lubricant system c)

When the start-up start-up command command is given, electromagnetism gear and auxiliary motor is electrified at the same time

8.3.7.4

The tripping conditions of turning gear

1)

The lubricant lubricant circuit of coal mill is not put into operation

2)

The lubricant lubricant circuit of speed reducer is not put into operation

Date: Date: 2008-09-15


Page 149

Rev. : A


SEC


3)

The temperature of bush of coal mill is equal to or higher than 70 degree

4)

The trouble time of fuel sprinkling sprinkling system lasts more than one hour.t hour.t

5)

After the turning gear is started up 2 seconds, the seal fan fails to start up

6)

The locking locking pole of turning gear is not in “loose” position

7)

One stop command is given

8.3.8 8.3.8.1

The pulverized coal conveyer The inspection before start-up

1)

The inspection of the mechanical section section should be normal normal

2)

The pulverized pulverized coal conveyer should should not be blocked by pulverized coal

3)

Accumulated pulverixed pulverixed coal, light source should not be found and the lighting should be sufficient.

4) 8.3.8.2 1)

The gas source of the guide baffle should be normal. normal. The pulverized coal pouring operation of the pulverized pulverized coal conveyer(A→ conveyer(A→B) Open the pulverized pulverized conveyer then lead it to the pneumatic flashboard flashboard of B pulverized bunker, and the pneumatic flashboard should be closed when it arrives at A pulverized bunker.

2)

Open the communication valves of the moisture absorption pipe

3)

Operate the startup button of the pulverized conveyer from A to B on the spot

4)

Make sure that the operation of the pulverized pulverized coal conveyer is normal, the direction is normal, the motor and the transmission device is normal

5)

Lead the lowering lowering pulverized coal guide baffle of A side of the cyclone separator to the pulverized coal conveyer

6)

Make sure that the operation of the pulverized coal conveyer is normal, normal, and make sure the pulverized coal has been conveyed from A to B

7) 8.3.8.3 1)

The changes of the position of pulverized coal in A, B bunker should be monitored. The normal maintenance of pouring pulverized coal (A→ (A→B) Inspect the operation of the pulverized pulverized conveyer periodically

Date: Date: 2008-09-15


Page 150

Rev. : A


SEC 2)


The signals of the pulverized coal conveyer and the guide baffle baffle of the cyclone separator should be normal no rmal when being monitored by a CRT. CRT.

3)

When B pulverizing pulverizing system operates and pulverized coal is poured from from A to B, the level of pulverized coal in B bunker rises rapidly, the changes of the level of pulverized coal should be should be paid.attention to.

8.3.8.4 1)

The abnormality treatment of pulverized coal pouring: When pulverized coal is poured and the pulverized pulverized coal conveyer trips, the guide baffle of A cyclone separator is should be made sure to be led to the pulverized coal bunker automatically

2)

When the pulverized coal conveyer operates and has sprinkling pulverized coal, it should should be inspected that whether the hand-operate d valve of the moisture absorption pipe is opened.

3)

When

the

chains

of

the

pulverized

coal

conveyer

are

broken,

the

guide

baffle of

A

cyclone separator should be led to the pulverized coal bunker at once, and stop the pulverized coal conveyer 8.3.8.5 1)

Stop pouring pulverized coal Lead the guide baffle of A cyclone separator to the pulverized coal bunker on the spot, and make sure the position of the pulverized bunker is right

2)

Stop the pulverized pulverized conveyer when it has no pulverized coal

3) Shut off the pulverized coal conveyer, and lead it to the pneumatic flashboard of B pulverized coal bunker 8.3.9 8.3.9.1

The operation of adding steel balls into coal mill The steel balls should be added during the operation when the current of coal mill is is equal to or less than 190A,.

8.3.9.2

The operation method of adding steel balls

1)

Prepare the steel balls that to be added.

2)

The quantity of the added steel balls is 1 ton/ times, and the current of ball mill is rose by about 1A

3)

Operate the button of “preparation of adding steel balls” on the spot, spot, the general electric

Date: Date: 2008-09-15


Page 151

Rev. : A


SEC


valve for adding steel balls are opened, and then the steel balls are filled into the locking cavity 4)

Operate the button of “adding steel balls” on the spot, then the general electric valve of adding steel balls are closed, the electric sub-valve are opened, and the steel balls are added into the coal mill

5) 8.3.9.3 1)

3 minutes later, the electric sub-valve for adding steel balls are closed automatically Attention When both the general electric electric valve and sub-valve for adding steel balls have no signals, the coal mill will trip.

2)

After adding the steel balls, make sure that the next operation of adding steel balls should be done only after the electric sub-valve is closed

8.3.10

The pulverized coal burner

8.3.10.1 The inspection and preparation before start-up 1)

Open and

the

pulverized

coal

feeding

flashboard

of

the

pulverixed

coal

feeder,

the hand-operated valve of the primary air pipe is in the position for adjusting adjusting

the opening degree. 2)

Various parts of the pulverized coal feeder, feeder, the speed governor and the motor should be checked whether they are all normal.

3)

The primary air pipe should not be leaked, and the platform of the coal feeder has no accumulated pulverized coal and combustible substance.

4)

Make sure that the controlled gas source of the primary air pneumatic valve is normal, and the hand-operated valve of the controlled gas source is opened.

5)

The sampling sampling valve valve of the primary primary air pressure meter meter is is opened.

6)

The switch switch of the local speed governor is in “ON” position

8.3.10.2 The startup conditions: 1)

The general protection of boiler is put into operation, and MFT MFT is is reset.

2)

The corresponding oil gun torch is put into into operation

3)

The steam flow is equal to or higher higher than 250T/H

Date: Date: 2008-09-15


Page 152

Rev. : A


SEC


4)

The level of the pulverized coal in pulverized pulverized coal bunker is higher than 5m

5)

The hot primary air pressure pressure is not too low.

8.3.10.3 The start-up of subgroup control (on DCS) 1)

Regulate the to-be-started-up speed governor of coal feeder to “zero” (SC50A/50B)

2)

Operate start-up command for the subgroup control of the front wall coal feeder or back wall coal feeder

3)

The corresponding primary air pneumatic baffle is opened.

4)

After the primary air baffle is opened for 10 seconds, the coal feeder is started up

5)

After the coal feeder is started started up for 5 seconds, the corresponding secondary air baffle is opened.

6)

All the baffles of the A. B, C bellows are placed in the manual state, then then the speed control of coal feeder is put into operation

7)

The lowest rotating speed is 3rpm, the corresponding pulverized coal’s quantity is 4T/H. The automatic control of the fuel increase and switch is operated according to the needs of load increase, and it should be confirmed that the pulverized coal burns well

8.3.10.4 The single control of start-up (on DCS) 1)

Make sure the start-up conditions are ready. ready.

2)

The speed of the to-be-started-up coal feeder is regulated regulated to “zero”

3)

The start-up start-up command of the single control of the corresponding primary air pneumatic baffle is operated and the valve should be confirmed opened.

4)

The start-up command of single control of coal feeder is operated, and then the coal feeder is started up.

5)

After the speed controller of the coal feeder is put into operation for 5 seconds, the corresponding corresponding secondary air baffle is opened.

6)

After the coal feeder starts up normally, normally, the rotation speed should be increased manually, manually, and it should be made sure that the pulverized coal burns well

Date: Date: 2008-09-15


Page 153

Rev. : A


SEC


8.3.10.5 The running running and operation of the pulverized pulverized coal jet burner 1)

The rotating speed of single coal feeder is set in “automation” (on DCS) When the number of the coal feeder operation is increased to 8, and the rotating speeds are all 5rpm, the rotating speed of the single coal feeder can be put into automation in turn,

and

SC50A/50B

is

regulated

by

the

general

rotation

speed.

The

operation is as follows: a)

The opening degree of the general speed governor of the coal feeder is regulated to 40% (on DCS or the spare tray)

b)

The speed governor of the single single coal feeder is used to regulate its its rotation speed in order to adapt to the signal need of the general speed governor, and the regulation of the rotating speed of the coal feeder is set to “automation”

c) 2)

As the methods described above, other coal feeders are set to “automation” in order. order.

The general speed governor of the coal feeder is set to “automation” When the quantity of the coal feeder and its rotating speed is adequate, and the volume of the pulverized coal reaches about 50%, the general speed governor can be set to “automation” in

order to

balance the

air volume /

fuel volume

ratio automatically, automatically, the operation is as follows: a)

The demand regulator of the general load should be placed in manual state, and its opening degree should be 45%

b)

The entrance regulation baffle of the induced draft fan and forced draft fans has been put into “automation”

c)

The smoke oxygen content should be normal, and its regulator should be put into into “automation”

d)

The general rotating rotating speed of the coal mill mill should be set to “automation” (FEO HIC 050)

e)

At this time, time, the general load needs, the rotating speed and the air flow of the coal feeder should be correspondingly increased or decreased.

3)

The start-up order of the pulverized pulverized coal coal jet burner a)

In principle, the start-up order should be operated from the middle of the arch to its

Date: Date: 2008-09-15


Page 154

Rev. : A


SEC both sides, put into

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL (FEF,

FED)

(FEG,

→

FEC)

→(FEH,FEB)

and

should

be

operation correspondingly for the front and back archs. b)

When the second auxiliary ejector is put into operation, put FEE→ FEE→ (FEI, FEA) to the coal feeder

c)

The operative rate of the pulverized coal jet burner should be consistent with the startup burning rate curves

4)

Operation maintenance and supervision a)

Supervision in the control platform

The primary air pressure should be equal to or higher than 36mbar The rotating speed change of the coal feeder should be balanced, the rotating speed should not fluctuate substantially when “automation” is set, otherwise the speed should be switched to manual control and the rotating speed of the coal feeder should be controlled equal

to or

less than

10rpm in

order to

prevent the

pulverized coal from blocking of the pulverized coal pipe. b)

Local maintenance

Various parts of the coal feeder, speed governor and motor should be inspected and confirmed in normal condition. The coal feeder has no abnormal sounds The operation of the pulverized coal feeding pipe of the coal feeder is smooth, and the temperature is normal The pulverized coal feeding pipe and the primary air pipe has no leakage of pulverized coal and air leakage The local place has no blocking pulverized coal and self-ignition phenomenon 8.3.10.6 The stop of the pulverized pulverized coal jet burner When the boiler stops, the pulverized coal feeding flashboard should be switched off before the coal feeder stops 1)

The subgroup command stops (on DCS) a)

The stop command of the subgroup control is stopped.

Date: Date: 2008-09-15


Page 155

Rev. : A


SEC


b)

When the coal feeder stops, the speed governor will automatically return return to “zero”

c)

After

the

coal

feeder

is

stopped

for

20

seconds,

the

corresponding

secondary air baffle is switched off. (If the oil gun torch keeps operating, the secondary air baffle near the oil gun torch should be opened) d) 2)

The primary air pneumatic baffle is closed

Stop of the single control a)

The rotating rotating speed of the to-be-stopped coal feeder is reduced to “zero”

b)

The stop command of single control is operated and the coal feeder is stopped.

c)

After

the

coal

feeder

is

stopped

for

20

seconds,

the

corresponding

secondary air baffle is closed. (the baffle keeps keeps open when the oil gun torch is operating) (FEA UV13, FEI UV24 UV24 single control is closed) d) 3)

The single control demand is is operated and the primary air baffle is switched off

The coal feeder’s stops for accident

The coal feeder trips when one of the following conditions is met a)


b)

The operation conditions of the coal burner defined by the flame scanning system are not fulfilled.

c)

When steam flow is less than 440T/H, the corresponding corresponding oil gun torch has no flame monitoring

d)

When steam flow is less than 270T/H

e)

The (3m)

related

pulverized

coal’s

level

in

the

bunker

is

too

low

(FMA/B LSLL06A/06B)

f)

The primary primary air pressure is too low (FSA PSLL03) with 5 seconds’ delay (<24mbar)

g)

The corresponding corresponding primary primary air baffle has not been opened

h)

The coal feeder fails to be switched on 30seconds after the start-up command is given.

i)

The corresponding corresponding secondary air baffle baffle fails to be not opened 2min after the start-up start-up

Date: Date: 2008-09-15


Page 156

Rev. : A


SEC


command is given. Note: Because of MFT action, if the oil gun torch is controlled in the distance, the baffle of the secondary air should be opened, FEA UV14, FEI UV24 should be closed after 60 seconds 8.3.11

Fire detector cooling fan

8.3.11.1 Inspection before start-up 1)

The air duct is complete and the system connection is good

2)

The strainer at the entrance of the fan is in good condition without without blocking

3)

The mechanical part and the motor is normal through inspection and the transmission belt is complete without looseness

4)

The motor offers electricity normally. normally.

5)

The outlet hand-operated valves of two fans are open

6)

Each

oil

cooling 7)

gun

fan

torch

and

the

hand-operated

valve

of

flame

scanning

of pulverized coal ejector should be opened

The measuring points of air pressure are complete, and the local indication gauges are are correct.

8.3.11.2 The start-up of the fan 1)

The start-up of the subgroup control a)

Switch off interlocking (the light is bright)

b)

Operate # 1 fan and choose the command (the light is bright)

c)

Operate the start-up command of subgroup control

d)

Make sure AC fan is operated, the green light is put out, the red light is bright, and the outlet air pressure is normal

e) 2)

The interlocking interlocking in put into operation, then the light is put out

The start-up of single control (on DCS) a)

Switch off interlocking (the light is bright)

b)

Operate the start-up start-up command of single control control of # 1 fan, then #1 fan is started up

Date: Date: 2008-09-15


Page 157

Rev. : A


SEC


c) After the option command of HSU001 HSU001 #1 fan is operated, the “ON” command of subgroup control should be operated. d)

Switch on the the interlocking interlocking (the light is put out)

8.3.11.3 The linkage linkage and periodic test for direct current fan 1)

The linkage of direct current fan a)

Switch on the the interlocking interlocking (the light light is is put out)

b)

# 1 fan is tripped, and #2 fan linked linked

c)

When the outlet pressure pressure of cooling cooling air fan is is less than 85mbar, 85mbar, and after the alarm issues with s 5 seconds delay, delay, #2 direct current cu rrent of cooling fan starts up automatically

d)

Make switch operate alternatively and automatically

Note: the switch of the flame scanning cooling fan should be operated only after some safety measures have been adopted in order to prevent the action of the boiler MFT 2)

The periodic test of direct current current fan (two fans can operate simultaneously at any time) a)

The 220VDC electrical electrical source is inspected and confirmed normal

b)

Operate start-up command of single control of #2 fan on DCS, then #2 fan starts up

c)

The operation of #2 fan is checked and confirmed normally running.

d)

The start-up command of single control of #2 fan is operated, then #2 fan stops

e) Make sure higher than

that the

flame scanning

cooling

air pressure

should be

85mbar, and the interlocking is normal (the light is put out) 8.3.11.4 Operation of maintenance and supervision 1)

The operation of the fan should should be periodically checked, and it should be made sure that the fan has no friction noise and its bearing’s temperature and vibration and its motor’s temperature are normal

2)

The entrance strainer of the fan should have not blocking phenomenon, otherwise, it should be cleaned cleaned in time

3)

The driven belt has not slippery, slippery, loose, and falling phenomenon, the local local air pressure should be normal, the air duct and the connected system has not air leakage

Date: Date: 2008-09-15


Page 158

Rev. : A


SEC


4)

The outlet air pressure pressure of the fan should be higher than 85mbar

5)

When the outlet air pressure is lower lower than 85mbar (PSL02), (PSL02), the alarm will be emitted, emitted, and after 5 seconds delay, the direct current fan is linked

6)

When the outlet air pressure is lower than 70mbar (PSLL03) with 10 seconds delays, the boiler has MFT action

8.3.11.5 Stop of the flame scanning cooling fan After the boiler is is stopped for 24 hours, the operation of the flame flame scanning cooling fan can be stopped 1)

The subgroup control is stopped (on DCS) a)

Operate stop command of HSN001 HSN001 subgroup control and group control, then the red light is put out, the green light is bright

b) 2)

Make sure the fan is stopped

The single control is stopped (on DCS) a)

Operate HSU002, and switch off interlocking interlocking (the (the light is bright)

b)

Operate stop command of single control, then the red red light is put out, the green light is bright

c) 8.3.12 8.3.12.1

Make sure the fan stops

Oil gun torch cooling fan Startup Check

1)

Ensure the air duct is complete, complete, and system connection is in good condition

2)

Check whether the mechanical part and the motor are normal or not, and ensure the driving driving belt is complete complete and not loose.

3)

Ensure motor energization

4)

Ensure the hand-operated valves of the outlets of the two fans are open

5)

Ensure all cooling dampers of the oil gun torch are open and the HV*5 hand-operated valve of the burning torch cooling air is open.

6)

Ensure the air pressure measuring point is complete, and the local local indicator is correct

Date: Date: 2008-09-15


Page 159

Rev. : A


SEC 8.3.12.2 1)


Fan startup Sub control startup a)

Switch-off interlock (lights on)

b)

Select fans to be started (lights on)

c)

Operate sub control startup order

d)

Confirm the selected selected fan is started, the green light is off, off, the red light is on, and the outlet air pressure is normal

e) 2)

Interlock is put into service (lights off)

Single control startup (on DCS) a)

Switch off interlock (lights on)

b)

Operate single control startup startup order, order, and the fan is started

c)

Select operation fan (lights on)

d)

Operate sub control “ON” order, order, the green light is off, and the red light light is on.

e)


8.3.12.3 Fan in reserve and transfer The fan transfer should be locally supervised, and should be started before being stopped. 1)

Sub control transfer (on DCS) a)

Check interlock is in service (lights off)

b) Select fan to be started (lights on) and fan to be shutdown (lights off) and the selection difference light is on. c)

Operate sub control startup order, order, and the difference light is off off when the fan to be started is started and the fan to be shutdown is shut down.

d)

Locally checks and ensures the operation fan is normal and the air pressure is more than 85mbar

2)

Single control transfer (on DCS) a)

Single-control starts the fan to be started

Date: Date: 2008-09-15


Page 160

Rev. : A


SEC


b)

Single-control shut down the fan to be shut down

c)

Operation selects the started fan (lights on) and shuts down the fan (lights off)

d) Locally check and ensure the operation of the started fan is normal and the air pressure is more than 85mbar e)

Ensure the sub control is at a condition of “ON”, “ON”, the green light light is off and the red light light is on.

f) 3)

Check interlock is in service (lights off)

Linkage of standby fan a)


b)

Standby fan starts starts when the operation fan trips. trips.

c)

Standby fan starts in five seconds seconds after the pressure of cooling cooling air outlet lowers to 85mbar and an alarm is given.

d) 8.3.12.4 1)

Automatic transfer happens alternatively Operation maintenance and supervising

Periodically temperature

2)

repair

fan

operation,

and

ensure

no

grating,

bearing

and vibration are normal, normal, and motor temperature is normal.

Ensure the driving belt has no skidding, looseness and shedding, the local air pressure is normal, and the air duct and connection system have no air leakage.

3)

Outlet air pressure should be more than 85mbar

4)

When the fault fan is in maintenance, interlock thereof thereof should be unlocked, the power of the motor of the fan should be cut, and the outlet valve should be closed.

8.3.12.5

Oil gun torch cooling fan shutting down

1)

Shut down the oil gun torch cooling fan after boiler is stopped for 24 hours.

2)

Sub control stopped (on DCS) a)

Operate HSN001 shutting shutting down order, order, the red light is off, and the green light is on.

b)

Confirm that the fan is shut down.

Date: Date: 2008-09-15


Page 161

Rev. : A


SEC 3)


Single control shutting down (on DCS) a)

Operate HSU002 to unlock the interlock (lights on);

b)

Operate single control shutting down order, order, and ensure that the red red light is off, and the green light is on;

c) 8.3.13

Confirm that the fan is shut down.

Steam air heater

8.3.13.1

Check before startup of the steam air heater

1) Ensure that the valves of the steam air heater and auxiliary device piping are well connected. 2)

Ensure

the

availability

motor-operated

valve

has

been

energized,

and

air

supply

is controlled.

3)

Ensure the condensate condensate system has been been put into operation.

4)

Ensure the auxiliary steam steam and the steam extraction is normal.

5)

Ensure all measuring instrument is complete and correct. correct.

6)

Ensure the following following instrument instrument sampling sampling isolating isolating valves are open. a)

Steam inlet pressure hand-operated valve

b)

Condensed water tank pressure gauge hand-operated valve valve

c)

Condensed water tank water level high switch switch hand-operated valve.

d)

Condensed water tank water level low switch switch hand –operated valve.

e)

Condensed water tank water level gauge water inlet valve. valve.

f)

Condensed water water tank water level regulating signal signal transmitter signal valve.

7)

Open the steam piping upper air valve

8)

Shut down the steam control valve; shut down the side side valve and open the front and real hand-operated valve.

9)

Open the steam air heater desuperheater water hand-operated valve; desuperheater water control valve auto on.

Date: Date: 2008-09-15


Page 162

Rev. : A


SEC


10)

Open the steam air heater steam intake valve.

11)

Open the steam air heater outlet valve.

12)

Open the hand-operated valve of condensed water outlet and inlet of the secondary steam air heater.

13)

Open the hand-operated valve of the condensed water blowdown flash tank, manually shut down the control valve.

14)

Open the water drain valve of the condensed water tank, and close the valve after remained water is drained.

15) Confirm that the hand-operated valve of the condensed water tank to #2 low water injection injection and drain drain tank, and manually close the control valve. valve. 8.3.13.2 Put steam air heater into operation Natural ventilation is adopted before the boiler ignition, the steam air heater is put into operation, and the outlet air temperature is more more than 90 degrees Celsius; in the normal operation of

the boiler, the

average temperature

of the

gas

is

maintained between

100 to

105 degrees Celsius, and the air temperature of the outlet is automatically controlled; the steam air heater is stopped when the heater is high loaded. 1)

Select mode at the “auxiliary steam” position of DCS.

2)

Pass out the steam air heater sub control startup order at DCS, to confirm that:

3)

The fifth extraction motor-operated valve is closed;

4)

The auxiliary steam motor-operated valve is open;

5)

The drain water motor-operated valve is open;

6)

The stem control valve is manually and gradually opened;

7)

The drainage valve is closed closed when the steam bursts out;

8)

Condensed water tank water level gauge is checked and the water level is normal;

9)

The water level control valve of the condensed water tank is “auto” on;

10)

When turbine operation condition is permitted, the turbine can be set as “auto” on;

11)

The steam desuperheater water control valve valve is set as “auto” on.

Date: Date: 2008-09-15


Page 163

Rev. : A


SEC


The operation of the steam source being switched over to “five section steam extraction” should be carried out when the operation condition of the turbine is permitted, and the specific operation is as follows: 1)

Select mode at the “five section section steam extraction” position of DCS; DCS;

2)

Pass out the steam air heater sub control startup order to confirm that the the and

steam supply the

drain

motor-operated

valve

is

open,

the

check

valve

is

open

water motor-operated valve is closed.

8.3.13.3 Operating maintenance and parameter 1)

The inlet steam temperature of the steam air heater should be between 130 degrees Celsius be

higher

to

than

200

degrees

Celsius

and

the

temperature

should

(at corresponding pressure) the saturation temperature by ten

degrees Celsius. 2)

Drain water tank outlet water temperature of the steam air heater should be 40 degrees Celsius.

3)

Condensed water water tank water level.

Water level is low

alarm

Water level is high 4)

800mm

Inlet steam pressure

Pressure is low

alarm

Pressure is high 5)

alarm

300mm

alarm

2bar 14bar

Secondary air temperature of air pre-heater inlet (according to the load)

6) Air and to 110

gas

average

temperature

should

be

between

100

degrees

Celsius

degrees Celsius. 7)

Flue gas temperature should be 150 degrees Celsius.

8)

Condensed water tank water level governing a)

The water level control valve should be controlled by the water level control circuit at “auto” position, thus maintaining the condensed water tank water level constantly. constantly.

b)

In normal operation, drain water in condensed water tank tank drains into drain tank of low-pressure heater.


SEC

Date: Date: 2008-09-15



Page 164

Rev. : A


SEC


c) When the water level of drain tank of low-pressure low-pressure heater is extremely high and alarm is given, the steam supply motor-operated valve will be automatically closed, and the drain water motor-operated valve will be automatically opened, and the condensed water gutter static expansion. d)

The water level of the condensed water tank should plus 500mmor plus 600mm.

e)

When the

the

water

level

auto

control

of

the

condensed

water

fails,

steam supply/drain water regulating valve can be switched switched to “manual” operation.

8.3.13.4 Steam air heater shutting down 1)

Pass out the sub control shutting down order at DCS to confirm that: a)

The motor-operated valve is automatically closed when “auxiliary steam supplies steam”;

b)

When the five section steam extraction supplies steam, The steam extraction motor-operated valve UV01B and the check valve UV01C are automatically closed; The drain water motor-operated valve UV01D is automatically opened; And the steam control valve TCV75A and the desuperheater water control valve (TCV75B) are automatically closed.

2)

Automatic shutting down of steam air heater Steam air heater tripping conditions: a)

Pass out steam air heater sub control shutting down order at DCS;

b)

The turbine trips when when the five section steam extraction supplies steam. The fifth extraction motor-operated valve and the check valve should be closed.

8.3.14

Boiler water recycle pump

8.3.14.1 Check before boiler water pump startup 1)

The connection of the pump, the motor motor and the system should be in a good condition;

2)

Check whether all valves valves of the boiler water pump are closed or not;

3)

Check whether all instruments and the alarm system system are in a good condition or not.

Date: Date: 2008-09-15


Page 165

Rev. : A


SEC


8.3.14.2 Put cooler into service 1)

Ensure the closure cooling water system has been put into operation;

2)

Ensure the water water drain valve of the cooler inlet inlet is opened, and is closed after the sewage is drained;

3)

Ensure the air valve of the cooler outlet is closed;

4)

Ensure the inlet inlet valve valve of the cooler is opened;

5)

Ensure the outlet valve of the cooler is completely opened;

6)

Ensure the outlet valve of the cooler is opened largely, largely, and confirm that the flow if the cooling water is larger than 27m3 /h.

8.3.14.3 Motor water injection piping washing 1)

Ensure the condensed condensed water pump is in operation, the water temperature is less that 40 degrees Celsius, the water quality is qualified and no hydrazine is added in;

2)

Check whether the water injection injection dual valve is closed or not;

3)

Check whether the water injection valve and the acicular valve are closed or not;

4)

Check whether whether the water injection injection tube is dismantle dismantle d or not;

5)

ensure the water injection main valve is opened;

6)

Ensure the water drain valve of the water injection main main tube and the water drain valve of the strainer are closed after the clean water is continuously discharged;

7)

7)

Ensure the water injection valve and the acicular valve are ajar, ajar, and

the water injection valve is closed after the clean water water is discharged discharged from water injection tube. 8.3.14.4 Water injection of the boiler boiler water pump 1)

The water injection of the boiler water pump should be carried out the boiler is filled with water;

2)

Check whether the check valve of the boiler water water pump outlet and the bypass bypass valve of which are closed or not;

3)

Ensure the high high pressure pressure side drainage valve of the cooler;

4)

Ensure the pump inlet and outlet differential manometer is in a good condition condition and open

Date: Date: 2008-09-15


Page 166

Rev. : A


SEC


the isolation valve of the pump; 5)

Ensure the water injection injection valve and the dual valve is opened;

6) Ensure the acicular valve controls the water injection flow to be less than or equal to 2.5L/min; 7)

Check

whether

the

high

pressure

side

drainage

valve

of

the

cooler

continuously discharges the water and the water is clean or not, and ensure ensure the air outlet valve is closed; 8)

Ensure the acicular valve valve is turned down and the water injection is maintained; maintained;

9)

When the boiler water pump is spot-turned, the dual valve, valve, water injection valve and the acicular valve are closed.

8.3.14.5 Boiler water pump spot turn 1)

After the water injection is completed, the insulation resistance against earth of the motor motor conductor indicated in the 1KV megameter should be more than five megohms;

2)

The boiler should be filled to a water level which is 100mm more than drum water level;

3)

Ensure the check valve of the boiler water pump outlet is locally opened;

4)

Ensure the boiler boiler water pump is stopped after having been started for five seconds, and 20 minutes later, the boiler is started for five seconds and then is stopped, to drain the air in the motor chamber.

5)

The boiler water pump should be put into operation and the water injection should be stopped

after

the

boiler

water

pump

having

been

spot

turned

for

times and no abnormity having been found. 8.3.14.6 Boiler water pump startup conditions 1)

The power supply of the motor is energized;

2)

The control power supply is energized;

3)

The motor motor is is stopped for more than 20 minutes;

4)

The cooling water flow of the motor is more than 27m3 /h;

5)

The water temperature inside inside the motor is less than 55 degrees Celsius;

Date: Date: 2008-09-15


Page 167

Rev. : A

three


SEC


6)

The outlet valve of the pump is unlocked;

7)

The temperature difference difference of the boiler water and the pump (TDSH10) (TDSH10) is less than 56 degrees Celsius;

8)

The drum water level is more than 600mm;

9)

The boiler water pump is spot-turned

8.3.14.7 Boiler water pump startup 1)

The drum water level should be higher than +100mm +100mm before the first boiler water pump is started;

2)

The local/remote local/remote switch of the pump should be positioned remotely;

3)

Single control: the boiler water pump can be singly started on DCS DCS when the startup conditions are met; Confirm the pump to be started; Select the pump on DCS and start the pump;

4)

Group control startup; Check whether the group control exits or not on DCS, (the green light is on); Select the started pump on DCS ( the red light is on); Start the pump with group control (the group control red light is on) and check whether the pump is started or not;

5)

Notes after startup; Check whether the differential pressure of the outlet and inlet, current and the motor water temperature of the operating pump are normal or not; The interlock can be put into operation only after the standby pump is stopped for 20 minutes; The pump should be stopped immediately if the motor temperature rises quickly and no downtrend appears.

8.3.14.8 Boiler water pump hot reserve The standby pump startup conditions comprise that:

Date: Date: 2008-09-15


Page 168

Rev. : A


SEC 1)


The bypass valve HV*14 HV*15 HV*15 of the check valve of the outlet is opened, and the pump pump body is heated;

2)

The upper interlock of the DCS has been put into operation.

8.3.14.9 Boiler water pump transfer 1)

Group control transfer (on DCS); a)

Select the standby pump (lights (lights on), and select the pump to be stopped (lights off);

b)

Integrate the group control startup, and check whether the standby standby pump is started or not and whether the pump to be stopped is stopped or not

c) 2)

The interlock automatically quits, and is put into operation again 20 minutes later.

Single transfer a)

Singly start the standby pump;

b)

Ensure that the pump is normally started;

c)

Stop the pump to be sopped;

d)

Ensure that the pump is stopped and the current current is reduced to zero, and 20 minutes later the interlock switch is put into operation.

3)

Automatic transfer The group control is closed, the interlock is put into the standby pump, and the startup conditions are complete; the standby pump would automatically be started if any of the operating pump trips; the interlock quits, and can be put into operation again after 20 minutes.

8.3.14.10 1)

The operation and maintenance of the boiler water pump

The normal temperature of the motor motor chamber should be 45 degrees Celsius, and an alarm will be given at 60 degrees Celsius, and the pump will give an extreme alarm and trips at 65 degrees Celsius.

2)

The normal value of the differential pressure of the the boiler water pump is more more than 1.4 bar, and the differential pressure value when two pumps are in operation is 1.4 bar and a boiler MFT action would be carried out when the differential pressure is less than or equal to 1bar.

Date: Date: 2008-09-15


Page 169

Rev. : A


SEC 3)


The temperature between the boiler water and the pump pump shell should be less than 50 degrees Celsius, and a high temperature difference alarm will be given at 56 degrees Celsius.

4)

The normal cooling cooling water flow of the cooler is more more than 27m3 /h, and when the cooling water flow is less than or equal to m3 /h, a low cooling water flow alarm will be gave, and 20 seconds later the pump will trip.

5)

The load of the boiler is is less than or equal to 60 percent MCR when only one boil water pump is in operation;

6)

When the temperature of the standby standby pump motor chamber rises to approximately 55 degrees Celsius, the standby pump should be started and put into use, and should be stopped after the temperature is reduced.

7)

The attendant should check the leakage of the boiler water pump high pressure side; when chief

leakage

attendant,

is

found,

the

attendant

should

report

to

the

and countermeasures should be taken immediately to prevent the

motor from burning loss. 8.3.14.11 1)

Boiler water pump shutting down

Ensure the water temperature of the downcomer downcomer of the drum is 90 degrees Celsius, Celsius, the inner

layer

air

valve

of

the

drum

is

opened,

and

when

the

water

temperature of the downcomer of the drum is less than 70 degrees Celsius, two boiler water pumps should be shut down; 2)

The cooling water flow should be maintained when when the pump is stopped;

3)

Boiler water pump that are stopped stopped for a long period should be periodically checked whether the motor are filled with water; ensure that the boiler water pump operates for at least 10 minutes every two months, and should be started and operated for 10 minutes every 15 days at the period of pressure maintenance.

4)

Shutting down operation of the pump a)

Group control shutting down; Select the group control shutting down order on DCS; Check whether all operating pump are stopped or not and whether the current is reduced to zero or not; The outlet check valve should be closed.


SEC

Date: Date: 2008-09-15



Page 170

Rev. : A


SEC b)


Singly shutting down Quit the boiler water pump interlock on DCS; Select the pump to be stopped and stop it with single control;

Ensure that the pump is stopped, and the current is reduced to zero. 8.3.14.12 1)

Boiler water pump operation in boiler acid cleaning

All boiler water pumps should be injected with water before acid cleaning and water filling.

2)

Only one boiler water pump should be in operation in acid cleaning, and the other two pumps are isolated.

3)

All cooler of the boiler boiler water pump should be put into operation, and the cooling water quantity should be more than 27m3 /h.

4)

The water injection pressure should be kept kept higher than pressure of the drum by 6bar in acid cleaning.

5)

Continuous water injection should be carried out to the operation pump in acid cleaning

6)

inject the water according to the operation; ensure that the injected water is drained completely, and the water injection quantity should be maintained more than or equal to 4.5L/min; the temperature of injection water should be less than 45 degrees Celsius.

7)

Before adding the liquor to the boiler, boiler, the pump should be started started and in operation.

8)

Continuous water injection should should be carried out to the isolated pumps.

9)

The outlet check valve valve and bypass valve should be closed.

10)

High pressure side drainage valve of the cooler should be closed.

11)

Inject the water according to the operation; maintain maintain the water injection quantity by more than or equal to 4.5L/min after the air is completely drained; water injection should be carried out continuously, and the water injection pressure should be higher than the drum pressure by 6bar. 6 bar.

9

Periodic work , test and shift ing of the boiler and and relevant relevant auxiliary equipment

NO.

Projects

Date: Date: 2008-09-15

Type


Period

Page 171

Remarks

Rev. : A


SEC 1

2

3

4


Oil gun torch Forced

draft

Periodic test

Once a week

Periodic shift

Every half month

Periodic shift

Every half month

Periodic test

Once a week

pulverizer Periodic test

Once a week

fan

lubricant station oil pump Induced

draft

fan

bearing cooling fan Flame fan

check

cooling

(DC) 5

6

Standby

coal

lubricant station oil pump Boiler blowdown

Periodic work

Once a day

Boiler proper soot blowing

Periodic work

Once a day

7

8

9

10

11

12

10

Air preheater soot blowing

Periodic work

Every eight hours

Local

Periodic work

Once a week

Periodic test

Once a month

water

level

Part

by

different

tiem

periods

and

gauge washing electromagnetic relief valve blowdown parameter Periodic work

operational

Once a hour

record Devices

patrol

and

Periodic work

Every two hours

inspection Accidents processing of boiler

10.1 10.1

Basic Principi a of Accid ents Processing

10.1.1 When the unit accidents occur, the operator on duty should quickly identify the cause of the accidents to restrict further development of accidents and prevent the expansion of accidents. When the accidents are confirmed to have direct threat on personal safety and equipment, the risks of personal safety and equipment should be decisively eliminated. At the same time attention should be paid to continued operation of non-fault equipment as far as possible so as to meet the

Date: Date: 2008-09-15


Page 172

Rev. : A


SEC


need of system load. 10.1.2 The operator on duty should seek to ensure power supply of electricity system of the power plant. 10.1.3 In order to accomplish the above tasks, the operator on duty must stick to his post and focus his mind to ensure the normal operation of equipment, eliminate all abnormal situations and correctly and fast implement orders given by superior officers. 10.1.4 When the unit has malfunction, the operator on duty generally should work according to the following steps to eliminate failures. 10.1.5 Rapidly eliminate the risks on personal safety and equipment and the equipment with malfunction malfunction should be immediately out of synchronization (or stopped) when necessary. 10.1.6 Correct analysis and judgement should be done to indentify the nature, location and scope of accidents and then proceed to treatment according to instrument indication, alarming signals of CRT and alarm window and external Faults of the unit. At the same time attention should be paid to continued operation of non-fault equipment. 10.1.7 Situation of each stage in failure removal should be reported to the shift supervisor as fast as possible so as to timely take countermeasures to prevent the failure expansion. 10.1.8 If the failure is caused by failure of t he system or other equipment, corresponding measures should be taken to maintain the unit to operate with a certain parameters so as to make it possible to quickly recover normal operation of the entire set of unit. 10.1.9 According to the unit operating characteristics, accidents caused in any part of the unit will have a direct impact on the safe operation of the entire unit. Therefore, all posts should exchange situations during malfunction occurance and closely coordinate with each other to rapidly treat with the failure under the unified command of the shift supervisor and the chief supervisor. 10.1.10 The chief supervisor should be administered by the shift supervisor during failure removal, and should rapidly participate in failure elimination and firstly report to the shift supervisor as much as possible when the malfunction occurs. At the same time, the chief supervisor should report the taken of

the

10.1.11 all

measures

to

the

shift

supervisor

and

comply

with

shift

supervisor

all

correct

commands

shift supervisor. supervisor. During

accident

treatment,

the

is

entitled

to

call

on

concerned personnel in the power to be on-site to assist to deal with the failure and

meanwhile, all relevant leaders must quickly hurry to the spot to help deal with the failure and give necessary instructions


SEC

Date: Date: 2008-09-15



Page 173

Rev. : A


SEC


to operators (all these instructions should be issued by the shift supervisor in general expect for special circumstances.) 10.1.12

Careful

should

analysis,

correct

judgement,

decisive

manipulation

and

rapid

action

be necessary during failure failure treatment. In addition, impatience impatience and panic should be

avoided, otherwise the difficult

to

handle.

failure

The

will

not

be

eliminated,

but

becomes

expansive

and

operator should repeat the received order when in treatment of

malfunctions and make it clear until get the order understood, and promptly make reports to those who give the orders after having fulfilled the orders. 10.1.13 The operator must promptly report to the chief supervisor the unfamiliar malfunctions so as to jointly study the causes and deal with the failure. When no specified malfunctions is included in

the

manual, the

operator should

analyze and

judge the

causes with

his own

knowledge, initiatively take countermeasures and report the failure condition to the superiors at all levels. 10.1.14 The operator on duty is not allowed to leave his post freely during the time when the unit malfunctions occurs until resuming to the normal condition. When the failure occurs at the shifting time, the shift should be deferred and the shift person should continue to work with the assistance of the relieve person to jointly deal with failure. The shift can only be done until failure is removed and commond is received from the shift supervior. 10.1.15 Forbidden and eliminate the case that people who do not involve in the failure removal stay at the place where failure occurs. 10.1.16 After the acccidents have been disposed, personnel at all posts should truthfully record in detail

the

disposal

on

unit

failure

situation,

occurance

time,

place

and

the

process

of

the registering book for shift respectively, respectively, and analyze the failure treatment on

the meeting after shift so as to sum up experience and draw a lesson. 10.1.17 The shift supervisor and chief supervisor are not allowed to leave the control room at the same time when the system failure occurs. 10.2 10.2

Boil er Emergency Emergency Shutdow n

10.2.1 If any one of the following conditions is met, the MFT starts and the boiler automatically stops: 10.2.1.1 The power failure of control system or abnormality of pressure for controlling air is delayed for three seconds. 10.2.1.2 No induced draft fan is running


SEC

Date: Date: 2008-09-15



Page 174

Rev. : A


SEC


10.2.1.3 No forced draft fan is running 10.2.1.4 No air heater is running 10.2.1.5 Total Total air flow is below the minimum value (two seconds’delay in action) 10.2.1.6 Water temperature is too high (from TE 052I) with no exhaust sustained for above six seconds

or

the

water

temperature

is

not

high

(from

TE

052I)

but

the

furnace

temperature is abnormal or too high (above six six seconds’delay) seconds’delay) 10.2.1.7 Steam discharge is undone (s ix seconds’ delay in action) 10.2.1.8 Drum level is too low (two seconds’ delay) 10.2.1.9 Drum level is too high (60 seconds’ delay) and 12% higher than the MCR flow. flow. 10.2.1.10 Non-biler water circulating pump is in operation and the tripping action is delayed two seconds. 10.2.1.11 Furnace pressure is too low or too high 10.2.1.12 Air cooling pressure of the flame detector is too low (600 seconds’ delay) 10.2.1.13 Flame detector breaks down; the last burner is delayed 15 seconds after the purge and storage are re-set or the entire detector breaks down. 10.2.1.14 Superheated steam pressure is too high (pressure switch) with six seconds’ delay in action. 10.2.1.15 The air temperature of electric precipitation entrance is too high with this action delayed two seconds. 10.2.1.16 The steam flow after the reflux starts is still greater than x1% before the reflux and only one circulating pump is in operation after T1. 10.2.1.17 The steam flow when the reflux starts is still greater than x1% before the reflux and only one circulating pump is in operation ope ration after t seconds (T1 + T2). 10.2.1.18 Only one emergency stop button is used. 10.2.1.19 When the reflux starts, control loop of at least one raw coal feeder is in a manual state. 10.2.2 The following processing procedures should be automatically done after the MFT action, otherwise human intervention should be adopted:

Date: Date: 2008-09-15


Page 175

Rev. : A


SEC


10.2.2.1 Cut off all fuel; 10.2.2.2 Pulverizer coal feeder and oil gun torch fully stop; 10.2.2.3 Fuel oil inlet solenoid valve is closed; 10.2.2.4 Pulverizing system fully stop; 10.2.2.5 Frontwall balance wind baffle plate and backwall balance wind baffle plate: A is 100%, B is 20% and C is 0%. 10.2.2.6 Turbine trips and generator runs out of synchronization; 10.2.2.7 High voltage bypass and low voltage bypass starts up automatically. 10.2.3 Manual processing methods after MFT action 10.2.3.1 Confirm that the boiler main stop valve FSRUV04A automatically closes, or the manual control should be employed to close the boiler main stop valve. 10.2.3.2 Confirm that the high voltage bypass rapidly starts up and automatically resumes to a certain opening so as to maintain the pressure of 15 bar of the reheater. If the the high voltage bypass does not start up, manual control should be applied to the hight voltage bypass so as to make it start. The high voltage bypass is then returned to a proper opening after 15 seconds and put in automatic control after the pressure of the reheater is set at 15 bar. 10.2.3.3 Attention should be paid to the drum water level. If the water level is too high, continuous relief valve and stable relief valve can coordinate for water level regulation. 10.2.3.4 Attention should be paid to that the operation of the boiler water pump should be normal and immediately suspended when there are abnormalities such as the shock, pressure difference, etc. 10.2.3.5 Confirm that after the secondary air baffle plates are locked for one minute, all secondary air baffle plates of the oil fuel burner should be in an opened state and the total air volume should be maintained at 30% MCR; and the purge procedure (for 5 minutes) of the boiler framework is then done. 10.2.3.6 If the reason of MFT action can not be identified or eliminated at the moment, the decision of stopping the primary air fan, forced draft fan and induced draft fan should be promptly made and the inlet baffle plates and the outlet baffle plates should be closed so as to maintain the boiler in a standly heat state.

Date: Date: 2008-09-15


Page 176

Rev. : A


SEC


10.2.3.7 Keep the air preheater, flame scanning cooling fan and cooling fan of oil gun torch running. 10.2.3.8 If the failure can be eliminated in a short time, the shift supervior after having received the order of starting up the units should started up the units as soon as possible according to the boiler stoppage duration and corresponding conditions so as to meet the demand of system load. 10.2.3.9 If the reason of MFT action is caused by the the primary air fan, forced draft

fan

or induced

draft

fan,

the

boiler

framework

should

be

thoroughly thoroug hly

purged

before re-ignition; all the primary primary air pipelines should be purged for 20 minutes before before the pulverized coal is supplied. 10.2.4 Emergency boiler shutdown 10.2.4.1 Any one of the following situations occurs, the “emergency boiler shutdown button” should be immediately pressed for boiler shutdown. a)

When in low-load operation, the combustion instability instability occurs and the boiler framework pressure substantially fluctuates around ± 5mbar and the steam flow rapidly declines.

b)

The safety valve has failure to operate even when boiler pressure exceeds the working working value low

of

safety

valve;

voltage bypass

meanwhile,

valve

and

the

the

high

voltage

non-atmospheric

bypass relief

valve

valve

of

and

the

reheater

are unable to start up automatically or manually. manually. c)

When blast of the main feed water piping, main main steam piping, piping, water wall, economizer, economizer, superheater and reheater occurs and endangers adjacent pipings.

d)

When all the boiler water level gauges are damaged and unable to monitor water level. level.

e)

When the boiler is overfed with with water with the water level higher than +25 mm and MFT has failure to operate.

f)

When the boiler is short of water with with the water level lower than -600 mm and MFT has failure to operate.

g)

When the combustibles reburn in the gas dust so that the flue gas temperature rises to above 200℃ in an abnormal state.

h)

When the

the

first

and

secondary

spray

attemperators

all

have

failure

and

steam temperature has drastic change and can not be controlled.

10.2.4.2 Treatment methods of “emergency boiler shutdown” are the same as that of “automatic


SEC

Date: Date: 2008-09-15



Page 177

Rev. : A


SEC


boiler shutdown”. 10.3 10.3

Shutdown Appli cation of Boil er If one of the following cases is met, one should ask for approval of the factory

director in charge and do the boiler shutdown in a normal normal manner after having received the order from the shift supervisor: 10.3.1 When pressure retaining parts which have leakage are still able to operate. 10.3.2 When the heating surface of boiler has been scorched and normal operation can not be maintained even some measures have been taken to deal with it. 10.3.3 When the quality of feed water or steam of the boiler has seriously worsened and normal operation can not be maintained even efforts have been made for adjustment and treatment. 10.3.4 When the metal wall temperature of the heat absorption area has extremely exceeds the allowable value and normal operation can not be resumed even great efforts have been made for treatment. 10.3.5 When the enclosed cooling water source of cooler of the boiler water pump motor is interrupted and the alternative water source can not be resumed resumed immediately. immediately. 10.3.6 When the high voltage bypass after tripping can not be closed. 10.3.7 When the safety valve has defects, failure to operate or can not be reseated. 10.3.8 When main motors of two air preheaters have failure and can not be resumed in a short time. 10.3.9

When

maintain

the

gas

dust

has

serious

deposition

of

ash

and

is

unable

to

normal operation after much effort.

10.3.10 When chief supervisory meter has failure and is unable to maintain normal operation and can not be resumed in a short time. 10.3.11 can

When

not

10.4 10.4 10.4.1

the

two

electric

precipitators

have

failure

and

normal

operation

be maintained after much effort.

Boiler Abno rmal Operation Operation Parameter Parameter High temperature of main steam

10.4.1.1 Faults

Date: Date: 2008-09-15


Page 178

Rev. : A


SEC


a)

Alarm is given due to “high temperature of main steam” (> 560℃);

b)

If the heat absorption surface has leakage or explosion, steam temperature temperature of various sections before the breaking point drops and temperature of various working substances after the breaking point increases.

10.4.1.2 Causes a)

The high pressure heater is out of operation and feed water temperature drops.

b)

The

attemperating

water

system

has

failure

or

automatic

malfunction the

attemperating water flow reduces abnormally. c)

Decrease of feed water pressure causes attemperating water flow reduction.

d)

Gas duct in the rear part reburns.

e)

Coal quality or combustion operating condition change.

f)

The flame center of boiler framework moves upwards.

g)

The heating surface has leakage and blast.

h) Air flow is too much. i)

Coal pulverizing system starts up.

j)

The boiler framework is scorched.

10.4.1.3 Countermeasures a)

When have

water

supply

system

and

spray

attemperating

water

system

failure automatically, automatically, manual adjustment should be immediately adopted. The

systems are then put into operation after the steam temperature becomes stable. b)

When in soot blowing of boiler framework, framework, the openings of the upper tertiary air baffle plate

and

the

lower

tertiary

air

baffle

plate

should

be

regulated

for

adjustment flame center. center. The openings of secondary air baffle plates of three rows of A, B and C should b e regulated when n eccessary. eccessary. c)

Adjust the air flow and maintain maintain the best excess air coefficient. (That is, to maintain the best oxygen content value).

d) Increase the drum

attemperating

Date: Date: 2008-09-15

water

flow

and


pay

attention

to

Page 179

relation

between

Rev. : A


SEC


pressure and the main feed water piping pressure. e)

The

high

surface,

steam

or

temperature

is

caused

by

leakage

or

blast

of

heating

the reburning of combustibles in gas duct and should be dealt with with

according to the relevant provisions. f)

If the temperature of main main steam keeps increasing after the above treatment measures measures have

been

according

taken,

the

turbine

should

be

adjust

together

with

the

boiler

to relevant provisions. But the temperature of main steam should not

exceed the limit and the unit load can not drop too much. g)

When the temperature of main steam stop valve in front of the turbine reaches 566℃, the turbine trip should be done.

10.4.2

Low temperature of main steam

10.4.2.1 Faults a)

Alarm is is given due to “low temperature of main steam” (< 560℃);

b)

Steam temperature of various sections drops and the steam piping has impact in severe case.

10.4.2.2 Causes a)

b)

The

attemperating

that

the attemperating water flow increases abnormally. abnormally.

The

feed

water

water

water

system

pressure

has

increases

failure

abruptly

or

so

automatic

malfunction

that

attemperating

the

so

flow increases.

c)

Coal pulverizing system is out of operation.

d)

Fouling of heating surface area.


When the automatic adjustment is abnormal, manual adjustment should be immediately immediately adopted so as to resume the normal operation.

b)

Reduce

the

attemperating

governor valve valve

in

case

Date: Date: 2008-09-15

has

water

serious

volume;

leakage

and

close

motor-operated

then

close

valve

if

hand-operated

of emergency. emergency.


Page 180

Rev. : A

the stop


SEC


c)

Soot blowing should be done to the superheater.

d)

Timely regulate the air volume volume and lift the flame center. center.

e)

If the temperature of main steam keeps decreasing after the above treatment measures have been taken, treatment should then be done according to the turbine manual (when the steam temperature drops to 510℃, the load of turbine should be properly reduced); turbine trip should be done when the temperature of main steam drops to 450℃.

10.4.3

High temperature of reheated steam

10.4.3.1 Faults a)

Alarm is given due to “high temperature temperature of reheated steam” (< 560℃);

b)

Temperature at various points points in the reheating system increases.

c)

If the heating surface has leakage or explosion, temperature at various points before the breaking

point

drops

and

breaking

point increases.

temperature

at

various

points

after

the

10.4.3.2 Causes a)

The

attemperating

water

system

of

reheater

that

the attemperating water flow reduces;

b)

Air flow is too much;

c)

The flame center moves upwards;

d)

The heating surface of water water wall wall is not clean; clean;

e)

Fuel or fuel operating condition has changed;

f)

The coal pulverizing system starts up.

has

automatic

malfunction

so


When the attemperating system system of reheater has failure automatically automatically, manual manual adjustment should be immediately adopted so as to ensure the reheated steam is in a normal condition.

b)

If

the

reduced

air

volume

and

Date: Date: 2008-09-15

is

too

much,

the

air

volume

should

be

properly

the combustion should be adjusted.


Page 181

Rev. : A


SEC c)


Strengthen soot blowing of the heating surface of water wall and reduce temperture of main steam when necessary. necessary.

d)

If the leakage and explosion of heating surface of the reheater causes the reheated steam temperature should

be

to

increase, in crease,

measures

of

temperature te mperature reduction

taken immediatedly and treatment should be done according to

corrsesponding provisions as well. e)

The openings of the upper tertiary tertiary air baffle plate and the lower tertiary air baffle plate should be regulated so as a s to lower the flame center. The openings of secondary air baffle plates of three rows of o f A, B and C should be regulated regula ted when neccessary.

f)

If the temperature of reheated main steam keeps keeps increasing after the above measures of temperature reduction have been taken, the turbine should be adjusted together with the boiler according to relevant provisions.

g)

When the temperature of reheated main steam increases increases to 566℃, the turbine trip should be done.

10.4.4

Low temperature of reheated steam

10.4.4.1 Faults a)

Alarm is given due to “low temperature of reheated steam” (< 520℃);

b)

Temperature at various points points in the reheater system decreases.

c)

If the heating surface has leakage or explosion, temperature at various points before the breaking

point

drops

breaking

point increases.

and

temperature

at

various

points

after

the

10.4.4.2 Causes a)

The

attemperating

water

adjustment

of

reheater

that

the attemperating water flow of the reheater increases;

has

malfunctions

so

b)

The flame kernel moves downwards;

c)

The unit load is too low;

d)

Fuel or fuel operating condition has changed;

e)

The main steam stop valve of intermediate-pressure cylinder cylinder or high-pressure exhaust check valve has failure on a single side so that the steam flow deviation between the left

Date: Date: 2008-09-15


Page 182

Rev. : A


SEC


side and the right side is caused. f)

Safety valve valve of reheater outlet operates or the outlet section has leakage or explosion.

g)

The coal pulverizing system shuts down.

h)

Fouling of heating surface area of reheater..


When the automatic adjustment of attemperating water of reheater is abnormal, manual adjustment should be immediately adopted so as to resume the normal operation. The motor-operated valve should be closed when necessary and the hand-operated valve should then be closed if the leak volume is too much.

b)

If the air volume is too much, the air volume volume should be properly increased.

c)

Regulate the openings of secondary air baffle plates of three rows of A, B and C and the openings of the upper tertiary air baffle plate and the lower tertiary air baffle plate; lift the position of flame center.

d)

Strengthen soot blowing blowing of the heating surface of the reheater. reheater.

e)

The turbine load should be reduced according according to provisions provisions when the reheated steam temperature continues to decrease to 510℃.

f)

When the temperature of reheated steam continues to decrease to 450℃, the turbine trip should be done.

10.5 10.5

Load Rejection Rejection of Unit Under one of the following cases, the boiler will automatically reduce load.

10.5.1 If one set of induced draft fan trips, the load reduces to 50% MCR. 10.5.2 If one set of forced draft fan trips, the load reduces to 50% MCR. 10.5.3 If one set of primary fan trips, the load reduces to 50% MCR. 10.5.4 If one set of air preheater trips, the load reduces to 50% MCR. 10.5.5 If one set of boiler water pump trips and the standby water pump can not be interlocked, the load reduces to 60% MCR. 10.5.6 If one set of feedwater pump trips and the standby pump can not be interlocked, the load

Date: Date: 2008-09-15


Page 183

Rev. : A


SEC


reduces to 60% MCR. 10.5.7 If the turbine trips, the boiler load reduces to 70% MCR. 10.5.8 If operating with auxiliary power, the boiler load reduces to 70% MCR. 10.6 10.6

Auxil iary Power Supply Interruptio n

10.6.1 Faults 10.6.1.1 Turbine trips and the boiler MFT action is done. 10.6.1.2 All running machines trip. 10.6.1.3 Each motor-operated valve stays at the place before power interruption. 10.6.1.4 Pressure of main steam, steam temperature and flow all decrease. 10.6.2 Countermeasures 10.6.2.1 Ensure that DC fan of the flame scanner is in operation and DC motor of air preheater starts up. 10.6.2.2 Ensure that the TV water level gauge and flame TV of boiler framework are in operation. 10.6.2.3 Check and ensure that emergency drain three-way valve FV003 of boiler water pump should automatically open and outlet valve of boiler water pump should be closed by hand when the temperature of motor chamber of boiler water pump keeps on a rise. 10.6.2.4 The seal fan should starts up after the diesel-engine generator operates. 10.6.2.5 If the boiler is treated with soot blowing when auxiliary power interrupts, immediate maintenance should be done and the soot blowing gun should be withdrawn. 10.6.2.6 The following steps should be done after the power supply is restored. a)

Make up water for the drum to the level of -100mm.

b)

Start up the boiler water pump after the closed closed cooling water system resumes normal operation.

c)

Start up the main motor of air preheater.

d)

Start up the AC cooling fan of flame scanner and stop the DC cooling cooling fan and then conduct the “interlocking”.

Date: Date: 2008-09-15


Page 184

Rev. : A


SEC


e)

Start up the cooling fan of oil gun torch and conduct the “interlocking”. “interlocking”.

f)

Check

and

valves

of attemperating

recirculation g)

ensure

valve

that

vaious

water

are

motor-operated at

the

valves

closing

and

position;

regulating open

the

of economizer.

Start up the lubricating oil system of coal mill.

10.6.2.7 Confirm emergency water tanks and supply water to following equipment when the closed cooling water system interrupts.

10.7 10.7

a)

Supply low-pressure cooling water to boiler water pump.

b)

Supply cooling water to bearings of auxiliary equipment.

c)

Supply cooling water to various oil coolers. Control& Instrument and Apparatus Power Supply Interrupti on

10.7.1 Faults 10.7.1.1 General power of thermal regulator and instrument lose. 10.7.1.2 After the general power loss alarm signal o f thermal regulator and instrument is given, the power indicator of instrument turns off and the alarm is warning. 10.7.1.3 Survey meters and digital instruments have failure to display. Transmitter of automatic control device loses power; the indicator turns off; relevant meters indicate zero and automatic device has failure. 10.7.1.4 The secondary instrument instruction disorders on CRT graphic display. 10.7.1.5 protection

Automatic

protection

has malfunction;

the

limit

device device

regulator

has

(regulating

power

failure

device)

ha s

and

power

the

limit limit

failure

and

automatically shuts down when in automatic operation. 10.7.1.6 Remote control of equipment on CRT graphic display has failure and the water level can not be controlled. 10.7.1.7 The rotating speed of coal feeder indicates zero. 10.7.1.8 Unit operation is instable or even has fire-off and tripping. 10.7.2 Causes

Date: Date: 2008-09-15


Page 185

Rev. : A


SEC


10.7.2.1 Electrical system or power bus has failure. 10.7.2.2 Switch or knife switch has failure and standby power fails to do automatic operation. 10.7.2.3 UPS power loses. 10.7.3 Countermeasures 10.7.3.1 If boiler has not fired off and the unit has not tripped when the thermal regulator and instruments lose power, various control equipment and a nd systems should be switched

to

manual control

and

stably

operate

in

the

original

operating ope rating

condition.

Strengthen the supervision and inspection of instruments on the spot and ensure the unit stable load as much as possible. If operation of corresponding valves and baffles is required, the manual operation can only be done after the contact work inside and outside the control room is well done. 10.7.3.2 Ensure the boiler framework stable combustion, supervise the primary meters, strengthen contact and emphasize on operation analysis referring to other relevant parameters without blind operation. Send personnel to monitor all water levels and make sure that the water levels are controlled in a normal range and strictly prevent accidents accidents of overfeeding or short supply of boiler and water impact of turbine. 10.7.3.3 Inform relevant personnel for thermal regulation and quickly restore control power of instruments. 10.7.3.4 unit

If

the

instrument

power

fails

to

timely

be

restored

which

threatens

the

safety operation, report should be made to the shift supervisor and the instruments shall shut

down due to failure. 10.7.3.5 If the protection is caused by loss of power of instruments or total power loss of boiler, turbine

thermal

regulator

and

instruments

has

met

the

conditions

of

emergency

shutdown, treatment should be done according to emergency shutdown. 10.7.3.6 If the boiler has fire-off, treatment should be done according to provisions for fire-off. 10.7.3.7 Make reports to group chief and shift supervisor after the unit shuts down; reignite and start up the unit in thermal condition according to instructions of the shift supervisor after the thermal regulator and instrument are done with energization. 10.8

Fire Acc iden t

10.8.1 Countermeasures for fire catching of the oil system. 10.8.1.1 If fire catching is found in the oil system, dry fire extinguisher or foam fire extinguisher


SEC

Date: Date: 2008-09-15



Page 186

Rev. : A


SEC


should be instantly adopted for fire-fighting and report should be made to the shift supervisor to promptly notify the firefighters to extinguish fire. 10.8.1.2 If the fire has not yet threatened the unit operation, measures should be taken to prevent fire spread and put it out as soon as possible. 10.8.1.3 Move away combustibles around the fire spot and cut off power supply of electrical equipment on the spot. 10.8.1.4 Strengthen the operation supervision and prepare for shut-down. 10.8.1.5 Attention should be paid to that the fire shall not spread around the spot and wetted fire-retardant materials should be covered around the equipment when necessary (pay attention to the rotating parts of the unit). Report should be instantly made to the shift supervisor for shutdown when the fire threatens the unit safety. 10.8.1.6 If the fire threatens the safety of main oil tank, emergency shutdown should be done; start up the emergency oil relieve valve (ensuring the lubricating oil supply is not interrupted before the turbine stops) when the rotating speed of turbine decreases. 10.8.2 Fire catching of pulverized coal pipeline 10.8.2.1 Causes a)

The primary air pipeline is worn and has pulverized coal leakage to the extent of heat insulation and has spontaneous combustion and fire-catching.

b)

The pulverized coal pipeline is blocked and is not cleared up in time.


Stop the corresponding coal pulverizing system and shut-off valve of coal mill mill outlet in accordance with specific conditions and extinguish fire with foam or fire-fighting water.

b)

When coal

fire

catching

occurs

pipeline, personnel for

due

to

incomplete

locomotive maintenance

block

off

should be

of

pulverized

contacted for

purging of primary air pipeline and corresponding treatment. 10.8.3 Notice items of fire extinguishing 10.8.3.1 If clothes which are not immersed in kerosene, diesel, petrol and other oils and wooden materials catch fire, foam fire extinguisher, water and sand should be employed for f ire fighting.

Date: Date: 2008-09-15


Page 187

Rev. : A


SEC


10.8.3.2 If oil tanks or oil in other containers catches fire, oil should be discharged from the emergency oil relieve valve and foam fire extinguisher or wetted raincloth could be used for fire fighting. 10.8.3.3 If the energized equipment catches fire, fire fighting should be done after the electricity is cut off; sand and foam fire extinguisher should not be used for fire fighting when the motor catches fire. 10.8.3.4 If found fuming, the motor should be promptly stopped running and the shift supervisor and chief supervisor should be informed of the situation. 10.8.3.5 Power

Observe

relevant

provisions

of Specification

for

Fire

Protection

of

Electric

Installation during fire fighting.

10.9 10.9

Processing Inferior Inferior Quality of Water Water and Steam Steam

10.9.1 Processing value of abnormal water quality of condensate

Items

With Electric

mixed

bed

Standard

Processing value

value

Stage I

Stage II

Stage III

≤0.30

030~0.40

0.40~0.65

>0.65

≤0.20

0.20~0.35

0.35~0.60

>0.60

≤2.0

>2.0

>5.0

>20.0

≈0

>2.0

-

-

conductivity (S/cm)

Without mixed bed With

mixed

Hardness

bed

(mol/l)

Without mixed bed

Note: emergency shutdown should be done when sodium content in condensate is more than 400g/l. 10. 9.2 Processing value of abnormal water quality of boiler feedwater Items

Date: Date: 2008-09-15

Standard

Processing value


Page 188

Rev. : A


SEC

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL value

Stage I

Stage I

Stage I

Electric conductivity (S/cm)

≤0.30

030~0.40

0.40~0.65

>0.65

Dissolved oxygen ( g/l)

≤7

>7

>20

-

-

-

Stage I

Stage I

Stage I

9~8.5

8.5~8.0

<8.0

<8.8 or 8.8~9.3

pH(25℃)

>9.3 10.9.3 Processing value of abnormal water quality of boiler water

Items

value 9~10

pH(25℃) Note: also

Processing value

Standard

contents

of

chloridion

and

sodium,

electric

conductivity

and

alkalinity

shoul

be measured.

Definition of above processing values of three stages: Processing value of Stage I: the possibility that corrosion, scaling and salt deposition are caused by impurities may may be existed existed and the standard value should be resumed within 72 hours. Processing value of Stage II: the possibility that corrosion, scaling and salt deposition are caused by impurities impurities is surely existed and the standard standard value should be resumed resumed within 24 hours. Processing value of Stage III: the corrosion, scaling and salt deposition are forming in a fast way and the boiler should be shut down within four hours. During each stage of abnormal processing, if the standard value fails to be resumed within the required time, processing method of a higher level should be employed and one of the methods to restore the standard value of water quality is to operate under lower pressure. 10.9.4 Principles of processing for abnormal water steam quality of unit 10.9.4.1

Promptly

inspect

whether

the

sampling

is

representative

or

not,

whether

the testing equipment is in normal condition and whether the test results are correct when the water steam quality degrades. Comprehensively analyze the change of water and steam quality in the system and make reports to the chief engineer for the situation after correct confirmation and judgement and take measures to ensure that the standard value of the water steam quality is surely resumed within the allowable time.


SEC

Date: Date: 2008-09-15



Page 189

Rev. : A


SEC


10.9.4.2 When each items of water steam quality reach the processing value of Stage I and the possibility that corrosion, scaling and salt deposition are caused by impurities may be existed and the standard value should be resumed within 72 hours. 10.9.4.3 When each items of water steam quality reach the processing value of Stage II and the possibility that corrosion, scaling and salt deposition ar e caused by impurities is surely existed and the standard value should be resumed within 24 hours. 10.9.4.4 When each items of water steam quality reach the processing value of Stage III and the corrosion, scaling and salt deposition are forming in a fast way and the boiler should be shut down within four hours if the water quality is still in bad condition. 10.9.4.5 One of the methods to restore the standard value of boiler water quality is to operate under lower pressure. 10.9.4.6 During each stage of abnormal processing, if the standard value fails to be resumed within the required time, processing method of a higher level should be employed. 10.10 10.10

Boil er Heating Heating Surface Slagging Seriously

10.10.1 Faults 10.10.1.1 When the water wall is scorched, the temperature of main steam and reheated steam will have an abnormal increase. 10.10.1.2 When the heating surfaces of the superheater and the reheater are scorched, the temperature of main steam and reheated steam will have an abnormal decrease. 10.10.1.3 The flue gas temperature has an abnormal increase. 10.10.1.4 When the coke slag is shedding, much change will occurs in the boiler framework pressure, which will impact the stability of combustion. 10.10.2 Causes 10.10.2.1 Low ash melting point in coal combustion; 10.10.2.2 Deflection of flame center during combustion; 10.10.2.3 Overload operation of the boiler for a long time. 10.10.3 Countermeasures 10.10.3.1 Adjust the combustion operating condition and properly lower the flame center in order

Date: Date: 2008-09-15


Page 190

Rev. : A


SEC


not to cause deflection of the flame center; 10.10.3.2 Decrease the flue gas temperature deviation of boiler framework outlet and lower the temperature of boiler framework outlet; 10.10.3.3 Properly strengthen the soot blowing; 10.10.3.4 Select coal with relatively high ash melting point and conduct according to specific combustion measures of corresponding coal type when the coal type alternation is unavailable; 10.10.3.5 Properly reduce the boiler operation load and strengthen the disturbance in the boiler; 10.10.3.6 Strengthen the monitoring fo r coking performance in the boiler. 10.11 10.11

Gas Duct Reburni ng

10.11.1 Faults 10.11.1.1 Flue gas pressure has a sharp increase in the gas dust; 10.11.1.2 Negative pressure in the gas dust decreases; 10.11.1.3 Flue gas exhausts in the clearance of valves and holes of the gas dust; 10.11.1.4 Fire alarm is given when the recombustion occurs in the air preheater. 10.11.2 Causes 10.11.2.1 Due to long-term application of coarse pulverized coal or improper ratio of air/coal, the incompletely-burned pulverized coal deposits in the gas duct. 10.11.2.2 Improper operation and adjustment or long-term upward moving of the flame center causes the incompletely-burned pulverized coal to enter the gas duct. 10.11.2.3 Feed pulverized coal in advance du ring the start-up. 10.11.2.4 Long-term operation under low load, relatively low temperature of boiler framework or the

relatively

great deal

small

excess

air

coefficient

worsen

the

combustion

and

cause

a

of combustibles to burn in the gas dust.

10.11.2.5 No purging is done to the boiler framework according to provisions after boiler shutdown. 10.11.3 Countermeasures 10.11.3.1 Adjust combustion when the abnormal increase of temperature is found in the gas duct and instantly conduct the soot blowing with soot blowing gun in the duct.

Date: Date: 2008-09-15


Page 191

Rev. : A


SEC


10.11.3.2 Make reports to the shift supervisor and do the emergency boiler shutdown if abnormal increase of temperature in the gas duct or flue gas still occurs after some measures have been taken. 10.11.3.3 The primary air fan, forced draft fan and induced draft fan should be instantly stopped after boiler shutdown and all the air valves and baffle plates should be closed for enclosement. 10.11.3.4 The following measures should be taken when the fire catching of preheater occurs: a)

Ask instructions from the shift supervisor and conduct the emergency boiler shutdown.

b)

Stop all the primary primary air fans, forced draft fans, induced draft draft fans and steam air heaters.

c)

Close the air baffle baffle plate and flue gas baffle plates of the air preheater.

d)

Open the inspection hole of the lower lower ash hopper of the air preheater. preheater.

e)

Instantly put the fire-fighting water device of air preheater into operation for fire fighting.

f)

Inspect the water discharge condition of ash hopper of air preheater and timely smoothen the air hopper so as to prevent the ash hopper collapse.

g)

The fire-fighting fire-fighting water supply can only be stopped after the fire completely extinguishes and the flue gas temperature decreases to a normal value.

h)

Water washing should be done to the air air preheater if the ash deposition is serious and the air preheater should be dried with the steam air heater after water washing.

10.11.3.5 Slowly and carefully open the inspection hole for inspection and start up the induced draft fan only after no fire sources is ensured. 10.11.3.6 Ignition and start-up can only be done after the equipment is checked and ensured no abnormality and the instruction from the shift supervisor is received. 10.12 10.12

Unit Trip

10.12.1 Faults 10.12.1.1 Main steam pressure is rapidly increased, high and low pressure bypass valves are automatically and swiftly open. 10.12.1.2 Main steam flow is swiftly dropped, high and low pressure bypass valves return 15 seconds after opening. 10.12.1.3 Reheat steam pressure is rapidly increased and reheater exhaust valve is automatically

Date: Date: 2008-09-15


Page 192

Rev. : A


SEC


opened. 10.12.1.4 Water level of drum is low be fore it gets high. 10.12.1.5 Main steam temperature and reheat steam temperature tend to be high before it drops low. 10.12.1.6 is

After

turbine

trips,

if

low

pressure

bypass

functions

abnormally

or

adjusted inappropriately, inappropriately, safety valve of reheater or of drum will start operating.

10.12.1.7 When main steam flow is under 420T/H with oil gun still unused, all coal feeders will trip and boiler MFT will start operating. 10.12.1.8 When low pressure bypass fails and closes down, reheater exhaust valve remains closed, boiler MFT will starts operating. 10.12.2 Countermeasures 10.12.2.1 Boiler load is automatically dropped to 70%MCR, or make it happen by hand. 10.12.2.2 High and low pressure bypass valves should be swiftly opened or have it opened by hand. 10.12.2.3 Make sure that exhaust valve of reheater is automatically opened, or open it by hand. 10.12.2.4 Before the oil gun is put into use, stabilize the load above 420T/H to avoid boiler MFT operation. 10.12.2.5 When the number of oil gun put into use exceeds 4 according to rules, gradually stop the pulverized coal feeder that has not yet been provided with oil guns and lower oil load to avoid closing low pressure bypass because of low vacuum in turbine. 10.12.2.6 Properly lower main steam pressure fixed value. 10.12.2.7

When

main

steam

pressure

drops,

place

high

pressure

bypass

under

automatic or manual position t o avoid the tripping of boiler b oiler because of the closure of high pressure bypass valve. 10.12.2.8 not

Attention

should

be

paid

to

drum

water

level,

when

water

feeding

can

work automatically, automatically, switch to manual regulation.

10.12.2.9 Maintain the superheat steam temperature and reheat steam temperature at above 500 DEG C, attention should be paid to desuperheater water to make sure that it is normal; if not,

Date: Date: 2008-09-15


Page 193

Rev. : A


SEC


control it manually. manually. 10.12.2.10 should 10.13 10.13

If

tripping

of

turbine

can

not

be

swiftly

restored,

boiler

combustion

be maintained and MFT operation be avoided. Steam Drum Full Feeded Feeded

10.13.1 Faults 10.13.1.1 When “water level height” reaches +25mm, alarm should be sounded, but if 10 seconds later, water level remains at the same level, o perate MFT. MFT. 10.13.1.2 Water level of TV water level gauge and local water level gauge is too high to be seen. 10.13.1.3 Feedwater flow is abnormally greater than main steam flow. 10.13.1.4 Steam gas temperature is rapidly dropped, main throttle valve flange emits white vapor, when it is serious, “water hammer” will take place as a result. 10.13.1.5 Superheat steam gas conductivity is high. 10.13.2 Causes 10.13.2.1 Feedwater automatic regulation fails to work; 10.13.2.2 water

Errors

caused

by

falseness

of

water

level

indication

or

relaxing

of

level surveillance;

10.13.2.3 Boiler load is low and feedwater regulating valve leaks too much; 10.13.2.4 Load or steam pressure fluctuation is too great; 10.13.2.5 Sudden opening of high pressure bypass or operating of drum safety valve; 10.13.2.6 All furnace water pumps trip; 10.13.2.7 When water level is in the form of “default”, its setting value is too high; 10.13.3 Countermeasures 10.13.3.1 When water level reach -75mm and high water level signal has been sent out, feedwater regulating should

should

be

be diminished,

immediately if

necessary, necessary,

switched stable

to relief

manual valve

status and

and

feedwater

continuous

relief

flow valve

should be coordinately regulated until drum drum water level returns to normal. 10.13.3.2 When feedwater regulating valve leaks too much, load should be increased properly, if

Date: Date: 2008-09-15


Page 194

Rev. : A


SEC


necessary to maintain normal water level. 10.13.3.3 When water regulation and meter indication are inaccurate, thermal engineering experts should be immediately sent for. 10.13.3.4 During operation, surveillance of drum water level and checking of local water level gauge should be reinforced, and mistakes should be avoided. 10.13.3.5 Desuperheater water should be disconnected according to steam temperature, and drainage in superheater and main steam valve should be started. 10.13.3.6 After MFT is operated, address problems according to methods following the operation of MFT. 10.13.3.7 After the above measures have been taken, if drum water wate r level still rises to pass +25mm, while MFT is still out of operation, the following emergency measures should be taken: a)

Press “emergency shut down” button;

b)

Stop feed (water) pump pump and make sure that the recirculating valve of coal economizer economizer has been opened;

c)

Make sure that main steam valve is closed;

d)

Open all drains of superheater system and main steam drain of turbine as well;

e)

Make sure that all desuperheater water valves have been closed;

f)

Water discharging should be reinforced until drum water level is seeable;

g)

When overflow has been ruled ruled out and drum water level have returned to normal, normal, boiler will not be restarted until shift supervisor have agreed to do so;

10.14 10.14

Steam Drum Short Feeded Feeded

10.14.1 Faults 10.14.1.1 Water levels shown in TV and local water level gauges are too low to be seen. 10.14.1.2 “Drum water level” keeps dropping after alarm is sounded when it drops to -415mm, and when it drops to -600mm, if 10 seconds after the “drumwater level record low” alarm have sounded, it remains at the same level, MFT should be operated. 10.14.1.3 Feedwater flow is abnormally less than steam flow (the other way round is true of coal economizer and water cooled wall leakage).

Date: Date: 2008-09-15


Page 195

Rev. : A


SEC


10.14.1.4 When water shortage sh ortage is serious, pressure difference of furnace water pump is low and it shakes. 10.14.2 Causes 10.14.2.1 Feed water control malfunction and feed (water) pump failure result in the decrease of water allowance or water main pressure p ressure becoming too low. 10.14.2.2 Falseness of water level indication results in operation that is wrong. 10.14.2.3 Feed water line leaks too much. 10.14.2.4 contact

Leakage

and

mis-operation

of

blow

down

valve

or

pollution

discharge

is inappropriate.

10.14.2.5 Cracking of water wall tube or economizer tube. 10.14.2.6 Load fluctuation is too great. 10.14.2.7 Opening indication of feedwater-regulating valve fall short of actual opening. 10.14.2.8 Feedwater electrically operated valve mis-close or feedwater regulating valve panel falls off. 10.14.3 Countermeasures 10.14.3.1 When water level is (-415mm) with furnace water pump operating normally and alarm is sounded, feedwater regulation should be immediately switched to manual status, and more water should be pumped into boiler to return drum water level to a normal level. 10.14.3.2 All drainage operation should be stopped. 10.14.3.3 Attention should be paid to changes of main steam temperature in the process of water inflow. 10.14.3.4 When the above measures have been taken, water level keep dropping to -600mm at which MFT begins to operate in 10 seconds, if not, the following measures should be taken. a)

Press “emergency shut down” button

b)

Stop the operation of furnace water pump, feed boiler with water when drum water level is lower than visible water level. If regulating valve panel falls off, furnace water pump should be immediately stopped, boiler be fully closed, electric unit be notified to stop furnace water pump power supply, supply, and at the same time, furnace water pump should be

Date: Date: 2008-09-15


Page 196

Rev. : A


SEC


closed off and attention paid to drum wall temperature changes. c)

Reasons for water shortage shortage should be identified and it should be properly solved, boiler can not be restarted until orders to do so have been authorized by shift supervisor.

d)

Water inflow time time and speed of water-empty boiler should be decided by director in charge who will issue the order.

10.15

Priming

10.15.1 Faults 10.15.1.1Drumwater level drastically fluctuates and water level inside water level gauge is unclear; 10.15.1.2 Feedwater self regulation is unsound; 10.15.1.3 Main steam temperature is dropped and steam conductivity is increased, when it is serious, water slug will will take place inside inside the main steam pipes. 10.15.2 Causes 10.15.2. Quality of feedwater or boiler water is unqualified; 10.15.2.2 Boiler load drastically dras tically drops or steam pressure drastically drops; 10.15.2.3 Oil entering into the steam system. 10.15.3 Countermeasures 10.15.3.1 Report to shift supervisor, supervisor, decrease and stabilize boiler load; 10.15.3.2 Open continuous continuou s relief valve, intensify stable relief valve, and lower the drum water level to -50mm; 10.15.3.4 Chemist should be notified to stop adding drugs and increase boiler water laboratory test. 10.16 10.16

High Furnace Pressur e

10.16.1 Faults 10.16.1.1 “Furnace pressure high I value” alarm sounds; 10.16.1.2 Indication of furnace draft meter skews positively; 10.16.1.3 Fume is emitted from leaking zone of furnace;

Date: Date: 2008-09-15


Page 197

Rev. : A


SEC


10.16.1.4 When “furnace pressure high II value” alarm sounds, MFT will take place. 10.16.2 Causes 10.16.2.1 Force fan can not track and check in time after single induced fan fails and trips; 10.16.2.2Automatic device of furnace draft fails; 10.16.2.3 Suction guide and outlet damper of induced fan or smoke damper of gas dust are mis-closed; 10.16.2.4 Combustion operation conditions deteriorate; 10.16.2.5 Pressure-bearing members inside furnace have been seriously burst. 10.16.3 Countermeasures 10.16.3.1 Guide vane of induced fan should be switched to manual status and its opening should be regulated to maintain the furnace negative pressure at a normal level; 10.16.3.2 Baffle plate that has been mis-closed should be restored to its original state in time; 10.16.3.3 When furnace pressure is high and MFT starts, problem should be addressed according to relevant rules followed by the resolution of the operation of MFT. MFT. 10.17 10.17

Low Furnace Pressur e

10.17.1 Faults 10.17.1.1 “Furnace pressure low” alarm sounds; 10.17.1.2 Indication of furnace pressure meter is increased in the direction of minus value; 10.17.1.3 When “furnace pressure low II value” alarm window sound the alarm, MFT will take place. 10.17.2 Causes 10.17.2.1 Induced fan can not track and check in time when single force fan fails and trips; 10.17.2.2 Furnace draft self regulation fails to work; 10.17.2.3 plates

Inlet

movable

vane

and

outlet

damper

of

force

fan

and

air

duct

are mis-closed;

10.17.2.4 Assisted wind regulating baffle plate fails or is mis-closed;

Date: Date: 2008-09-15


Page 198

Rev. : A

baffle


SEC


10.17.2.5 Boiler combustion working condition deteriorates or boiler fire goes out. 10.17.3 Countermeasures: 10.17.3.1 Flushing should be burned steadily by adding oil; 10.17.3.2 Regulate the opening of induced fan suction guide; maintain the furnace draft at a normal level; 10.17.3.3 When draft self regulation fails, manual regulating should be switched on; 10.17.3.4 Return baffle that has been mis-closed to its original state; 10.17.3.5 When “furnace pressure low II value” alarm window sounds the alarm, operate MFT according to MFT relevant rules. 10.18 10.18

Boiler Burni ng Out

10.18.1 Faults 10.18.1.1 Furnace pressure suddenly drops on a large scope, and primary and secondary wind pressures drop simultaneously; 10.18.1.2 “Furnace losing flames” alarm sounds; 10.18.1.3 Flame detector shows no sigh of flame; 10.18.1.4 Flame check of burner at all levels all disappears; 10.18.1.5 MFT operates; 10.18.1.6 Steam temperature, steam pressure and main steam flow rapidly drop; 10.18.1.7 Water level goes down before it goes up. 10.18.2 Causes: 10.18.2.1 Failure and tripping of force fan, induced fan and primary fan, etc. or operation of boiler tripping protection; 10.18.2.2 When load is low, low, mixture ratio of wind and coal is seriously maladjusted; 10.18.2.3 When load is low, low, coal quality become worse and coal powder become thick, resulting in the deterioration of burning working condition; 10.18.2.4 Oil is not put in to stabilize burning when the combustion is unstable;

Date: Date: 2008-09-15


Page 199

Rev. : A


SEC


10.18.2.5 Operational manner of burner is inappropriate; 10.18.2.6 When load is low, flame is blown out by furnace soot-blowing and water wall tube blast or furnace draft is too great; 10.18.2.7 Water wall does not soot-blow, resulting in the falling of coke on a large acreage; 10.18.2.8 Oil system fails or oil-receiving electromagnetic valve is mis-closed when oil is burning; 10.18.2.9 House supply interrupts or MFT mis-operate. 10.18.3 Countermeasures: 10.18.3.1 Problems should be addressed according to relevant rules followed by the resolution of the operation of MFT; 10.18.3.2 After causes are identified and removed, start induced and force fan with over 30% that of air volume blowing furnace for 5 minutes, after that, reignite the furnace; 10.18.3.3 After fire is extinguished, the lifting of fire-extinguishing protection is banned and igniting by deflagration is adopted. 10.19

Fuel Trip ri p

10.19.1 Faults 10.19.1.1 Send out signal alarm to prompt ‘total loss of fuels’. 10.19.1.2 MFT happens to the boil. 10.19.1.3 All pulverizing systems trip and fuel oil supply is stopped. 10.19.1.4 No flame is shown in flame scanner of the furnace. 10.19.2 Causes 10.19.2.1 Coal in all coal silos is run out of. 10.19.2.2 All pulverizing systems trip. 10.19.2.3 Trouble happens to oil system during combustion or oil intake electromagnetic valve is closed by mistake. 10.19.3 Countermeasures 10.19.3.1 Eliminate the trouble according to MFT troubleshooting.

Date: Date: 2008-09-15


Page 200

Rev. : A


SEC


10.19.3.2 Find out the reason and recover operation as soon as possible. 10.20 10.20

Water Water Wall Wall Tubes Txplo sio n

10.20.1 Faults 10.20.1.1 Steam pressure is down and water level in drum is dropped. 10.20.1.2 Negative pressure in furnace is reduced or turns to positive pressure. 10.20.1.3 The opening of baffle plates at the entrance to the induced draft fan is abnormally increased. 10.20.1.4 Smoke comes out from the part where the sealing is not good in the furnace. 10.20.1.5 Steam ejection sound or explosion is heard from the furnace. 10.20.1.6 Water supply is abnormally larger than the steam flow. flow. 10.20.1.7 The combustion is not stable and even may go out. 10.20.1.8 The flue temperature is dropped. 10.20.2 Causes 10.20.2.1 Poor quality of furnace water, which causes serious scale formation in pipelines. 10.20.2.2 The entrance orifice of water wall is blocked, which causes bad water circulation. 10.20.2.3 Serious coking in water wall, which causes uneven heat exposure. 10.20.2.4 Flame deflection, which causes uneven heat exposure in local water wall. 10.20.2.5 Water wall is damaged by large dropping lump coke. 10.20.2.6 Bad welding of water walls. 10.20.2.7 Serious sulfur corrosion. 10.20.3 Countermeasures 10.20.3.1 If there is leakage happening to water wall but the water in the drum can be kept at a normal level, short run operation in proper reduced load is permissible, but the chief attendant should inform a factory director and ask for arrangement of boiler shut down which should be done according to regular shut down procedures. 10.20.3.2 If the water water wall is seriously damaged and the water in steam drum is not kept kept at a

Date: Date: 2008-09-15


Page 201

Rev. : A


SEC


normal level, the following measurements should be conducted. 10.20.3.3 Press ‘emergency shut down’ to stop the furnace quickly. quickly. 10.20.3.4

After

the

boiler

is

shut

down,

the

induced

draft

fan

should

be

kept

running and the furnace kept at a negative pressure. pressure. Stop the induced draft fan and change the ventilation into natural ventilation when it is considered to be proper and keep the furnace at a negative pressure to emit flue and steam inside. 10.20.3.5 Continue supplying water to the furnace to maintain the water level of the drum; close static-row and link-row motor-operated valve and hand-operated valve. 10.20.3.6 If the leakage of the water wall is extremely serious, and the water level in the drum can not be kept after the furnace is stopped, the furnace water pump and feed water pump should be stopped as well as recirculation valve of economizer. 10.20.3.7

The

deposited

in

economizer

should

the economizer and

be

received

the ash hopper of

enough the

care

and

ashes

air preheater should be

cleared up timely to prevent accidents of ash hopper and flue duct collapse caused by ash deposit. 10.21 10.21

Econo mizer Tubes Explo sio n

10.21.1 Faults 10.21.1.1 Water level in drum is dropped. 10.21.1.2 Water supply is abnormally larger than the steam flow. flow. 10.21.1.3 Abnormal noise is heard at economizer part. 10.21.1.4 Ash hopper at the lower part of economizer is blocked by wet ash or ash water is leaked from the ash hopper. 10.21.1.5 Flue temperature at the water leakage side is dropped. 10.21.1.6 There exists great difference of flue temperature at A side and B side of the entrance of the air preheater. prehe ater. 10.21.1.7 The opening of baffle plates at the entrance to the induced draft fan is increased. 10.21.2 Causes 10.21.2.1 Poor quality of feed water, which causes serious scale formation in pipelines and to burn tube.


SEC

Date: Date: 2008-09-15



Page 202

Rev. : A


SEC


10.21.2.2 It is worn by flying ash. 10.21.2.3 The recirculation valve of economizer is not operated according to provisions in boiler starting or shutdown. 10.21.2.4 The tube is blocked when installation or maintenance. 10.21.2.5 Poor quality of tube or welding. 10.21.3 Countermeasures 10.21.3.1 Increase water supply to keep the water level in the drum. 10.21.3.2 Operate it at a lower load and pressure and ask for factory director to decide the boiler shut down time. 10.21.3.3 If the water level is not kept at a normal level after water supply increasing, stop the boiler immediately with the approval of the chief attendant. 10.21.3.4 Try to keep the water level in drum as possible after the boiler shut down and close continuous

drainage

valve

and

regular

drainage

valve,

hand-operated

valve

and

recirculation valve of economizer. 10.21.3.5

The

deposited

in

economizer

should

the economizer and

be

received

enough

care

and

ashes

the ash hopper of the air preheater preheater should be


Superh eater Tubes Explo sio n

10.22.1 Faults 10.22.1.1 Main steam pressure is dropped. 10.22.1.2 Water supply is abnormally larger than the steam flow. flow. 10.22.1.3 flue

duct

The

negative

pressure

in

the

furnace

turns

positive

and

pressure

in

is increased; steam is ejected from the part where the sealing is not good in in the flue flue

tube. 10.22.1.4 Abnormal noise is heard at the leakage of superheater. 10.22.1.5 Flue temperature at the leakage side is dropped. 10.22.1.6 If roof tube, wall enclosure tube or low over leakage cause high over and medium over steam temperature rising, and if the medium over and high over leak, the main steam temperature rises.


SEC

Date: Date: 2008-09-15



Page 203

Rev. : A


SEC


10.22.1.7 Large steam temperature difference between the two sides. 10.22.1.8 The opening of baffle plates at the entrance to the induced draft fan is abnormally increased. 10.22.2 Causes 10.22.2.1 Steam quality is deteriorated in the long run and scale formation in the tube causes over heat on the tube wall. 10.22.2.2 Over heat or coking happens frequently in superheater. 10.22.2.3 It is seriously worn by flying ash. 10.22.2.4 Recombustion happens to some section of superheater. 10.22.2.5 Ash gun is wrongly installed or trouble comes up during op eration and the gun is broken. 10.22.2.6 The tube is not qualified or the welding quality is poor. 10.22.3 Countermeasures 10.22.3.1 When the over heater tube leaks, reduce load and pressure for operation and ask for factory director to arrange to t o shut down the boiler. 10.22.3.2 If the superheater tube is seriously damaged, it should prevent the worsening of any accident. 10.22.3.3

After

the

boiler

is

shut

down,

the

induced

draft

fan

should

be

kept

running and the furnace kept at a negative pressure. pressure. Stop the induced draft draft fan and change the ventilation into natural ventilation when it is considered to be proper and keep the furnace at a negative pressure to emit flue and steam inside. 10.22.3.4

The

deposited

in

economizer

should

the economizer and

be

received

enough

care

and

ashes

the ash hopper of the air preheater preheater should be


Reheater Reheater Tubes Explo sio n

10.23.1 Faults 10.23.1.1 The pressure at the outlet of reheater is dropped. 10.23.1.2 Main steam flow is increased.


SEC

Date: Date: 2008-09-15



Page 204

Rev. : A


SEC


10.23.1.3 Abnormal noise is heard nearby the reheater and when explosion, the negative pressure in the furnace turns to positive and even steam or flue is ejected from the part where the sealing is not good in the furnace or flue duct in serious case. 10.23.1.4 The opening of baffle plates at the entrance to the induced draft fan is abnormally increased. 10.23.1.5 The steam temperature difference at the two sides of the reheater is large and the temperature at the trouble side rises. 10.23.2 Causes 10.23.2.1 The steam quality is poor, which causes scale formation inside or maintenance of the furnace after shutdown is done improperl y, which corrodes the reheater tube. 10.23.2.3 It is worn by flying ash. 10.23.2.4 Poor quality of tube or welding. 10.23.2.5 The furnace temperature is not controlled strictly during operation and steam supplying protection to the reheater is not sufficient during starting and shutdown. 10.23.3 Countermeasures 10.23.3.1 If the reheater tube is not seriously damaged, operate it in a lower load and ask for the factory director to arrange boiler shut down. 10.23.3.2 If the reheater tube is seriously damaged, do emergency shutdown after consent of the chief attendant. 10.23.3.3

After

the

boiler

is

shut

down,

the

induced

draft

fan

should

be

kept

running and the furnace kept at a negative pressure. pressure. Stop the induced draft draft fan and change the ventilation into natural ventilation when it is considered to be proper and keep the furnace at a negative pressure to emit flue and steam inside. 10.24 10.24

The Break of Steam Steam Pipes or Feedw Feedw ater Pipes Outsid e the Boiler

10.24.1 Faults 10.24.1.1 Humility, water seepage or water leakage or steam leakage in damaged part. And even leakage noise is heard. 10.24.1.2 Loud noise is heard when the pipe is explodes and steam and water are ejected and supports and hangers may be damaged.

Date: Date: 2008-09-15


Page 205

Rev. : A


SEC


10.24.1.3 Steam or feed water pressure and the flow change are abnormal. 10.24.2 Causes 10.24.2.1 Poor material quality and unqualified fabrication, installation and welding, which affect free expansion. 10.24.2.2 Local

wall

Long

run

operation

under

over

pressure

and

over

heat

conditions.

of wearable parts (such as parts near elbow and porous plate) get thin, which lower

metal strength. 10.24.2.3 Pipe heating and water drainage are not sufficient during boiler ignition process, which causes serious water impact. 10.24.2.4 Unqualified feed water quality, which causes pipe wall corrosion. 10.24.2.5 Dramatic changes of media flow, temperature and pressure happen during operation, which causes fatigue and damage to the duct. 10.24.3 Countermeasures 10.24.3.1 If the pipe is not severely damaged and is capable of supporting the normal operation and will not worsen the troubles: 1) Adjust various parameters of the boiler, properly reduces the load to keep the normal operation and report to chief attendant and apply for boiler shutdown. 2) Provide security measurement around the damaged part and prevent steam or water from hurting personnel. 3) Pay close attention to the damaged parts and precast any accident that may happen. 10.24.3.2 Immediately stop the boiler in any emergency case that the severely damaged pipe or trouble may cause accident. 10.24.3.3 Separate the damaged p ipe section from the system as soon as possible after the boiler shut down. 10.25 10.25

High Steam Drum Pressur e

10.25.1 Faults 10.25.1.1 High pressure indicated in the pressure gauge of the drum. 10.25.1.2 High pressure indicated in superheat steam pressure gauge. Alarm window is lighted and alarm is sounded.

Date: Date: 2008-09-15


Page 206

Rev. : A


SEC


10.25.1.3 When the superheat steam pressure is up to 18.5MPa, the high pressure bypass valve and the low pressure bypass valve of the turbine are automatically opened (not been provided yet). 10.25.1..4 When the superheat steam pressure is up to 2.05MPa, the electromagnetic release valve automatically opens. 10.25.1..5 When the superheat steam pressure is up to 2.25MPa, the safety valve at the outlet of superheater starts to work. 10.25.1..6 When the superheat steam pressure is up to 20.62MPa, the safety valve of the drum starts to work. 10.25.1.7 After the electromagnetic release valve or the safety valve starts to work, the water level in the drum first goes up and then drops. 10.25.2 Causes 10.25.2.1 The load is declined abruptly. 10.25.2.2 The safety valve fails to move. 10.25.2..3 The first valve of the electromagnetic release valve fails to open or the electromagnetic release valve has not been shifted to automatic status. 10.25.2.4 Coal feeding controller (automatic combustion control) of the boiler is not dislocated or the turbine speed regulating system fails. 10.25.2.5 The adding of high pressure bypass and the low pressure bypass is not successful. 10.25.2.6 Pulverizing system works at an abnormal status. 10.25.2.7 Automatic control system fails. 10.25.3 Countermeasures 10.25.3.1Immediately take depressurization measurements: a)

Reduce coal feeder rotation speed and add oils for facilitating combustion combustion according to the combustion situation in the furnace. Stop the pulverizing system if necessary. necessary.

b)

Open high pressure bypass valve and low pressure bypass valve valve of the turbine.

c)

Manually open electromagnetic release valve.

Date: Date: 2008-09-15


Page 207

Rev. : A


SEC


10.25.3.2 Shift the operation mode of CCS coordination control system to boiler basic mode. 10.25.3.3 When the pressure in drum surpasses the safety valve working pressure and the safety valve fails to move, stop the boiler manually and takes corresponding measurements to reduce the pressure. 10.25.3.4 When the boiler pressure is recovered, close the electromagnetic release valve and contact the turbine group to close the high pressure bypass valve and low pressure bypass valve. 10.25.3.5 Pay close attention to the work conditions of the automatic regulation control device of the drum water level and the steam temperature and shift the mode to manual mode to regulate it manually if necessary. necessary. 10.26 10.26 10.26.1

Auxi liary Failure Failure Faults and countermeasures of air preheater

10.26.1.1 Too Too low rotating speed 1)

Faults a)

When the rotating speed of the air preheater during operation is as low as 0.2rpm, the main motor trips and the red and yellow lamps flash.

b)

Alarm for too low revolution is sounded.

c)

The low speed motor is automatically started and if the over low speed lasts lasts more than 80s, the low speed motor will automatically stop and the baffle plates of flue and air are closed.

d) 2)

If the control control power fails, fails, the main main motor trips and the low speed motor starts. starts.

Countermeasures a)

Check whether whether the main motor and hydraulic coupling coupling work normally;

b)

Notice thermal operation personnel to check check the rotating rotating speed speed detector;

c)

Check whether there is jamming or bump in the air preheater;

d)

Control the continuous rotation on spot for a necessary period if possible for cooling; cooling;

e)

Confirm the baffle plate of the inlet of the flue and the first thermal air baffle plate and the second thermal air baffle plate are closed when the air preheater fails and is shut down.

Date: Date: 2008-09-15


Page 208

Rev. : A


SEC


10.26.1.2 High bearing temperature (≥ (≥60℃) 1)

2)

Faults a)

Alarm is sound for high temperature of bearing (TSH15, TSH25)

b)

Lubricating oil pump starts automatically. automatically.

Countermeasures a)

When the bearing temperature temperature is not less than 60℃ and the lubricating oil pump fails to start, manually start it on DCS.

b)

Check whether the oil pump runs normal and the oil level and the oil quality are regular. regular.

c)

If the temperature shows no decline after the starting starting of oil pump for a long time, check whether the oil pressure difference o f the filter is normal on site. If th e pressure difference is too large, shift to another filter and ask for maintenance of the filter at the trouble side.

d)

Check whether the cooling water water flows smoothly and whether there is leakage on the oil pipeline.

e)

The oil pump is automatically stopped stopped when the oil temperature is declined to 50℃.

f)

Check whether the air duct leaks, ifif any, any, notice relative personnel for maintenance.

10.26.1.3 Bearing oil pump trip 1)

2)

3)

Faults a)

Yellow lamp and red lamp on the oil pump flash flash

b)

Alarm is sound for high temperature of bearing

Causes a)

Oil pump motor fails or leak electrically

b)

The mechanical part fails

Countermeasures a)

Notice relative personnel to eliminate the motor troubles timely

b)

Recover 380V power supply

Date: Date: 2008-09-15


Page 209

Rev. : A


SEC


c)

Eliminate the mechanical part troubles

d)

Strictly monitor the air preheater bearing oil temperature temperature and take necessary measures measures to cool the oil.

10.26.1.4 Complete shutdown of the air preheater 1)

Faults a)

MFT operation;

b)

Interlocking trip happens to various various auxiliary equipments and flameout happens in the boiler;

2)

c)

Sector-shaped sealing baffle plate withdraws automatically;

d)

The alarm that air preheater preheater systems A and B fail is sounded from the alarm window. window.

Causes a)

The power of air preheater motor motor is lost;

b)

The rotating speed of the air preheater preheater is lower than 0.2rpm and the low speed motor fails to start within 80s.

3)

Countermeasures a)

Resolve it according to the method for MFT. MFT.

b)

Confirm the air preheater is stopped;

c)

Confirm the flue baffle plate of the air preheater inlet and the second thermal air baffle plate of the outlet are closed;

d)

Find out the reason and remove the trouble. Prepare the boiler for restart.

10.26.1.5 1)

Trip of one air preheater

Faults a)

Lamp at the trip side of the air preheater flash flash and the alarm trump is sounded;

b)

Induced draft fan, force fan and primary air air fan at the corresponding side trip;

c)

The alarm that air preheater fails at the trip side is sounded from the alarm window;

Date: Date: 2008-09-15


Page 210

Rev. : A


SEC d)


The load is recovered to 50% of MCR, and six pulverizer pulverizer coal feeders including FEA, FEA, FEE and FEI trip.

2)

3)

Causes a)

Mechanical jamming happens to the air preheater at the trip side;

b)

The motor of the tripping air preheater fails or losses losses power;

c)

Shutdown button or emergency button is pressed by mistake.

Countermeasures a)

The load is automatically inclined to 50% of MCR, MCR, the load of the set is turned to 50% of MCR and the alarm is trigged.

b)

Confirm the flue baffle plate of the air preheater inlet and the primary and the second thermal air baffle plates of the outlet are closed, otherwise close them manually.

c)

Air fan at the corresponding corresponding side automatically trips and the baffle plate at the the outlet and the inlet automatically close; o therwise close them manually.

d)

Six pulverizer coal feeders including FEA, FEE and FEI trip automatically; otherwise otherwise trip them manually.

e)

Provide a proper amount of oil gun torches to facilitate facilitate and stabilize stabilize combustion.

f)

Find out trip Causes and start relative equipment again after they are inspected and proved to be normal.

g)

Monitor the shutdown side.

h)

Control the flue temperature and the air temperature at the inlet and the outlet of the air preheater.

i) 10.26.2

Send out a fire alarm. Induced draft fan faults and countermeasures

10.26.2.1 Complete shutdown of two induced draft fans 1)

Faults a)

MFT

Date: Date: 2008-09-15


Page 211

Rev. : A


SEC b)


The motors of the two induced draft fans are powered off and the outlet baffle plate is automatically closed.

c)

If the electric electric protections system system starts starts to work, work, the alarm that induced draft system system fails is sounded from the alarm window.

d)

The two force fans are interlocked and the two primary fans are stopped completely completely,, the total air amount and the air pressure are dropped to zero instantly. instantly.

e) 2)

The negative pressure in in the furnace changes greatly and the fire in the boiler goes out.

Causes a)

When the furnace pressure is not less than 41mbar or not more than -25mbar, -25mbar, MFT fails to start within 5s.

b)

The number of the secondary secondary air baffle baffle plates of spark plug plug which is opened is less than 18.

3)

c)

All force fans trip.

d)

All air preheaters trip.

e)

The motor power is cut off.

Countermeasures a)

Dispose it according to the countermeasures to MFT. MFT.

b)

When the baffle plates of the inlet and the outlet fail to open, open them timely timely or slowly slowly open the regulation baffle plate, keep the furnace draft pressure between 0Pa and 100Pa and the ventilation in the furnace balanced to prevent furnace explosion.

c)

If the induced draft fan fails to recover to start, keep the furnace in natural ventilation for above 15min.

d)

If the induced fan recovers to start, strictly strictly conform to the furnace cleaning procedures when the boiler recovers to start.

10.26.2.2 Trip of one induced draft fan 1)

Faults a)

Alarm that induced induced draft fan fails at the trip side is sounded from the alarm window. window.

Date: Date: 2008-09-15


Page 212

Rev. : A


SEC b)


The inlet baffle plate and the outlet baffle plate of the induced draft fan at the trip side are closed automatically. automatically.

2)

3)

c)

The furnace draft pressure turns positive.

d)

Force draft draft fan and primary air fan at the side corresponding to the interlinking trip. trip.

Causes a)

The fan vibration is not less than 120μ 120μm

b)

The shutdown button is pressed by mistake

c)

Electric baffle plate of the outlet is automatically closed

d)

The electric protection system starts to work

e)

Mechanical faults

f)

The air preheater at the corresponding side trips

g)

The drive drive power supply at the corresponding corresponding side is cut off

h)

The shift of air fan rotating speed fails

Countermeasures a)

If MFT takes place, shoot it according to the troubleshooting method for MFT. MFT.

b)

The load should be automatically reduced reduced to 50% of MCR, the alarm that the set load is recovered to 50% of MCR is sounded from the alarm window.

c)

Six pulverizer pulverizer coal feeders of FEA, FEE and FEI trip automatically; automatically; otherwise shut down the six pulverizer coal feeders of FEA, FEE and FEI manually. manually.

d)

Provide a proper amount of oil gun torch for facilitating facilitating combustion. After the combustion is stable, determine whether to stop the pulverizer coal feeder according to its rotating speed to avoid that the feeding is not proper due to the low rotating speed.

e)

If the force fan and the primary primary air fan at the corresponding corresponding side fail to trip automatically, automatically, stop them manually but keep the air preheater at the corresponding side running.

f)

After the cause for tripping tripping is found out, and the induced draft fan is inspected and proved to be normal, the induced draft fan then can be restarted.

Date: Date: 2008-09-15


Page 213

Rev. : A


SEC g)

Monitoring at the shutdown side:

Monitor outlet


of

the

flue

temperature

and

the

air

temperature

at

the

inlet

and

the

the preheater and fire alarm.

Check the induced draft fan bearing temperature and the temperature of the motor coil and the bearing. 10.26.2.3 High temperature at bearing and coil 1)

Alarm is sounded when the air fan bearing temperature TE01B, TE01D and the motor bearing temperature TE01F, TE01F, TE01H are high.

2)

Find out the cause of high temperature at the bearing when the alarm is sounded and remove it immediately.

3)

If the bearing temperature is up to 95℃, the induced draft fan should be stopped.

4)

Alarm is sounded when the motor coil temperature TE01I, TE01L and TE01M is high.

5)

Find out the cause of high temperature at the coil when the alarm is sounded and remove it immediately.

6)

Check whether the motor is over loaded

7)

Check whether the air cooler cooler is normal and whether the filter screen at the inlet is blocked.

8)

If the coil temperature is up to 120℃, the induced draft fan should be stopped

10.26.3

Force fan faults and countermeasures

10.26.3.1 Complete shutdown of two force fans 1)

Faults a)

Tripping;

b)

The baffle plates of the inlet and the outlet of the force fan are automatically closed; closed;

c)

The total air pressure pressure and the total air amount are dropped to zero;

d)

If the force fan trips trips due to accidents, the induced draft fans should should be automatically stopped completely as well as the primary air fans

e)

Alarm that force fan systems A and B fail is is sounded from the alarm window. window.

Date: Date: 2008-09-15


Page 214

Rev. : A


SEC 2)


Causes a)

All induced draft fans trip;

b)

All air preheaters trip;

c)

The furnace pressure is more than 41mbar or less than -25mbar while while the MFT MFT does not starts within 5s.

d) 3)

The motor power is cut off.

Countermeasures a)


b)

If the force fan outlet baffle plate is closed, closed, open it manually in time to keep ventilation in the furnace and prevent furnace from explosion.

c)

If the force fan fails to recover to start, keep the furnace in natural ventilation for above 15min. furnace

If

the

force

fan

recovers

to

start,

strictly

conform

to

the

cleaning procedures when the boiler recover to start.

10.26.3.2 Trip of one force fan 1)

Faults a)

The baffle plates of the tripped force fan inlet and outlet are closed automatically;

b)

The cooling air balance disconnection damper is closed;

c)

The load of the force fan in operation is increased. When it is running at a low speed, it should be automatically shifted to high speed;

2)

d)

The negative pressure of the furnace is increased instantly, instantly, which may may cause MFT MFT;

e)

The load load is automatically reduced to 50% of MCR;

f)

Pulverizer coal feeder of FEA, FEE and FEI automatically trip.

Causes a)

Air fan vibration is not less than 120μ 120μm;

b)

The air preheater at the corresponding side side trips;

c)

The air preheater at the draft fan trips;

Date: Date: 2008-09-15


Page 215

Rev. : A


SEC

3)


d)

Electric protection system starts to work;

e)

Mechanical faults;

f)

Shutdown button or emergency button is is pressed by mistake;

g)

The outlet baffle plate of the air fan during operation is automatically closed;

h)

The drive power supply is cut off.

Countermeasures a)


b)

The load is automatically dropped to 50% of MCR, MCR, the load of the set is turned to 50% of MCR and the alarm is trigged.

c)

Six pulverizer pulverizer coal feeders including FEA, FEE and FEI trip automatically; automatically; otherwise otherwise shut them down manually. manually.

d)

Provide After

a

proper

amount

of

oil

gun

torches

for

facilitating

combustion.

the combustion is stable, determine whether to stop the pulverizer coal feeder

according to its rotating speed to avoid that the feeding is not even due to the low rotating speed. e)

The baffle plates of the tripped air fan outlet and inlet inlet are automatically closed as well as cool air balance baffle plate; plate ; otherwise it should be closed manually.

f)

After the cause for tripping is found out, and the force fan is inspected and proved to be normal, it then can be restarted.

g)

Monitor the shutdown side:

Monitor outlet

of

the

flue

temperature

and

the

air

temperature

at

the

inlet

and

the preheater and fire alarm.

Check the temperature of the force fan motor and the bearing. 10.26 10.26.4 .4 Faults Faults and coun termeasures termeasures of primary air fan 10.26.4.1 Outage of two sets of primary air fans 1) Faults a)

Alarm that “primary “primary air pressure is very low” is given. given.

b)

MFT takes place, pulverizer coal feeding is stopped and boiler boiler is in fire-off.

c)

Furnace draft maximizes instantly.

Date: Date: 2008-09-15


Page 216

Rev. : A

the


SEC


d)

Auto shutdown of inlet baffle plate and outlet baffle plate of primary air fan as well as hot primary air baffle plate.

e)

Alarm of “fault “fault of primary air system” is given.

2) Causes a)

Outage of all induced draft fans

b)

Outage of all air preheaters

c)

Power failure

3) Countermeasures a)

Solve by the countermeasure to MFT

10.26.4.2 Tripping of one primary air fan 1) Faults a)

Auto shutdown of inlet and outlet baffle plate of the tripping air fan and auto shutdown of hot primary air baffle plate of the air pre-heater at the corresponding side

b)

Instant increase increase of furnace furnace draft which may result in MFT

c)

Primary air pressure decreases, maybe maybe to very low degree and MFT takes place if the pressure does not recover in 10 seconds.

d)

Auto decrease of loading to 50%of MCR

e)

Alarm window window gives alarm of “fault of primary air fan” at tripping side.

f)

Auto tripping of six sets of FEA, FEE, FEI pulverizer coal feeders.

2) Causes a)

Tripping of air pre-heater at the corresponding side

b)

Tripping of induced draft fan at the corresponding corresponding side

c)

Fan vibration≥ vibration≥80μ 80μm

d)

Electric protection

e)

Mechanical failure

f)

Auto shutdown of outlet baffle plate of fan during operation

Date: Date: 2008-09-15


Page 217

Rev. : A


SEC g)


Shutdown button or emergency button is pushed by mistake.


Solve by the countermeasure to MFT.

b)

If loading auto decreases to 50% of MCR, alarm window window gives alarm that unit loading recovers to 50% of MCR.

c)

Inlet and outlet baffle plates of fan trip, hot primary air baffle plate auto shuts down, otherwise, manually shut it down.

d)

Six sets of FEA, FEE, FEI pulverizer coal feeders auto shut down, otherwise, manually manually shut them down.

e)

Put proper oil gun torch to support combustion, combustion, judge whether to shut down pulverized coal feeder according to rotating speed of pulverized coal feeder after the combustion is stabilized, and avoids uneven power feeding due to low rotating speed of pulverizer coal feeder.

f)

The machine machine can only be started up after ascertaining tripping tripping reason and make sure there is no other fault through checking up.

g)

Monitoring of shutdown side

Smoke temperature and air temperature at the inlet and outlet of air pre-heater as well as fire alarm Temperature of primary air fan and motor bearing 10.26 10.26.5 .5 Faults Faults and co untermeasures of coal pu lverizing s ystem 10.26.5.1 Emergency shutdown of coal pulverizing system 1) Coal pulverizing system should be shut down by “emergency shutdown (HSXH001)” in case one of the following happens: a)

MFT takes place place but coal pulverizing pulverizing system dose not trip.

b)

Coal pulverizing system is on fire and in explosion danger or explosion takes place.

c)

Rotor emits violent vibration and impact sound.

d)

People and equipment are endangered.

Date: Date: 2008-09-15


Page 218

Rev. : A


SEC e)


Cyclone separator is blocked and exhaust air is filled with lots of pulverized coal, coal, which results in quick rise of steam temperature and steam pressure of boiler.

f)

Coal pulverizer does not trip when one condition for coal pulverizer pulverizer tripping exists.

2) Coal pulverizer should be shut down in case one of the following happens: a)

Power of main motor abnormally increases or decreases.

b)

Outlet temperature cannot be monitored monitored due to display failure of outlet temperature of coal pulverizer.

c)

Cyclone separator is blocked.

d)

Cyclone separator is seriously blocked.

e)

There is abnormal metal impact sound in coal pulverizer. pulverizer.

f)

During pulverized coal pouring, pulverized coal conveyer trips but guiding baffle plate does not auto guide to pulverized coal bunker.

10.26.5.2 Spontaneous combustion or explosion of coal pulverizing system 1) Faults a)

Outlet negative pressure of coal pulverizer and inlet negative pressure of pulverized coal exhauster change in large fluctuation.

b)

Outlet temperature of coal pulverizer rises abnormally.

c)

Spark is found at inspection hole and untight places of system.

d)

During explosion, explosion, pulverized coal leakage and smoke leakage are found at untight places of

system,

explosion

valve

protrudes

or

exposes

and

negative

pressure

at

furnace changes into positive pressure. e)

Metal wall wall temperature temperature of pulverized coal bunker rises abnormally abnormally during spontaneous combustion of pulverized coal in pulverized coal bunker.

2) Causes a)

Pulverized coal deposits for a long time in coal pulverizing system.

b)

The temperature temperature at broken coal outlet of coal pulverizer pulverizer is over high.

Date: Date: 2008-09-15


Page 219

Rev. : A


SEC c)


Raw coal is of high volatile matter and outlet temperature of coal pulverizer in running is not reduced correspondingly.

d)

There is foreign fire or explosive in system.

e)

Over high oxygen content in the system


In

case

increase

of

spontaneous

coal feeding

combustion

amount,

reduce

at

inlet

of

pulverized

classifier, reduce or cut off system draft

and

coal

pulverizer,

coal

amount

stop coal

feeder;

at

properly loop

apply

of fire-

fighting equipment to put out a fire on occasion and all damper baffle plates should be closed if gas fire-fighting equipment is applied. b)

In case horizontal tube at coal pulverizer inlet is on fire, coal pulverizing system should be stopped running to extinguish fire.

c)

In case of spontaneous combustion of pulverized coal bunker, coal pulverizing system or pulverized not

coal

conveyer

should

be

stopped

running

immediately.

Must

convey pulverized pulverized coal towards towards the pulverized pulverized coal bunker and close moisture moisture

absorption piping towards the pulverized coal bunker to reduce pulverized coal completely; after pulverized coal level is reduced to certain height, increase pulverized coal level immediately and press pulverized coal to extinguish fire; apply fire-fighting equipment if pulverized coal press does not work (clean and dry pulverized coal bunker after application). d)

After coal pulverizing system explodes, emergency shutdown of coal pulverizing pulverizing system should be carried out, close hand-operated valve and coupling cock valve for moisture absorption

piping

of

pulverized

coal

bunker,

confirm

tight

closing

of

all

damper baffle plates, extinguish internal and external fire fire source and repair explosion explosion door. e)

Normal coal pulverizing can only be carried carried out after water in the system is drained away as far as possible and the system is fully ventilated and dried if fire water is applied during the fir fighting process.

10.26.5.3 Coal interruption in coal pulverizer 1) Faults a)

Coal interruption alarm is given and pulverized coal feeder trips after 30 seconds.

b)

Noise level of coal pulverizer increases.


SEC

Date: Date: 2008-09-15



Page 220

Rev. : A


SEC c)


Outlet temperature of coal pulverizer rises; outlet temperature first reduces and then rises if pulverized coal bunker is empty.

d)

Negative pressure at pulverized coal bunker decreases.

e)

Rotating speed of pulverized coal feeder maximizes during auto rotation.

2) Causes a)

There is no coal in raw coal bunker.

b)

Raw coal bunker is blocked.

c)

Driving part of pulverized coal feeder is in fault and driving driving belt skips or loosens.

d)

Scraper chain for pulverized coal feeder breaks breaks and falls down.


Control outlet temperature of coal pulverizer at setting value value and properly turns down regulation baffle plate at inlet of exhaust air fan.

b)

Note man on duty for combustion and conveying to feed coal or dredge coal bunker (start up air gun).

c)

Note maintenance personnel to eliminate equipment fault.

d)

In case coal interruption lasts for 15 minutes and coal feeding cannot be recovered, coal pulverizer should be shut down and pulverized coal exhauster and exhaust air fan should be shut down on condition.

10.26.5.4 Coal jamming in coal pulverizer 1) Faults a)

Negative pressure at all points of system increase.

b)

Power of coal pulverizer pulverizer increases increases and power decreases in serious serious condition.

c)

Noise of coal pulverizer decreases.

d)

Pulverized coal coal runs out at inlet and outlet of coal pulverizer. pulverizer.

2) Causes a)

Coal feeding amount is over larger.

Date: Date: 2008-09-15


Page 221

Rev. : A


SEC


b) Noise measurement signal signal is incorrect and speed controller of coal feeding does not work. c)

Measurement of rotating speed of coal feeding is incorrect.

d)

Water content of raw coal is large, grindability decreases and hot smoke air temperature at inlet is over low.

e)

Ventilation decreases and coal feeding amount is not reduced during manual manual operation.

f)

Bypass valve of coal pulverizer is

opened by

mistake, which results in

over low of ventilation in coal pulverizer and low temperature. 3) Countermeasures a)

Decrease coal feeding amount or shut down pulverized coal feeder on occasion.

b)

Properly turn up baffle plate at inlet of exhaust air fan to increase system ventilation and carry

out

pulverized

coal

pumping

and

attention

should

be

paid

to

maintaining outlet temperature of coal pulverizer at 110 DEG C. c)

Turn down coal pulverizer bypass at normal position.

d)

In case outlet temperature of coal pulverizer increases, close hot smoke air manual baffle plate HV001 on occasion and manually open cold air baffle plate TCV62B.

e)

In case all above countermeasures do not work, shut down main motor of coal pulverizer and restart up to carry out pulverized coal pumping after turning runs for 30 minutes.

f)

In case pulverized coal coal pumping does not work, coal pulverizing pulverizing system system should should be shut down and manual drainage towards coal pulverizer should be carried out after relevant departments approve and there are definite and effective countermeasures.

10.26.5.5 Blocking of classifier 1) Faults a)

Negative pressure at outlet of coal pulverizer decreases.

b)

Negative pressure at inlet inlet of pulverized pulverized coal exhauster increases. increases.

c)

Exhaust air volume decreases.

2) Causes

Date: Date: 2008-09-15


Page 222

Rev. : A


SEC a)


Air lock for pulverized coal returning pipe is blocked blocked due to over large amount of returning pulverized power.

b)

Large humidity humidity of returning returning pulverized coal results results in blockage. blockage.

3) Countermeasure a)

Decrease

coal

maintaining b)

feeding

amount

and

attention

should

be

paid

to

outlet temperature of coal pulverizer at setting value.

Knock pulverized coal returning pipe and air lock lock to dredge pulverized coal returning pipe.

c)

If the above countermeasure does not work, coal pulverizing system should be shut down and note maintenance personnel personnel to repair.

10.26.5.6 Blockage of pulverized coal separator 1) Faults a)

Negative pressure at outlet of coal pulverizer decreases and negative pressure at inlet of pulverized coal exhauster increases obviously.

b)

When becoming series, pulverized coal exhausting amount and pulverized pulverized coal filled in exhaust air increase, steam temperature and steam pressure rise at the same time and oxygen content in fuel gas reduces.

c)

Rotating speed of pulverized coal feeder reduces during self movement movement of total fuel.

d)

Lock air under cyclone separator at blocking side does not work.

2) Causes a)

Pulverized coal is over damp, which results in blockage of pulverized pulverized coal pipe of cyclone separator.

b)

Lock air under separator does not work.

c)

Coal pulverizing system is not shut down in time when when pulverized coal bunker is full.

d)

Pulverized coal conveyer trips and guiding baffle plate does not guide towards pulverized coal bunker during pulverized coal preparation.

e)

Guiding baffle plate guides towards towards pulverized coal conveyer by mistake.

Date: Date: 2008-09-15


Page 223

Rev. : A


SEC f)


During pulverized coal pouring, aerodynamic gate (UV06) from pulverized coal conveyer to pulverized coal bunker is not opened.


Knock position of air lock to dredge pulverized coal discharging pipe.

b)

Coal pulverizing system should be shut down if pulverized coal bunker is full.

c)

Have guiding baffle plate guide towards pulverized coal bunker if guiding baffle plate moves by mistake.

d)

In case pulverized coal conveyer trips during pulverized coal pouring and guiding baffle plate

does

not

guide

towards

pulverized

coal

bunker,

have

guiding

baffle

plate guide towards pulverized coal bunker immediately immediately and coal pulverizing pulverizing system should be shut down if guiding baffle plate cannot be rotated for being pressed by pulverized coal. e)

After

coal

pulverizer

is

shut

down

during

serious

blockage,

maintain

pulverized coal exhausting and operate exhaust air fan, however, baffle plate at inlet of exhaust air fan cannot be over opened pulverized

coal

feeder

to guarantee

normal operation of

and dredge pulverized coal discharging pipe of cyclone

separator. 10.26.5.7 Tripping of exhaust air fan o r coal pulverizer 1) Faults a)

Tripping signal is given, green light lights and red light and yellow light sparks.

b)

Fan is out of operation.

c)

Negative pressure at all points of system reduces to “zero”. “zero”.

d)

Exhaust air volume reduces to “zero”.

e)

Hot smoke baffle plate is closed closed and coal pulverizer and pulverized coal feeder trip.

2) Causes a)

Power and motor are in failure.

b)

There are tripping conditions.

c)

Local shutdown button is pressed by mistake.

3) Countermeasure


SEC

Date: Date: 2008-09-15



Page 224

Rev. : A


SEC


a) Pulverized coal feeder and coal pulverizer pulverizer are shut down and turning gear is put into service. b)

Check out tripping reason and restart up after solving fault.

10.26.6 Faults and countermeasures of pulverized coal feeder 10.26.6.1 Pulverized coal feeder cannot be started up 1) Causes a)

Without starting up conditions

b)

Primary air aerodynamic overall opening signal is not received.

c)

Motor of pulverized coal feeder is not powered.


Start up once starting up conditions are held.

b)

Clear the fault that primary primary air aerodynamic overall valve valve cannot be opened in place.

c)

Note power department to power motor of pulverized pulverized coal feeder.

10.26.6.2 Rotating of pulverized coal feeder cannot be speeded after starting up 1) Causes a)

Switch for local rotating rotating speed control cabinet is not put in place of “ON”.

b)

Rotating speed regulator is in fault or not powered.


Put switch for local rotating speed control cabinet in place of “ON”.

b)

Contact heat engineering personnel and clear fault.

c)

Rotating speed regulator is powered.

10.26.6.3 Over large fluctuation of rotating speed of pulverized coal feeder in service 1) Faults a)

Over large fluctuation fluctuation of rotating speed of pulverized coal feeder

Date: Date: 2008-09-15


Page 225

Rev. : A


SEC b)


Rotating speed increases or decreases abnormally when all pulverized coal coal feeders are in auto operation.

2) Causes a)

Unsmooth blockage of scraper for pulverized coal feeder

b)

Damage of mechanical part of pulverized coal feeder

c)

Fault of rotating speed regulator

3) Countermeasures a) Pulverized coal feeder is shut down at once to clear fault 10.26.6.4 Blockage of primary air pipe and pulverized coal discharging pipe 1) Faults a)

Primary air pressure of single pipe is is abnormal and alarm is given in DCS, PSH or PSL.

b)

Rotating

speed

of

all

pulverized

coal

feeders

during

auto

operation

is

increased abnormally and boiler temperature and steam pressure reduce during auto operation. c)

Outer wall wall temperature of blocking primary air pipe and pulverized coal discharging discharging pipe is lower than that of normal pipes and is obviously lower than that of normal pipes during serious blocking or equal to room temperature.

d)

Pipe makes a clunk when being knocked.


The pulverized coal feeder is is shut down and primary air aerodynamic valve and hand operated valve are closed.

b)

Dredge the primary primary air pipe and pulverized coal discharging pipe.

10.26.6.5 Pulverized coal feeder does not discharge pulverized coal 1) Faults a)

Rotating is

speed

of

all

increased abnormally

boiler

during

Date: Date: 2008-09-15

pulverized p ulverized and

steam

coal

feede rs

temperature

during and

auto aut o

steam

operation

pressure

manual operation reduce.


Page 226

Rev. : A

of


SEC


b)

Temperature of the primary primary air pipe is lower than or close to room temperature.

c)

Pipe makes a hollow sound when being knocked.


Make sure sure all pulverized coal discharging gates should be all opened.

b)

Knock upper wall of pulverized coal bunker to exhaust air of pulverized coal.

c)

Contact maintenance personnel to check out whether mechanical parts of pulverized coal feeder are in fault.

d)

Carry out pulverized coal drop of pulverized coal bunker regularly subject to regulations.

10.26 10.26.7 .7 Faults Faults and cou ntermeasures of fi re detector coo ling fan 10.26.7.1 Faults 1)

Alarm that air air pressure at air pressure outlet is low is given and MFT takes place when air pressure is low to 70mbar.

2)

220V direct fan auto starts up.

10.26.7.2 Causes 1)

Driving belt of fan loosens and skips.

2)

Screen at fan inlet is blocked by impurities.

3)

Hand operated valve at fan outlet is closed by mistake. mistake.

4)

Electric protection takes place or power is off.

10.26.7.3 Countermeasure 1)

When AC fan is is in fault and trips or alarm of “low “low outlet air pressure” is given, DC fan should auto start up, otherwise, manual starting up should be carried out at once.

2)

In case DC fan cannot auto start up, air pressure pressure is low to 70mbar and MFT does not take place, emergency boiler shutdown button should be pressed to stop boiler operation.

3)

Take effective measure to prevent flame scanner from being damaged.

10.26 10.26.8 .8 Faults Faults and cou ntermeasures of o il gu n cool ing f an 10.26.8.1 Low air pressure

Date: Date: 2008-09-15


Page 227

Rev. : A


SEC


1) Faults a)

Alarm of low air pressure

b)

When interlock interlock is is put into operation, standby fan is linked.

2) Causes a)

Air leakage of air system

b)

Shedding of connecting hose

c)

Tripping of fan in operation

d)

Driving belt of fan loosens and skips.


After standby fan is started up, find out the reason for low air pressure.

b)

In case standby fan is not started up, it should be started up manually at once.

c)

If the fault is caused by air leakage or mechanical reason, report to man on duty and note maintenance personnel to clear the fault as soon as possible.

10.26.8.2 Tripping of fan 1) Faults a)

Yellow light of tripping tripping fan sparks and red light light sparks. sparks.

b)

Alarm of low air pressure is given; when interlock is put into operation, standby fan is started up.

2) Causes a)

Jam fault of machine and overcurrent overcurrent of motor

b)

Motor is off power or in fault.


Operate standby fan and clear clear fault of fan.

b)

When standby fan is not started up, standby should should be started up at once.

c)

Find out reason for motor and power fault and clear faults.

Date: Date: 2008-09-15


Page 228

Rev. : A


SEC


10.26.9 Faults and countermeasures of steam air heater 10.26.9.1 High water level of condensation water tank 1) Faults a)

Alarm of high water level level of condensed water tank (LSH03) is given.

b)

High water water level of local condensed water tank water level gauge


Make sure normal operation of water level control valve LCV05A on-site and open hand operated valve thereof.

b)

Make sure normal operation of water level control valve LCV05B on-site and open hand operated valve thereof.

c)

Contact heat personnel to inspect whether water level controller controller is in normal normal operation.

10.26.9.2 Low water level of condensation water tank 1) Faults

2)

a)

Alarm of low water level of condensed water tank is given.

b)

Low water water level of local water level gauge for condensed water tank

Countermeasure a)

Check out whether water drain valve is closed.

b)

Check out whether water level control valve is in normal normal operation.

10.26.9.3 High steam pressure 1) Faults Alarm of high steam pressure (PSH57) is given. 2) Countermeasure a)

Check out whether steam control valve valve TCV57A is in normal operation.

b)

Check out whether bypass valve valve HV015 HV015 thereof is closed.

c)

Make sure sure control valve for water level of condensed water tankand hand operated valve

Date: Date: 2008-09-15


Page 229

Rev. : A


SEC


thereof are opened, otherwise, manually open HV004 to release pressure. d)

In case steam steam control valve valve is in fault, inlet and outlet hand operated valves should be closed and bypass hand operated valve should be opened to regulate manually.

10.26.9.4 Low steam pressure 1) Faults Alarm of low steam pressure (PSL57) is given. 2) Countermeasure a)

Check out whether steam control valve valve PCV57A is in in normal operation.

b)

Average temperature of air smoke of air per-heater per-heater is over setting valve and opening degree of steam control valve is small, steam air heater can be shut down.

c)

Check out positions of all valves of system and make sure there is no leakage.

10.26 10.26.10 .10 Faults Faults and co untermeasures of boiler w ater circulating pump 10.26.10.1 Two sets of boiler water pump trip, a standby pump is not started up or a boiler water pump is in operation with differential pressure<1bar 1) Faults a)

MFT takes place.

b)

Emergency indicating light for boiler water pump lights.

c)

Alarm of “boiler water pump fault” is given.

2) Causes a)

Closed cooling water is interrupted or closed cooling water <27m3 /h (for 20 seconds).

b)

Electric fault makes pump motor power off.

c)

Temperature for boiler water pump≥ pump≥65 DEG C.

d)

After two pumps trip, trip, standby pump does not have starting up conditions (temperature of standby pump>55 DEG C).

e)

Boiler water pump pump sub-control sub-control shutdown button is pressed by mistake.

3) Countermeasure

Date: Date: 2008-09-15


Page 230

Rev. : A


SEC


a)

After MFT MFT takes place, solve by the countermeasure to MFT. MFT.

b)

Comprehensively inspect boiler water pump system at once to find out tripping causes and take countermeasure.

c)

Eliminate tripping tripping reason and restart up boiler water pump after making sure there is no other fault.

d)

In case

closed cooling

water

successfully, emergency enhance

water

pump trips

three-way

feeding

and reclosing

valve

to emergency

should water

be

tank,

is not

carried out

opened have

at

closed

once; cooling

water operate as soon as possible and prevent over high temperature of boiler water pump which results in motor. 10.26.10.2 Two sets of boiler water pump trip, a stand by pump is started up or a boiler water pump trips but standby pump is not started up. 1) Faults a)

Loading auto reduces to 60% of MCR and alarm of “loading recovering” is given.

b)

FEA, FEE, FEI pulverized coal feeders auto trip. trip.

2) Causes a)

Standby pump does not standby condition (temperature of pump>55 DEG C).

b)

Closed cooling water amount of motor of tripping tripping pump<27m3 pump<27m3 /h.

c)

Temperature of tripping pump≥ pump≥65 DEG C.

d)

Independent shutdown button of pump in operation is pressed by mistake.

e)

Power for tripping pump motor is off.


Alarm that loading auto recovers to 60% of MCR and alarm window unit loading to 60% of MCR is given.

b)

FEA, to

c)

FEI

pulverized

coal

feeders

aut o

trip,

otherwise,

they

trip

due

manual interruption.

Put proper oil gun torch to support combustion, judge whether to shut down pulverized coal feeder according to rotating speed of pulverized coal feeder after the combustion is

Date: Date: 2008-09-15


Page 231

Rev. : A


SEC


stabilized, and avoids uneven power feeding due to low rotating speed of pulverizer coal feeder. d)

Comprehensively take

e)

inspect

tripping

pipe,

find

out

reason

for

tripping

and

some countermeasure.

After fault is cleared and make sure there is no other fault, a boiler water pump can only be started up and gradually recover system.

10.26.10.3 A boiler water pump strips and standby pump is successfully started up Find out tripping reason, eliminate the cause as soon as possible and put the pump into interlocking and standby status.

11

Appendix

11.1 11.1

The cont rastive list of the absolute pressure pressure and and temperature temperature in saturated saturated states states

Absolute

pressure

(Mpa)

Saturation (DEG C)

temperature Absolute pressure

Saturation

temperature

(DEG C)

(Mpa) 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.25

45.83 60.09 69.12 75.88 81.34 85.95 89.96 93.51 96.71 99.63 102.32 104.81 107.13 109.32 111.37 113.32 115.17 116.93 118.62 120.23 127.43

1.80 1.90 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00 9.50 10.00 10.60 11.00

207.11 209.80 212.38 223.94 233.84 242.54 250.33 257.41 263.91 269.93 275.55 280.82 285.79 290.55 294.97 299.23 303.31 307.21 310.96 315.30 318.05

0.30

133.54

11.60

322.10

Date: Date: 2008-09-15


Page 232

Rev. : A


SEC 0.35 0.40 0.45 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70

11.2 11.2

BOIL BOIL ER & AUXIL IARI ES OPERA OPERATI TI ON MANUAL 138.87 143.62 147.92 151.84 158.83 164.96 170.42 175.36 179.88 184.07 187.96 191.61 195.04 198.29 201.37 204.31

12.00 12.60 13.00 13.60 14.00 14.50 15.00 15.50 16.00 16.50 17.00 18.00 19.00 20.00 21.00 22.00

324.65 328.40 330.83 334.40 336.64 339.40 342.13 344.80 347.33 349.80 352.26 356.96 361.43 365.70 369.78 373.69

Boiler Cold start-up Curve

Date: Date: 2008-09-15


Page 233

Rev. : A

VI ETNAM QUANG QUANG NI NI NH THERM TH ERM AL POWER POWE R J OINT OI NT STOCK STOCK COMPANY COM PANY A nthrac acit ite e Coal oal Shanghai Electric (Gro (Gr oup) Corporation 2×300 M W Anthr Fired Fired Pow Power Sta Statio tion n BOIL ER & AUXI AUX I L I ARI AR I ES OPERATI ON MANUAL MANUA L 11.3 11.3 11.3.1

Boiler Hot star-tup Curve Boiler Warm star-tup Curve

Date: Date: 2008-09-15


Page 234

Rev. : A

VI ETNAM QUANG QUANG NI NI NH THERM TH ERM AL POWER POWE R J OINT OI NT STOCK STOCK COMPANY COM PANY A nthrac acit ite e Coal oal Shanghai Electric (Gro (Gr oup) Corporation 2×300 M W Anthr Fired Fired Pow Power Sta Statio tion n BOIL ER & AUXI AUX I L I ARI AR I ES OPERATI ON MANUAL MANUA L 11.3.2

Boiler Hot star-tup Curve

Date: Date: 2008-09-15


Page 235

Rev. : A

VI ETNAM QUANG QUANG NI NI NH THERM TH ERM AL POWER POWE R J OINT OI NT STOCK STOCK COMPANY COM PANY A nthrac acit ite e Coal oal Shanghai Electric (Gro (Gr oup) Corporation 2×300 M W Anthr Fired Fired Pow Power Sta Statio tion n BOIL ER & AUXI AUX I L I ARI AR I ES OPERATI ON MANUAL MANUA L 11.3.3

Boiler Very Hot star-tup Curve

Date: Date: 2008-09-15


Page 236

Rev. : A

VI ETNAM QUANG QUANG NI NI NH THERM TH ERM AL POWER POWE R J OINT OI NT STOCK STOCK COMPANY COM PANY A nthrac acit ite e Coal oal Shanghai Electric (Gro (Gr oup) Corporation 2×300 M W Anthr Fired Fired Pow Power Sta Statio tion n BOIL ER & AUXI AUX I L I ARI AR I ES OPERATI ON MANUAL MANUA L 11.4 11.4

Boiler drume level vs load Curve

Date: Date: 2008-09-15


Page 237

Rev. : A

Shanghai Electric (Group) Corporation 11.5

VI ETNAM QUANG QUANG NI NI NH THERM TH ERM AL POWER POWE R J OINT OI NT STOCK STOCK COMPANY COM PANY 2×300 M W Anthr A nthrac acite ite Coal Fi F ired Power Station Station BOILER & AUXIL AUXIL IARIES OPERATI OPERATI ON MANUAL

Boiler O2 in flue gas vs load Curve

Date: Date: 2008-09-15 No.: QN1-SEC-G-04-TP-003

Page 238

Rev. : A

Boiler Operation Manual QN1 SEC G 04 TP 003(239)

Recommend Documents