Indonesia 1×660MW HARBIN POWER ENGINEERING CO., LTD.
Paiton
Coal Fired Thermal Power Plant
Operating and Maintenance Manual PAITONG Project Volume II: Operation Manual 660MW UNIT O&M Manuals
Volume II
Operation Manual
HARBIN POWER ENGINEERING CO., LTD.
OCT., 2009
Indonesia 1×660MW Paiton Coal Fired Thermal Power Plant Operating and Maintenance Manual Volume II: Operation Manual Chapter 1: Operation Manual of Boiler
Indonesia 1×660MW Paiton Coal Fired Thermal Power Plant Operating and Maintenance Manual Volume II: Operation Manual Chapter 1: Operation Manual of Boiler
Harbin Power Engineering Company Limited
OCT., 2009
Content Chapter I Summary of the Unit................................................................................................... 1 Section I
Unit Design Summary ............................................................................................. 1
Section II Boiler Equipment Overview .................................................................................... 4 Chapter II
Unit auxiliary equipment start and stop .............................................................. 31
Section I
General rule ......................................................................................................... 31
Section II Air preheater ......................................................................................................... 33 Section III
Induced Draft Fan................................................................................................ 37
Section IV Force Draught Fan.............................................................................................. 40 Section V Primary Air Fan .................................................................................................... 43 Section VI Sealing Fan ......................................................................................................... 46 Section VII Flame Detection Cooling Air Fan ....................................................................... 47 Section VIII Boiler Water Pump ............................................................................................ 48 Section IX Boiler-front Fuel Oil System Start and Stop ........................................................ 54 Section X Coal Mill, Coal Feeder and Its System ................................................................ 58 Section XI Drum Double-color Water Gauge ....................................................................... 65 Section XII
Periodic Blowdown and Continuous Blowdown Start and Stop....................... 66
Section XIII Boiler Soot-blowing System.............................................................................. 69 Section XIV Air compressor Start and Stop ......................................................................... 76 Chapter III
Unit Start and Stop.................................................................................................. 79
Section I Boiler Cold State Start ........................................................................................... 79 Section II Other State Start ................................................................................................. 103 Section III Boiler Stop and Maintenance ............................................................................ 104 Chapter IV
Unit Operation and Maintenance .........................................................................113
Section I Chapter V
Regulation and Maintenance of Boiler Operation ................................................113
Interlocking protection and test........................................................................... 164
Section I Boiler interlocking protection ............................................................................... 164 Section II
Boiler shutdown due to Failure........................................................................... 185
I
Chapter I Section I
Summary of the Unit Unit Design Summary
1. Unit overall design Indonesia Paiton Coal Fired Thermal Power Plant plans to put the coal-fired subcritical condensing steam turbine-generator unit with capacity of 1 × 660MW into business operation in September 2009. The boiler is HG-2187/17.5-HM14 provided by the People's Republic of China Harbin Boiler Factory Co., Ltd; steam turbine is provided by the People's Republic of China Harbin Steam Turbine Factory Co., Ltd, model: N660-16.7/538/538; generator is provided by the People's Republic of China Harbin Electrical Machinery Plant Co., Ltd., generator‘s model: QFSN-660-2, three-phase synchronous turbo-generator. DCS system of the engineering, including the control functions such as data acquisition (DAS), simulation quantity control (MCS), sequential control (SCS), boiler furnace safety supervision (FSSS), steam turbine control (DEH), feedwater pump turbine control (MEH), electric auxiliary power monitoring (ECS) and so on, it is the control system with the sound control functions of the complete unit, which is provided by the People's Republic of China Shanghai Westinghouse Control systems Co., Ltd. The boiler is the Π--type coal fired drum boiler with the sub-critical pressure, primary intermediate reheating, control cycle drum boiler, four-angle tangential combustion mode, single furnace balanced ventilation, solid deslagging and all-steel framework, designed coal is lignite. The maximum continuous load (ie, BMCR working condition) is taken as the design parameter of the boiler. When the load of the unit is 693MW, the maximum continuous required rating evaporation for the boiler is 2187t/h; when the load of the unit is 660MW, the boiler's rated evaporation capacity is 2064.1t/h. The coal pulverizing system adopts the positive pressure direct blowing style, each boiler is equiped with six (6) HP1163 bowl-type medium-speed coal mills. In BMCR condition, five (5) coal mills are running, the other one is in standby. Each boiler is provided with two (2) sealing fans of the coal mill with capacity of 100%, one is used for the operation, the other one is in standby. Each boiler has six (6) coal feeders, pressure-proof type measurement coal feeder, which is equipped with the frequency control motor, the amount of coal supply can be automatically adjusted according to the boiler load. Two movable blade adjustable axial flow primary air fans with the capacity of 50% are equipped, so as to provide the primary hot and cold air for the coal transportation. FDF adopts the movable blade adjustable axial flow fan with the capacity of 2x50%. The induced draft fan adopts the static blade adjustable axial flow fan with the capacity of 2x50%. Boiler adopts 2 Ljungstrom trisector air preheater. In order to prevent the low temperature corrosion, the heating surface component at the preheater cold-side is manufactured by the corrosion-resistant low-alloy steel plate. Burner assembly is set up with six layers of pulverized coal nozzles, eight layers of secondary air nozzles, in which the fuel nozzle is set up on the third layer, OFA air nozzle is set up on the first layer. 24 burners are the four-corner arrangement, tangential firing, swing direct flow burner, maximum swing angle primary air is ±27°, secondary air is ±30°, OFA air nozzle can swing horizontally 12°. The superheated steam temperature of the boiler adopts two-stage spray desuperheating; the primary spray-type desuperheater is arranged between the low temperature superheater and
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division panel, and the secondary spray-type desuperheater is arranged between the superheater‘s back panel and final superheater, the desuperheater adopts the flute pipe type. The temperature of the reheater is mainly adjusted by swinging the burner, the inlet conduit of the reheater is equipped with two atomizing nozzle-type spray-type desuperheater to prepare for emergency. Superheater system processes: drum →saturated vapour outlet pipe→ inlet header of the roof pipe →roof pipe (roof by-pass pipe ), (wall enclosure system bypass pipe to the rear pass side wall upper header) →outlet header of the roof pipe → (two way, one way: from the rear pass roof pipe → rear pass‘s rear wall pipe→ rear pass‘s rear wall lower header →rear pass‘s side wall lower header →rear pass‘s rear side wall header→ rear pass side wall upper header; the other way, rear pass front wall pipe →rear pass front wall lower header →rear pass extension side wall lower header (rear pass side wall lower header) →rear pass extension part side-wall pipe (rear pass front side wall pipe) →rear pass side wall upper header) → low-temperature superheater‘s inlet connecting pipe →level low-temperature superheater‘s inlet header→ level low-temperature superheater → vertical low-temperature superheater → vertical low-temperature superheater‘s outlet header →primary desuperheater inlet connecting pipe → superheater‘s
primary
desuperheater→ primary desuperheater outlet connecting pipe → division screen inlet header → superheater‘s division panel→ division panel outlet header→ division panel and rear panel connecting pipe→ rear panel inlet header→ superheater rear panel→ rear panel outlet header→ secondary desuperheater inlet connecting pipe→ superheater‘s secondary desuperheater→ secondary desuperheater outlet connecting pipe→ final superheater inlet header→ final superheater→ final superheater out header → superheater‘s outlet conduit →steam turbine‘s high-pressure cylinder. Reheater system process: steam turbine‘s high-pressure cylinder → cold end reheater pipeline→ reheater‘s spray-type desuperheater→ wall re-inlet header→ front (side) wall radiation reheater→ wall re-outlet header→ wall re-outlet header to the reheater front panel‘s inlet header connecting pipe → reheater front panel‘s inlet header→ reheater front panel→ final reheater → final reheater‘s outlet header→ reheater outlet conduit →steam turbine‘s medium pressure cylinder. The unit is provided with the steam turbine bypass system, capacity of 70% BMCR, the main steam enters the boiler‘s reheater through the high-pressure bypass and reheat cold section steam pipeline, the reheater ‗s outlet steam flows into the condenser through the low pressure bypass. The vertical shaft lower header at the rear of the boiler is equipped with the start drainage water bypass line with capacity of 5%, which can meet the requirements of the hot and cold state start of the unit. When starting up the boiler, the bypass is used for drainage, so as to achieve the accelerated heating purpose of the superheater. Boiler water circulation system has three circulating water pumps: two pumps can run with full load, three pumps can also run. If a single pump is only put into operation, the boiler load must be reduced to 60% MCR. When starting up the boiler, at least two pumps should be put into operation. 134 different types of soot blowers are installed in the furnace, all levels of convective heating
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surfaces and rotary air preheater, etc, in order to maintain the cleanliness of the heating surfaces, the operation of the soot blower adopts the process control. Unit mainly bears the basic load and with certain peak regulation ability, the scope of peak regulation: rated output of 40% to 100%. Unit can meet all the automatic devices adopted by the unit when the boiler load is 40% BMCR and above. Ignition and combustion-supporting adopt # 0 light diesel oil. 16 oil guns are designed to contribute with 20% BMCR load. The minimum stable combustion load is 37% TMCR. Boiler‘s life expectancy is more than 30 years. The unit can run not only with a fixed pressure but also a sliding pressure. When the boiler is running with low load or starting; sliding pressure operation is recommend to obtain a higher economic effieicy. Boiler is equipped with two (2) induced draft fans, force draught fans and primary air fans repectively. The induced draft fan is the adjustable static blade axial flow fan with the capacity of 2x50%, two (2) force draught fans and primary air fans are the adjustable movable blade axial flow fan with the capacity of 50%. The force draught fan and primary air fan are arranged in the force draught fans room at the rear of the boiler, the induced draft fan is arranged in the induced draft fan room at the back of the electric dust collector. The unit is configured with 6 oil-free screw air compressors, 3 are used to provide the compressed air for the instrument; 3 are used to provide the compressed air for maintenance. Along with the air consumption change of the system, the air compressor will be loaded and unloaded automatically in order to adapt to the air consumption of the conveyor system. The ash and slag are separately removed from the plant for dry ash and slag multipurpose utilization; the slag is removed by the slag silo system with the mechanical deslagging scraper, the boiler bottom slag is removed by the continuous deslagging mechanical transmission system with the water immersion-type scraper slag conveyor, after the bottom slag is discharged by the water immersion-type scraper slag conveyor, it is directly transported to the slag silo for storage, which is sent regularly from the automotive to the multipurpose utilization user or storage yard. Ash system adopts the positive pressure dense phase pneumatic ash handling system. Boiler is equipped with 2 double-chamber four- electric field electrostatic precipitator, 32 ash hoppers. The fly ash quantity is 90% of the total amount of boiler ash and slag, the efficiency of electrostatic precipitator is more than 99.5%. One ash silo is set up; the fly ash is conveyed to the ash silo for the storage by the positive pressure dense phase pneumatic conveying system. The coal sources are the Indonesian coal, the coal of the power plant adopts the sea transportation. The coal is unloaded with the ship unloader, which is conveyed to the coal yard or the raw coal bunker of the main building through the coal conveyer belt; Power plant uses the sea water as the living and industrial water source; the reverse osmosis technology is used for the sea water desalination. This project is connected to the 500kVGIS distribution device of the old power plant by 500kV isobaric line‘s outgoing line, the standby power is connected to the 150kV distribution device from the old power plant, high voltage auxiliary power voltage class uses the primary voltage of 6kV; the turbine, boiler and generator are implemented the centralized control by the computer distributed
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6. Force draught fan outage 6.1. Gradually close and stop the inlet movable blade of the force draught fan. 6.2. Shut down the force draught fan. 6.3. Close the force draught fan‘s outlet baffle. 6.4. Open the force draught fan‘s outlet connecting baffle. 6.5. Shut down the force draught fan‘s oil system depending on the situation. 7. Force draught fan must be the emergency shut down in the following circumstances 7.1. When the force draught fan or motor smokes and on fire. 7.2. When the bearing temperature of the force draught fan increases sharply more than 90℃. 7.3. When the motor bearing temperature of the force draught fan increases sharply more than 95℃. 7.4. When endangering the safety of person and equipment. Section V
Primary Air Fan
1. Preparation before starting the primary air fan 1.1. Inspect the primary air fan before starting in line with the provisions of the general rule. 1.2. Confirm that the primary air fan power has been supplied. 1.3. Confirm that the oil system power has been supplied and used in the primary air fan and motor oil system: 1.3.1. Check that the tank oil level is normal, more than 75% mm. 1.3.2. Check that the air fan oil tank temperature is normal at 3o℃ to 40℃; in case the oil temperature is lower than 30℃, the electric heater is put into operation automatically; in case the in case the oil temperature reaches to 30℃, the electric heater is shut down automatically. The tank temperature of the fan motor is normal at 3o℃ to 45℃; in case the oil temperature is lower than 20℃, the electric heater is put into operation. 1.3.3. Open the pressure gauges and hand operated valve of the pressure switch, so as to switch the filter screen reverse flow valve to the working position. 1.3.4. Start # 1 (# 2) oil pump of the fan, set # 2 (# 1) oil pump as the "automatic", switch the oil pump select switch to the ―#1 main #2 auxiliary ‖ or ― #2 main #1 auxiliary‖. Start # 1 (or # 2) oil pump, the interlocking tests of all oil station pump are normal. 1.3.5. Inspect that the hydraulic oil pressure and lubrication pressure are normal. 1.3.6. Inject the cooling water of the cooler. 1.4. Contact theI&C personnel, supply the power supply of the moving blade adjustment device of the primary air fan.
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1.5. Check the moving blade hydraulic regulating device, carry out the full-open (+15°), full-off (-30°) test of the adjustable moving blade, dial (local and main control room) indication is in line with the moving blade position, and then placed the moving blade in the closed position. 1.6. Confirm that the primary air fan interlock protection device is put into operation... 1.7. Primary air fan start condition: 1.7.1. The hydraulic oil pressure of the primary air fan is normal, more than 2.5MPa, motor lubrication pressure is normal, more than 0.1MPa; 1.7.2. The lubricant flow of the primary air fan is normal, more than 3L/min; 1.7.3. Tank oil level of the primary air fan is normal, more than 75% mm; 1.7.4. Oil tank temperature of the primary air f an is normal; 1.7.5. Bearing temperature of the primary air fan is less than 80℃; 1.7.6. Coil temperature of the primary air f an motor is less than 110℃; 1.7.7. Bearing temperature of the primary air fan motor is less than 85℃; 1.7.8. Primary air fan and motor pump are operating; 1.7.9. One induced draft fan is at least operating; 1.7.10. One force draught fan is at least operating; 1.7.11. Outlet baffle of the primary air fan is closed; 1.7.12. Inlet moving blade of the primary air fan is closed; 2. Primary air fan start 2.1. Start the primary air fan, the outlet baffle of the primary air fan is opened automatically after delaying 5s. Check that the outlet connecting baffle of the primary air fan is opened automatically. 2.2. Adjust the inlet moving blade of the primary air fan so that the primary air pressure slowly rises to about 10kPa. 3. Parallel start primary air fan steps: 3.1. Confirm that the inlet moving blade and outlet baffle of the primary air fan to be started are closed, meet the start condition. 3.2. Start the primary air fan to be paralleled, the outlet baffle is opened automatically after delaying 5s. Check that the outlet connecting baffle of the primary air fan is closed. 3.3 Slowly open the primary air fan‘s moving blade to be paralleled, confirm the air quantity and current increase of the primary air fan, correspondingly turn off the inlet moving blade of the operated primary air fan, the primary air header pressure are maintained basically unchanged. 3.4. When the moving blade opening, current and air quantity of two primary air fans are basically same, the parallel is completed.
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4. Start primary air fan process Press the ‘primary air fan start sequential control' button on the sequential control screen of the primary air fan, then process is carried out in the following steps: 4.1. Start the primary air fan and motor lubricating oil station; 4.2. Close the primary air fan‘s outlet baffle; 4.3. Close the primary air fan‘s inlet moving blade; 4.4. Start the primary air fan. 4.5. Start the primary air fan‘s outlet baffle. 6. Primary air fan operation and maintenance 6.1. When adjusting the primary air fan load, the load deviation of two fans may not be too large, so as to prevent the fan from entering the unstable working condition for the running. 6.2. In the normal operation, the outlet air pressure of the primary air fan shall not exceed 13kPa. In case the air pressure can be not maintained due to the ash blocking in the air preheater etc, the unit output should be reduced. 6.3. Regularly inspect and monitor that the parameters are normal such as primary air fan lubricant, oil pressure, oil temperature and oil quantity of the control oil system, as well as fan bearing temperature and so on. 6.4. Check that the primary air fan vibration is not more than 4.6mm /s. In case the bearing vibration is high to alarm, should immediately check the fan operation in situ, if necessary, can appropriately reduce the load and observe the operation; in case the bearing vibration continues to rise to 11mm/s and load decrease is invalid, should report to the shift foreman and apply for the outage. 6.5. Check that the oil tank level is normal, the oil system is not leaking... 6.6. Check that the filter screen differential pressure indication of the primary air fan oil station is less than 0.15MPa, as well as the filter screen differential pressure indication of the motor oil station is less than 0.05MPa. In case the differential pressure is more than or equal to 0.15MPa or 0.04MPa, they should be switched to the standby filter screen, contact the maintenance department to clean-up the filter screen. 6.7. Check that the instrument indication of the fan, air system, oil system and cooling water system are normal. 6.8. The standby pump should be regularly switched, should pay attention to the lubrication pressure and control oil pressure when switching. 7. Primary air fan outage 7.1. Gradually shut down the primary air fan‘s inlet moving blade. 7.2. Shut down the primary air fan.
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7.3. Close the primary air fan‘s outlet baffle. 7.4. Shut down the oil system. 8. The primary air fan must be the emergency shut down in the following circumstances 8.1. When the primary air fan or motor smokes and on fire. 8.2. When the bearing temperature of the primary air fan increases sharply more than 90℃. 8.3. When the motor bearing temperature of the blower increases sharply more than 95℃. 8.4. When endangering the safety of person and equipment... Section VI Ⅰ.
Sealing Fan
Sealing fan start
1. Preparation prior to starting 1.1. Inspect the sealing fan before starting in line with the provisions of the general rule. 1.2. Confirm that the sealing fan power has been supplied. 1.3. Open the cooling water intake, backwater valves of the sealing fan bearing. 1.4. Sealing fan start condition: 1.4.1. Sealing fan‘s bearing temperature is more than or equal to 50℃; 1.4.2. At least one primary air fan is running; 1.4.3. Close the sealing fan‘s inlet regulating baffle, 1.4.4. The coal mill‘s seal air inlet motor - operated valve is closed. 2. Start the sealing fan 2.1. Start the sealing fan, check the normal operation, normal current, and slowly adjust the sealing fan‘s inlet regulating baffle so that the sealed air pressure is higher than the primary air pressure of 4.0kPa. 2.2. After checking the stability of the sealing air pressure, the automatic regulation of the sealing fan is put into operation. 2.3. After checking that the air pressure is normal, the back-up sealing fan is set up as the "standby." Ⅱ.
Sealing fan operation and maintenance
1. Under normal circumstances, a sealed fan is maintained for the operation, another sealed fan is maintained as the back-up. 2. If the running fan is tripped or header air pressure is lower than 12kPa, the back-up fan should be linked. 3. Regularly check that the inlet regulating baffle of the sealed fan is in good automatic condition, 46