Training Material For Operators

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300MW PROJECT
Contract No. 32003/QNTPJSC-SEC DateOct. 31, 2005
Vietnam Quang Ninh 2300MW Thermal Power Plant Project
Training Material for Operators

Approval: Review:
March 11, 2008 Compiled By Shanghai Electric (Group) Corporation
Vietnam Quang Ninh Phase I 2300MW Project
QUANG NING THERMAL POWER JOINT STOCK COMPANY
QUANG NING THERMAL POWER JOINT STOCK COMPANY 2300MW PROJECT
Training Material for Operators
Approval: Review: Compilation:
Zhou Zhicheng; Yu Jinwei Bu Zhanshuang; Zhu Guo; Li Lin Tang Lu; Jiang Fangyi; Kong Qingwu; Shi Songmei; Yu Hai; Qian Tianguang; Ma Zhixun
Index
VOLUME A VOLUME B VOLUME C VOLUME D VOLUME E BRIEF INTRODUCTION TO THE UNIT .................................................. 3 BOILER OPERATION.............................................................................. 65 STEAM TURBINE OPERATION .......................................................... 111 ELECTRICAL OPERATION ................................................................. 166 CHEMICAL OPERATION ...................................................................... 215
VOLUME F FLUE GAS DESULFURIZATION AND ASH HANDLING OPERATION ............................................................................................................................................ 249 VOLUME G VOLUME H FUEL OPERATION ................................................................................ 299 APPENDIX -- OPERATION AND MANAGEMENT SYSTEM OF
THERMAL POWER PLANT ........................................................................................... 344 VOLUME I VIDEO MATERIAL ................................................................................... 359
Volume A Brief Introduction to the Unit

1 Project Overview
1.1 Construction Scale and Investor Quang Ninh thermal power plant project, the first-phase project involves 2X300MW coal-fired units, the project is planned as 4X300MW installed capacity finally. The plant site is at Ha Long, Quang Ninh, Vietnam. The investor consists of three shareholder members: Electricity of Vietnam Corp. (EVN), Vietnam National Coal Corp., Vietnam Construction Import-Export Corporation. The project is undertaken by China Shanghai Electric Group Co., Ltd (SEC) in the manner of EPC Turnkey contract; After being completed, the power plant will operate as base-load plant of Vietnam to meet the future power requirements of Vietnam. The boiler fuel is anthracite. Selection of W-flame boiler is recommended. Fuel oil can be used for stable combustion and start-up/shutdown secondarily. Rated power of the steam turbine generator is 300MW, and the design power factor of the power plant is 0.7. 1.2 Project Progress and Plan At present, civil work and equipment installation works have been started. The project is planed to receive electric power by unit no.1 auxiliary power system on April 1, 2008(110kV start up/standby transformer), chemical commissioning will be started on March 12, 2008, the steam-line blowing for boiler no. 1 will be started on August 20, 2008, the initial synchronization for unit no.1 will be started on August 28, 2008, PAC for unit no.1 will be completed on February 16, 2009. The initial synchronization for unit no.2 will be started on April 20, 2009, PAC for unit no.2 will be completed on September 18, 2009. 1.3 Main Contractor and Service Provider Main contractors and service Providers joining the project construction are as follows: EPC Turnkey contractor: Shanghai Electric Group Co., Ltd (SEC); Three main equipment suppliers: Three large power equipment manufacturers affiliated to Shanghai Electric Group Co. Ltd; DCS vendor: Emerson Electric (China) Co., Ltd. Project implementation unit: Construction project management team for SEC Vietnam Quang Ninh project; Main engineering design unit: China Northwest Electric Power Design Institute; Main engineering construction unit: The First Electric Power Construction Company of Jiangsu Province, China;
Main engineering commissioning unit: China Hubei Zhongxing Electric Power Test & Research Co., Ltd
2 Main Electrical Wring and in-plant Electrical System

2.1 Main Electrical Wring 2.1.1 Vietnam Quang Ninh power plant phase I project involves two units, i.e. #1 unit and #2 unit, the capacity for each unit is 300MW. The connection type of #1 unit generator and main transformer is unit connection, with circuit breaker at generator outlet, #1 main transformer is a three-phase transformer. The connection type of #2 unit generator and main transformer is also unit connection, with circuit breaker at generator outlet,#2 main transformer is three single-phase transformers; 2.1.2 Connection to system voltage:#1 unit is 220kV,#2 unit is 500kV. #1 unit is connected to 220kVbusbar at Quang Ninh substation via a three-phase 220kV step-up transformer and overhead line; #2 unit is connected to 500kVbusbar at Quang Ninh substation via a single-phase 500kV step-up transformer and overhead line; Quang Ninh substation is about 3km from Quang Ninh power plant. Startup/Standby transformer is connected to Hoanh BoGiap Khan overhead line by means of a 110kV circuit breaker. 2.1.3 Grounding Mode: Generator neutral point grounding via resistance of the grounding transformer; High-voltage side of main transformer grounding directly; Low voltage side of HV auxiliary transformer grounding via a resistance of 3.8 ; High-voltage side of Startup/Standby transformer is grounded directly; low-voltage side grounding via a resistance of 3.8 . 2.1.4 Configuration of Main Primary Electrical Equipments for Current Project The current project does not provide Booster station, the demarcation point with Vietnam is at outgoing line bridge of transformer site. Each unit has one generatortransformer set, there is a circuit breaker at generator outlet, and there is not any circuit breaker at the outlet of main transformer. After passing through knife switch, line bridge, the outgoing lines of two generator-transformer sets is connected to Booster station via lines,3km from the power plant.110KV starting power source is connected to 110KV starting transformer via a knife switch,SF6 circuit breaker, the transformer is a three-phase star-shaped transformer with auxiliary windings . 2.2 In-plant Electrical System 2.2.1 Auxiliary Power Wiring 2.2.1.1 HV Auxiliary Power The voltage grade for HV auxiliary power is 6.6kV. The 6.6kV system is grounded
via resistance, resistor can withstand short-circuit current of 1000A/30s and can withstand the maximum short-circuit current of 1200A, the time withstanded meets the requirement of protection operation time. Connecting mode of HV auxiliary power operating power supply is T-connection at generator outlet. HV auxiliary transformer is split transformer. HV auxiliary power busbar is single busbar, each unit has two busbar sections; for #1 unit, they are 6.6kV1A section and 6.6kV1B section; for #2 unit, they are 6.6kV2A section and 6.6kV2B section; the 6.6kVdual auxiliaries of the unit and the boiler are connected by each busbar section respectively. There are two sections for 6kV common busbar, i.e. 6.6kV0A section and 6.6kV0B section. 6.6kV common section is supplied by auxiliary section of #1, #2units. HV Startup/Standby transformer is selected as split transformer with balance coil. 2.2.1.2 LV Auxiliary Power The voltage grade for LV auxiliary power is 400/230V. The power supply mode for LV auxiliary power in main building is: PC+MCC (power center and motor control center). Each unit is equipped with two LV turbine transformers, two LV boiler transformers, and two LV electrostatic precipitator transformers. LV operating load of each unit is supplied by PC or MCC. The power supply of LV operating transformer is connected by 6.6kV auxiliary section. There are two LV common transformers. LV common load common in main building is supplied by PC and MCC, The power supply of LV common transformer is connected by 6.6kVcommon section. Each unit is equipped with one lighting transformer, the lighting transformer is connected to the power source by 6.6kV auxiliary 1A section or 2A section. 2.2.1.3 LV AC Emergency Power Supply The connection type of unit emergency PC power supply is such that, one way is connected by boilers PC section, another way is supplied by diesel generator unit. Each unit is equipped with two 400/230V emergency PCs; each unit is equipped with one 400/230V turbine emergency MCC and one 400/230V boiler emergency MCC. Each unit is equipped with one diesel generator unit, the capacity of diesel generator unit is 680kW. 2.2.2 LV Auxiliary Power System in Auxiliary Buildings Power supply mode of LV auxiliary power in auxiliary buildings is: PC+MCC. Auxiliary buildings configuration: two LV transformer for coal conveying, water supply, chemical water treatment, circulating water, ash handling, management for front area of the plant each, one LV transformer for ash yard. Their capacity are:
coal conveying transformer 2500kVA, water supply transformer 1000kVA, transformer for chemical water treatment 1250kVA, transformer for circulating water 500kVA, transformer for ash handling 1000kVA, transformer for front area of the plant 1250kVA, transformer for ash yard 315kVA. The power supply of individual LV transformers is connected by 6.6kVcommon section. 2.2.3 Power Supply Mode of LV Auxiliary Motor LV motor is supplied by both power center (PC) and motor control center (MCC). 75kW and higher motor is supplied by PC; 75kW and less motor is supplied by MCC; motors over 200kW is supplied by 6.6kV section. 2.2.4 Grounding Mode of Auxiliary Power System Neutral Point The grounding mode of neutral point for 6.6kV HV auxiliary power system is resistance grounding; The grounding mode of neutral point for 400/230VLV auxiliary power system is resistance grounding. 2.2.5 The control mode of electric dust removing system is PLC. 2.2.6 The control mode of coal conveying system is PLC. 2.2.7 Main switch cabinet can be controlled by remote or local control, remote control signal coming from DCS or PLC. 2.3 AC UPS Each unit is equipped with one UPS, the capacity is 80kVA; Common service system is equipped with one UPS, the capacity is 20kVA. There are three UPS for Quang Ninh phase I project, each UPS system consists of two main cabinets, one bypass cabinet and one feeder cabinet. 2.4 DC system There are three DC systems for Quang Ninhphase I project, among witch: one for #1 unit, one for #2 unit, one for common service system. Each unit is equipped with two storage batteries, installing in electrical building; central control building is equipped with one common storage battery. The capacity of the battery is 1500Ah/group (for the unit); 400Ah/group (common). The type of the battery is valve-regulated lead-acid battery. Connection mode of DC system is: single busbar section. 2.5 Secondary Connection, Relay Protection and Automation Device 2.5.1 Control room: one control room shared by four units, central control room is located at the floor of 12.5m in the central control building. 2.5.2 Control, Signal, Measurement
2.5.2.1 Control mode of generator-transformer set and auxiliary power system: DCS DCS monitoring range: A. Items controlled by generator-transformer set system control function group(SCS-G) : 1. Switching on/off of Generator-transformer set circuit breaker and corresponding disconnecting; Control of main transformer on-load tap changer; Switching on/off of generator excitation system degaussing; Selection of generator excitation system AVR operating mode; Switching on/off of ASS.
2. 3. 4. 5. B.
Items controlled by control function group(SCS/A) of auxiliary power system: 1. Switching on/off of high-voltage side circuit breaker for HV Startup/Standby transformer and corresponding disconnecting switch; Switching on/off of low-voltage side circuit breaker for HV Startup/Standby transformer and corresponding disconnecting switch; Control of HV Startup/Standby transformer on-load tap changer; Control of HV auxiliary transformer on-load tap changer; Switching on/off of HV side circuit breaker for HV/LV auxiliary transformer and branch circuit breaker at LV side; Control of LV auxiliary power supply, standby and branch circuit breaker.
2.
3. 4. 5.
6.
DCS monitoring range: including generator-transformer set, auxiliary power system (containing startup/standby power source), emergency power supply, element protection, AVR, UPS and DC system in main building. Hard manual operation range: 1. 2. 3. 4. 5. 6. Control switch of circuit breaker at generator outlet; Emergency trip pushbutton for degaussing switch; Emergency starting pushbutton for diesel engine; Starting pushbutton for turbine DC emergency lubricating oil pump; Starting pushbutton for standby oil pump at hydrogen side of generator; Starting pushbutton for standby oil pump at air-side of the generator.
Conventional instrument in unit control room and visual flash alarm device
Conventional instrument: 1. 2. 3. 4. 5. 6. Line voltage at phase A,C of generator stator; B-phase current of generator stator; Generator excitation current. Flashing alarm indicator: Protection action of generator-transformer set Exceptional signal of unit plant(including: gas, temperature, overload, loss of excitation, grounding, Cooler fault, voltage circuit broken, abnormal operating mechanism of circuit breaker and control circuit broken, etc.)
2.5.2.2 The function of the system function group for generator-transformer set During starting period, operating personnel can select Manual or Auto mode. Generator and system are controlled by program or soft manual operation (keyboard operation), and the voltage is increased up to synchronization with initial load. 2.5.2.3 Functions of control function group of the auxiliary power source 1. Switching on and off for HV house service operating power supply and HV Startup/Standby transformer via soft manual operation; Switching on and off for LV auxiliary transformer in main building, HV/LV side circuit breaker via soft manual operation;
2.
2.5.2.4 Function of Data Acquisition and Monitor System (DAS) 1. Display function: including operation display, group display, bar chart display, trend display and alarm display point; Table-making and record function: including periodic record, sequence of event(SOE), emergency review record, etc.; Historical data memory and retrieval; Performance calculation.
2.
3. 4.
2.5.3 Configuration of Generator-transformer Set Protection: 100% grounding protection of generator stator; generator differential protection; interturn protection for generator stator; generator negative sequence overload; excitation failure protection; rotor earth fault protection; loss-of-excitation protection; reverse power protection; generator overload protection; differential protection of main transformer; zero-sequence overcurrent protection of main transformer; zero-sequence differential protection for main transformer; differential protection for plant service higher transformer; overcurrent protection for plant service higher transformer; differential protection for excitation transformer; overexcitation
protection for main transformer; generator overexcitation protection; breaker failure protection;20KV earth-fault protection; three-phase overcurrent protection for excitation transformer; non-electric-parameter protection for main transformer. 2.5.4 Configuration of 110KV Start up/Standby Transformer Protection Differential protection; zero-sequence differential protection; impedance protection; overcurrent protection; breaker failure protection; non-electric-parameter protection. 2.5.5 System Protection Configuration Protection range: #1 unit 220KV outgoing lines,#2 unit 500KV outgoing lines,110KV startup/standby power supply incoming lines Protection configuration: #1 unit 220kV outgoing lines: main protection:1 differential protection +1 distance protection, backup protection: overcurrent protection + earth-fault protection + breaker failure protection. #2 unit 500kV outgoing lines: 2 differential protections +1 distance protection, backup protection: overcurrent protection+ earth-fault protection + breaker failure protection. 110kV incoming lines: 1 breaker failure protection + 1 Backup protection
3 Main Equipment, System Condition

3.1 Boiler Proper and Auxiliary System: 3.1.1 Alstom is responsible for the design of boiler proper and provides the technical support for its commissioning and performance test. Shanghai Boiler Works, Ltd. will undertake its manufacture. The boiler type is double arch shape, W-flame, single furnace, primary intermediate reheat, forced water circulation, subcritical steam drum boiler. Two units with one domestic manufactured start-up boiler, serve as startup steam supply at unit startup; boilers design coal is anthracite, coming from Vietnams local CAM PHA and HON GAI coal mines. The Plant shall be able to operate continuously from the minimum load 70% of the Rated Output when fired with design coal and any ambient conditions without fuel oil support and under automatic control. The Plant shall operate at loads between 30% - 70% of Rated Output with fuel oil support and under automatic control. 3.1.2 Pulverized Coal Combustion System The main function of combustion system is to convey the pulverized coal to burner nozzles required for meeting the boiler load, and to provide safe and efficient combustion condition for the inside furnace. Pulverized coal stored in the coal bunker is distributed proportionally by means of rotary feeder (or called compound feeder), then fed to ejector (or
called venturi tube), mixed with hot primary air, and then conveyed to burner nozzles by steam air. All rotary feeders operate in the same speed (revolution); the boiler load is adjusted by selecting the quantity and rotating speed of the feeder. Each boiler is equipped with 2 pulverized coal bunkers, each bunker is equipped with 8 rotary feeders, and each feeder has two burners, so each boiler has 16 feeders in total. Each rotary feeder is connected to 2 ejectors. The ejectors are linked to 2 corresponding burner nozzles (each ejector is connected to one nozzle) via pulverized coal piping, so each boiler has 32 ejectors and burner nozzles respectively. 32 burner nozzles are installed in 2 archs (furnace archs) (each furnace arch has 16 nozzles), and the mixture of pulverized coal/primary air is injected to the refractory lining area of the furnace at proper speed, and then the pulverized coal is ignited safely. In order to import the air required for combustion process, 34 secondary air nozzles are installed between and beside the pulverized coal nozzles, 64 tertiary air nozzles are installed below the furnace arch between the front wall and the rear wall. For each pulverized coal bunker, one rotary feeder is connected to the extreme fine coal powder bin of the bunker, which is used to store the superfine pulverized coal collected in exhaust gas filter of the pulverizing system. The rotary feeder can provide powder to corresponding 2 very fine coal burners. The burners is arranged at the furnace arch of the furnace, so that boiler will operate under partial lad conditions, superfine pulverized coal will combust quickly and generate hot atmosphere for other burners; while wall-mounted burner is used to spread the flame under high load condition, optimizing the emission of NOX. Combustion system is designed for hot air coal feeding, using heavy oil as the oil for boiler startup and stable combustion, as per TCVN 6239-2002 standard. The boiler is designed for secondary ignition, heavy oil gun is ignited by the electric spark of the high-energy ignitor, and the pulverized coal is ignited by heavy oil gun in the manner of steam atomization. The project configuration consists of oil tank of 25000 tons, 2 oil drain pumps, two AC/DC oil feed pumps of 100% capacity, 1 dirty oil pump and 1 sewage pump. Fuel oil system is designed on the basis of single header circulation system for oil supply and return of the boiler, the oil supply piping, return oil piping are routed to boiler burners.
3.1.3 Oil Burner Each furnace arch has 8 heavy oil (HFO) burners, i.e. each boiler is equipped
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with 16 oil burners. The HFO is reached to atomization state by the auxiliary steam whose pressure is constantly 5.25 bar (g), the auxiliary steam is also used to purge the burners. The heavy oil is ignited by a high-energy ignitor, each HFO burner is equipped with a special flame detector. The cooling air is supplied to the burners and flame detectors by means of two separate special circuits. Upon stopping, the oil burner will withdraw about 330mm from the burner nozzle to prevent from boiler radiation (avoiding the oil burner being burnt). Full oil combustion ability (LHV base value) is 30% of BMCR fuel calorific value, 12 burners can reach the combustion ability of 30% BMCR (two burners in each furnace arch stop operation), and the regulation rate of the burner is 1:5. The J11 type oil burners are utilized. The boiler is designed for secondary ignition, heavy oil gun is ignited by the electric spark of the high-energy ignitor, and the pulverized coal is ignited by heavy oil gun in the manner of steam atomization. The project configuration consists of oil tank of 25000 tons, 2 oil drain pumps, two AC/DC oil feed pumps of 100% capacity,1 dirty oil pump and 1 sewage pump. Fuel oil system is designed on the basis of single header circulation system for oil supply and return of the boiler, the oil supply piping, return oil piping are routed to boiler burners. 3.1.4 Pulverizing System Pulverizing system is bin storage type, flue gas drying & pulverizing system, draft ventilation. Each pulverizing system consists of raw coal supply system, hot air supply system, ball mill and its auxiliary system, pulverized coal conveying and unloading system, and exhaust system. The mills are two single in-out BBI roller mills, mill exhauster and exhaust fan are centrifugal fans. The raw coal in the bunker is conveyed into the feeder via coal chute, and it is fed into the mill by the feeder, then it is pulverized to powder by means of mutual impact and squeeze among the ball, body and the raw coal itself. Hot air and cold air are mixed and entered into the mill through a adjustable damper, used to dry the pulverized coal in the mill. With the pumping of the mill exhauster, hot air and pulverized coal are mixed at mill outlet and then fed into the classifier separator, the coarse particles are separated out, then returned to the raw coal piping via the coal return pipe and shutoff door. While the fine pulverized coal is fed into the cyclone pulverized coal separator for further separation, satisfactory pulverized coal is fed into the bunker, residual gas-solid mixture is went through the exhaust fan by means of bag filter, the collected fine pulverized coal is conveyed to a special fine coal powder bin, the remaining flue gas is discharged to atmosphere. One pulverized coal conveyer is shared by two pulverizing systems, it is both used to convey the pulverized coal from the mill to pulverized coal bunker, and also used to convey the pulverized coal from the mill to another bunker 3.1.5 Boiler Flue Gas, Coal Pulverizing System The flue gas system is designed for balanced draft mode, both induced draft fan and forced draft fan are axial-flow fans, the forced draft fan is of adjustable rotary
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blade, while the induced draft fan is of adjustable stationary blade. Boilers air and flue system consists of two induced draft fans, two forced draft fans, two air preheaters, furnace and convection flue gas pass, electrostatic precipitator, another two cooling fans for oil gun and two AC/DC cooling fans for flame scanning. The air is divided into secondary air and primary air. After having been heated by a steam air heater, the primary air and the secondary air coming out of the forced draft fan and primary air fan are fed to an air preheater, then some secondary air is fed to 34 secondary air gates (17 for each arch), some is served as combustion air for 64 tertiary air gates, the remainder is served as attemperating air for pulverizing system. After having been heated by a steam air heater and a air preheater, the primary air coming out of the primary air fan are fed to an primary air box, and then the pulverized coal is conveyed to 32 pulverized coal burners respectively. After passing through the electrostatic precipitator, the burned flue gas is pumped out by the induced draft fan, and is discharged to a stack via a desulphurization plant, a desulphurization booster fan or via a desulphurization bypass directly. There are two AC cooling fans for oil gun, one of which for operation, another for standby, their cooling air at the outlet is used for cooling 18 oil guns and ignition guns. There are two cooling fans for flame scanner, i.e. one AC fan and one DC fan. During normal operation the AC fan operates, while the DC fan serves as standby, the air pressure at the outlet is not less 70mbar, so that there is sufficient air flow to coil the flame scanner of individual burners (oil gun, pulverized-coal burner). 3.1.6 Steam-Water System 3.1.6.1 Water System The feed-water flows into the steam drum via a economizer, and mixes with the boiler water in the drum. The boiler water coming out of the drum goes through a downcomer, and converges at the inlet header of a boiler water circulating pump, then enters 3 boiler water circulating pumps via 3 inlet pipes. The boiler water circulating pump is used to guarantee the normal water circulation of the water wall. The throttling orifice is installed at the inlet of each circular water wall, in order to ensure evenly distribution of water flow, and thus avoiding the thermal deviation due to non-evenly distributed water flow. The outlet of the lower circular header is divided into four water wall sections, i.e. front wall, rear wall, left wall, and right wall. The water wall is membrane water wall. Two side water walls are splitted into three parts. The boiler water in the middle water wall is gathered in an outlet header, and imported into the drum via a steam lead pipe. The boiler water of the front and rear water walls is gathered in a
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shaped header at the arch, and went through the supporting tube, supporting header ,then individually imported into the drum via the steam lead pipe. Rear water wall at furnace arch, goes through the flue to the outlet header at rear water wall, and then leads to the drum by steam lead pipe. Additional water wall tubes constitute, from two sides, additional water wall at lower part of horizontal flue and two sides. The outlets of additional water wall at two sides are connected to the outlet header of additional water wall for side wall respectively, and then led into the drum via the steam lead pipe. From what has been discussed above, the water circulation circuit of the boiler is: steam drum downcomer boiler water circulating pump circular header at lower part of water wall water wall outlet header of water wall steam lead pipe steam drum . 3.1.6.2 Steam-Water Separation Steam-water mixture due to heat absorbing from the water wall, is led into the top of the drum via a steam lead pipe, and flow down along the narrow slit formed in the inner steam lead plate in the whole length of the drum. Guide plate is concentric with the drum, so that steam flow rate and the heating surface of the drum is evenly distributed, this can reduce the temperature difference between drum walls, allow the temperature of upper and lower surfaces of the whole drum as consistent as possible. At the lower end of the guide plate, steam-watermixture is pushed to two rows of cyclone separators, after going through the separation of first, second, third stages, the saturated steam is led out from the upper part of the drum. The separated water return to the water side of the drum, go into the circulation again. 3.1.6.3 Superheated Steam Saturated steam separated from the drum is led to the inlet header of the ceiling via the outlet pipe of the saturated steam ,and led to the middle part of shaped header at the outlet of a ceiling superheater through the ceiling superheater. The outlet of the shaped header is led to the side wall enclosure superheater of the flue of the end shaft through its two side walls, and then is led to the circular header at the lower part of a wall enclosure tube. There are two partition plates in the circular header. Of which, most of the side wall enclosure superheater close to the front gather in the front through the circular header, and go through the flue to the ceiling superheater at the end via the superheater of a front wall enclosure tube, then come to the superheater of a rear wall enclosure tube at upper part of rear wall for end shaft flue before leading to the inlet header of a low-temperature superheater (LTS). A little wall enclosure tube superheaters close to the rear are gathered in the rear through the circular header, and led to the inlet header of LTS through the rear wall enclosure superheater at the lower part of rear wall for end shaft flue. Low-temperature superheater is divided into two stages, the first stage is horizontal, counterflow, arranged in end shaft flue, and the second stage is vertical, arranged in the flue. The steam of low-temperature superheater enters
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medium-temperature superheater after desuperheating of first-stage, medium-temperature superheater is arranged at boilers outlet, it is platen type. The steam of medium-temperature superheater enters high-temperature superheater alternately after desuperheating of second-stage. The desuperheating water for the first, second stages of the superheater come from the front of feed-water regulating valve at the outlet of a high pressure heater. High-temperature superheater is arrgnged at the rear of a high-temperature reheater in a horizontal flue, in the manner of counterflow followed by forward flow, after going through the outlet header of the high-temperature superheater, main steam piping is led to turbine high-pressure cylinder to do work. 3.1.6.4 Reheated Steam The exhaust steam after doing work by turbine high-pressure cylinder, through desuperheating of cold reheat steam header, enters shaped header at the inlet of a low-temperature reheater from the A, B sides. The desuperheating water of the reheater is taken from the intermediate tap of a feed-water pump. The low-temperature reheater is a wall radiant heating surface, arranged in the front of water wall of three walls (i.e. front, left, right) at upper part of the furnace. The heated steam gathers in shaped header at the outlet of a low-temperature reheater ,and enters high-temperature superheater after crossing from left to right . The high-temperature superhe is arranged at the rear of medium-temperature superheater in the manner of forward flow. The heated reheated steam enters a hot reheated steam header via the outlet header of the high-temperature superheater, then flows to turbine IP cylinder to do work. 3.1.7 Ash and Slag Handling and Ash Yard The slag removing mode of the boiler for the project is dry ash extraction. The bottom ash is discharged to a slag slurry pool by means of slag crusher and vacuum pumps. The fly ash collected from the air preheater, economizer and electrostatic precipitator is conveyed to a large-scale ash silo (2 ash silos, volume 2500 m3 each). The dry ash is injected to the slag slurry pool by further mixing of ash and water, then is conveyed to a ash yard by a ash slurry pump (the dry ash also keep the mode of comprehensive utilization); each unit is equipped with 2 wet water seal slag removal units, using for removal of ash and slag at bottom of the boiler. The slag removal system allows for slag removal by means of slag crusher hydraulic jet pump. The boiler slag-removing plant at the upper part of the system is a W type submerged slag hopper, slag hoppers available storage capacity can maintain the slag volume in 8 hours at MCR, the slag-removing period is on the shift (8 h) basis, automatic discharge programmly. The slag removal system consists of:slag hopper proper , sealing damper device , slag hopper for water seal tank , steel frame overflow collecting device , balanced connecting device , cleaning nozzle , inspection window, access door , gate device . 2 slag removal systems operate at regular intervals, the operating time is set to 2 hours and 20 minutes (each boiler operates 1 hour, cleaning 10 minutes). Each
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boiler has 2 slag discharging openings, only one of which can operate for half an hour per time, 2 boilers operate in order. Ranging from the chamber outlet of slag discharging door of a slag hopper to discharge port of delivery pipe for hydraulic jet pump, the main equipments of the slag removal system are: slag crusher, hydraulic jet pump, delivery pipe and various valves, the system also include water supply part for seal water. After entering the slag crusher through a slag discharging door, the slag is crushed and then fed to a hydraulic jet pump at the bottom, the pump transports the mixture of water and ash to a slag pool via a wear-resistant pipe. 3.1.8 Dust Removal and Desulphurization System The use of electrostatic precipitator with 4 electric fields is recommended. During the construction of phase I project, a stack with dual steel flue will be constructed, its height is 200 m. A flue gas desulphurization plant with 100% capacity will also be built at the same time ,forced oxidation wet limestone-gypsum desulphurization process is applied, equipping with flue gas heat exchanger(GGH); 3.1.9 Compressed Air System Compressed air systems are all considered on the basis of less lubricant, equipped with 3 air compressors of 50% capacity. 3.1.10 Safety Valve The boiler is equipped with 8 spring loaded safety valves manufactured by US Crosby Company, their specific layout is as follows: 3 for drum, 1 for superheater outlet piping, 2 for reheater inlet piping, 2 for reheater outlet piping 2. There is also 1 solenoid relief valve (ERV) in superheater outlet piping, the brand is U.S. VTI, delivery of complete equipment by US Crosby Company. The boilers maximum evaporation is 995t/h, the total discharge volume of the drum safety valve is 881.796t/h, accounting for 88.62% of maximum evaporation. The discharge volume of the superheater safety valve is 153.86t/h, accounting for 15.46% of maximum evaporation, the sum of the total discharge volume for drum and superheater safety valve is 1035.656t/h, accounting for 104.09% of maximum evaporation. The maximum flow rate of the reheated steam is 848.6t/h, the sum of the total discharge volume for safety valve at reheater inlet is 512.94t/h, accounting for 60.45% of the maximum flow rate for reheated steam. The sum of the total discharge volume for safety valves at reheater inlet and outlet is 379.157t/h, accounting for 44.68% of the maximum flow rate for reheated steam. The sum of the total discharge volume for safety valves at reheater inlet and outlet is 892.097t/h, accounting for 105.13% of the maximum flow rate for reheated steam. Power-operated relief valve discharge volumeis166t/h, accounting for 16.68% of the total evaporation of the boiler, its discharge is excluded in the discharge volume of the safety valve. 3.2 Steam Turbine and Auxiliary System: 3.2.1 Steam Turbine The main machine is N300-16.67/538/538 type subcritical, reaction, primary
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intermediate reheat, double cylinder double exhaust, single-shaft, condensing steam turbine, manufactured by Shanghai Turbine Company, Ltd., its rated output is 300MW. The whole length of the turbine proper part 18.1m, its total weight is approx. 760t. 3.2.1.1 HP/IP Casing: HP/IP casing is double shell structure, outer casing all-in-one, flow part is of reverse layout. HP/IP outer casing is alloy steel casting, dividing into two half from the horizontal split. The upper half casing is rested on the lower half casing, the lower half casing is supported by four upwardly bent cat-claw, basically, the claws support surface is consistent with casing split. For two splited HP and IP inner casings, their material and casing-splitting type are the same as the outer casing. The inner casing is supported by horizontal split of the outer casing, and the top and the bottom of the inner casing is guide by aligning pins, to keep the correct position in respect to the turbine axis, and to allow its free expansion and shrinkage with the temperature. Inside the HP/IP outer casings, there are HP inner casing, HP retaining ring, IP retaining ring, balance piston gland seal at HP exhaust side, and the end gland seals are installed at two ends . 3.2.1.2 Low Pressure Casing: Low pressure casing is of three-layer structure ,consisting of one outer casing, two inner casings and one thermal shroud ,LV inner casing and outer casing are made of steel plates by welding. There are inner casing, retaining ring, inner thermal shroud, intake guide ring, exhaust guide ring in the LP outer casing, and end gland seals are installed at two ends. 3.2.1.3 Rotor : HP & LP rotors are fabricated by integral alloy steel forgings. HP & LP rotors are all double-flow design, reverse flow layout. One separate stub is connected to front bearing end of HP & LP rotors by a bolt, in order to constitute the thrust collar of a thrust bearing and to drive main oil pumps impeller and overspeed governor. The LP rotor is also fabricated by integral alloy steel forgings .After having finished the installation and fabrication of blades, the hot-chamber test and exact dynamic balance test shall be carried out for LP rotors. The LP rotor is symmetrical double-flow design, three are bull gear of turning gear between the rotor and generator rotor coupling. There is 1+11stages for HP rotor, 9 stages for IP rotor, 27stages for LP rotor. The HP rotor is combined impulse and reaction type, the first stage (regulating stage) is impulse type. The connection between HP-IP rotors and LP rotor and the one between LP rotor and generator rotor are carried out by rigid couplings. The HP & LP rotors are connected to LP rotor by one flange type rigid coupling. In this way, the rotary unit is axial positioned by the thrust bearing of a HP rotor, the LP rotors is connected to the generator by rigid couplings in order. Accordingly, the main rotary units (including HP & LP rotors, LP rotor, generator and excitation
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device, etc.), are supported on seven bearings. 3.2.1.4 Direction of rotation for the turbine: clockwise (facing head). 3.2.1.5 The unit is equipped with HP/LP two-stage series bypass system with 60%BMCR capacity The bypass system consists of control ,valves(including: HP bypass desuperheating and pressure relief valve BP, HP bypass spray control valve BPE,HP bypass spray isolating valve BD, and LP bypass desuperheating and pressure relief valve LBP,LP bypass spray control valve LBPE, and three-stage spray control valve TSW)as well as hydraulic-operated actuator. The control is carried out by DCS. the function of the bypass system : 1. 2. To improve the startup performance of the unit; During normal operation, HP bypass device becomes the safety device for overpressure protection for main steam pressure, the LP bypass device will regulate the reheated steam pressure according to the unit load; Bypass system device can adapt the operating mode of constant and sliding pressures, and perform the load regulation in conjunction with unit control; If the grid or the unit load rejection due to fault trip occurs ,the bypass device will operate quickly, thus the boiler could maintain operation at minimum load; When the unit starting and performing load rejection, it will protect the boiler reheater; Recovery of working medium, reduction of the noise; The HP bypass can protect the new steam piping, the LP bypass can protect the condenser.
3.
4.
5.
6. 7.
3.2.1.6 Main Steam Piping The main steam systems design parameters are: 17.50 Mpa(g), 5460C, 995 ton/hour maximum steam flow rate at VWO . From the outlet of a boiler superheater, the main steam is fed to the turbine hall via a main steam piping with ID 368X39 sizes. In the vicinity of the turbine proper, the main steam piping is splitted into two pipings, with ID273X29 size, these two pipings are connected to left and right main steam stop valves respectively .The material of main steam piping is ASTM A335 P91 alloy steel .The main steam stop valve is directly connected to HP speed governing valve cabinet. The main steam stop valve is designed to quickly shut off the main steam entering the turbine if the turbine fault occurs or during stable conditions, as well as to shut off the steam at normal shutdown. The equalizing valve of the main steam stop valve is used to warm up the turbine during turbine cold start-up, and to balance the front and rear pressures of the main steam stop valve body before opening the main steam stop valve. The steam is supplied to the first stage nozzle for the turbine by HP speed governing steam valves via their own
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ducts. The HP speed governing steam valve is used to control steam flow rate in order to adapt load requirement. The main steam piping is designed to have expedited water system, and have the following functions: 1) Timely discharging the remaining water in the piping during unit startup or in the case of boiler shutdown without startup in recent days, otherwise there is the risk of water entering the turbine. During warming up, timely discharging the steam condensate and cold steam in the piping, improving steam temperature rising speed during warming up. The pneumatic drain valve is opened during unit startup, to drain the condensate generated by preheated steam. If the unit load rises up to 15% of rated load, the pneumatic drain valve shall be automatically closed. If the unit load reduces to below 15% of the rated load or the unit trips, the pneumatic drain valve shall be automatically opened. The pneumatic drain valve can also be opened or closed manually in the control room. The pneumatic drain valve is designed to be forced to open or close if the instrument air loses. Each drain water piping is connected to the proper drain flash tank (the flash tank is connected to the condenser). Before entering proper flash tank, all drain pipes are diagonally inserted into drain header at an angle of 45 to the direction of steam flow. Drain header is connected to the flash tank.
2)
3.2.1.7 Reheated Steam Pipe The design parameters for cold reheated pipe are: 4.241 Mpa (g), 341.5C., and the maximum flow rate is 822.498 t/h BMCR. The cold pipe is designed such that one steam pipe is connected to a HP cylinder with 812.8x17.5 size, using for feeding the exhaust steam from the HP cylinder to a boiler reheater. Before entering reheater, two splitted branch pipes with 558.8X16 size, are connected to the left and right inlets of boiler reheater. By wholly analyzing of the cold pipe and hot pipe, the cold pipe size has achieved optimization condition .In order to control hot reheated steam temperature and protect the final reheater, the emergency water spray devices are installed at the inlet of hot sections in two cold steam branch pipes to ensure that the hot outlet temperature is within the allowable range. These attemperators are supplied by Shanghai Boiler Works,Ltd. The desuperheating water supply is taken from the intermediate tap of a motor-driven feed-water pump. The isolation dampers for hydraulic test are installed in two cold steam pipe brach close to the inlet for emergency water spray, in order to isolate the exhaust pipe for turbine HP cylinder during hydraulic testing of the boiler. The pneumatic check valve for exhaust pipe of turbine HP cylinder is installed in cold main pipe, before extraction of No.7 HP heater and HP bypass, in order to prevent the steam from flowing back into the HP cylinder during operation of the HP bypass. The position of the check valve shall be taken into account. Since during turbine trip and HP bypass operation, in addition to preventing the steam of a HP bypass from entering the cylinder, it should also be noted that the system is supplied to the auxiliaries and the turbine shaft gland system by the HP bypass via a cold pipe. A spring loaded safety valve is installed at the inlet of a reheater, and two spring loaded safety valves are
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installed in the left and right hot pipes at the outlet of the reheater respectively. The overpressure protection function for the safety valve (the reheater and the whole cold pipe) complies with ASME standard. The total discharging capacity of all valves shall be equal to or more than the max. Design steam flow rate of the reheater. There may be drainage in the cold pipe if: 1) The condensate forms at unit warming up, or during the unit turning and shutdown; Emergency spray failure occurs, plenty of emergency spray water may enter into the cold pipe; If the tube buddle of HP heater no.7 breaks, plenty of feed-water would enter into cold steam pipe.
2)
3)
3.2.1.8 Hot Reheat System The design parameters for the hot pipe are: 4.241 Mpa (g) and 546C temperature, Max. pipeline design flow according to BMCR and reheater capacity 882.498 t/h. Two hot pips with ID508X26mm size are connected to a reheater at the outlet of the reheater. The main pipe with ID635X33 size, which is combined by two parallel hot pipes, feeds the reheated steam to the turbine. Before entering the turbine, the main pipe is splitted into left and right branches, they are connnected to the left and right reheat stop interceptor valves (RSIV) for a IP cylinder, the function of the RSIV is to quickly shut off the reheated steam from the boiler, in order to prevent overspeed due to the steam entering into the IP cylinder. The RSIV consists of a screen, a main steam stop valve, a governor valve. The final reheater is equipped with a well-designed drainage system, its main functions are: 1) In the event of unit startup ,warming up of turning gear ,low load , long standby time after shutdown , etc., the steam in the hot pipe would be condensed to water if the temperature goes down, there will be a risk of water entering the turbine unless removing these water ; During hot pipe warming up especially during hot start,
2)
The condensate and cold steam in the hot pipe shall be discharged as soon as possible, in order to speed up warming up of the pipe and temperature rise. 3.2.1.9 Extraction Steam System The extraction steam system allows for eight-stage non-regulated extraction, heating three LP heaters and one deaerator and four LP heaters. The first, second, third stage extraction steams are supplied to No. 8, 7, 6 HP heater respectively; the 4th stage extraction steam is supplied to deaerator and auxiliary steam system; 5th, 6th, 7th, 8th stage extraction steam are supplied to No. 4, 3, 2, 1 LP heater. The functions of extraction steam are: 1) To heat feed-water, improve the thermal efficiency of the system;
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2) To minimize the thermal shock for boiler metal by reducing the temperature difference between the feed-water and the boiler tube metal; 3)To remove the oxygen and other non-condensable gas in a deaerator by heating of the feed-water; 4) To supply steam to auxiliary steam system. Three vertical HP heaters are installed in a deaerator, No. 8, 7, 6 HP heaters are located at an elevation of 15.40 m ,the deaerator is installed in the outside of a deaerator bay, with an elevation of 24 m, No. 4, 3 LP heaters are installed at an elevation of 8 m in the deaerator bay, No. 2 and 1 LP heaters share a mixed-type heater with one shell, horizontally installed at condenser throat, with an elevation of 7.5 m. Except for sections 7, 8 extraction steam, all extraction pipes are continuously equipped with motor-driven shut-off valves and starting check valve, once the turbine trips, the starting check valve and motor-driven shut-off valve are both closed at the same time. The function of the motor-operated valve is to prevent the water from entering the turbine. There is a huge risk of turbine overspeed, due to the fact that four stage extraction steams are connected to a deaerator water tank filled with plenty of water and the water tank is placed at an overhead location, and multiple steam supply branch pipes are connected to a auxiliary steam supply system. Consequently, two starting check valves are sequentially installed in the vicinity of the four stage extraction steam opening of the turbine as double protection to prevent any accident. Furthermore, a motor-driven shut-off valve and a self-resetting check valve are installed in a auxiliary steam branch pipe. During change in mode of operation, if the auxiliary steam supply changes in direction, the motor-operated valve and the check valve will be closed automatically to prevent the steam from entering the turbine. 3.2.2 Feed Water System The function of the feed water system is to feed the feed-water from the deaerated water tank to the inlet of a boiler economizer. Before entering the economizer, the feed-water is heated by the extraction steam from the turbine to improve the thermal efficiency of circulation. The feed water system also supplies desuperheating water to a boiler reheater to control the temperature of the superheated steam. Furthermore, the feed-water from the abstracted part of a intermediate tap for a feed-water pump is fed to a attemperator in front of the reheater to control the temperature of the reheater and to avoid overtemperature of the reheater. The feed-water is also served as the desuperheating water of a HP bypass to control the main steam temperature flowing through the HP bypass. Each unit is equipped with three motor-driven feed-water pumps with 50% capacity. The feed-water pump is of vertical arrangement, multiple-pole double-housing, barrel-type centrifugal pump. Each feed-water pump is integrated with its booster pump, sharing a motor with the same shaft. Each feed-water pump is equipped with a minimum flow automatically & continuously regulating device made in the US. If the
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flow rate of the feed-water pump is less than the minimum flow rate required for cooling of pump body, the water temperature in pump body will quickly go up, some water would vaporize and cause cavitation phenomenon on the guide vanes and impeller of the pump, resulting in vibration of the pump body and even damage to the pump body. Consequently, a recirculation piping with control valve is installed between the outlet of the feed-water pump and the deaerator inlet. The minimum flow control valve is a continuously adjustable starting valve. If the outlet flow rate for the feed-water pump is less than minimum allowable flow rate, the minimum flow control valve is opened, the feed-water is fed to a condenser to ensure that the feed-water flow rate is more than minimum allowable flow rate, preventing inside of feed-water pump from causing vaporization phenomenon due to low flow rate. The minimum flow piping is led out from the front of the check valve at the outlet of the feed-water pump, after going through a manual gate valve, a minimum flow control valve, another manual gate valve and a check valve, returning to a deaerated water tank. During standby period, the minimum flow control valve shall be in the full open position. The feed-water pump is equipped with perfect working oil and lube oil system. The working oil is used for hydraulic coupling of feed-water pump, the lube oil is used for lubrication of bearing for feed-water pump set. The feed-water flow rate is controlled by three elements impulse signal(drum level, steam flow rate and feed-water flow rate), during the unit startup, or in the case of low load, the feed-water flow rate is controlled by a single element impulse signal(drum level ). The feed water system, at various loads, supplies feed-water to an economizer, an attemperator, an attemperator preceding the reheater and an attemperator in a turbine HP bypass, required by flow rate, pressure and temperature load.(in the case of startup, BMCR case, house load operation, etc.). The feed water system is designed to supply feed-water of 955t/h, 281 to the economizer inlet at BMCR condition for the boiler. During normal operation, the feed-water from a deaerated water tank to the inlet of an economizer header flows through the following equipments: a booster pump, No. 8 HP heater, No. 7 HP heater, No. 6 HP heater. During startup, if the boiler load is 630% of BMCR condition, the feed-water is controlled by a control valve in a bypass pipe for the feed-water pump, if the boiler load 30% BMCR, 50% BMCR condition, then the feed-water is switched to two feed-water pumps operated in parallel, in this case, the control mode can satisfy the feed-water requirements at 50100 BMCR condition for the unit. The booster pump is used to increase the pressure at the inlet of the feed-water pump to avoid the vaporization of the feed-water at the inlet of the feed-water pump. 3 booster pumps with 50 capacity are vertical arrangement, single impeller, single suction, centrifugal type. The function of the strainer installed in the booster pump is to prevent foreign matters, which may be accumulated in the feed-water tank
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of the deaerator or in the intake pipe during installation and overhaul period, from entering the pump to protect the water pump. After stably operating for some time, the strainer can be replaced by a nipple to reduce the pipe resistance. The safety valve in the pipe of the booster pump is used to protect the booster pump and its inlet pipe to avoid overpressure. The outlets of three feed-water pumps are connected to the outlet piping, so the high-pressure feed-water coming out of the operating pump may enter a stand-by pump body via the outlet of stand-by pump(if the check valve at the outlet of the stand-by pump is not tight),in this case ,if the inlet shut-off valve for the booster pump of the stand-by pump is closed, then the booster pump of the stand-by pump and its inlet pipe may cause overpressure. There is no special requirement for seal water due to the mechanical seal of the feed-water pump, however, the bearing cooling water shall be provide to bring away the heat due to friction during operation of the bearing for the feed-water pump. The desuperheating water is supplied to the boiler superheater and turbines HP bypass by the feed water system. The attemperator in the desuperheating water pipe is equipped with a flow rate measurement device and a control station. The emergency desuperheating water piping for the reheater is led out from the intermediate tap of the feed-water pump to the emergency attemperator in front of the reheater, as emergency water spray. 3.2.3 Condensate System The function of the condensate system is to pump out the condensate from a condenser hot well and to feed to the deaerator, and to control, to heat deaerator condensate, as well as to carry out other functions in order to ensure safe operation, improving systems thermal efficiency. The system is a regenerative heating system, equipped with two condensate pump s with 100 capacity, 4 LP heaters, a gland steam heater. Various attemperator spray waters and other water are led to the upstream of a gland steam heater. The control valve designed to control deaerator water level, minimum flow recirculation piping, and desuperheating spray device for LP casing are installed at the downstream of the gland steam heater. The system is also equipped with a condensate storage tank, a regulating storage tank to the control valve for condenser hot wells make-up water, a condensate transport pump designed to ensure the normal level of the condenser, two condensate pump, one for operation, one for standby. The system can provide adequate and satisfactory condensate water in various conditions. At boilers BMCR condition, the condensate flow rate is 756.369 ton/hour, the temperature is 141.1. The condensate water pumped from a condenser hot well, going through a continuously operated gland steam cooler and a LP heater after boosting by a condensate pump, is fed to the deaerator. The condensate water is heated and deaerated during transportation, and the condensate volume is controlled to control the level of deaerator feed-water tank and to reduce the instantaneous
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pressure drop.
There is no condensate polishing system for the project.
The condenser is single shell, there are two flow paths inside it. The bottom of the turbine is longitudinal arrangement, surface type. The bottom of the condenser is a rigid support, the top and the exhaust outlet for turbine IP cylinder are connected by the flexible expansion joints. The exhaust steam from the turbine is condensed to condensate water by means of the recirculating cooling water flowing through the condenser tube bundle, the condensate water is collected in a hot well and discharged by a condensate pump. The condenser throat is equipped with No. 2 and 1 LP heaters, LP cylinder spray water, a LP bypass reducer and three-stage reducer. Two motor-driven, constant speed, vertical arrangement, barrel-type condensate pumps with 100 capacity are installed in a condensate pump pit, one for operation, one for standby. The condensate water is pumped out from the hot well by the condensate pump and drained after pressurizing to overcome the frictional resistance for the piping, heaters, etc. and the static pressure difference between the deaerator and the condenser. The condensate pump may cause vibration in the event of thermal change due to the abnormal conditions in the unit(sudden load rejection, bypass operation, sudden change in condenser pressure, etc.), consequently, the pump body and the first stage impeller shall be designed to anti-cavitation type according to the vacuum condition. The mechanical seal water supply piping for condensate pump is connected to the rear of a motor-operated valve at the outlet of the condensate pump, and equipped with a check valve and a sealed pressure regulating valve. The initial seal water for the condensate pump is taken from a condensate transport pump. The system is equipped with minimum flow recirculation piping, in order to ensure that the condensate pump is operated over the minimum flow rate, and to avoid the cavitation of the condensate pump. The recirculation piping for the condensate pump is led in from the downstream of water side for gland steam heater, after going through a flow rate measurement device, a level control valve, a isolation valve and a throttle orifice, returned to the condenser. The control valve is installed in the minimum flow recirculation piping to control the recirculation flow rate in various conditions. The gland steam heater is a surface type heat exchanger, designed to condense the leakage steam from the gland seal and a LP valve lever. The gland steam cooler maintains the vacuum condition by means of gland steam extraction fan, so as to prevent the steam from leaking into the atmosphere and turbine lube oil system. In order to maintain the above-mentioned vacuum condition, there must be sufficient condensate flow rate to condense the above-mentioned leakage steam by means of gland steam cooler, the system minimum flow rate recirculation piping is therefore led out from the piping in the rear of gland steam cooler, then returned to the condenser. The minimum flow rate recirculation piping condensate pump is designed according to the minimum flow rates allowed by the condensate pump and the gland steam cooler, whichever is greater, so as to ensure the safe operation of the pump in the
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case of startup and low load condition and normal operation of the turbine gland steam system . The heating & deaerating system for condensate mainly consists of 4 full capacity surface type LP heater(No. 1, No. 2, No. 3 and No. 4 LP heaters) and a mixed heating type, spray disk, box-type deaerator and its deaerated water tank. No. 1 and No. 2 LP heaters are arranged at condenser throat. No. 3 and No. 4 LP heaters are vertical, with small bypass system. If the heater reaches high-high level, the motor-operated valves at the inlet and outlet of the heater will be closed. The heater can be overhauled individually, because the condensate water is led to bypass. No. 1,2 LP heaters use the motor-driven gate valve as the big bypass for an isolation valve, if the level of any LP heater reaches high-high value, the motor-operated valves at the inlet and outlet are closed, the motor-operated valve in the big bypass is opened. The level signal derives form the level control signal of SCS system. The deaerator employs sliding pressure operation mode, the steam is supplied by four-stage extraction for the turbine during normal operation, and is supplied by an auxiliary steam system during startup or in the case of low load. The deaerator water level is controlled by a level control valve installed in the condensate main pipe. There is a check valve in the vertical section of deaerator inlet pipe to prevent the steam in the deaerator from flowing back into the condensate system. Each unit is equipped with a condensate storage tank, mainly used to make up water to condenser hot well during normal operation or during startup. The water supply for storage tank is demineralized water from the chemical water treatment room, its level is controlled by a control valve in the intake pipe. The storage tank is equipped with an overflow pipe and a drain pipe. The water is drained by the drain pipe if water tank level is High High. Water supply to the storage tank is controlled by a check valve and a level control valve. The top of the storage tank is connected to the atmosphere. Each storage tank is equipped with a condensate transfer pump, mainly used to fill the deaerator, boiler and closed-cycle cooling water system with water during startup, and to supply sealing water to the condensate pump and to make up water to the condenser. There are a screen and a manual gate valve at pump inlet, and there are a check valve and a manual gate valve at pump outlet. The minimum flow rate recirculation pipeline is led out after the gate valve, the pipeline is equipped with a gate valve and a throttle orifice. In addition, the pump is also equipped with a bypass piping with a gate valve and a check valve installed. Water make up to the condenser is carried out by means of condenser draft via a bypass piping during normal operation of the unit. In case direct vacuum water makeup is not enough, the condensate transfer pump is opened to make up water to the condenser.
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A piping is led out from the upstream piping at the inlet of a gland steam cooler, serving as the water supply manifold for various desuperheating spray waters and other miscellaneous waters. Various LP desuperheating spray waters are: LP bypass desuperheating spray water; spray water for fuel oil heating & desuperheating; spray water for gland steam desuperheating; three-stages pray water for LP bypass desuperheating; spray water for fuel oil atomization and oil gun purging attemperator; spray water for turbine proper flash tank desuperheating. Miscellaneous waters include: make-up water for vacuum pump; make-up water for closed water; spray water for IP cylinder; make-up water for chemical dosing; seal water for vacuum breaking valve; water seal for gland steam cooler. 3.2.4 Turbine Regulating & Controlling System - DEH Control System; 3.2.4.1 Overview The regulating and safety system for K156 turbine adopts a digital electro-hydraulic control system(DE), and the hydraulic part adopts high-pressure anti-fuel oil system (EH). In order to realize the integration with the DCS hardware, the DEH hardware adopts I/AS system from FOXBORO Company, OVATION system from Siemens Westinghouse Power Corp., etc., resulting in excellent effect in resource share, communication, etc. DEH constitution: the system is divided into electronic part for DEH system, EH oil supply system, EH hydraulic servomotor, emergency protection actuator, TSI and ETS system. The HP fire-resistant oil is used as the medium for the system to provide power oil to various hydraulic servomotors and safety components and to ensure the quality of the oil. The HE hydraulic servomotor can directly control the open and close for the steam valve. There are 2 hydraulic servomotors for main steam stop valve, 4 hydraulic servomotors for high-pressure governor valve, 2 hydraulic servomotors for reheat main stop valve, 2 hydraulic servomotors for reheat steam regulating valve in total. The open or close for the hydraulic servomotor and its opening is all controlled by DEH electric signals, and the fast-closing function for receiving ETS trip signal is also available. The emergency protection actuator consists of emergency trip control block, diaphragm valve, overspeed trip mechanism and comprehensive safety device, etc., providing the system with the functions of overspeed protection and emergency shutdown. TSI and ETS system is a device designed to detect the state of the turbine, integrate various shutdown signal, and send shutdown signal after logic operation of PLC, for the purpose of safety, individual channels are configured with online test function.
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3.2.4.2 EH oil Supply System 1) EH System Composition and Principle EH oil supply system EH oil, oil tank assembly, precision filter, high pressure accumulator, oil-return accumulator, etc. composition. The main function of oil supply device is to provide the actuator with required hydraulic power, and maintain the normal physical and chemical properties of the hydraulic oil. It consists of oil tank, oil pump-motor assembly, control block, oil filter, magnetic filter, overflow valve, accumulator, natural circulation type cooling system, fire-resistant oil regeneration & filtering system, EH oil tank heater, ER terminal box and some standard equipments designed to give alarm, indication, and control to oil pressure, oil temperature, oil level. 2) Oil Tank It is fabricated from stainless steel plate by welding, with a sealing structure. There is a manual relief valve below the EH oil tank to drain the fire-resistant oil in the EH oil tank. 3) Oil Pump Based on the stability of system operation and the special properties of its working medium, the system adopts plunger type variable capacity pump, flexible coupling. The pump is connected to the motor by a flange sleeve to facilitate the maintenance of the pump and the motor. After startup, the oil pump supplies oil to the system and fill the accumulator with oil at full flow rate. If the oil pressure reaches to the set pressure of 14Mpa for the system, the high pressure oil will drive the control valve on the constant pressure valve, the control valve operate the variable mechanism of the pump, thus the output flow rate of the pump is reduced. If the output flow rate of the pump is equal to the oil volume consumed by the system, the variable mechanism of the pump maintain at some position. If it is required to increase or reduce the oil volume consumed by the system, the pump will automatically change the output flow rate, thus maintain the oil pressure of the system at 14Mpa. Two pumps are installed below the oil tank to ensure the positive suction head of the oil pump. 4) Control Block Assembly The control block assembly is installed at the side of the oil tank, it is designed to install the following components: a) High - pressure filter Two high - pressure filters are located in the high - pressure EH oil pipeline at the oil pump outlet, used to filter the EH oil entering the system.
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b)
Overflow valve Two overflow valves, which have the function of the safety valve, are located in the high - pressure EH oil pipeline at the outlets of the two oil pumps, used to monitor the oil pressure of the system, and if the oil pressure of the system is more than the design value, the EH oil will return to the EH oil tank, in order to ensure the operating pressure of the system is within the normal range, to prevent the system from enduring unnecessary high pressure.
c)
Right-angle check valve Two right-angle check valve is installed in the high - pressure EH oil pipeline at the outlet side of the EH oil pump, in order to prevent the high pressure EH oil from flowing back.
d)
Differential Pressure Transducer Two differential pressure transducers are located in the high - pressure EH oil pipeline at the oil pump outlet, used to detect the flow condition of the high- pressure filter, and to give corresponding alarm signal. These two differential pressure transducers are remote transmission differential pressure transducers. If the differential pressure reaches to 0.69Mpa due to high - pressure filter being clogged by dirt, the transducers give a signal to warn and they are required to clean or replace.
e)
Accumulator Two accumulators are installed above the control block for the oil tank, the accumulator assembly includes 2 groups of high pressure accumulator, shut-off valve(inlet), shut-off valve(outlet), pressure gauge, they constitute two separate systems respectively. The accumulator can be separated from the mains by closing the corresponding shut-off valves at the inlet and outlet, consequently, online maintenance for the accumulator can be made. The accumulators are used to absorb the high-frequency pulsating component at the oil pump outlet, thus to stabilize the oil pressure of the system.
5)
Air Filter(also serving as oil filler): It is installed above the oil tank to ensure that there is adequate filtering accuracy to air during the oil supply device breathing and to absorb the moisture in the air, thus guaranteeing the cleanliness of the oil system.
6)
Magnetic Filter A set of three magnetic rods making from permanent-magnetic steel are installed in the oil tank cover as a magnetic filter, in order to absorb the metal impurity in the EH oil. The complete magnetic filter can be taken out for cleaning and maintenance.
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7)
Magnetic reverse column liquid level alarm device A magnetic reverse column liquid level alarm device is installed in the side of the EH oil tank. If the level changes, it will drive the switch mechanism, and give an alarm or shutdown signal when the level reaches to the set value.
8)
Natural circulation- oil filter system In addition to the oil filter device installed in the oil supply mains, the oil supply system is equipped with two oil coolers and a oil filter, in order to ensure the oil temperature for the oil tank is within the normal operation range and to ensure the quality of the EH fire-resistant oil during operation under abnormal conditions. The return-oil filtering efficiency for the system is low during normal operation of the unit, therefore, the quality of the EH oil would deteriorate after system operating for some time, the requirement for the oil quality cannot be met unless performing the oil circulation again. The oil supply device is equipped with a separate natural circulation- oil filter system, in order to ensure the normal operation of the unit, and to ensure the cleanliness of the oil system and the long-term reliable operation of the system. The natural circulation- oil filter system allows for on-line circulation of the oil. The system can be started to cool and filter the oil even in the case of too high oil temperature or low oil cleanliness. The system allows the cooling and filtering of the oil to be carried out even if the servo system is out of service. The oil pump can be started or stopped by the control button on an ER electric control box. The natural circulation- oil filter system consists of an oil pump-motor assembly, a 3 micron oil filter, two coolers and two water solenoid valves. Circulating oil pump also can be controlled by a temperature switch, and can be started or stopped manually (start button on the electric control box).
9)
Fire-resistant oil regenerative device It is an indispensable part to ensure the eligible oil quality of hydraulic control system. The regenerative device shall be actuated to improve the oil quality if the cleanliness of the oil, water content and acid value does not comply with the requirements. The mating regenerative device for the EH oil supply device has three filter elements, one of which is diatomaceous earth filter element, used to regulate the physical and chemical properties of triaryl phosphate ester fire-resistant hydraulic fluid, and to remove the moisture and reduce the acid value of the fire-resistant hydraulic fluid. The other two filter elements are used to adjust the grain size of the fluid. A differential pressure indicator is installed in the housing of each filter element. The differential pressure indicator gives an alarm signal to show that the filter element has to be replaced if its degree of pollution reaches to design value.
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The regenerative pump unit is used to supply oil to the oil regenerative device, the diatomaceous earth filter and glass fibre filter are all replaceable filter elements, they can be replaced by closing the corresponding valves and opening the top cover of the filter housing. 10) Return-oil filter A 3 micron return-oil filter assembly is installed in the pressure return oil pipeline beside the oil tank. A demountable cover is installed in the filter housing for easy replacement of the filter element. 11) Electric heater The electric heater for the EH oil tank is installed in the outside of the bottom for the EH oil tank. If the oil temperature of the EH oil tank is more than 20C, the heater shall be switched on manually instead of starting the main oil pump; if the oil temperature of the EH oil tank is more than 53C or oil tank level is below the low oil level, the heater is stopped. 3.2.4.3 EH Oil Actuator 1) Overview Each hydraulic servomotor is connected to the system by 3 oil pipings, one of which is used to supply the high pressure oil from the EH oil supply system to each hydraulic servomotor as its power oil supply, each hydraulic servomotor is equipped with a e a isolation and shut-off valve at the inlet of high pressure oil, the valve can be closed without stopping the main oil pump if any element is needed to be replaced during on-line maintenance. For each hydraulic servomotor, another return oil piping is connected to the pressure return oil mains of the system, there is a check valve at the outlet, in order to prevent the pressure return oil from leakage due to flow back during on-line maintenance. The other piping is a safety oil piping, a check valve is also installed at the outlet, used to relieve the safe oil pressure for any hydraulic servomotor to quickly close the hydraulic servomotor without affecting the operating condition of other hydraulic servomotors. The safety oil piping for main steam stop valves hydraulic servomotor (TV) and reheat main stop valves hydraulic servomotor (RSV) are connected to the oil main for emergency trip (AST). The safety oil piping for control valves hydraulic servomotor (GV) and reheat control valves hydraulic servomotor (IV) are connected to the oil main for overspeed protection (OPC). The AST main and OPC main are all connected to the emergency trip control block, in the control block, there are two parallel check valves between the AST main and the OPC main, the AST could pass if the direction is OPC direction, and nonreturn in reverse direction, this allows for only relieving of OPC oil pressure and maintaining of the AST oil pressure in the event of overspeed protective action, while upon relieving the AST oil pressure, the OPC oil pressure is automatically relieved without operating related OPC solenoid
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valve. 2) Classification of actuator All actuators are single side oil-feeding, opened by oil pressure, closed by spring. The actuator is divided into two types, i.e., switch type actuator, controllable actuator. 3) Switch type actuator a) There are left and right IP main steam valve actuators each classifying into switch type actuator in EH system actuator for the unit. IP main steam valve actuator receives the control signal from the ETS control system; there is an unloading valve beside the oil cylinder of the hydraulic servomotor. Once draining the emergency trip oil for automatic shutdown (AST oil )in the case of turbine emergency, the unloading valve is quickly opened, the pressure oil in the lower cavity of a piston rod for the actuator is rapidly drained, thus the main steam stop valve is closed in no time by means of the spring force. There is a solenoid valve for action test at the top of a unloading valve (the solenoid valve is a two-position four-way solenoid valve), the high pressure oil is connected to the pressure return oil by the solenoid valve. After the DEH control device having given a signal when the action test for the main steam stop valve has to be carried out, the solenoid valve will open and drain some pressure oil of the lower cavity of the actuator piston, so that the main steam stop valve is closed by means of the spring force, leading to the purpose of performing action test for the main steam stop valve. Composition for main components: Isolation valve: HP Fire-resistant oil is supplied to a solenoid valve through the isolation valve to operate the actuator for a automatic IP closer. The high pressure oil-line can be disconnected by closing the valve, in order to stop the steam valve during turbine operation, and to replace the screen, maintain or replace solenoid valve, unloading valve and oil cylinder, etc. The valve is installed in the actuator control block. Unloading valve: the unloading valve is installed in the actuator control block, its main function is as follows: if it is necessary to do the emergency shutdown in the event of unit fault, the emergency trip oil for automatic shutdown (AST oil) is drained by the action of the emergency trip device, the pressure oil of the lower cavity of a piston rod for the actuator is rapidly drained, thus the main steam stop valve is closed by means of the spring force.
b)
c)
d)
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Check valve: two check valves are installed in the control block, one leads to automatic shutdown emergency trip protection (AST) main piping, its function is to prevent the oil in AST main piping from flowing back into return oil chamber; another check valve leads to return oil main piping, its function is to prevent the oil in the return oil piping from flowing back into the hydraulic servomotor. The oil pressure for the lower cavity of a piston rod for the actuator may be reduced or disappeared by closing the filling isolation valve for the actuator, so that on-line maintenance for the hydraulic servomotor can be made without sopping other steam valves in operation. Movable solenoid valve: the IP main steam valve actuator is equipped with a movable solenoid valve, this valve is a two-position four-way solenoid valve, receiving the control signal from the DEH. Travel switch: the travel switch is installed in valves full open or full closed position, the travel switch operates and indicates the open or close condition of the valves.
4)
Introduction to servo actuator a) In EH system actuators, the servo actuators are: 2 HP main steam valve actuators, 4 HP control valve actuators, 4 IP control valve actuators. Operation principle of servo valve The electric signal designed to increase or decrease the opening of the steam valve after computer operation and treatment, after going through a servo amplifier, is converted to a hydraulic signal in an electro-hydraulic servo valve, causing the main valve plug of the servo valve to move, and the amplified electric signal is used to control the channel of HP Fire-resistant oil, causing the HP Fire-resistant oil to enter the lower cavity of the actuator piston rod, and causing the actuator piston to move up, thus driving and opening the HP steam regulating valve, or the pressure oil is drained from the lower cavity of the piston rod, the piston is moved down by means of spring force, thus the steam valve is closed. When the actuator piston moves, two linear displacement sensors (LVDT) are driven at the same time, the displacement of the actuator piston is converted to an electric signal, as a negative feedback signal, it is added to the signal received after computer treatment, actually, these two signals are subtracted due to their reverse polarities. The high pressure oil cannot feed to the lower cavity of the actuator piston rod only if the signal inputted into the servo amplifier is zero and the main valve for the servo valve returns to the middle position after original input signal and the feedback signals having been added, at the moment, the steam valve stops to move and stays at a new operation position.
b)
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c)
Main elements of the servo actuator Isolation valve: HP Fire-resistant oil is supplied to an electro-hydraulic servo valve through the isolation valve to operate the actuators for various steam valves. The high pressure oil-line can be disconnected by closing the valve, in order to stop the steam regulating valve during turbine operation, and to replace the screen, maintain or replace electro-hydraulic servo valve, solenoid valve, unloading valve, displacement sensor and oil cylinder, etc. The valve is installed in the actuator control block. Screen: in order to ensure the cleanliness of the HP Fire-resistant oil supplied to the electro-hydraulic servo valve and the normal operation of orifice, nozzle and pilot valve in the electro-hydraulic servo valve, all HP Fire-resistant oil are filtered by a 10 micron screen before entering into servo valve. Electro-hydraulic servo valve: electro-hydraulic servo valve consists of a torque motor, two-stage amplification & mechanical feedback system. The first stage amplification is a double nozzle and flapper system; the second stage amplification is a pilot valve system. Displacement sensor: linear displacement sensor consists of core rod, coil, housing, etc. Unloading valve: the unloading valve is installed in the actuator control block, its main function is as follows: if it is necessary to do the emergency shutdown in the event of unit fault, the emergency trip oil is drained by the action of the emergency trip device, the pressure oil of the lower cavity of a piston rod for the actuator is rapidly drained, at the moment, the valve is closed by means of the spring force, regardless of the output signal strength for the servo amplifier. Check valve: two check valves are installed in the control block, one leads to safeguard oil (AST or OPC) main piping, its function is to prevent the oil in AST or OPC main piping from flowing back into return oil chamber; another check valve leads to pressure return oil main piping, its function is to prevent the oil in the pressure return oil piping from flowing back into the hydraulic servomotor. The oil pressure for the lower cavity of a piston rod for the actuator may be reduced or disappeared by closing the filling isolation valve for the actuator, so that on-line maintenance for the hydraulic servomotor can be made. Travel switch: the travel switch is installed in valves full open or full closed position, the travel switch operates and indicates the open or close condition of the valves.
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3.2.4.4 Emergency Trip Control Module 1) Outline To prevent occurrence of serious damage to the unit in the accident resulted from abnormal performance of certain equipment during running of turbine, Emergency Trip System is mounted in the unit. In case of abnormal circumstance, the system will perform emergency stop of turbine to ensure safety of turbine. The system will shut down all steam valves whenever the turbine parameters monitored by Emergency Trip System exceed their settings. 2) Parameters monitored are shown as follows: Turbine overspeed, thrust bearing wornout, bearing oil pressure low, condenser low vacuum, fire-resistant oil pressure low and bearing vibration high, etc. Besides, one remote control interface is provided to receive all external trip signals. 3) Composition and function of Emergency Trip Module a) AST - OPC Solenoid Valve Assembly Overspeed protection - autostop emergency trip protection solenoid valve assembly consists of two parallelly connected overspeed protection solenoid valves20 / OPC - 1, 2, two non-return valves, four serially connected autostop emergency trip protection solenoid valves and one control module. The assembly is mounted in H.P. fire-resistant oil system and is controlled by OPC and AST of DEH controller. During normal operation, two OPC solenoid valves are in de-energized N.C. condition to close OPC oil drain passage of OPC main header so that oil pressure in down cavity of actuator piston rod of HP steam governing valve can be established. When the rotation speed exceeds 103% of rated speed, OPC operates and sends output signal to open two solenoid valves by excitation, which enables the oil in OPC main header to flow to EH oil tank through non pressure oil return line. In this wise, corresponding release valve on control valve actuator will be opened quickly to shut down all HP, MP and extraction non-return valves promptly. Four AST solenoid valves with series-parallel connection arrangement are controlled by ETS. In normal operation, these four AST solenoid valves are in energized closed condition to close oil drain passage of AST main header so that oil pressure in down cavity of actuator piston rod of main steam valve and governing valve can be established. In case of emergency of the unit, AST signal output will be sent to open these four solenoid valves by de-energization, which enables the oil in AST main header to flow to EH oil tank through non pressure oil return line. In this wise, corresponding release valves on main steam valve actuator and governing valve actuator will be opened to shut down all steam valves promptly. Four AST solenoid valves are
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arranged in series-parallel connection mode to ensure safety and reliability of turbine. Two sets i.e. AST/1 and AST/3, AST/2 and AST/4 are parallelly connected respectively and then the two sets will be serially connected. Under this circumstance, whenever emergency occurs to the turbine, operating of any solenoid valve in any set will release the oil pressure in AST main header to ensure safety of turbine. In case of reset, oil pressure in AST main header can be established with only one set in closed condition and the turbine will be available for start-up. Oil in AST and in OPC is isolated by two non-return valves of AST solenoid valve assembly. These two non-return valves are designed as follows: when OPC solenoid valve operates, oil pressure in AST main header will not be disturbed; when AST solenoid valve operates, oil pressure oil pressure in OPC main header will be lost. b) Diaphragm Valve Diaphragm valve is connected to LP turbine oil system and HP fire-resistant oil system. Its function is described as follows: when emergency tripper operates or emergency trip device sends out trip signal in case of overspeed of turbine, oil in main header for mechanical overspeed- manual shutdown will be drained through emergency tripper slide valve. When the oil pressure is reduced to certain value, diaphragm valve will open to drain the oil in AST main header so that HP, MP main steam valves and HP, MP governing valves can be closed by EH system and the turbine safety can be ensured with compelled shutdown of turbine. During normal operation of the unit, security oil in LP turbine oil system will pass through the upper cavity of the diaphragm valve to overcome the spring force as to maintain the valve in closed position, block the oil drain passage of AST main header and enable all HP, MP main steam valve actuators and HP, MP governing valve actuators in service. Either independent operating or simultaneous operating of mechanical overspeed facility- emergency tripper or manual trip slide valve (in security control device) will reduce or extinct the oil pressure of security oil in turbine oil system so that the diaphragm valve will be opened by spring force. Then AST oil will flow to EH oil tank through non pressure return oil main header and all valves will be closed. Air Pilot Valve
Air pilot valve is an interface between extraction non-return valve and EH system. For the unit mounted with air pilot valve, all extraction non-return valves are pneumatic type and air pilot valve controls compressed air source of extraction non-return valves. Open of air pilot valve relies on OPC oil pressure while close of the valve relies on spring force. During normal operation of the unit, air pilot valve will be opened by OPC pressurized oil to feed compressed air to all extraction non-return valves. Open and close of extraction non-return valves can be
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established by operating solenoid valves on extraction non-return valves from DCS; when OPC oil pressure is released, air pilot valve will be closed by spring force to isolate compressed air supply and open vent line in the meantime so that residual air in extraction non-return valves pipes can be discharged. In this case, in spite of whatever instruction given from DCS, extraction non-return valves will not be closed and overspeed of the unit can be prevented. d) Emergency Trip Test Device It includes two condensation vacuum test modules, one EH oil pressure low test module, one bearing oil pressure low test module, two bearing oil pump emergency oil pump starting test modules. Dual channel redundancy design is adopted for each module and each channel is designed with local manual stop valve and remote control solenoid valve. On-line test and maintenance is also available. e) Mechanical Overspeed and Manual Shut-down Device Mechanical overspeed and manual shut-down device contains emergency tripper, emergency tripper slide valve and security control device. Its function is to cut off steam admission of turbine promptly, shut down turbine and send alarm under the circumstance as follows. 1) When turbines working speed reaches 109%-110% of rated speed, emergency tripper operates to close HP, MP main steam valves and HP, MP governing valves. 2) When manual tripping handle operates, HP, MP main steam valves and HP, MP governing valves will be closed. f) Emergency Tripper Emergency tripper is tightened with screw thread of inverse rotating direction at the end of extended shaft of turbine rotor and is locked in position by positioning screw. Striking ball is fixed in a transversal hole on the shell and its center is offsetted with rotary shaft so that it can move outboard at any time by centrifugal force. Emergency tripper controls one emergency tripper slide valve. When the turbine runs normally, slide valve will prop against the left lock position. If turbines working speed reaches 109%-110% of the rated speed, the centrifugal force of the weight dropper will overcome the restraining force of the spring and the striking ball will burst out and hit on the jar latch by which the jar latch will start rotating on the rotary shaft. The rotation of the jar latch will enable emergency tripper slide valve to move rightwards to connect security oil with oil drain line so that diaphragm valve will be opened promptly and security oil in AST main header of HP oil system will also be released. Finally, all main steam valves and governing valves
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will be closed and the unit will be shut down. Rotate manual tripping handle in front of the front bearing box to shut down the turbine manually. g) Emergency Tripper Slide Valve Emergency tripper slide valve is the control and test device in Emergency Trip System. It is installed inside the front bearing box and contains three slide valves: one trip slide valve, one test isolation slide valve and one manual trip slide valve and three levers: one manual trip lever, one test lever and one manual tripping condition establishment lever. Test isolation slide valve can be used to isolate the valve from pressurized main header. During oil injection test, oil injection test stop valve should be opened manually and pressurized oil will enter the down cavity of fly ball of the emergency tripper through nozzle. At the moment, fly ball will burst out by overcoming the compressing force of the spring. h) Overspeed Test: Anumber of tripping speed test shall be carried out on turbine. Only manual tripping test is not sufficient as manual tripping test can only testify tripping connecting rod part while knockout test of the striking ball is not done. During test of over-speed trip facility and when the turbine speed gradually goes up to the tripping value, speed meter shall be monitored carefully. One operator shall be deployed next to the manual tripping handle through out the test to ensure that turbine can be tripped manually in case of failure of auto trip at required speed. If the above situation occurs, turbine should be shut down for checking of emergency tripper to ensure the striking ball is not jammed inside the shell. After proper checking, overspeed test should be conducted again. If the striking ball still fails to burst our, the spring may be over compressed and prevents the weight dropper from knocking the striking ball out at specified speed. To adjust the pre-compressing force of the spring, retaining collar of the spring should be screwed outward to some extent to reduce the compressing force. There will be a 25rpm difference in tightening or loosening the retaining collar of the spring for each thread. After change of spring compression, overspeed test shall be re-conducted. i) Security Control Device After tripping of the unit, reset of the unit must be made by moving manual reset lever or by operating remote reset device. This reset operation must be done after the speed of the rotor is reduced to the speed at which striking ball returns to its normal position (approx. 2% of normal speed). Security control device provides the unit with remote solenoid valve and cylinder for establishment of tripping conditions. When it receives
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signals for establishment of tripping conditions from DEH, solenoid valve will be charged. Air admission will be started at one end of the cylinder and air discharge at the other end, which enables the cylinder to push the connecting rod of emergency trip slide valve to reset emergency trip slide valve. Afterwards, power supply for solenoid valve will be cut off. Air will enter the other end of the cylinder to enable the piston and reset lever to return to "Normal" position. 3.2.5 Circulating Water System The open circulatory system is used as the circulating water, open cooling water system, the intake point is at the river estuary, and slight brackish water is used for cooling. Three sets of full capacity circulating water pumps are adopted in the Stage 1 works, of which two sets work and one is standby, and trash racks and rotary sieves are equipped. The circulating water system is mainly used to take away the vaporized latent heat of steam of condensing steam discharged from the turbine, making steam condensed in the condenser. The circulating water system shall provide the condenser with sufficient qualified cooling water under all conditions that units are in operation. The condenser has a single shell, as split, dual-flow, surface heat exchange type, and is levelly laid on the basis of the turbine. Its throat part is flexibly connected with a low pressure cylinder and its bottom is rigidly supported. The structure of the condenser water room shall meet the needs of cleaning rubber balls and shall not have flowing dead angle and whirlpool to eliminate the stranded phenomenon of rubber balls in the water room and avoid the decline in the rate of receiving balls. The condenser rubber ball system is used for cleaning tube bundles, to ensure the heat exchange coefficient and the vacuum of the turbine. The both sides of the condenser are separately equipped with a rubber ball cleaning device. The system is independent and comprises a rubber ball pump, a ball receiving mesh, a ball storage room and pipeline. 3.2.6 Open Water System The open water system includes two sets of 100% capacity open pumps, with the main parameters of Q = 2230t/h and H = 15m, a set of 100% capacity filter and above-mentioned heat exchange cooler, pipeline, valves and related equipment. The open water system is used to provide continuously cooling water to the heat exchangers of the closed water system, to ensure the high-efficiency operation of the closed cooling water system with the backwater of the closed cooling water system. At the same time, the open water system also provides water to the equipment and coolers with a large quantity of water and low quality requirement.
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Open water begins with the circulating water system of the steam room and returns to the circulating water system of the turbine room through the following equipment: A Closed cooling water heat exchanger; B Vacuum pump cooler. The closed backwater and open water in the open water cooling heat exchanger are from the circulating water, flows through the filters, open pumps and closed cooling water heat exchanger, and discharges to the lower reaches of the circulating backwater butterfly valve at the condenser exit. A branch is provided at the lower reaches of the open pump and through the vacuum pump cooler, and the branch backwater discharges to the lower reaches of the circulating backwater butterfly valve at the condenser exit. Before open water enters the open water pump, the open water will be through an automatic filter, which can remove debris in the sieves and discharge the debris to the lower reaches of the circulating backwater butterfly valve at the condenser exit. The filter can automatically clean during operation. Before open water starts, the inlet and outlet valves of all the relevant equipment shall be opened, and then the equipment is filled with water to pump air through the pressure of the circulating water, and all air doors are closed after the air is emptied, when the open pump starts. During the normal operation, the two sets of the equipment in parallel shall follow the principle that one is in operation and the other is standby. If the operating pump fails, the standby pump shall automatically start. According to the specific operation situations, the heat exchangers can be manually switched by the operators. During the normal operation, on the basis of the temperature of all the cooled media, the open water exit valves of the corresponding coolers shall be appropriately manually adjusted, or be input into the automatic state. After operation for some time, the sieves of the filter can be cleaned rotarily. When the pressure difference at the import and exit of the sieve reaches the specific value, the control room will send an alarm signal, and meanwhile the electric cleaning valve will automatically start and wash reversely all the sieves. 3.2.7 Closed Water System A considerable quantity of heat in the power plant is from the friction of equipment bearings in operation or from the heat transferred from high temperature fluid to the bearings. At the same time, some of the equipment in the process will also generate heat. To ensure the safety of the equipment and prevent the bearings from being burned out due to overheating, the equipment shall be cooled and their heat shall be transferred. The system is used to provide the equipment with sufficient and qualified temperature cooling water so as to ensure the safety of the equipment. The equipment bearings are necessarily cooled by the low-flow and relatively pure cooling water, so the closed circulation shall be used for the cooling water.
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The closed cooling water system shall provide the following equipment with cooling water: mechanical sealing coolers and lubricant coolers of water supply pump motor, working oil coolers of electric pump, coolers of electric pump motor, hydrogen coolers of generators, sealing oil coolers at the hydrogen side of generators, cold water coolers in generators, coolers of condensation pump motor, lubricant coolers of turbine body, EH oil coolers of turbine, coolers of steam sampling device, apparatus and maintenance air compressor, cooling water of coal mill, upper bearing coolers of air preheater, lubricant stations of air blower, and lubricant stations of one-time fans. The scope of the designed closed water system includes two sets of 100% capacity closed cool pumps, two sets of 100% capacity heat exchangers, a set of 30 m 3 water tank and connecting pipelines, backwater pipeline of closed cooling water, and isolation doors and adjusting doors of cooling equipment and so on. The system comprising two sets of 100% closed cooling pumps, a 30m3 expansion tank, water supply, all backwater, branches, isolation doors, control doors and others is a closed circulating system for cooling the equipment. Closed backwater at about 45 degrees enters the closed cooling pump and goes into the heat exchanger from the pump and then into all the water supply pipelines, to provide different users with cooling water. The cooling backwater of different users is collected and then enters the closed cooling pump, thus completing a cycle. A 30-meter high water tank is situated on the 24-meter elevation deaerator layer, and can balance the fluctuations of the system flow and absorb the impact on the pipelines from the thermal expansion of the closed water, for providing the hydrostatic heads of the closed pump with water. The normal water level in the closed water tank shall be at a half of the water tank, to maintain the adequate thermal expansion space. The control valve for controlling water level of the water tank is positioned on the pipeline. The water tank is the same as the atmosphere and is equipped with an overflow pipe and water discharge pipe, and water in the water tank will be discharged at all the normal pressures. The design pressure of closed cooling water is about 7bar, and the temperature is 50 degrees The closed cooling water tank is installed with a water level transmitter for transmitting water level digital signals to DCS in an uninterrupted manner, and DCS will send water level control orders to the water level regulating door (1 LCF61AA061) to control the water level of the water tank. When the water level drops to the low I value, the transmitter will send alarm signals to DCS, and at the same time alarm signals will be sent in the control room. When the water level is up to the low value, the closed cooling pump will trip in a chaining manner. 3.2.8 Fire Fighting System According to the different equipment, fire hydrants, portable fire extinguishers, foam fire hydrants and water spraying fire-fighting manners will be used.
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The imports and exits of air and flue gas of air preheaters are equipped with temperature detectors, and when the temperature of the air the flue gas is 28 higher than the normal temperature, the fire detection system will alarm automatically in the main control room; 3.2.9 Operating manner of the units: the units are provided with basic loads, and can adapt to the need for peak shaving and operate under the constant pressure or sliding pressure; 3.3 Toning System 3.3.1 Overview The toning system consists of the original water treatment system, drinking water treatment system and demineralized water and wastewater treatment system and others. Chemical water is from the ao Van lake, which is located at 17 km from the power plant in Hoanh Bo County of Quangning province and is a man-made lake, with 14.6 million cubic meters capacity, and meanwhile the lake is also used as a living water source of the current Project; 3.3.2 Water Purifying System Purification station system is designed in accordance with the capacity of 4 300MW planning units, the equipment will be installed by different stages, the capacity of treatment water of 4 300MW units is about 350 m3/h, and the quantity of treatment water of 2 300MW in the current Project is about 200 m3/h. The mechanical accelerating clarification tanks of the purifying station in accordance with the capacity of 4 300MW units are planed and laid, the current Project of 2 300MW is in total equipped with two mechanical accelerating clarification tanks and filter tanks with 200% treatment capacity, and with a supporting coagulant dosing system, coagulant aid dosing system and sodium hypochlorite dosing system. 3.3.3 Wastewater System of the Whole Plant 3.3.3.1 The production and industrial wastewater in the plant will be sent to the general wastewater treatment system to be treated and then be sent to the activated carbon filter or ash removal system and the coal yard. The wastewater from the coal stack will be collected by the wastewater pond in the coal transmission plant for precipitation, and the clean water after clarification is sent to the water supply tank of the ash discharge system. The precipitated coal sludge is collected for recovery. The living sewage and industrial wastewater with oil and coal are separately pooled and discharged to the sewage treatment station to be treated, and then are sent to the interception pond in the general wastewater treatment system. Rainwater in the plant is pooled to the groove and is through the oil-water separation tank and then is discharged into the rivers or the circulating water drains. Rainwater with coal ash is discharged into the precipitation tank in the coal yard.
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1)
The backwashing water and renewable wastewater of the boiler recharge water treatment systems are discharged into the neutralization pond of the recharge water treatment room nearby for neutralization, and then into the wastewater storage tank. The sewage from boilers is first collected in the rinsing water pond of air preheater and dust collector and then is discharged into the wastewater storage tank. The treated wastewater with oil (oil less than 1 m9/I) is discharged into the regular wastewater pond. The living sewage is treated by the living sewage treatment equipment, and is discharged into the regular wastewater pond after meeting the emission standards. Wastewater of the other systems is directly discharged into the regular wastewater pond. Occassional wastewater is first collected by the Maple Group drain tank near the main plant, and then is discharged into the occasional wastewater pond.
2)
3)
4)
5)
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3.3.3.2 System Output The treatment capacity of the wastewater treatment system is designed in accordance with 180 t/h(Stage 1). 3.3.3.3 System Processes as follows: Occasional wastewater Occasional wastewater pond Occasional wastewater lift pump Wastewater storage tank Regular wastewater lift pump pH adjusting pond Mixture and coagulation pond Clarification pond Clarification pond Clarification water transmission pump Activated carbon filter Neutralization pond Efluent pond Efluent pump Ash pond The material of the main connecting pipeline within the system is UPVC. 3.3.3.4 Wastewater Treatment Process 1) In the occasional wastewater tank, occasional wastewater is mixed by the aeration device to oxidize and neutralize water quality and then is sent into the regular wastewater pond. Wastewater in the regular wastewater pond is mixed by the aeration device, resulting in the uniform water quality, and at the same time is oxidized by oxidant. Then, the wastewater is sent to pH adjusting pond, in which hydrochloric acid or sodium hydroxide is added to reach pH of 5.5 to 9.0. The wastewater is sent to the coagulation pond. Coagulation agent (FeCl3) is
2)
3)
4)
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added in El pipe of the wastewater output pump. 5) The adjusted wastewater is sent into the clarification pond, where suspended solids are removed. The overflow water of the clarification pond is collected by the clarification pond, and then is pumped into the activated carbon filter for in-depth treatment. Water output from the activated carbon filter goes into the neutralization pond, in which hydrochloric acid or sodium hydroxide is added to reach pH of 5.5 to 9.0. The wastewater meeting the emission standards is used for the ash treatment system. The settled suspended solids in the clarification pond are sent into the sludge concentration tank for concentration, and then into the ash storage pond of the ash treatment system of the plant by the sludge pump for follow-up treatment.
6)
7)
8)
9)
3.3.3.5 System Control Mode 1) The movement of the occasional wastewater pump interlocks with the liquid level of the occasional wastewater pond. When the distance between the low liquid level of the occasional wastewater pond and the bottom is 500 mm, the occasional wastewater pump will alarm, and when it is 300 mm, the pump will stop. When the distance between the high liquid level of the occasional wastewater pond and the bottom is 25 mm, the occasional wastewater pump will alarm, and when it is 3000 mm, the pump will start. The movement of the regular wastewater pump interlocks with the liquid level of the regular wastewater pond. When the distance between the low liquid level of the regular wastewater pond and the bottom is 500 mm, the regular wastewater pump will alarm, and when it is 300 mm, the pump will stop. When the distance between the high liquid level of the regular wastewater pond and the bottom is 3500 mm, the regular wastewater pump will alarm, and when it is 4000 mm, the pump will start. The coagulation pond shall be installed with a level meter. Under the normal circumstances, the distance between the low liquid level of the coagulation pond and the bottom shall be maintained at 3000mm. If the distance is 500 mm, the pump will alarm and if it is 300 mm, the pump will stop. Water will stay in the clarification pond for l. 2h to 1.5h, and the bottom of the clarification pond is equipped with an automatic mud discharge valve. Water can be discharged under the mud level or timing. The operation and backwashing of the activated carbon filter are both under automatic control. The flow velocity through each filter shall not be more than
2)
3)
4)
5)
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12 m/h. 6) The backwashing cycle of the activated carbon filter is one time a day per set. The starting time for backwashing depends on the pressure difference between the import and exit of the filter. The backwashing water is drained into the regular wastewater pond. When the filter needs be backwashed, the liquid level of the clarification pond must be high. In the wastewater treatment system, each dosing metering pump is manually controlled. The system is installed with an on-line pH value monitoring instrument.
7)
8)
3.3.4 Boiler Recharge Water Treatment System 3.3.4.1 The normal output of the equipment of the boiler recharge water treatment system is 240t/h, and the maximum output is 290 t/h. The boiler recharge water treatment system is provided with two columns of class 1 unit type desalting devices (2 sets of 60 t/h activated carbon filters 1set of 120 t/h reverse flow cation exchanger 1set of 120 t/h decarbonizer 10 m3 middle tank reverse flow ion exchanger) 2 sets of 120 t/h mixed beds. 3.3.4.2 Recharge Water Process: raw water contact, flocculation, sedimentation tank ultrafiltration water supply pump chlorination laminated filter ultrafiltration device ultrafiltration water tank ultrafiltration pump activated carbon filter cation exchange carbon dioxide remover middle water tank middle pump anion exchange mixed ion exchange desalting water tank desalting pump main plant; 3.3.4.3 Functions of System 1) 2) Providing boilers with desalting water; Providing the laboratory, sampling and analysis system and closed circulating and cooling system and other with desalting water; Providing desalting water when cleaning and washing boilers and turbine and starting units.
3)
3.3.4.4 Water Source and Water Quality Water for recharging the boilers is from Cao Van reservoir. Effluent water quality of the system: Total hardware Electrical conductivity (25) Silicon (as SiO2) 3.3.4.5 System Output 0 <0.2 S/cm (25 C) <10 g/L
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The output of the boiler recharge water treatment system is designed by 125 t/h. Desalting equipment is in total provided with two columns, each of which has 125 t/h output. Under the normal circumstances, one column is in operation and the other is standby. Material of the pipeline is mainly SS 304. 3.3.4.6 System Connection and Operating Mode 1) Operating mode of activated carbon filters Activated carbon filters are connected in parallel as the operating mode, the backwashing of filters automatically runs under the program control, and the backwashing cycle can be determined in accordance with operational experience (20 hours or 24 hours), or the volume of cycle water or also the pressure difference between the import and exit water manually. The imports and exits of filters are equipped with a manometer, and the imports are provided with flow indication and total records. Backwashing water is supplied by the water supply profession. 2) Operating mode of desalting equipment Level 1 desalting equipment of the water treatment system is in serial connected and mixed beds are in parallel connected. The exit of the cation exchange is equipped with sodium meter, and the exit of the anion exchange is equipped with a conductometer, controlling the operation destinations of Level 1 desalting equipment, or according to the influent water quality and operating experience of the equipment, the operation destinations of control equipment with cycle quantity of water. The stoppage and commissioning of cation and anion exchanges, carbon remover and middle pumps are automatically controlled by program, the liquid level of the middle pumps and water tanks interlocks, and when the distance between the liquid level of the middle water tank and the outlet is 500 mm, the pump will alarm, and when it is 300 mm, the middle pumps will stop running. The equipment is also automatically regenerated under the program control. The mixed ion exchange is in parallel connected in operation. The operating destinations of the equipment depend on the surveillance of the conductometer and silicon meter at the exit of the mixed bed and the cycle quantity of water of the equipment (the time can be displayed, with seven days normally). Regeneration and commissioning of the equipment are automatically under the program control. The operation of the desalting water pumps and self-use desalting water pumps and others can be controlled in the control room by the LCD keyboard, and their operations can be controlled at the site, wherein the self-use desalting water pumps enter the program and automatically operate.
44
The liquid level of the desalting water pumps and the self-use desalting water pumps interlocks with that of the desalting water tanks, and the pumps will alarm when the distance between the liquid level of the desalting water tanks and the outlet is 500mm, the desalting water pumps or self-use water pumps stop running when it is 300 mm, and the pump will alarm when the liquid level of the desalting water tanks and the overflow is 500 mm, and the water will stop when it is 300 mm. 3) Acid-base System Hydrochloric acid and sodium hydroxide for regeneration of the water treatment system are transported by automobile. Acid-base will be pumped by the acid-base pump to the high storage tank. The acid-base in the high storage tank relying on gravity flows into the measuring box in the acid-base measurement room, and then is sent the exchanger by the measuring pump for regeneration. The acid-base storage room of the Project is equipped with 2 sets of 25 m3 hydrochloric acid storage tanks, lye storage tanks and acid-base dumping pumps respectively, for storage of acid-base for the boiler recharge water treatment system. Security shower facilities and others are also considered. The liquid level of the acid-base dumping pump and acid-base storage room interlocks, and while dumping acid (base), when the distance between the liquid level of the acid (base) storage tank and the top of the storage tank is 800 mm, an alarm will be given, and when it is 500mm, the pump stops. While acid (base) enters into the measuring box, when the distance between the liquid level and the top is 700 mm, an alarm will be given, and when it is 500mm, the acid (base) valve will be shut down automatically. During regeneration, when the distance between the liquid level of the measuring box and the bottom is 500 mm, an alarm will be given, and when it is 300 m, the acid (base) valve will be shut down automatically. 4) Regenerative waste liquid emission and compressed air system The regenerative waste liquid of the water treatment system is discharged into the wastewater pond underground in the acid-base storage room, the wastewater pump room at the upper part of the wastewater tank is equipped with wastewater transportation pumps (each wastewater pond is equipped with 2 sets, of which one is in operation and the other is standby), and the wastewater is neutralized to PH of 6 to 9 and then is pumped to the wastewater treatment system. The effective volume of the wastewater pond is 2 200m3. 5) The water recharge treatment system of the Project is equipped with two compressed air storage tanks, and the compressed air is connected with the compressed air pipe for the instruments of the main plant and is provided to the operation of pneumatic valves of the boiler recharge water treatment
45
system and to the mixed resin of the mixed bed. 6) Layout of the recharge water treatment system of the boiler. See H0101-03 figure for the layout of the boiler recharge water treatment room and laboratory building. The laboratory building has two floors and is equipped with electronic equipment room, power distribution room and laboratories and so on. The filtration desalting room occupies 36 18, and is equipped with a pump room and acid-base measuring room. There are two outdoor 2000 m3 desalting water tanks and compressed air tanks equipped, and there is an acid-base storage tank room in addition at the southeast of the water treatment room and a regenerative wastewater pond below zero meter, etc. 3.3.5 Circulating Water Chlorination Treatment System A Chlorination system is installed in the circulating pump room, and chlorination is used in front of at the entrance to the cooling water, to inhibit microbial growth. The storage approach of dumping chlorine by chlorine vehicle is used in the current Project, without a separate chlorine generation system. 3.3.6 Chemical Dosing System 3.3.6.1 Drugs include: 1) 2) 3) 4) Hydrochloric acid: Sodium hydroxide: Flocculants: 31% HCl 30% NaOH 30% FeCl3
Sodium hypochlorite: 10% NaCIO
3.3.6.2 Chemical Dosing System includes the following major equipment: a) Acid dosing system Acid is sent to the high acid storage tank by the acid dumping pump and then into various dosing points through the measuring pump. b) Alkali dosing system Alkali is sent to the high alkaline storage tank by the alkali dumping pump and then into various dosing points through the measuring pump. c) Flocculants dosing system 30% FeCl3 is first added into the dissolution tank with a blender, and then into the measuring box with a blender and finally into various dosing points through the measuring pump. d) Sodium hypochlorite dosing system
46
Sodium hypochlorite is added into the dissolution tank directly, and then into various dosing points through the measuring pump. 3.3.6.3 Roots blower system Roots blower system is to provide compressed air to mix the regular and occasional wastewater ponds, where wastewater will be completely mixed and sediments will be mixed into suspending status 3.3.7 Hydrogen Preparation System The system is the supporting hydrogen preparation and supply equipment for Vietnamese Quang Ninh Power Plant (4 x300w) Project. The system is separately set up with three sets of HM water electrolysis hydrogen equipment, middle-pressure and high-pressure compressor systems and middle-pressure drying systems, a set of closed cooling water device, middle-pressure caching equipment, high-pressure storage equipment and hydrogen distribution devices and auxiliary water tanks, vacuum pumping devices, nitrogen system for purging, and a control system. 3.3.7.1 Three sets of HM water electrolysis hydrogen equipment The basic equipment configuration of HM system includes two parts, that is, hydrogen generator and power supply. The former includes all the mechanical components and the pipe and valve system that meets the requirement of the electrolysis technology. The generator is used to control the system and operate instruments. The panel surfaces of instruments show the process conditions and the necessary data for effective operation of the system. After the necessary conditions for the technology are input into the generator, the corresponding products will come out. HM ~ ClD2 generator is designed to operate at Class 1 District 2 position of order in the National Electric Code (NEC). The power supply contains the equipment for conversion of input AC into DC necessary for electrolysis. The power supply is required to be installed at a separate place without category (that is, not explosion-proof). The inputs for operation of the system include high-pure water, electrolysis electricity, washing nitrogen for driving, and cooling water for removing waste heat. After consumption of these inputs, the system will output l00Psig (Tk9/cm2) hydrogen, and oxygen injected into the atmosphere is output with a half of the yield of hydrogen. The whole sets of generator devices must contain the equipment providing water, nitrogen, cooling water and electrolysis input and must contain a pipe and valve system transporting hydrogen product and hydrogen and oxygen emitted respectively. The system is designed into automatic operation. When the prepressing system is used to trigger, the automatic start program will enable the system into operation, until the pressure prepared for gas transportation. The gas productivity of the system is in full compliance with the user's demand until
47
the maximum capacity of the generator. If no gas is transported, the system can be maintained under the pressure of the standby mode for transportation at any time. All the key operating parameters are continuously monitored. If the conditions within the system deviate from the allowed scope, the system will automatically stop. If after the system stops, the system will be maintained at the pressure under which the system can immediately output in the event of the restoration of electricity. The design of the system is based on the safe and reliable operation, but preventive maintenance shall be regularly implemented to maintain the reliability of the system, this is a very important point, and routine maintenance covers inspection and calibration of components, verification and replacement of electrolyte and calibration of controllers and instruments. In event of failure of the components, the instruments and display of the system will provide useful information to determine the reasons and the locations of failure for stopping the system. The system must provide pure water, purge nitrogen, cooling water and power supply, and is equipped with deoxidation and drying devices, so that the purity of product gas exit is no less than 99.95%, the dew point reaches 50.C above (the effect will be better if using frozen water), and the maximum volume of gas product is 8.4 m3/h and the volume can automatically be adjusted under the size of the pressure. The Project is equipped with three sets of HM equipment to meet user demand for hydrogen. 3.3.7.2 Purification and Middle-pressure Compression System Hydrogen the HM equipment is through Level 1 compressor and is compressed from 0.7 MPa to 3.2 MPa, and the Project is equipped with three sets of parallel compressors and each compressor can independently or in parallel operate. A protection device is separately set up at the ultra-high pressure at the exit and the low pressure at the import to prevent danger. The capacity of three sets of middle-pressure purifiers matches with that of the middle-pressure compressor, meeting the total capacity of three sets of HM hydrogen preparation equipment. Purification includes deoxidation and drying two major parts, high-efficiency Pd catalyst is used for deoxidation, and two towers that are connected in parallel and work alternately are used for drying, to guarantee the continuity of using hydrogen. The purity of product gas exit is no less than 99.99% and the dew point reaches above 70. C. The industrial cooling water is used in the system, which needs the power supply necessary to be provided. 3.3.7.3 High-pressure Storage System
48
Three high-pressure compressors with the processing capacity of 25m3/h are set up, and a hydrogen buffer tank with the working pressure of 3.2 MPa is set up in front of the compressor. Three sets of welded steel storage tanks are used in the high-pressure storage system, with the working pressure of l4MPa. The system needs the power supply and cooling water provided to the compressor system. 3.3.7.4 Hydrogen decompression distribution system and vacuum device High-pressure storage device connected supplies the generator units with air through decompression, and the pressure is 0.6 MPa after decompression. According to the size of air pressure, hydrogen can be automatically added. For the operation and safety, a standby trailer interface and vacuum device are set up. 3.3.7.5 Supplementary system of pure water The system is equipped with a cube of raw materials water tank to supply the three sets of HM water electrolysis systems with pure water that meets the requirements, and pure water will be supplemented automatically according to the water level of the water tank through the signal of the water tank, to ensure that the water level of the water tank remains at a relatively constant position (the detection device for the pure water quality is provided at each set of HM device). 3.3.7.6 Control System Apart from some under the local control, a PLC control system is used for the entire equipment. 3.3.7.7 Closed cooling water device The closed cooling water device is used to provide cooling water to three sets of HM water electrolysis equipment and is equipped with the coolers and pumps set up in parallel, and with a cooling water pressure and temperature alarm device as well as automatic supplementary device of water level of the water tank. The device provides the quantity of cooling water l0t/h. 3.3.7.8 Nitrogen System Nitrogen system consists of eight nitrogen cylinders and convergence devices and supplies nitrogen to the system for pressure test, purging and prepressing. 3.4 Thermal Control System The centralized control mode based on stoves, machines, electricity and network is used for a unit, and two units share a unit control room, to monitor and control the units in operation in the control room. DCS is adopted for the
49
thermal control and the remote I/O access DCS system is used for temperature measuring points required to be monitored. The remote I/O or remote control station is used to control the circulating pump room, fuel pump room and air compressor room. Each unit is set up with two large screens; 3.5 Start Boiler Fully automatic SZS type steam boiler is a double-drum longitudinal water pipe boiler. The water pipe boiler is divided into boiler body and economizer two parts, with the entire film type water cooling wall structure, good air tightness and strong anti-knocking, light mainframe, small size in shape, short time for start-up and shutdown and so on. The boiler has a unique single return convection tube bundle structure and reasonable flue gas process, and its tail is provided with a separate economizer, reducing exhaust gas temperature, and avoiding low temperature corrosion to the heating surface and increasing efficiency of the boiler. The boiler is configured with a spring-type explosion proof device, which can release flue gas pressure speedily when the hearth explodes accidentally. The water pipe boiler superheater is safe and reliable, with reasonable layout and strong fuel adaptability, and the pipe wall temperature of the superheater is easily controlled. When the resistance of the superheater system is not big, the high velocity of working substance can cool the superheater pipe sufficiently. The reasonable flow rate of flue gas avoids control of fouling on the pipe and the pipe wall temperature, with small thermal deviation and stable steam temperature. SZS type steam boiler is controlled by PLC and is configured with a PLC, touch screen, program controller, water level controller, load controller and other control, monitoring and display devices. The water level controller is used for controlling proportion or digital influent water of the boiler to ensure that the water level of the boiler is in the normal range; the program controller is used to control and monitor the combustor, to achieve automatic operation in the entire process; the load controller detects continuously the boiler pressure and transmits continuously the pressure signals to the program controller, so that the program controller according to the change in the load makes a timely adjustment of combustion. PLC analyzes and determines signals transmitted from all the control elements, monitors all the control elements, and meanwhile inputs the processing signal into the touch screen, which will display the operation situation of the boiler and control the operations of the boiler. When heavy oil is tested in the SZS type steam boiler, the heavy oil need be heated, and two-stage ignition mode is used, light diesel oil is first ignited and starts and then the heated heavy oil is input. The heat from fuel under combustion is transferred to water of the film water cooling wall in the form of radiation, the other part of heat is transferred to water in the convection tube
50
bundle and steam in the superheated steam tube bundle in the form of convection through high-temperature flue gas, and the flue gas continues to enter the economizer and transfers heat to water in the economizer in the form of convection and finally is discharged into the chimney. The steam process of the SZS type steam boiler is: the processed softened water enters into the heating surface of the economizer and superheated steam boiler through the feed pump, and a small quantity of water supply from the boiler feed pump enters into the superheater and desuperheater through the electric control valve, and then into the economizer. The water temperature after being heated by the economizer rises, water from the feed pipe seat of the upper boiler drum body enters into the upper boiler drum distribution pipe. The boiler is not equipped with a separately centralized sewer pipe, cold water from the lower piece of the convection tube bundle at the low temperature section of the tail falls to the lower boiler drum, the water cooling wall coating the hearth and the convection tube bundle at the high temperature section are the rising pipe, and the steam and water mixture rises to the boiler drum, to establish the natural water cycle through the height difference of water. The steam and water mixture bubble rising to the upper boiler drum is through the internal separator device of the boiler drum, the separated steam through the connecting pipeline enters into the import container, and the saturated steam is heated through the superheater and its temperature rises and then is used for the superheated steam.
4 Model and Parameters of Mainframe and Main Auxiliary Machines

4.1 Boiler Supplier: Shanghai Electric Group Co., Ltd. Model: SG-995/17.3-MXX
Type: subcritically controlled circulation drum boiler, double-arch W flame single hearth, axial combustion, one-time middle reheater, two-stage attemperation, balanced ventilation, open layout, solid deslagging, all-steel frame and entire suspension structure boiler. Model of Boiler Main parameters of Boiler Double-arch W flame, single hearth, one-time middle reheater, mandatory boiler water circulating subcritical steam drum boiler t/h 995 SG-995/17.3-MXX
Type of Boiler
Overheating Steam
Maximum continuous evaporative capacity B
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MCR Rated evaporative capacity RO Steam pressure B-MCR RO Steam temperature B-MCR RO Steam flowB-MCRRO Import exit steam pressure B-MCR Reheating steam Import exit steam pressure RO Import exit steam temperatureB-MCR Import exit temperatureRO steam t/h MPag t/h MPag MPag % % % % 889.1 17.29/17.13 541/541 882.498/736.407 3.53/3.34 3.14/2.98 320/540 309/540 281/273 5.23 0.00 2.72 0.195
Water supply temperature B-MCR/RO Heat loss evacuation of smoke
Heat loss from incomplete chemical combustion Heat balance Heat loss from incomplete mechanical combustion Radiation loss Physical heat loss of clinker Boiler efficiency Consumption fuel Manufacturer Technical Specification for Start-up Boiler Item Rated capacity Rated pressure evaporation evaporation steam inflow Unit t/h MPa of computed
% Kg/h
91.56 126 China y Shanghai Boiler Works, Ltd.
Design Parameter 30 1.6 350 20
Rated temperature Rated temperature
52
Applicable fuel Adjustment mode of fuel Atomization mode Control mode 4.2 Steam Turbine
Light diesel oil, heavy diesel oil Full auto proportion adjustment Steam atomization PLC
Specification for Steam Turbine Body Equipment Name of Item Model Design Parameter N300-16.67/538/538 Subcritical, middle reheat type, high-middle pressure combined cylinder, single axis, double cylinders and double exhaust steam, condensing steam type 300MW 315MW 330MW 3000rmin Clockwise direction from the nose to the generator Three-height, deoxidation Stage 8 1Rgulating stage+11Pressure stage Stage 9 Stage 72 four-lowness and one-
Type
Rated power TMCC working condition TWO working condition Rated rotating speed Rotation direction Number of regenerative stages Number of stages Steam extraction High-pressure cylinder Middle-pressure cylinder Low-pressure cylinder
Through-flow stage of turbine
Rated steam pressure in front of the main high-pressure turbine door Rated steam temperature in front of the main high-pressure turbine door Rated flow of the main turbine Exhaust pressure high-pressure cylinder Exhaust temperature high-pressure cylinder of of
16.67Pa
538 909.3t/h 3.57MPa 320.2 3.21MPa
Rated steam pressure in front of the joint middle-pressure turbine
53
Name of Item door steam temperature in front of the joint middle-pressure turbine door Rated flow of reheated steam Water supply temperature Net heat consumption ratio of rated working condition Rated back pressure Alarm back pressure of turbine Maximum allowed back pressure operating
Design Parameter
538 741.4th 273.3 7900.7 49 Kpa 16.9Kpa 18.6Kpa 20.3Kpa 80 121 571.9 th 6.25kPa 25(designed temperature) 34 average annual water
Tripping back pressure of turbine Alarm exhaust temperature Maximum allowed exhaust temperature operating of
Exhaust steam flow low-pressure cylinder Rated exhaust pressure Cooling water temperature
Maximum cooling water temperature when maintaining the rated power: Height of the low pressure last stage blade Height of the low pressure secondary last stage blade Idle time with all vacuum Idle time without vacuum Maximum load when the main switch is disconnected but not trip due to overspeed Rotating speed of jigger Rated heat consumption Cut-off mode Rotation direction Manufacturer
905mm 479mm 45(min) 20(min) 338.9MW 2.51rmin 7915.3kJ/kW.h 7900.7kJ/kW.h Throttling control, nozzle control Clockwise from the turbine to the generator Shanghai Turbine Co., Ltd.
Technical Specification for Steam Turbo-generator Item Model Design Parameter QFSN3002 Item Idle load Design Parameter 987A
54
Item
Design Parameter Three-phase synchronous turbine generator, Self-static excitation system. Water hydrogen 0.31MPa 353MVA 300 MW 315MW(maximum water temperature of cooler exit is 28) 371MVA
Item excitation current
Design Parameter
Type
Idle load excitation voltage
113V
Cooling mode Rated hydrogen pressure Rated capacity Rated power active
Full load excitation current Full load excitation voltage DC resistor stator coil of
2510A 302V 0.00212/phase 0.209F/ phase
Earth capacity of stator coil DC resistance of rotor coil
Maximum continuous output Maximum continuous output capacity Rated power passive
0.0923
Self inductance of rotor coil First order critical speed Second order critical speed Excitation mode Manufacturer Iron loss of stator Copper loss of stator winding 75: Stray loss Synchronous reactance direct axis of
0.857H
186MVar 0.85(Lag) 50Hz 20000V 3000r/min
870rpm 2380rpm Self excitation Shanghai Dianjichang 435KW
Power factor Frequency Rated voltage Rated speed Frequency Number of phase Number of poles Efficiency Connection mode rotating
50Hz 3 2 98.8 Internal/External YY /Y
816KW 538KW 186
Short circuit ratio
0.6
55
Item
Design Parameter 0.6 B 3400KW
Item Copper loss of rotor winding 75 Mechanical loss Noise
Design Parameter 721KW 707KW 85Db1m away from the shell
Short circuit ratio Insulation grade Total losses Supplier
SHANGHAI ELECTRIC GROUP Co., Ltd.
Note: the cooling water mode is water - hydrogen hydrogen cooled, that is, the stator coil, connecting wires and outgoing line casing are cooled with water internally, and the rotor windings, stator core and ends are cooled with hydrogen. 4.3 Technical Specification for Master Transformer Name of Equipment Manufacturer Model Number of phase Rated Capacity Rated Voltage Rated Current Cooling Mode Connection Section Idle load loss Load loss Idle load current Impedance Voltage Mode of Regulation Voltage 14.0 Load 14.5 Load No. 1 Master Transformer Shenyang Co., Ltd. Transformer No. 2 Master Transformer Shenyang Transformer Co., Ltd. DFPZ-120000/500 Single-phase 50Hz 3120000KVA (550/1.732101.0 /20KV 396/6000A ODAF YNd11
SFPZ-360000/220 Three-phase 50Hz 360000KVA 242101.0/20KV 860/9623A ODAF YNd11
5 Fuel
5.1 Function of Fuel System The function of the fuel system meets the needs for coal of 4x300MW units, and because the size of coal particles of Quang Ninh Project is less than 15mm, the system is not equipped with any small coal room and equipment. Two sets of roll screens are situated at No. TT6 transfer station and are used to filter stones and battens with dimensions of over 100 mm in coal outside the plant and replace the vibrating screen to treat the too wet coal. Coal-fired is shipped by the Employer through the delivery devices to the demarcation line of the plant south of the site and is terminated at No. TT6 transfer station. Beginning with the TT6 station, the coal-fired can be directly sent at No.2 transfer station
56
through a dual-way belt to the raw coal warehouse of the boiler or the dry coal sheds or open coal yard. There are two dry coal sheds, with the total reserves of 68,000 tons, and the open coal yard can provide the reserves of minimum 30,000 tons. Coal can be fed into the boiler and be stored in the coal yard in 24 hours a day. Coal at the coal yard can be fed to the boiler through a dual-way belt. 5.2 Description of Fuel System: Anthracite for burning in the Power Plant is from Hon Gai coal mine in Cam Pha region, Quang Ninh province, and coal-burned through coal transport belt is transported to the Power Plant. A two-way belt is used for the coal transport system, and Stage 1 and Stage 2 in total will be provided with four dry coal sheds, two open coal yards and three stacker reclaimers. 5.2.1 Coal Dumping System Two generating units in Stage 1 have approximately 1.65 million t consumption of coal a year and the total amount of coal in Stage 1 and Stage 2 will be about 3.3 million t/a year. The system through No. 6 transfer station receives coal-burned transported from the coal mine through a two-way belt responsible for by the Employer. The amount of coal transported from No. 6 transfer station to the coal yard or the raw coal warehouse of the boiler shall be 1000 t/h under the normal circumstances, and the No. 6 transfer station is installed with: a coal sampling device, roll screen, reversible belt coal feeder with a belt weighing function, a metal detector on 3A and 3B belt respectively, and a workshop. The workshop is used for unloading coal and can accommodate four people to work, and is equipped with air-conditioning and office supplies. No. 6 transfer station is provided with suitable structure/pulley group and coal feeder which can transfer smoothly coal-fired from the outside belt to the Power Plant. 5.2.2 Coal Storage System The dry coal shed has two stacking places and has a total storage capacity of 68,000 tons of coal. The open coal yard can provide a minimum storage capacity of 30,000 tons of coal. The total storage capacity of all coal yards is 98,000 tons of coal, meeting the consumption of coal-fired for 2 300MW units for 16 days. The reserves of the dry coal shed with 68,000 tons can meet the consumption of 2 300MW units for 11 days. The dry coal shed is provided with a stacker with the output of 1000 t/h and a portal scraper taker the output of 1000t/h. The open coal yard is provided with a bucket wheel stacker with the output of 1000 t/h, a crawler pushing coal machine and tire-type loader. 5.2.3 Coal Transport System Coal-fired for the Power Plant (transported by the belt responsible for by the Employer) is first transported to No.6 transfer station, and then transferred to
57
the coal yard or the boiler coal warehouse. The specification for the belt between No. 6 transfer station and the coal yard or the boiler coal warehouse is width = 1200 mm, operating velocity v = 2.5m/s and capacity = 1000t/h. The belt at 1A/B section is equipped with an unloader that feeds coal to the raw coal warehouse of the boiler. The coal sampling device and moisture detection device at 2A/2B section of the belt is equipped. A belt weigher is provided at 2A, 2B, 3A, 3B, 8 and 9 sections of the belt, a metal detection device and de-ironing separator are equipped with 3A, 3B, 7 and 10 of the belt, and No. 6 transfer station is equipped with a roll screen, with a reversible belt type coal feeder of the weighing device, for the entrance coal sampling system. 5.2.4 Characteristics and Parameters of Coal-burned Properties of Boiler Fuel (Coal) S/ N Ingredient Thermal value High post calorific value Low post calorific value 1 2 3 4 5 6 7 8 Total 1 2 3 4 5 6 7 Total 1 Physical properties Hardness, grindability 45-70 47 Element analysis CAs received basis HAs received basis OAs received basis NAs received basis SAs received basis AAs received basis MAs received basis Car Har Oar Nar Saror Aar War % % % % % % % 46.83-63.75 2.56-2.97 1.66-2.68 0.73-0.86 0.27-0.66 25.48-34.0 5.55-12.0 54.62 2.62 2.09 0.77 0.41 30.49 9.00 100 Industrial analysis Total moisture As received basis External moisture Internal moisture Moisture after drying Fixed carbonAs received basis Volatile component As received basis Ash contentDry basis Ash contentAs received basis War Ws Win Wad Cfar Var Ad Aar % % % % % % % % 5.55-12.0 4.81-9.88 0.78-2.35 0.80-2.41 49.54-63.15 5.82-8.61 28.0-37.36 25.48-34.0 9.00 7.63 1.48 1.39 53.68 6.83 33.5 30.49 100.00 HHV LHV Kcal/kg Kcal/kg 4680-5300 4490-5157 4980 4790 Symb ol Unit Scope data of Design data
58
index 2 Dust coal particle size 0-15 mm +10mm 5-10mm 2.5-5mm 1.25-2.5mm 0.63-1.25mm 0.315-0.63mm -0.315mm 3 Density Characteristics of Boiler Fuel (Heavy Oil) Characteristic value of heavy oil Characteristic Density 15 Viscosity 50 Sulphur content, calculated weight at at Numerical value No.1 No.2A No.2B No.3 Testing method TCVN 6594:200 ASTMD1298 ASTM D445 TCVN67O1:200O ASTM D2622/AS1MD129/ ASTM D4294 TCVN3753:1995 ASTM D97 TCVN2690:1995/ASTM D482 TCVN2692:1995/ASTM D95 % % % % % % % 6.16-17.5 9.89-18.3 15.60-21.71 8.73-13.76 12.36-18.13 6.80-14.45 11.47-31.47 0.92-1.10 14.89 10.02 20.77 1.00 100 10.53 14.22 18.62
0.965 0.991 0.991 0.991 87 180 180 380
by
2.0%
2.0%
3.0%
3.5%
Pour point Ash content %
+12 0.15
+24 0.15
+24 0.15
+24 0.35
Water content, calculated by 1% volume Purity, calculated weight by 0.15%
1%
1%
1%
0.15%
0.15%
0.15%
ASTM D 473
Conradson residue, 6% calculated by weight Flash point 66
16%
16%
22%
TCVN 6324:2000/ASTM P189ASTM D4530
66
66
66
TCVN 66O8:20O0/ ASTM D382S/ASTM D93
59
HHV, kcal/kg LHV, kj/kg
10,000 10,000 10,000 10,O00 40,800Usual
ASTM D4809
D240/
ASTM
6 FGD Unit
6.1 Overview Desulfurization process is limestone - gypsum wet desulfurization process, and the installation is a spray air tower and a boiler is equipped with a tower. The wet mill is used as the limestone preparation system, with 2 sets designed, and the design capacity of a single mill is 100% amount of limestone required under the working condition of BMCR for 2 sets of boilers when the category of coal is designed according to combustion. A flue gas heat exchanger (GGH) is installed. Desulfurization surveillance and control equipment is installed in the ash control building. A set of DCS system is provided to control desulfurization of two boilers and the utility system. The Project now is not provided with a desulfurization wastewater treatment system, and the desulfurization wastewater is directly discharged into the slurry pond of the plant. 6.2 Absorption Tower Flue gas from the lower part the absorption tower enters into the absorption tower and flows to the top, and contacts with suspended substance that flows reversely and contains adsorbent. Washing fluid relying on the circulating pump enters into the upper part of the absorption tower through the circulating slurry pipeline and the spray layer, and slurry through the spray nozzle forms small droplets with specific diameter and falls to the cyclic oxidation reaction trough of the absorption tower under the action of gravity. These droplets in the process of falling absorb acidic components in flue gas, such as SO2, SO3, HF and HCl. And while SO2 and acid gases in flue gas are eliminated by the absorption tower, flue gas will be evaporated by water from the circulating slurry and reaches the saturated steam state, and will be cooled to the adiabatic saturation temperature. In order to prevent the circulating slurry from depositing, the absorption tower is equipped with three agitators. In addition to the stirring role, the agitators can also oxidize the cloth gas in air. The Project is designed with a large enough slurry pond to meet the requirement of formation of good gypsum crystals (CaSO42H2O). The circulating slurry in the absorption tower is sent by the gypsum discharged pump to the ash slurry tank. 6.3 Demister A two-stage demister is equipped at the upper part of the spray layer in the absorption tower to separate slurry droplets accompanied with flue gas flowing upwards. The separated slurry droplets relying on gravity return directly to the absorption tower. Slurry droplets easily attach to the leaves of the demister,
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which must be regularly washed, to ensure the unimpeded flue gas passage of the demister. At the same time, the washing water of the demister is supplied to the most of the water evaporated by flue gas. Fresh limestone slurry must be continuously added into the absorption tower system to supplement the consumed limestone in the absorption reaction. At the same time the relevant by-products (mainly gypsum) must also be drained to control the concentration of the solid matter of the absorption slurry. 6.4 Oxidation Air 2 absorption towers are equipped with three sets of oxidation fans in total, which are Roots fan, wherein 2 sets are in operation and 1 is standby. Oxidation air is input into the slurry tank of the absorption tower, and the agitators will spread bubble evenly throughout the slurry tank. Such oxidation gas sent will be well distributed into the slurry, in order to oxidize sulfite into sulfate. 6.5 Reheat System of Flue Gas In the process of desulfurization, flue gas is cooled by the circulating slurry to adiabatic saturation temperature. Flue gas before entering the existing chimney is re-heated, in order to prevent the formation of condensation water in the chimney. The major equipment of the reheat system of flue gas includes gas/gas heater (GGH) and its ancillary equipment. In order to take advantage of heat the untreated flue gas from the boilers, a rotary gas/gas heat exchanger is adopted. The temperature of flue gas is improved by net flue gas that is through the device at the exit of the absorption tower, increasing the uplift buoyancy of flue gas in the chimney and the exit and preventing condensation water in the chimney from generating the corrosion phenomenon to the maximum extent. The setting of the gas/gas heat exchanger increases power consumption and maintenance costs of the desulfurization equipment, but it is necessary. The principle of the gas/gas heat exchanger (the same as the boiler air preheater): two flue gas flows move in the opposite direction mutually. The gas/gas heat exchanger works in a poor working condition, so it has a higher and more stringent requirements for sealing, leakage, contact surface anti-corrosion of flue gas, and purging and others than the boiler air preheater. To minimize the volume of the untreated flue gas leaked into the side of the clean flue gas, a controllable leakage prevention system is set up, that is, a heating element that takes a certain amount of the net flue gas after the heat exchange to fill between the original flue gas side and the net flue gas side. As the sealing air pressure is higher than the side pressure of the original flue gas, the original flue gas is prevented from flowing to the net flue gas side at most.
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The reheater is equipped with a set of cleaning device to remove dust on the heating surface, and steam and pressure water are used as the removal media of the cleaning device. Under the normal circumstances, purging is conducted by steam, when it runs for a certain time (initially set for five days, or according to the pressure decline at the import and exit of GGH), and high-pressure water will be used for cleaning. After the system stops, low pressure water shall be used for washing. 6.6 Booster Fan System In order to compensate the pressure loss resulted from the absorption towers, flue gas reheater and flue, the booster fan is adopted, which is installed at the upper reaches of the original flue gas side of the flue gas reheater and is a fixed-blade adjustable axial-flow fan. 6.7 Flue System A main flue is connected between the desulfurization flue system and the exit of the induced draft fan of the boiler. The section between the main flue and the chimney is equipped with bypass flue gas baffles to ensure the normal operation of the boiler and generating units when the desulfurization device fails. FGD is equipped with a separate flue system, including: the original flue gas flue, which begins with the main flue of the untreated flue gas baffles through the booster fan and GGH, until the import of the absorption tower, the net flue gas flue, which begins with the exit of the absorption to GGH, and then returns to the main flue to the chimney with the net flue gas baffles on the ends. Part of the original flue and the entire net flue are done with anti-corrosion (glass flake) lining protection. The flue system is provided with double-layer baffles. The baffle sealing system will send sealing gas to these baffle, realizing zero leakage. 6.8 Limestone Storage and Transportation, Grinding and Slurry Supply System Description of Limestone System: Limestone unloading and supply to FGD Plants, the Employer is responsible for the provision of limestone with diameter of 5 to 20mm particles, which are shipped to limestone unloading station near the power plant with 100-200T ships. The units with 4x300 MW Capacity have limestone consumption of about 120,000 tons per year by calculation. Limestone unloading begins with the limestone unloading station, and limestone will be unloaded from the ships of the Employer and transported to the limestone shed shared by four sets of units, and then further transported to the lime warehouse. Limestone supply system includes but not limited to the following equipment: a scoop rotating crane arranged on the limestone pier commonly used by the four sets of units, with the output of not less than 70 T/H and the Volume of grab unit of 2 m3, a limestone shed which reserves is about
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6,000 tons and can supply limestone to four sets of units under the working condition of BMCR to operate with the maximum sulphur coal content for burning for about 12 days, and a set of belt transport device meeting the demand for limestone for four sets of units. Beginning with the limestone station, the belt through the limestone shed to the limestone warehouse is provided with the specification: width = 500 mm, running velocity v = 1.0m/s and capacity = 60t/h; the transport belt for all the sections is a single-way belt and the specific information is shown in the related flow chart. The limestone meeting the design requirements is shipped to the production site with trucks and enters into the downstream equipment through the discharge bucket, and the dust during discharging and near is minimized with a set of dust removal system. Limestone gravel at the bottom of the discharge bucket is transported through the vibrating feeder to the ripple baffle change belt transporter and to two limestone warehouses. The entire transport system is designed based on the closed negative pressure and can reduce flying ash to the minimum. The bottom of each stone storage warehouse is provided with a weighing belt feeder, which sends limestone to the vertical roller mill. The feed inlet of the mill is equipped with a wind locking device. The vertical roller mill is a machine to grind materials based on the relative movement of the grinding rolls and abbrasive wheels. When materials are in the operating area of the roll grinding device, the bulk materials will be crushed, small materials after being pressed form a layer of material bed and particles rub and shear mutually, so that the corners and edges are peeled off and crushed, and thus it belongs to the material bed grinding. At the same time in the grinding process, the hot gas in the mill through the wind ring can dry materials containing water and thus it also belongs to the wind-sweeping mill, which is a high-efficiency separator that can carry the crushed materials at the wind ring place of the edge of the abbrasive wheels with the gas at a certain speed to the upper part; under the effect of the separator rotor, the qualified products are discharged out of the mill with the air flow, and the separated coarse particles relying on gravity return to the abbrasive wheels for grinding again. Material particles move in a reciprocating manner for 20 to 30 times every minute, the materials are repeatedly ground, dried and separated until meet the fineness requirements of finished products, and the qualified products are sent to the cloth bag dust precipitator at the upper part of the limes powder silos with the cyclic wind discharging power. The finished products are sent by the power bucket of the cloth bag dust precipitator through the impeller feeder to the lime powder silos. The bottom of the power silos is equipped with an impeller feeder and spiral weighing transporter, which sends limestone powder to the limestone slurry box for slurry preparation.
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Limestone slurry pump sends limestone slurry to each absorption tower. 6.9 Flue Gas Desulfurization Device is also installed with: Process water system, industrial water system, air system for instrument, auxiliary steam system, and emptying, emission and other auxiliary systems together with the equipment and systems above complete the task of flue gas desulfurization.
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Volume B
1 Overview of boiler
Boiler Operation
Boiler is one of the very important equipment in the thermal plant, and boiler house covers the biggest and spacious area in the power plant. The boiler body is the highest facilities, among which the stack is the tallest building, which is normally in more than 200m in the modern and large-scale thermal plant.
The definition and composition of boiler
It is heat exchanging equipment which utilizes the chemical energy released from the burning of the fuel (solid fuel, liquid fuel and gas fuel) into thermal energy, and transfers the hot water or steam. The boiler comprises the "pot" and "furnace". the "pot", which means the steam and water flow system, including drum, headers, water wall and convection heating surfaces, etc; is the heat absorption part of heat exchanging equipment; the "furnace", which means the combustion space of fuel and flue gas and air flow system, including furnace, convection flue gas duct and chimney, etc, is the heat release part of heat exchanging equipment.
Types of boiler
The boiler is classified in the various ways:
3.1 According to the structural style, it is classified into pot shell boiler ( fire tube boiler), water tube boiler, and fire and water tube boiler 3.2 According to the different purpose, it is classified into station boiler, industrial boiler and living boiler, etc. 3.3 According to the capacity, it is classified into large-scale boiler medium-size boiler and small-scale boiler. 3.4 According to the steam pressure, it is classified into low pressure boiler, medium-pressure boiler, high-pressure boiler and super high pressure boiler, etc. 3.5 According to the types of fuel and energy, it is classified into coal-firing boiler, oil-fired boiler, gas-fired boiler, waste heat(afterheat)boiler, etc.
3.6 According to the mode of fuel burning in the boiler, it is classified into grate furnace, fluidized bed furnace and chamber furnace. 3.7 According to the flow mode of media in the vaporization system, it is classified into natural circulation boiler, associated circulation boiler (i.e. forced circulation boiler), once-through boiler and combined circulation boiler, etc. 3.8 According to the state of media, it is classified into steam boiler and hot water boiler.
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Layout for typical W type flame boiler
Abstract for W flame boiler
The type of burner in the boiler mainly includes: direct current direct flow burner rotational flow burner, and W-shaped flame burner, etc. 5.1 The W-shaped flame boiler has the different structure comparing with that of traditional coal-firing boiler. Its chamber comprises the lower chamber and upper chamber. The chamber is 80%-120% deeper than the burn up chamber. The top of front goose neck constitutes the arch. The nozzles for coal fine flow and secondary air are fixed on the arch (nozzles for coal fine flow and spent air are only fixed on the arch in some W-shaped flame boiler). The coal fine flow from the lower nozzle spreads after firing, and backfolds and turns up after meets the tertiary air in the lower part of chamber, and goes up along the center axis of chamber, thus W-shaped flame is generated, and combustion product flow rises and enters the burn up chamber.
5.2 W-shaped flame boiler generally comprises slag tap boiler and dry ash extraction
boiler. Practice shows that the biggest problem in the W-shaped flame slag tap pulverized coal-fired boiler is the high emission of NOx, and serious high temperature corrosion on the water wall tube, and long maintenance time, poor performance of peaking, etc, thus normally the profile of slag tap boiler will not be adopted: W-shaped flame, dry ash extraction, pulverized coal-fired boiler can stably burn the anthracite and lean coal of Vdaf = 6%20%, or even burn the anthracite, Vdaf = 4%, therefore it is the commonly recommended type of boiler.
Abstract for the boiler in Vietnam Guang Ninh Thermal Plant
6.1 The boiler body will be designed by Alstom, who will provide the technical support for commissioning and performance test; and Shanghai Boiler Works, Ltd. will responsible for the manufacturing. The boiler is in bi-arch type, W-shaped flame, single furnace, once intermediate reheating, forced boiler circulation, sub-critical drum boiler. Two units are equipped with one startup boiler, which is used to provide the startup steam at startup. 6.2 The coal designed for the boiler is anthracite, which comes from CAM PHA mines and HON GAI mines, Vietnam. 6.3 Firing system: The mode of coal fine transferred by hot air deliver is adopted in the firing system. 16 pulverized fuel feeders, one for two in dual direction, and 32 burners are equipped in boiler. The capacity of the coal burner is to fire the design coal for 100% BMCR. The fuel oil for startup and stable firing adopts the heavy oil, while in accordance with Standard TCVN 6239-2002. The two-stage ignition is adopted for boiler. The electric spark from high energy igniter will ignite the heavy oil gun, and later will ignite the pulverized coal, and the oil gun will be atomized by the oil gun. 2*5000t oil tanks, 2 oil unloading pumps, 2 AC/DCQ oil feed pumps in 100% capacity, 1 sump pump and 1 sewage pump are installed in the project. The fuel oil system is in the single header circulation for supply and return, and oil supply line and oil return line are fixed to boiler burners. 67
6.4 Oil burner: 8 heavy fuel oil(HFO) burners are equipped at each goose neck, namely 16 burners are equipped in each boiler. The auxiliary steam at the static pressure 5.25 bar (g) is used to atomize the HFO, and used to cleaning the burner. The heavy fuel oil is ignited by the high energy igniter, and special flame detector is provided for each HFO burner. The cooling air is provided to the burners and flame detectors through two independent loops. When stops, the oil burner withdraws about 330mm from burner nozzle, in order to avoid the influence of boiler radiation ( and to avoid the burning loss of oil burners) The total oil combustion capacity (LHV basic value) is 30% BMCR fuel heat input, while 30% BMCR burning capacity can be obtained with 12 burners in service (two burner out of service in each goose neck) the turndown ratio of burner is 1:5. J11 type oil burner is adopted. 6.5 Flue gas and air system, pulverized coal system The mode of vacuum pressure, balanced draft is adopted for flue gas and air system. The flue gas enters the FGD from ESP, and then into atmosphere, or to atmosphere directly through FGD bypass. The axial fans are adopted for ID fan & FD fan, while the movable blade in FD fan is adjustable, and the fixed blade in ID fan is adjustable. Pulverization system is in storage type, dry and pulverization system by flue gas, ventilation in negative pressure. Two single-in and single-out BBI steel ball coal mills are provided in each boiler, PA fan (pulverized fuel exhauster) adopts the centrifugal fan. Spent air is filtered by the bag-type dust collector, after the coal dust is collected, and then the spent gas is discharged to atmosphere through spent gas fan. 6.6 The ash removal dregs and ash yard: The dry ash extraction is adopted, and ash and dregs in the boiler bottom goes through slag breaker, and hydraulic ejector, and then is discharged to dregs sludge pond. The fly ash collecting from the air preheater, economizer and ESP will be transferred to large-scale ash storage (2 storage, 2500m3 each); and then the dry ash, after mixing with ashy water, is pumped to the dregs sludge pond, and then is sent to ash yard by the sludge pump (the multipurpose use for the dry ash is maintained at the same time). 6.7 Dedusting and desulphurization system: 4 fields ESPs are adopted. 1 number dual steel shell chimney in 200m height is installed for this project. The flue gas desulphurization device of 100% capacity, which will be constructed at the same time, adopts forced oxidized limestone wet desulphurization process with calcium sulphate, and flue gas heat exchanger (GGH). 6.8 The compressed-air system: It is all considered based on the less oil lubrication, totally 3 air compressors of 50% capacity are installed. 6.9 Safety valve: The boiler is provided with spring type relief valve, produced by Crosb company, USA, 68
totally 8 number; they are fixed at: 3 at the drum, 1 on the outlet of superheater, 2 on the inlet of reheater, 2 on the outlet of reheater; and one electromagnetism relief valve (ERV) is provided at the outlet of superheater, USA VTI make, provided in package by Crosby company, USA. The maximum evaporation capacity of boiler is 995t/h, and total release of safety valve on drum is 881.796t/h, covering the 88.62% of maximum evaporation capacity, and the release of safety valve at the superheater is 153.86t/h, covering 15.46% of maximum evaporation capacity; the combination of total release of safety valves on drum and superheater is 1035.656t/h, covering 104.09% of maximum evaporation capacity. The maximum flow of reheat steam is 848.6t/h, and total release of safety valve on reheater inlet is 512.94t/h, covering 60.45% of maximum flow of reheat steam; the total release of safety valve on inlet of reheater is 379.157t/h, , covering 44.68% of the maximum flow of reheat steam; and total release of safety valve on the inlet and outlet of reheaters is 892.097t/h, covering 105.13% of maximum flow of reheat steam. The release of power relief valve is 166t/h, covering 16.68% of the boiler total evaporation, and its release is not included into the release of safety valve.
7 The introduction on function, configuration and operation for boiler equipment and systems.
7.1 7.1.1 Oil burner system Function of system
The oil burner introduces the fuel into the furnace, which warms the boiler and performs the ignition of coal dust. The oil burner adopts the high energy igniter for ignition; and air is introduced through damper in order to accelerate the combustion. 7.1.2 System configuration
In each basic system(FBA, FBB, FBC, FBD, FBE, FBF, FBG, FBH, FBI, FBJ, FBK, FBL, FBM, FBN, FBO, FBP), the burners provided are all fixed on the arch of boiler (facade or back). One oil burner system mainly includes: 1) One flame detector system(BE 001)and related amplifier(BS 001), which are fixed inside the local control panel, are used to monitor the burning of oil burners. One electronic igniter(004 AL), which includes: One high-energy ignition transformer(TR 004) One ignition electrode One electrical-driven actuator(UV 004),which is used to insert the burner, the electric igniter is controlled by the electromagnetic valve(UY 004), and electric spark is generated between the electrode and ground wire, in order to ignite for the oil burner. This electrode is provided with 1300 V 50 Hz voltage by the ignition transformer. 69
2) 3) 4) 5)
6)
One auxiliary atomized fuel gun(005 LA), which is used to atomize the fuel oil. It includes: Description on logic control loop
7.1.3
Enables for start of oil burner, only when all the following conditions are enabled, can the oil burner be put into single operation: a) Push ON button b) The boiler universal safety storage is set up. c) Normal/ maintenance selector switch is not on "maintenance" position d) The duration of withdrawing of high energy igniter (limit switch ZSL 004) exceeds 3 minutes e) Fuel universal safety valve is opened(Limit Switch FPO ZSH 014) f) Cleaning steam valve is closed(Limit Switch ZSL 002)
g) The fuel pressure is correct Start-up operation When all these conditions are satisfied: - If related PC burners are not put into service, then close the related damper by energizing the closed electromagnetic valve(FE* UY 003). - Put the high energy igniter into operation condition. - After the igniter is put into service (limit switch ZSH 004), the command for insert of oil fuel gun will be given. - Once the fuel gun is inserted, the fuel supply loop will be opened. After 15 minutes after open of fuel supply loop ( limit Switch ZSH 006), the fuel flame test procedure can be considered, and regard the oil burner as being put into service. All the conditions for close of oil burner If any of following conditions is satisfied, the oil burner will stop: a) The boiler universal safe rules is not set (please refer to basic system FSE) b) Fuel oil pressure low than minimum pressure (pressure switch delays for 5 seconds) c) The fuel universal safety valve is at close position(limit switch) The special condition of close of one burner If one of following conditions is satisfied, the related oil burner will stop: The related combustion air damper is not at open position ( limit switch FE * ZSH 003), and the regulation can only be made 20 seconds after the burner is put into service. 70
a) The conditions for maintenance of oil burner, which is required for the flame detection is not satisfied (single scan). b) Cleaning steam valve is closed(Limit Switch ZSL 002). c) Fuel oil filling valve and atomization valve are not at open position ( limit switch ZSH 006 and ZSH 001). This instance can only be considered 20 seconds after the command for the related burner operation is given. d) The oil gun is not at insert position ( limit switch ZSH 005) e) Normal operation/ maintenance selector switch is not at "maintenance" position f) The atomizing pressure is too low within 50 seconds.
g) The oil burner is not put into service 60 seconds after the command for oil burner startup is given. 7.2 Coal dust burner
7.2.1 Function of system The coal dust is ignited by fuel oil burner. nozzle is also participated the burning. 7.2.2 System configuration The coal will be provided by two same coal dust systems to coal burner. Each coal dust system includes: 7.2.2.1 7.2.2.2 7.2.3 7.2.3.1 Coal dust supply system Primary air system Operation Start up the coal burner "group " The secondary air surrounding the coal dust
If the corresponding fuel oil burner is in service, the coal burner group can be open manually. The coal burner group can be put into service by opening the primary air damper, and open the coal dust feeder and combustion air damper, according to the related requirements. 7.2.3.2 Close the coal burner "group "
Close the primary air damper and secondary air damper (except the corresponding FO burners are in service) by tripping the corresponding pulverized fuel feeder, and close the coal burner group. 7.2.4 7.2.4.1 Logic control loop Sequence of coal burner startup
Startup conditions 71
a) b)
The boiler universal safety memory is set up (refer to subsystem FSE) The commensurable fuel oil burner is checked (single monitoring), and boiler load is sufficient. The corresponding level of coal dust silo shall not be too low (coal level switch FMA or FMB LSLL 006 A to P). Primary air pressure shall not be too low(from transmitter FSA PT 060A/B/C) Sequence of coal burner trip
c)
d) 7.2.4.2
Trip conditions Boiler main fuel trip:The conditions for maintenance of fuel oil burner, which is verified and defined by the burning monitoring system are not met or boiler load is too low; b) The corresponding level of coal dust silo is too low (coal level switch FMA or FMB LSLL 006 A to P). c) Primary air pressure low(FSA PT 060A/V/C). This operation will be delayed for 5 seconds; d) The pulverized fuel feeder is in service, and the corresponding primary air damper is not open. e) The power is not applied to the pulverized fuel feeder. Pay attention to this condition 30 seconds after the command for open is given. f) The corresponding secondary air damper is not opened. Pay attention to this operation 2 minutes after the command for open is given. g) If the fast load reduction occurs ( auxiliary power and turbine trip), four burners FED FEP, FEL and FEB shall trip. h) If the fast load reduction occurs ( auxiliary trip), eight burners FED, FEJ, FEP, FEC, FEL, FEG, FEB, and FEM shall trip. 7.3 7.3.1 Induced air system Function of system
The ID fan is used to remove the flue gas from the outlet of boiler and send them to chimney. 7.3.2 System flow
Through the outlet of furnace, the flue gas goes through following heat exchangers Low temperature heater; Medium temperature superheater High temperature reheater 72
High temperature superheater Low temperature superheater Economizer
Two same loops are provided at the outlet of boiler (in the left and right), each mainly includes: One rotary type air heater;
One ESP; One ID fan (001 ZV) driven by motor(001 MO) One air feeding cut-off damper (UV 001)
Two loops A and B meet only at the flue gas desulphurization workshop and prior to chimney. 7.3.3 Operation
ID Fan start-up Startup condition a) Prior to startup of fan, in order to avoid the too low furnace pressure, there must be one draught free circulation passage between air inlet (upstream of FD fan) and furnace. Therefore, the following components must be opened. b) c) d) The combustion air damper at the burner; At least one of the FD fan cut-off damper; The inlet blade of corresponding FD fan;
The corresponding air preheater must be in service. The corresponding ID fan impeller fan impeller must be in close position. The cut-off damper for corresponding ID fan must be closed ( limit switch UV001 ZSL 001).
ID Fan trip Trip conditions a) Boiler main fuel trip. If the boiler trips for more than 20 second, and if the furnace pressure is too low(FTO PSLL 001),ID fan will trip The corresponding ID fan trip Two minutes after the charging of the ID fan motor, the cut-off damper for air feeding is not opened ( limit switch ZSH 001). The delay of two minutes shall be adjusted; The corresponding air heater is not in service 73
b) c)
d)
e) f)
The fan has big vibration(detector VT 001) The temperature of one of bearing in the corresponding ID fan overhigh (taken by TE 001 A/C) The combustion air passage is not set up; There is electrical fault with the motor of the corresponding ID fan. Air supply system Function of system
g) h) 7.4 7.4.1
It is to provide the secondary air for burners and tertiary air for furnace. 7.4.2 System configuration
Two same loops are provided on one boiler: subsystem FCA in the left and subsystem FCB in the right. The description on FCA system is as follows: The loop mainly includes: - 1 fan with dual inlet vane(001 ZV)and 2 silencers (001 ZI, 002 ZI)driven by motor(001 MO), and 1 electrical-driven damper (UV 001) fixed at the outlet of FD fan - One cold air passage fixed between right and left sides, which is isolated by the pneumatic-driven damper (UV 002). When necessary, the passage can provide the seal air loop for soot blower, (in order to avoid the flue gas returns to soot blower); - 1 air preheater - 1 regenerative air preheater with related damper; -1 hot air balance air passage;
- 2 bellows,each is provided with 3 air compartments(=2x3), which leads to burners with long-distance pneumatic control damper(PCV 11A,PCV 11B, PCV 11C, PCV 21A, PCV 21B and PCV 21C)and combustion air flow measurements (three way sensors); - 2 hot air system (hot air inlet) used for coal milling system; - 4 loops for lower tertiary air system with pneumatic control damper(PCV 014, PCV 024)(one in the upper, the other in the lower)and upper tertiary air system with pneumatic control damper(PCV 015, PCV 025) - 2 loops (one in the front, the other at the back) used for the micropowder coal burner, on which side, 4 burners are provided; and on each burner one manual damper is fixed; the damper will be regulated in the trial run. 7.4.3 Operation 74
Start of FD fan Starting conditions: a) b) c) d) Related ID fans are in service; The related air preheaters are in service The related inlet vane is shut(limit switch ZSL 051) The related air outlet damper is shut(limit switch ZSL 001).
Trip of FD fan Trip conditions a) Boiler main fuel trip. If boiler trips after five minutes, the FD fan will trip under extremely high pressure of chamber (FTO PSHH 001), Related ID fans trip; Two minutes after the charging of the FD fan motor, the outlet damper is not opened ( limit switch ZSH 001). This operation will be delayed for 5 seconds; The related air preheaters are not in service Fan has overhigh vibration( transmitter VT 001), the operation will be delayed for 10 seconds. The temperature of one of bearing in the corresponding ID fan is overhigh (taken by TE 001 A/C) There is electrical fault with the motor of the related FD fan. Primary air system Function of system
b) c)
d) e)
f)
g) 7.5 7.5.1
It is to provide the air to transfer the coal dust from PC silo to burner. 7.5.2 System configuration
The system mainly includes:

-
2 PA fan(010 ZV, 020 ZV), with inlet vane and silencer(010 ZI, 020 ZI), driven by HT motor(010 MO, 020 MO) 2 electrical driven dampers(UV 010, UV 020) on the outlet of fan; 2 bleed-steam air preheater
2 regenerative air preheaters with cut-off damper Bellows
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Start of PA fan Starting conditions: a) b) c) d) The related ID fans are in service The related regenerative air preheaters are in service The related inlet vane is shut(limit switch 60 A or ZSL 60 B) The related air outlet damper is shut(limit switch ZSL 10 or ZSL 20).
Trip of PA fan Trip conditions a) b) c) d) e) Boiler common safety devices The related ID fans are not in service The related regenerative air preheaters are not in service The fan has overhigh vibration(detector shown as VT 010 or VT 020) The temperature of one of bearings in the corresponding FD fan is overhigh (taken by TE 010 A/C or TE 020 A/C) Two minutes after the start command is given, one or two related air outlet dampers is not opened ( limit switch ZSH 010, ZSH 020 or FRA ZSH 01 B) Electrical fault with PA fan Pulverized system Function of system
f)
g) 7.6 7.6.1
It is used to pulverize, dry and transfer the coal dust to coal dust silo. 7.6.2 System configuration
Two pulverization loop systems are provided for each boiler, namely FMA and FMB, which mainly includes: - Raw coal supply system - Hot air supply system - Ball mill and ancillories - The coal dust supply and coal dust feeding system - Exhaust air system The flow diagram of system configuration is as follows:
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7.6.3
Operation
System start-up - Lubricating oil system for ball mill starts. - The exhaust air system (air exhaust fan and bag filter) is in service, and fan is running at lowest speed and produces the vacuum pressure in pulverization system. - Coal dust feeding system is in service. - The flue gas pumping loop setup. put into service. The separation temperature control loop is
- When the temperature is proper, start up the main motor and ball mill. - Coal feeder is operated at primary speed. When the boal feed is filled with coal (the sound of coal feeder is normal), all the control loops are put into normal operation. System is in normal operation When the pulverization system is in service: - The air exhaust fan is in service, and the delivery is stable. 77
- The coal dust fan is in service, and related cut-off dampers are opened. - The power is applied to the main motor of coal mill, and the lubrication system is put into service, and seal fan with drive gear guard is in service. - The cut-off damper on the suction lead of flue gas is opened, and outlet temperature of coal mill is regulated through secondary air regulation damper. - The coal feeder and governor gear are in service. Stop - Through the medium of automatism/manual control station slowdown coal feeder velocity and delivery, till minima. - To stop the coal feeder; after the coal dust is discharged completely from the coal mill (which takes 5-10 minutes), stop the main motor and lubrication system. - Stop the coal mill motor. - The secondary air damper at the flue gas inlet is closed and flue gas inlet damper is closed. - The coal dust preparation system stops, and then stop the exhaust air system. 7.7 7.7.1 Drum and superheater system(primary system) Function of system
This system is to produce the steam in the proper pressure and temperature and make them adaptable to the needs of turbine. 7.7.2 System configuration
The system mainly includes: 7.7.2.1 7.7.2.2 7.7.2.3 7.7.2.4 7.7.2.5 Feed water system Economizer Boiler drum Water wall-boiler circulating system Superheater
Encasing superheater Superheater LTS (low temperature superheater), ITS ( intermediate temperature superheater), HTS(high temperature superheater) 7.7.2.6 7.7.3 Drainage flash tank and continuous blowdown vessel Operation
78
System start-up If necessary, open each drain valve to open the continuous blowdown. Close the feed water control valve( FCV 052) and matched feedwater cut-off valve ( UV 019) , start the feed water control valve ( FCV 52 D) and open matched feedwater cut-off valve( ( UV 020A, UV 020B), in order to control the water level in drum. Open the economizer recirculation valve (UV 001). Close the water spraying valve (UV 053A, UV 053B, UV 054A, UV 054B) and control valve (TCV 053A, TCV 053B, TCV 054A, TCV 054B). Open the boiler cut-off valve (UV 004A) completely, or not close the high pressure by-pass valve ( FCV058) completely. Stop Except the economizer recirculating cut-off valve, close all the automatic valve and control valves. Close the air vent manually, if a long shutdown is foreseen, open the nitrogen injection valve for boiler. Close the main feedwater valve and cut-off valve, start the feed water control valve, in order to control the water level in drum. 7.8 7.8.1 Reheater system(secondary system) Function of system
This system is to regulate MP steam as per the requirements of turbine. 7.8.2 System configuration
The steam coming from the high pressure cylinder of turbine will combine with that coming from the high pressure by-pass of turbine, and then is sent to reheater after being reduced its temperature at each side. The water spraying loop is provided with: Check valve (YV 001) Two electrical-driven check valves(UV 055 A, UV 055 B) Two attemperation control valves(UV 055 A, UV 055 B)
Reheater includes: One low temperature reheater, vertical and radial type ( wall-installed type heat exchanger); One high temperature reheater, vertical loop type;
The reheater inlet cool steam-return line is provided with drainage loop, on which the hand valve is provided (HV 015) and electrical-driven check valve (UV 002). 7.8.3 Operation 79
System start-up Open the exhaust valve on outlet of reheater Close the cut-off valve and control valve for water spraying.
Stop the system All the automatic valves and control valves are closed. 7.9 7.9.1 Oil gun and igniter cooling air system. Function of system
This system is to provide the suitable cooling air flow to each oil gun (totally 16 numbers) and each igniter (totally 16 numbers). The operation cautions are related to PID F0021. 7.9.2 System configuration
This system comprises following equipment: a) Fans( 010 ZV, 020 ZV )driven by 2 motors (010 MO, 020 MO) b) 2 cut-off dampers(UV 010, UV 020) and related valves(UY 010, UY 020) c) dual coil electromagnetic
1 pressure switch (PSL 002), which is used to measure the low pressure in the loop; Grating in the gas duct which are used to provide the air to 16 number oil guns and 16 igniters.
7.10 Air preheater 7.10.1 Function of system
This system is to preheat the combustion air and primary air with the consistent and well-burnt temperature, and cool the flue gas leading to the chimney, in order to increase the boiler efficiency. 7.10.2 System configuration
This device including 2 regenerative air preheater, 1 air preheater installed on the left side (basic system FRA), and another one installed on the right side (basic system FRB). 7.10.3 Operation
7.10.3.1Normal operation of system During the normal operation, two air preheater will run together with normal motors, and the cut-off damper for secondary air are kept open all the time. If the corresponding PA fan is in service, then open the outlet damper of primary air. 7.10.3.2Stop When the air preheater stops, its related outlet air damper will close, so that the related ID fan will trip, and isolate the air line leading to ID fan outlet damper. 80
7.11 Boiler water circulation pump and its cooling system 7.11.1 Overview The boiler unit water circulation system is designed on the basis of two out of three circulating pumps in service for full load operation, the rest one is at standby. If one set of pump is in service, the boiler load must be reduced to 60% of BMCR (boiler maximum continuous rating), namely continuous rating is kept under 60% BMCR, on which condition, one set of pump can be put into service; if the entire circulating pump stop, the boiler is not permitted to be in service. The cooling system for the boiler water pump motor comprises high pressure pipe and low pressure pipe. 7.11.2 Initial filling and exhaust of pump Prior to connecting all the cooling water pipes, filling and cleaning pipes, and high pressure side of pump cooler with the circulating pumps, foreign materials, such as scale, welding slag inside shall be flushed away completely, in order to prevent any foreign materials entering the pump motor. It is recommended that acid cleaning shall be performed on the high pressure cooling water pipes, which connects with the pump, before the pipes are connected with pump. In order to remove the possible air pocket, sufficient care shall be taken to remove the air inside the pump, while performing the water filling into the pump, Fill the water from the bottom of motor slowly, with the maximum filling rate 2.5l/m. 7.11.2.1 Preparations prior to pump startup Following conditions must be met prior to pump startup: a) b) Confirmed that water is filled completely and air is removed. Confirmed that valves (43)(50)(51)(55)(56)are opened, and flow of cooling water is as per standard. If the pump is started under hot stand by condition, the valves (11) (11a)shall be opened. To see if the outlet temperature and trip value of motor cavity are correct, and see if all the instruments are in good performance, and ensure the temperature difference between the header and pump shell shall not exceed 56. To check the differential pressure transmitter, and confirm that the pump control system is put into service and functions properly. Confirmed that insulation properties of motors are in accordance with standards, and power voltage is normal. Boiler water level is at high level.
c)
d)
e)
f)
7.11.2.2 Start of pump a) Confirm the pump outlet valve (10), valve (11, 11a) and lower pressure cooling 81
water valve (43)(50)(51)(55)(56)are all opened. b) c) d) e) f) Check all the items listed in the Preparations for pump startup. The drum is at high water level The differential temperature between the pump shell and header is within 56. Close the by-pass valve (11, 11a) after the startup of pump. After the same boiler water pump stops, restart interval shall exceed 10 minutes.
7.11.2.3 Stop of pump 1) Boiler is at hot conditionpump stops for hot standby Stop motor b) Keep the outlet valve (10)and lower pressure cooling water valve (43) (50) (51) (55) (56)all at open. c) Open the by-pass valve (11,11a). 2) Boiler at cold condition--pump is at the cold stand by condition a) Keep the outlet valve (10) and low pressure cooling water valve all at open. b) If the pump stops for quite long time, and the water is filled inside the pump, the check shall be performed regularly and start of stand by pump for at least 10 minutes per month. 7.11.2.4 Drainage for pump a) If the drainage from pump is necessary in purpose of check, boiler shall be shut down and the drainage from boiler shall be performed firstly. Only after the boiler is cooled and the boiler water is drained, can the drainage from pump and motor can be performed. The drainage from the drainage pump shell shall not be performed through the motor cavity. Operational check
b)
7.11.2.5 a)
Current
The current shall be stable, and is within the limit specified in the manufacturer's manual. b) Insulation resistance
The insulation resistance of winding, which varies according to the temperature, shall be measured at the cold condition, (water temperature is at 20), and the inside of junction box shall be kept dry. The resistance shall not be lower than 200 megohm. c) Temperature of motor cavity 82
Under normal condition, the outlet temperature of motor cavity, shown by the thermometer (37) and temperature indication switch (7), shall be lower than 60, Alarm activates when the temperature reaches 60, at this moment, and the following possible cause for high temperature shall be checked. If the temperature continuously rises to 65, the pump has to be stopped, if the cause for high temperature can not be fixed, disassembly shall be performed (after the pump cools down and drainage is done) for further inspection.
8 Descriptions on function and process of boiler control system

8.1 Boiler sweeping system 8.1.1 System function It describes the operating procedures for boiler furnace sweeping, and close and open-loop control system. This system is used to sweep the furnace and flue system. The furnace sweeping must be performed prior to boiler boiler lightup. The furnace sweeping is the activities to remove the gas or suspended combustible materials inside the flue gas passage, by means of establishing the sufficient air cycle in a continuous manner. 8.1.2 Operation The furnace sweeping is the necessary prerequisite for the boiler lightup. The furnace sweeping is the activities to remove the gas or suspended combustible materials from the furnace, heat exchanger and flue gas passage, by means of establishing the sufficient air cycle in a continuous manner. Definitions: "furnace sweeping" is defined as the continuous air cycle practiced in the furnace and heat exchanger in the required duration, with the circulation air flow 5 times the circulation volume, flowrate 25%-40% of boiler BMCR mass flow. And the cycle duration shall not less than 5 minutes." The operators shall perform the leakage test on the heavey fuel oil loop when implementing the furnace sweeping procedures. 8.1.2.1 Startup condition for furnace sweeping The boiler sweeping can be started only after following conditions are met a) The unit overall safety is set up, namely power for control system enables, and instrument air pressure is normal. At least one ID fan is in service (refer to unit system FTA-FTB) At least one FD fan is in service (refer to unit system FCA-FCB) All the oil burners are shut off (refer to FBA, FBB, FBC, FBD, FBE, FBF, FBG, FBH, FBJ, FBK, FBL, FBM, FBN, FBO, FBP for valve limit switch). 83
b) c) d)
e) f) g)
No pulverized fuel feeder is in service(refer to unit system FEA - FEP) All the ESPs are shut down. Flame is not detected by all the flame detectors(refer to function descriptions for FBA, FBB, FBC, FBD, FBE, FBF, FBG, FBH, FBJ, FBK, FBL, FBM, FBN, FBO, FBP for detector limit switch). Shut off the fuel oil main cut-off valve Cut off all the coal dust burners, namely close the primary air damper valve(FEA, FEB, FEC, FED, FEE, FEF, FEG, FEH, FEI, FEJ, FEK, FEL, FEM, FEN, FEO, FEP function descriptions). The burner combustion damper is at the sweeping position (dedicated air damper is opened, and others closed). Total air flow (primary air and secondary air) is within 25%-40% of MCR flow (refer to section 4.2.1). Furnace sweeping command activates When all the above conditions are met, the timer for 5 minute sweeping is energized; when the furnace air flow and time are completed, set up the boiler sweeping memory( when furnace sweeping completes). Furnace sweeping functions properly, then oil burner must be lighten up. During the furnace sweeping, the loss of any condition will stop the sweeping, and at the same time, 5 minute timer must be reset and renew the timing.
h)
i)
j)
8.1.2.2 Disables for the furnace sweeping After the furnacde sweeping, any of the following conditions occurs, "sweeping time finish" memory reset, and restart the sweeping procedures (as per operator's requirement). a) The unit overall safety is set up, namely power for control system disables, and instrument air pressure is normal. No ID fan is in service. No FD fan is in service. At least one set of oil burner is not shut off(refer to FBA, FBB, FBC, FBD, FBE, FBF, FBG, FBH, FBJ, FBK, FBL, FBM, FBN, FBO, FBP for valve limit switch). At least one pulverized fuel feeder is in service(refer to unit system FEA - FEP) The fuel oil main isolation valve is detected as close (one set oil burner is at starting condition (the action will delay 30s). At least one set of coal burner is not shut off, namely primary air damper door is not shut off (refer to function descriptions for FEA, FEB, FEC, FED, FEE, FEF, FEG, FEH, FEI, FEJ, FEK, FEL, FEM, FEN, FEO, FEP) Total air flow is lower than 25%MCR flow. 84
b) c) d)
e) f)
g)
h)
i)
Flame is not detected by at least one set of flame detectors(refer to function descriptions for FBA, FBB, FBC, FBD, FBE, FBF, FBG, FBH, FBJ, FBK, FBL, FBM, FBN, FBO, FBP for detector limit switch). boiler fuel master trip(BMFT)
8.2
8.2.1 System function The enables for the boiler light up and boiler master fuel trip (BMFT). 8.2.2 System configuration Unless otherwise specified, the basic system, which connects with the turbine is specifically for the control of boiler. When the master fuel trips, all the feul flow of burner will be shut off repidly. 8.2.2.1 Boiler protection can be divided into: Necessary conditions for lightup; Condition for master fuel trip The necessary condition for lightup enables and operation When boiler sweeping finishes, set for sweeping termination memory (refer to FFY basic system). The power for the control system enables, and control air pressure is correct (signal "unit overall safety setting"). At least 1 ID fan is in service(refer to DM function FAT - FTB) At least 1 exhaust blower exhaust blower is in servide(refer to DM fundtion FCA FCB) At least 1 rotary air preheater is in serviee(refer to DM funetion FRA - FRB)
8.2.2.2
b)
c) d)
e)
f) Air total colume flow is greater than mimimum value (refer to DM function FRG) g) h) i) Drum water level is not high Drum water level is normal At least 1 circulating pump is in work. (motor contactor auxiliary switch) and related differential pressure are greater than minimum value (refer to DM function FLA) Furnace pressure is normal, and is lower than maximum value and higher than minimum value (calculation method, pressure changeover 2oo3 table). The cooling air for flame scanner is in service, e.g. air pressure is greater than minimum(pressure changeover FAR PSLL 003)
j)
k)
l) The steam pressure of superheater outlet is not over high (calculated with 2oo3 table,FSR PT 050A/B/C) 85
m) The inlet temperature of ESP shall not be too high n) o) The emergency switch shall not be opened(refer to section five) If the water temperature is high (take from TE 0521), or there is some steam or water temperature is not high (taken from TE0521), furnace temperature probe is used and furnace temperature is not high.
Notice:The air vent shall be opened. 8.2.2.3 The necessary condition for fuel trip enable and operation a) Loss of control system power or control air pressure abnormal, this action delays for 2 seconds. No ID fan is in service. No FD fan is in service. No air preheater is in service. Total air flow lower than minimum valve (action delays for 2 seconds) Water temperature is over high (taken by TE 052I), failure of exhaust lasts more than 6 seconds, or water temperature is not high (taken by TE 052I), but furnace temperature is abnormal or furnace temperature is over high (delays for more than 6 seconds). Steam exhaust is not opened (action delays for 6 seconds) Drum level too low(two second delay) Drum level too high(60 second delay)and higher than 12% MCR flow. No circulating pump is in service, and trip action delays for 2 seconds. The furnace pressure is too low or too high The pressure of cooling air for flame detector is too low(600 second delay) The flame detector fails, 15 second delay after the resetting for the last burner sweeping storage, or whole detector fails.
b) c) d) e)
f) g) h) i) j) k) l)
m) The superheated steam pressure is too high (pressure switch), action delays for 6 seconds. n) o) ESP inlet air temperature is too high, this action delays for two seconds After the circulation starts, steam flow is still higher than x1% prior to return, and only one circulating pump is in service after T1. When the circulation starts, steam flow is still higher than x1% prior to return, and only one circulating pump is in service after t seconds (T1+T2). Only one emergency button is used. 86
p)
q)
r)
When the return flow starts, at least 1 raw coal supply device control loop is in manual condition, and air flow exceeds y%.
5 steam blowing lines: Instance A = SH valve open(limit switch opens)and main steam valve on turbine high pressure body opens (limit switch opens) and turbine high pressure body not closes (limit switch not closes) Steam flows through the high pressure and low pressure body of burbine (through reheater). Notice: Under any circumstance, the startup of high pressure turbine will open the steam pipe in the outlet of high pressure body. b) Instance B = boiler outlet SH valve not open (limit switch not open) or main steam valve for the turbine high pressure body not open (limit switch not open), or turbine high pressure regulation valve close (limit switch closes), but the steam flows through the opened high pressure by-pass valve (limit switch not closes) and steam flows through the reheater and then exhausts. Or c) Instance C = boiler media and low pressure body, if the midium pressure body main steam valve opens (limit switch opens) and the midium pressure regulation valve not closes ( limit switch not closes) Or d) Instance D=flows through low pressure by-pass valve and reaches condenser (limit switch not closes). Or e) Instance E = if the exhaust valve in the outlet of reheater doesnot close ( limit switch not closes). This valve will be regulated manual/automatic station in the central control room, according to the temperature and flow of startup steam.
8.3 Analog control system (coordinated control system) 87
8.3.1 System function This ststem describes the closed loop principle for the management of coal-firing boiler and related turbines. This system allows automatic operation according to the load command under normal operation condition. 8.2.1 Operation
The control loop in manual and automatic mode can be adopted for the boiler analog control system. 8.2.1 Descriptions on analogue loop Lists of control loop Name Unit load control Detailing of boiler load command signal Fuel flow control Unit fast cutback control Combustion air flow control Oxygen flow control Feedwater flow control Superheated steam temperature control Superheated steam temperature control Reheat steam temperature control Furnace pressure control Extraction-steam air preheater High pressure by-pass control Hi pressure bypass desuperheating control high pressure bypass control Primary air pressure control Raw fuel feeder speed control Coal mill level control Tertiary air flow control Secondary air balance control 88
Soot blower steam pressure control Auxiliary control loop 9 9.1 9.1.1 Descriptions on complete boiler start-up and shut down Preparations for start-up of new boiler: Boiler first acid cleaning
As for high-pressure boiler, it is necessary to maintain the proper cleanness on the inside surface of steam pipe to prevent the corrosion. By means of acid cleaning prior to the first operation, cleanness can be achieved by removing the chippings inside almost of evaporating pipe through the acid cleaning prior to first operation. 9.1.2 Boiler steam blowing (blowing for pipes in superheater and reheater) It is inevitable that there is some welding slags, rusty scale and other foreign materials inside the boiler superheater, reheater and its steam system steam system, etc, in the newly installed unit. Prior to the official transferring of steam from boiler to turbine, all these foreign materials shall be flushed away as much as possible, in order to ensure the safe and economical operation of unit. Scope of boiler steam blowing: a) b) Boiler superheater system, main steam line. Boiler reheater system, cold section of reheating pipe, hot section of reheating tube. High pressure by-pass system. Boiler main steam one, two stage attemperation water pipe, reheating steam accident spray pipe.
c) d)
9.1.3 Method of steam blowing:the steam blowing is to be performed in the first stage, pipe flushing by energy storage and pressure reduction; and in the stage of pipe flushing, fuel firing mode is adopted. The particle collector is fixed in the inlet of reheater. 9.2 9.2.1 Procedure for startup and shutdown of boiler Cold start-up
Due to power grid limit or needs of repair and maintenance of partial equipment in the plant, after performing the pressure reduction, shutdown on the boiler, the boiler will be put under cold condition. Under the design condition, it takes about 6.5 hours from cold startup to full load operation. This manual provides the preparations prior ro startup of boiler and startup procedures, in order to guarantee the safe and effective operation of unit. 89
9.2.2.1 Preparations and condition for startup Following checks shall be made prior to startup: a) To see if there is any foreign materials inside all the areas, and if all the markings have been cleaned, and inlet and doors are closed. b) If all the stay bar or impediment, which will limit the free expansion of boiler have been dismantled. c) Both air and flue gas conduit are in cleanness, and are ready for operation. d) To see if the startup equipment, interlock and safety devices function properly. e) Soot blower can be put into service, and be in withdrawal position. f) Extendable temperature probe for furnace flue gas can be put into service.
g) Check the boiler instrument and related equipment, and be sure they are ready for service. h) Both boiler feedwater pipe and feed water pump can be put into service. It is suggested that during the unit startup, remote manual operation shall be adopted to control the feedwater flow, untill a continous stable flow is achieved. i) Economizer recirculation valve is opened, and fill the boiler through the main feedwater control valve. Drum water level approaches high high water level. Close attemperation water control valve and put it on manual position. Open the related manual cut-off valve and automatic cut-out valve, and make them ready for service.
j)
k) Check carefully the boiler circulation pump, make sure that condensate water has been injected coming from condensate pump. Related instrument device are ready for service. Open the inlet valve and drainage check valve. l) The atomization steam can be put into service, and atomization/sweeping selector switch is at the correct position.
m) To check the air heater, and make sure they are ready for service. n) To check the lubrication system for all the mechanical equipment. o) To check operation of the cooling air system, and position of manual valve, and make sure they are ready for service. p) Firefighting system is put into readiness, and check fire detection system for air preheater. q) Following equipment are enabled for startup: Cooling fan for flame scanner, Seal fan for oil burner, 90
Two air preheaters,
Two ID fans,
Two FD fans, Two PA fans, All oil burners; Coal dust manufacturing equipment coal dust manufacturing equipment coal dust manufacturing equipment r) Check the ash and dregs removal equipment, and make sure they are readu for service. Both flue gas and air damper door are at startup position. All the boiler valves, superheater and reheater drainage,vent valve are at start position. Operate the valve with reference to the valve operation sequence table provided in end of this part. Both raw coal hopper and coal dust silo have stored the fuel, and are readu for service. Heavy fuel oil is ready for service, and checks the related heat tracing and pretreatment system, and make sure they are ready for service. ESP is available and ready for service. Rapping device and isolator heating system can be put into service; low temperature alarm or low level alarm has been cleared.
s) t)
u)
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9.2.2.2 Precautions for the initial light up: In order to guarantee the maximum safety margin at the startup, 30% full load operation air shall be maintained all the time, so that: Sufficient combustion environment can be established in the furnace. And accumulation or stagnation of explosive coal and air mixture is prevented due to the poor lighting or delay after the fuel enters the furnace. b) With the increase of boiler load, operator shall check the increase of air flow, in order to make sure that the there is some design excess air is maintained. The excess air shall be checked periodically. Refer to "Curve of design excess air and boiler load" in the end of this section. c) When the igniter or atomization/sweeping media is not availalbe, attempt to light the burner is strictly prohibited. d) If the burner is not lighten up within 15 seconds after the fuel supply to the burner nozzle, the fuel shall be cut off and re-start the 5 minute furnace sweeping procedure. 91
e) During the startup, preferably the oil burner fixed at the arch center of furnace shall be used for light up. The burning rate can be adjusted on the basis of not exceeding the furnace outlet gas temperature maximum 550C. In order to ensure the furnace outlet gas temperature outlet gas temperature lowers than 550 550C, the required burning rate burning rate can be normally shown by the corresponding corresponding pressure rise gradient (air flow % means the air flow under the MCR condition). In the first stage of pressure rise, 6% BMCR burning rate corresponds 30% air flow. When the pressure rise becomes slowly, burning rate can increase up to 12%BMCR, air flow is 40%. f) When the boiler warm up finishes, temperature rise rate of saturated steam must be controlled 100 C/h in the first hour, and 110C/h in the second hour. Refer to the Startup curve
g) It is not allow to exceed the boiler limit parameters. sketch provided in the end of this section.
The start-up curve gives the corresponding corresponding boiler pressure rise rate and temperature rise gradient of saturated steam. 9.2.2.3 Superheater and reheater protection under cold startup. If the furnace light up for combustion, protection for superheater and reheater assembly must be made properly, especially when the steam is not required at the unit startup and shutdown. When there is no steam flowing through the turbine, sufficient steam passage must be guaranteed. During the startup, the steam flowing through the high pressure by-pass is adopted to protect the superheater, and start of steam exhaust or low pressure bypass system is adopted to protect the reheater. The minimum steam flow for the normal protection is considered as 10%BMCR (about 100t/h). In the first stage of boiler startup, sufficient steam can not be generated to cool and protect the superheater and reheater assembly which is operated under high temperature flue gas, thus special care shall be taken to ensure that the heat exchanger will be operated under overhigh temperature. In order to protect the superheater and reheater before the continous steam flow is established, burning rate shall be controlled in order to make the outlet flue gas temperature lower than 550C. 9.2.2.4 Cold startup sequence: a) Start two boiler circulation pumps, if necessary, readjust the drum water level to make it approaches low level. To select the third boiler water pump, and make it under hot standby condition. b) Open the air and flue gas system, namely: 92
- To start two air preheaters - To open air outlet cut-off damper for combustion air. - Put the cooling air system for flame scanner and seal air system for fuel oil burnerin to service. - To start one ID fan, and make the furnace pressure at the automatic state. - To open one FD fan. - Care shall be taken that during the startup of the first FD fan, the damper on other fan shall be closed and regulation door shall be opened. - Increase the flow of secondary air to meet the minimum flow requirement, namely 30% full load flow. - And then start up second ID fan and FD fan. - Put all the fan and combustion air flow command into automatic control state. - Put the air dampers of secondary air and tertiary air, FCA/B PCV 11A, 11B, 11C, 21A, 21B, 21C, 14, 15, 24, 25 into automatic control position. Check if the suggested positions of dampers are correct: FCA/B PCV 11C and 21C -100% opening FCA/B PCV 11B and 21B opening 20% FCA/B PCV 11A and 21A-close FCA/B PCV 14, 15, 24 and 25-close a) Start up the air heater (if the auxiliary steam can be put into service), and verify the temeperature set point at automaticl condition. Start up two PA fans, and put the pressure control device into automatic position Put the withdrawable probe into service. Open the reheater and start up the exhaust valve FRS UV 01. Open the economizer recirculation valve FSR UV 002. Open the back flue gas vertical duct, and large screen superheater (intermediate temperature superheater) drain valve FSR UV 003 and 005. Verify that the cold section of reheating drain valve FRS UV 002 is at automatic position. When the air flow reaches 30% nominal flow, perform the furnace sweeping procedure 5 minutes. Check the state of boiler safety gate, etc. 93
b)
c) d) e) f)
g)
h)
i)
j)
Open the boiler isolation door and high pressure by-pass valve. Put the high pressure by pass valve into automatic position, and set the high pressure by-pass pressure at 60bar. Keep the high pressure by-pass valve at continuous opening (minimum opening around 20%). Put 2 oil burners (FBI+FBN or FBH+FBF fixed at arch center into service, and locally check the function of burner and quality of burning. If needed, regulate burning rate. During the pressur rise, control the burning rate properly, to make sure the furnace outlet flue gas temperature lowers than 550C. During the first hour of startup, the temperature rise temperature rise rate of saturated steam is 100C/h, and in the second hour, it is 110C/h. The boiler pressure rise rate shall be in accordance with related requirements (refer to startup curve).
k)
l)
m) When the drum pressure rises up to more than 2bar, close ITS and drain valve at the back flue gas vertical duct. n) The drum water level will rise due to the heating expansion of water inside the boiler. If neede, open the intermittent blowdown valve fixed at the outlet of circulating water pump, in order to lower and maintain the normal water level inside the drum. Increase the burning rate. If needed, put more oil burners into service. Contiuously measure the furnace outlet temperature (<550C) and temperature rise rate of saturated steam (<110C/H). Put the feed water control valve into automatic position as soon as possible. During this stage, to adjust the drum water level by startup valve FSR-LCV-52D. Once the permanent feedwate flow more than 100t/h is established, close the economizer recirculation valve immediately. When the steam flow is higher than 100t/h, retreat the withdrawable probe. When the vacuum in the condenser is established, put the low pressure by-pass and calibrate the pressure rating of reheater into 8 bar. After opening the low pressure by pass line, close the startup exhaust valve of reheater. To check if the water spraying attemperation valve is at automatic position, if the temperature set point is in accordance with the rolling requirements. Once the reheat steam parameters are within specified range, turbine rolling shall be performed immediately (refer to section 2.1.5 and Manual for Turbine). When the high pressure reaches 60bar, put the high pressure by-pass valve from minimum opening to automatic pressure control mode. Open the by-pass line to keep the high pressure steam pressure at 60bar. 94
o)
p)
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r) s)
t)
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v)
w) Put the boiler pressure control at automatic position, manuall adjust the fuel oil pressure and/or put more burners into service,continue to increase the burning rate in order to obtain the 200t/h steam flow. During this stage, it is recommended that 10 to 12 burners shall be put into service. x) y) Start ESP When the steam flow is greater than 200t/h, prepare to put the coal burner into service. When the enables are met, put one rotary type pulverized fuel feeder into service. Continuously monitor the superheating/reheating steam, and prepare to synchronize the turbogenerator with grid.
z)
aa) When the feedwater flow is greater than 200t/h, start up the feed water control valve, and the differential pressure shall be less than 5bar (replace the drum water level valve with main feed water valve LCV5) 9.2.2.5 Turbine rolling and synchronization: a) When the boiler load reaches around 20% (namely 200t/h steam flow), and high pressure steam pressure is 60 bar, and low pressure by pass line is at 8 bar, and after the high pressure by pass/low pressure by pass steam temperature meet the requirements, turbine rolling can be made (refer to Manual of Turbine). When the turbine is raising the speed, keep the boiler steam flow at 200t/h, and steam temperature at the high pressure cylinder is 400C, and that at intermediate pressure cylinder 390C. After the cylinder warm up finishes, and enables are met (refer to Manual of Turbine), synchronization of generator can be done. Introduce the steam into turbine. Gradually shut the high pressure by-pass line, and make the overheat steam flow through high pressure cylinder. Gradually shut the low pressure by-pass and make the reheat steam flow through the intermediate pressure cylinder and low-pressure cylinder.
b)
c)
d)
e)
9.2.2.6 Load up: a) Only fuel oil burner is put into service, and the boiler maximum load can reach 30%. When the steam flow is higher than 200t/h, start one rotary type pulverized fuel feeder, after it becomes stablized, pout another pulverized fuel feeder fixed at opposite side of furnace arch. Keep the oil burner lighting, in order to ignite the coal dust. To adjust and distribute the secondary air in the furnace arch bellow, in order to ensure that the flame submerges (after the rotary type pulverized fuel feeder is put 95
b)
c)
into service, FCA/B PCV 11A/B/C and 21A/B/C damper control station shall be put into service also). d) When the steam flow is higher than 250t/h, start up the pulverization equipment as per requirements (refer 2.1.7, Startup of pulverization system). Put more coal burners into service according to load and pressure rise. Total coal dust quantitiy required can be set at automatic mode, and control the burning rate by means of set points set according to the requirements of boiler load. When the high pressure by pass is shut, gradually adjust the burning rate and increase the pressure. The temperature rise gradient of saturated steam shall be lower than design limit (refer to startup curve). If needed, keep the oil burner in service till the coal burner for burning achieves the preset number. Besides, it is recommended that 4 oil burners shall be kept on after the boiler reachese full load, in order to bake the non-burned zone. Put the turbine control and boiler load requirement at automatic mode, at which time, operator can select to use the boiler-turbine coordinated-control mode (ajust the boiler with turbine or adjust the turbine with boiler). Generally, the adopt the mode of adjusting the boiler with turbine: control the load with the turbine valve opening, and control the steam pressure with burning rate. Put the steam temperature control into automatic mode. set point has been achieved. Verify that the correct
e)
f)
g)
h)
i)
j)
Check the total air flow, and make sure that it can meet the needs of actual burning rate at any time. When the targeted load is achieved, verify if the boiler operating condition is in accordance with design data. Please refer to slide pressure-excess air curve in section 1.1 and end of this section.
k)
9.2.2.7 Putting the pulverization equipment into service. When the boiler steam flow reaches more than 250t/h, start up one set of pulverization loop automatically in sequence. 9.2.3 Normal shutdown-cooling
The following prcedures for the normal shutdown is based on the following assumption: when the load decreases, unit is running at the full load automatic control condition; and operator requires to decreases the boiler pressure till it completely cools down. If the internal inspection is required for the boiler, the soot blowing shall be made on all the heating surfaces (which takes around 4 hours). 9.1.3.1 According to the slide pressure set point, start to decrease the unit load gradually. To observe burning rate and if it is decreases according to the reduction of steam flow. Retreat the super fine burner fixed in the front of boiler wall (if it is used), if needed, retreat other coal burners. Perform the retreating in the sequence from 96
the burners fixed at both sides first, and then those in middle. 9.1.3.2 The decrease rate of steam temperature shall be in accordance with the turbine manufacturer's regulations. 9.1.3.3 Shut down the pulverization equipment (refer to operating procedure of pulverization equipment). 9.1.3.4 At the 75% boiler load (steam flow 750t/h), put the oil burners which responds to the operating PC burner, and continue to derease the load. Monitor the furnace temperature measurement pyrometer. 9.1.3.5 When the boiler load goes under 70% BMCR (618t /h), change the from "complete furnace flame monitoring flame detection" mode to "single flame detection" mode. Retreat the PC burner as per requirement, and keep to put the corresponding oil gun into service (till pulverized fuel line is swept). 9.1.3.6 If the turbine load continues to decrease, monitor the opening of high pressure by-pass valve and pressure set point. 9.1.3.7 Prior to disynchronization, continue to reduce the turbine load and pressur till to its minimum. 9.1.3.8 Put the air preheater soot blower into servide and maintain at the continuous sweeping mode. 9.1.3.9 Retreat the last PC burner, and adjust fuel flow as per requirement. pressure and reduce the rate. Control the
9.1.3.10 It is suggested to reduce the air flow slowly according to the reduction of fuel supply. The air flow shall not be under 30% full load flow. 9.1.3.11 Once automatic control can not meet the requirements for normal adjustment, put all the fuel control unit at manual position. Retreat the oil burners one by one (those at front and back arch in symmetry or retreating in diagonal manner). 9.1.3.12 When the unit is disynchronized, all the oil burners can be retreated, and sweep all the PC pipe correctly. 9.1.3.13 After the boiler trips, open the ring header drain valve FSR UV 003,005 on the flue gas vertical duct,and according to the turbine manufacturer's manual, open the drainage blowdown valve on the main steam pipe and turbine main pipe. 9.1.3.14 Keep the cooling fan for flame scanner in service. 9.1.3.15 Keep two boiler circulation pumps in service. Keep one boiler feed water pump in service, and keep the drum at the normal water level. Open economizer recirculation valve. 9.1.3.16 Control the boiler cooling rate, and make sure that the metal temperature difference measured by any two thermocouples on the drum shall be within 50C. 97
9.1.3.17 After the flame is out, keep the FD fan run at least 10 minutes, in order to remove the residual flue gas inside the furnace. Keep the air preheater in service, if needed, keep the fan in service, in order to speed up the boiler cooling. 9.1.3.18 If the boiler needs to be exhausted to atmosphere, when the downcomer temperature reaches 90C, the drum exhaust valve must be opened. Prior to the water discharge from boiler, boiler water temperature shall be kept under 70C. Stop the boiler water circulation pump, and prior to water discharge from boiler, close the water supply, drainage and preheat pipes. 9.1.3.19 Keep the deslagging equipment in service till boil cools down. 9.1.4 Normal shutdown-hot standby
Boiler hot standby means that the boiler shutdown time is comparatively short, and the existing pressure and temperature is maintained continuously. The procedures basically are same with those for shutdown cooling, however, the differences are: a) At the time of load reduction, rate shall be far lower than that for normal shutdown cooling. Soot blower is put into service for air preheater. When the turbine stops, boiler shall continuously fired, in order to ensure that pressure prior to banking shall reach more than 140bar. After the boiler reduces to preset pressure, and turbine stops, retreat the last one burner, and then close all the superheater drain and vent, boiler cut-off valve and high pressure by-pass and seal the boiler with banking. Open the reheater drain and vent valve. Keep FD fan in servie for 10 minutes. Keep the following equipment in service: - Air preheater, - Burner and cooling fan for flame scanner, - Boiler water circulation pump, - Deslagging device. g) Open the economizer recirculation valve.
b) c)
d) e) f)
9.1.5 Hot start-up Suppose that the boiler outage last shortly, and boiler will maintain at a certain pressure (drum pressure at more than 140bar), and suppose that sufficient coal dust has been milled and stored in the coal dust silo, prior to shutdown, and the boiler startup mode is hot startup. The preparations for hot startup are similar to that for cold startup, where the differences 98
are: Air preheater is still in service, Burner and flame detector are still in service, Deslagging device is in service, Two boiler circulation pumps are still in service, Both superheater exhaust and drain valves are kept at close position. a) b) Open the reheater and start up the air evacuation valve FRS UV 001. Make sure that no drain valve is opened on the reheating pipe, automatic drain valve FRS UV 002 enables and be put into service. Open superheater automatic drain valve, according to the opening time of valve: Back drain valve in the heating surface in flue gas vertical duct, FSR UV 003, Inlet drain valve FSR UV 005, Drain valve in main steam pipe on the outlet of superheater, FSR UV 004.
c)
9.3 Procedure for accident boiler shutdown: 9.3.1 Accident boiler shutdown-main fuel trip The control, interlock and protection system which are equipped in the boiler, will give the command for main fuel trip (MFT), when the safety condition is lost. After the accident fuel trip activates, we shall immediately: Confirm that main fuel valve self-closes, otherwise close it immediately. Boiler drum water level must be resumed, at least at least one boiler circulation pump is in service. Close the single fuel valve on each burner. Resume/maintain the air flow used prior to trip or minimum 30% flow, and sweep the furnace for 5 minutes. According to cause to the fuel accident trip, spare some time for check and restore, and then restart the boiler or isolate it safely. Main trip procedures must be decided after discussing with person-in-charge for operation, especially if the sweeping or exhaust is required for the coal mill.
9.3.2 Boiler shutdown-tube leakage If one or more leakage occur on the tubes of boiler, the optimal boile shutdown mode shall be selected according to the damage level, difficulty of maintaining the drum level, actual conditions of grid load. If the leakage is slight, and water level can be maintained within normal range, boiler 99
shall keep its service according to the grid load, till it is shutdown for maintenance at the convenient time. In such cases, boiler can be shut down in the regular procedures. Although the boiler can be kept in service for a period of time under this circumstance, the possibility of puncturing other tubes by the leakage. As long as the leakage from tube doesn't result in the loss of drum water level, or its level is lower than low alarm, or the furnace ventilation is failed to be maintained, the boielr must be shut down under regular procedures. Boiler can be cooled down rapidly. When the drum metal wall temperature reaches 70C, water can be discharged from boiler.
10 Handlings for the boiler typical accident.

10.1 Principle and notices for accident handlings
10.1.1 In case of accident, the operator shall be kept in somber minded, and shall make correct judgment, and shall adopt all the feasible means to kill the root of accident, and restore the unit to normal operation rapidly, in order to meet the needs for system load. 10.1.2 In case of accident, the shift supervisor shall be informed, who will contact the unit personnel for handlings together. Under the shift supervisor's direction, handle with the accident rapidly and decidedly according to the accident handling regulations. 10.1.3 When the automatic control system doesn't function properly, the operators shall adopt the "manual" mode to handle the accident immediately according to their judgment, in order to avoid the escalation of accident. 10.1.4 When the outfire accident occurs, all the fuels shall be cut off immediately, and handle as per the operation procedure specified in the regulations. 10.2 Accident automatic shutdown (conditions for MFT activation)
10.2.1 After MFT activates, the following operations shall be made automatically, otherwise, manual intervention shall be made: 10.2.1.1 10.2.1.2 10.2.1.3 10.2.1.4 10.2.1.5 Cut off all the fuel; Shut off all the pulverized fuel feeders and oil guns; The electromagnetic valve for the fuel oil supply closes; The whole pulverization system stops; The balance air damper fixed in front and back wall:A is 100%, B is 20%, and C is 0%. Turbine trips, and generator desynchronizes with grid High, low by-pass activates automatically. 100
10.2.1.6 10.2.1.7
10.2.2 After the MFT activates, manual handlings are: 10.2.2.1 Confirm that boiler main steam valve FSRUV04A closes automatically, otherwise manually close the boiler main steam valve. Confirm that the high pressure by-pass opens rapidly, after 15 seconds, it automatically resumes to a certain opening, in order to maintain the reheater pressure at 15bar. If high pressure by-pass doesn't open, switch the high pressure by-pass control into manual mode, and open the high pressure by-pass. After 15 seconds, close back to an appropriate opening, set the reheating steam pressure at 15bar, and then switch it into automatic control. Pay attention to the drum water level, if it is too high; perform the level adjustment together by means of IBD and CBD. Pay attention to the boiler water pump for its normal operation, if abnormal vibrations, differential pressure occurs, stop the pump temporarily immediately. If cause to MFT can not be investigated and ascertained or killed, decision shall be made timely to stop the PA fan, FD fan, ID fan, and close the inlet and outlet dampers. The boiler is maintained at the hot standby condition. Maintain the air preheaters, cooling fan for flame scanners and cooling fan for oil guns in service. If the fault is cleared in short time, upon receiving the stat command, start the unit as soon as possible according to the outage time, the corresponding condition, in order to meet the needs of system load. If MFT activation is caused by the ID fan or FD fan or PA fan, furnace shall be ventilated and swept thoroughly prior to lightup again; and prior to putting the coal dust into service, all the PA pipes shall be swept for 20 minutes.
10.2.2.2
10.2.2.3
10.2.2.4
10.2.2.5
10.2.2.6
10.2.2.7
10.2.2.8
10.3
Emergency boiler shutdown
10.3.1 Shut down the furnace by pushing " emergency boiler shutdown button" immediately, if one of following instances occurs: 10.3.1.1 When the furnace is operated under low load, and combustion is not stable, and pressure of furnace fluctuates in the range of 5mbar, and steam flow reduces rapidly. When the boiler pressure exceeds the trip value of safety valve and safety valve fails to activate, at the same time, high and low by-pass valve and reheater exhaust valve can not be opened automatically and manually. If the blasting occurs in main feed water pipe, main steam pipe, waterwall, economizer, superheater, reheater, and it endangers the neighboring tubes. All the boiler water level gauges are damaged, and water level can not be monitored. 101
10.3.1.2
10.3.1.3
10.3.1.4
10.3.1.5 10.3.1.6 10.3.1.7
MFT fails to activate, when the boiler is at excess high water level. MFT fails to activate, when the boiler is at excess low water level. When the combustibles inside the flue gas duct re-ignited, which makes the flue gas temperature abnormally increases to more than 200. When the two stages of spray attemperation are fault, steam temperature rapidly changes, and becomes out of control.
10.3.1.8
10.3.2 The handling method for "emergency furnace shutdown" is the same with that for "automatic furnace shutdown". 10.4 Boiler shutdown under instructions
10.4.1 Under following conditions, perform the normal shutdown after obtaining the approval of responsible plant manager, and order from shift supervisor: 10.4.1.1 10.4.1.2 There is leakage in the pressure parts, and operation can be maintained. There is coke on the heating surface, and it is difficult to maintain the normal operation despite the effort given. The quality of boiler feed water or steam deteriorates severely, normal operation can not be resumed, despite adjustment is made with effort. The metal wall temperature on the heating surface exceeds the permissive seriously, normal operation can not be resumed despite the adjustments by parties. The close-loop cooling water source for furnace water pump motor interrupts, and emergency water supply can not be restored immediately. After the high pressure by-pass activates, it can not be closed. There is defect with safety valve, it fails to activate or can not return to its seat. The motors for two air preheaters are all fault, and can not be resumed in short time. Severe ash is accumulated in flue gas duct, normal operation can not be maintained despite efforts from parties.
10.4.1.3
10.4.1.4
10.4.1.5
10.4.1.6 10.4.1.7 10.4.1.8
10.4.1.9
10.4.1.10 The main monitoring gauges or meters are malfunction, the normal operation can not be maintained, and restored in short time. 10.4.1.11 Two ESP are fault, and can not resume to normal operation despite effort from parties. 10.5 Load reduction under accident The boiler will reduce the load automatically, if any of following instances occurs. 10.5.1 One induced draft fan trips, load reduces to 50%MCR. 102
10.5.2 One FD fan trips, load reduces to 50%MCR. 10.5.3 One PA fan trips, load reduces to 50%MCR. 10.5.4 One air preheater trips, load reduces to 50%MCR. 10.5.5 One furnace water pump trips, and stand by water pump can not be started automatically, load reduces to 60%MCR. 10.5.6 One feedwater pump trips, and stand by pump can not be started automatically, load reduces to 60%MCR. 10.5.7 Turbine trip, boiler load reduces to 70%MCR. 10.5.8 Run with auxiliary power, boiler load reduces to 70%MCR. 10.6 Boiler outfire
10.6.1 Phenomena 10.6.1.1 10.6.1.2 Flame can not be seen from A and B flame television. Furnace negative pressure fluctuates significantly, and transient negative pressure to its maximum. Steam temperature and steam pressure sharply decline. Water level firstly becomes lower and then higher. Main steam flow falls.
10.6.1.3 10.6.1.4 10.6.1.5
10.6.2 Cause 10.6.2.1 10.6.2.2 Loss of coal dust power supply, the oil gun is not put into service. Coal dust silo is too low, which caused the uneven coal supply or even interruption from the pulverized fuel feeder. The boiler load is low, and oil gun has not been put into service to stabilize the burning. When the boiler reduces the load, the air flow does not reduced in time. Coal quality changes significantly, however, the combustion has not been adjusted in time. Coal dust is too gross; Blasting is serious in the water wall screen; Coke from furnace large area collapsed; Air and coal ratio not matched;
10.6.2.3
10.6.2.4 10.6.2.5
10.6.2.6 10.6.2.7 10.6.2.8 10.6.2.9
10.6.2.10 MFT action 10.6.3 Handlings 103
10.6.3.1
If MFT activates, handle with it according to the method for handling after MFT (refer to clause 3 in Chapter 11 and Chapter 12). If MFT doesn't activate, the "emergency furnace shutdown" button shall be pushed immediately, and stop all the pulverized fuel feeders, oil guns pulverized fuel feeder and pulverization system. Maintain the fan in service, and adjust the air flow at 30%MCR, and sweep the furnace at least 5 minutes before the re-light up. To resume the ignition by "outbreak firing" is strictly prohibited. Pay attention to the drum water level, if needed, switch from "automatic" to "manual" according to different situations. Pay attention to the change of steam temperature, disconnect the attemperation water system, if needed. Notice shall be taken that water pumps shall be in normal operation, if the vaporization, serious vibration occurs on boiler water pump, stop them immediately.
10.6.3.2
10.6.3.3
10.6.3.4
10.6.3.5
10.7
One ID fan trips
10.7.1 Cause 10.7.1.1 10.7.1.2 10.7.1.3 10.7.1.4 10.7.1.5 10.7.1.6 10.7.1.7 Fan vibration 1200 Push of stop button by mistake Automatic close of outlet electrical-driven damper Electrical protection activates Mechanical fault Air preheater in the opposite side trips Loss of power supply in the opposite side
10.7.2 Handlings 10.7.2.1 10.7.2.2 If MFT activates, then handle with method for handling after MFT activation. Load shall be reduced to 50%MCR automatically, alarm window alarms when the unit load returns to 50%MCR. FEA, FEE, FEI six pulverized fuel feeders trips automatically, otherwise, stop the FEA, FEE, FEI pulverized fuel feeders manually. Put the appropriate number of oil guns for combustion, till the combustion stabilizes, decision of stopping the pulverized fuel feeder in consideration of its speed, in order to avoid the poor coal supply quality due to slow speed of pulverized fuel feeder. The FD fan, PA fan in the opposite side doesn't trip, stop them manually. 104
10.7.2.3
10.7.2.4
10.7.2.5
Keep the air preheaters in the opposite side in service. 10.7.2.6 After the cause to trip is investigated and ascertained, and the ID fan is confirmed normal, restart the ID fan.
10.8
One FD fan trips
10.8.1 Cause 10.8.1.1 10.8.1.2 10.8.1.3 10.8.1.4 10.8.1.5 10.8.1.6 10.8.1.7 10.8.1.8 Fan vibration120 Air preheater in the opposite side trips; ID fan in the opposite side trips; Electrical protection activates Mechanical fault Stop button or emergency button is pushed by mistake Fan outlet damper is closed automatically during the service; Loss of power supply.
10.8.2 Handlings 10.8.2.1 10.8.2.2 If MFT activates, then handle with method for handling after MFT activation. Load shall be reduced to 50%MCR automatically, alarm window alarms when the unit load returns to 50%MCR. FEA, FEE, FEI six pulverized fuel feeders trips automatically, otherwise, stop the FEA, FEE, FEI pulverized fuel feeders manually. Put the appropriate number of oil guns for combustion, till the combustion stabilizes, decision of stopping the FEB, FEH, the pulverized fuel feeders in consideration of speed of pulverized fuel feeder, in order to avoid the uneven coal dust supply due to slow speed. The inlet and outlet damper of the tripped fan closes automatically, and cooling air balance damper closes automatically, otherwise close them manually. After the cause to trip is investigated and ascertained, and the FD fan is confirmed normal, restart the FD fan.
10.8.2.3
10.8.2.4
10.8.2.5
10.8.2.6
10.9
One PA fan trips
10.9.1 Cause 10.9.1.1 10.9.1.2 10.9.1.3 Air preheater in the opposite side trips; ID fan in the opposite side trips; Fan vibration80 105
10.9.1.4 10.9.1.5 10.9.1.6 10.9.1.7
Electrical protection activates Mechanical fault Fan outlet damper is closed automatically during the service; Stop button or emergency button is pushed by mistake.
10.9.2 Handlings 10.9.2.1 10.9.2.2 If MFT activates, then handle with method for handling after MFT activation. Load shall be reduced to 50%MCR automatically, alarm window alarms when the unit load returns to 50%MCR. The inlet and outlet damper of the tripped fan closes automatically, and hot PA air damper closes automatically, otherwise close them manually. FEA, FEE, FEI pulverized fuel feeders trips automatically, otherwise, stop them manually. Put the appropriate number of oil guns for combustion, till the combustion stabilizes, decision of stopping the pulverized fuel feeder in consideration of its speed, in order to avoid the poor coal supply quality due to slow speed of pulverized fuel feeder. After the cause to trip is investigated and ascertained, and check and confirm normal, restart the PA fan.
10.9.2.3
10.9.2.4
10.9.2.5
10.9.2.6
10.10 One air preheater trips 10.10.1 Cause 10.10.1.1 Mechanical jam on air preheater at trip side; 10.10.1.2 Tripped air preheater motor fault or loss of power 10.10.1.3 Stop button or emergency button is pushed by mistake. 10.10.2 Handlings 10.10.2.1 Load shall be reduced to 50%MCR automatically, alarm window alarms when the unit load returns to 50%MCR. 10.10.2.2 Confirm that air preheater inlet gas damper and outlet hot PA air/secondary air damper close, otherwise close them manually. 10.10.2.3 The fan in the opposite side trip automatically, and inlet and outlet dampers close automatically. Otherwise, close them manually. 10.10.2.4 Six FEA, FEE, FEI pulverized fuel feeders trip automatically, otherwise, stop them manually. 10.10.2.5 Put appropriate number of oil gun for combustion, and stabilize the combustion. 106
10.10.2.6 After the cause to trip is investigated and ascertained, and confirmed normal, restart the air preheater. 10.10.2.7 Monitoring on the shutdown side 10.10.2.8 Flue gas temperature and air temperature at air preheater inlet and outlet. 10.10.2.9 Fire alarm. 10.11 Boiler excessive high water level 10.11.1 Cause 10.11.1.1 Feedwater self-regulation malfunction 10.11.1.2 Mistake operation due to incorrect water level indication or insufficient monitoring of water level; 10.11.1.3 Boiler load low, large leakage in feedwater regulation valve 10.11.1.4 Load or steam pressure fluctuates significantly; 10.11.1.5 High pressure by-pass open suddenly or drum safety valve activate 10.11.1.6 All the furnace water pumps trip. 10.11.2 Handlings 10.11.2.1 If the water high level signal is given, switch the feedwater regulation to manual immediately, and reduce the feedwater flow. If needed, regulate together with operations of IBD and CBD, till the drum level resumes to normal. 10.11.2.2 If there is serious leakage in feedwater regulation valve, if needed, increase the load in order to maintain the normal water level. 10.11.2.3 If the water level adjustment and gauge or meter indication are not correct, C&I personnel shall be contacted for timely handlings. 10.11.2.4 Strengthen the monitoring on drum water level and calibration of field water level meter, in order to avoid the mistake operation. 10.11.2.5 Disconnect the attemperation water in consideration of the steam temperature, and open the superheater and drain water before the main steam valve. 10.11.2.6 If MFT activates, then handle with method for handling after MFT activation. 10.11.2.7 If the above-mentioned measures have been adopted, however the drum water level still rises up to +25m, and MFT fails to activates, the following emergent measures shall be adopted immediately: 10.11.2.8 Push the "emergency furnace shutdown" button 10.11.2.9 Stop the feed water pump, and confirm that economizer recirculation valve has been opened. 107
10.11.2.10 Confirm that main steam valve is closed 10.11.2.11 Open the drain valve in the superheater system and drain valve for turbine main steam; 10.11.2.12 Confirm that each attemperation water valve is closed; 10.11.2.13 Increase the discharge of water, till drum water level is visible. 10.11.2.14 When the cause to full water is eliminated, and drum water level resumes to normal level, restart the boiler after asking the instructions from the shift supervisor, from whom the agreement is obtained. 10.12 Excessive low water level 10.12.1 Cause 10.12.1.1 Feedwater regulate malfunctions, and feed water pump is fault, which results in the less feedwater supply, or feedwater main pressure too low. 10.12.1.2 Mistake operation due to incorrect water level indication. 10.12.1.3 Large leakage in feedwater pipe. 10.12.1.4 When blowdown valve leakage and mistake operation, or blowdown connection is not proper. 10.12.1.5 Blasting of water wall screen or economizer tube. 10.12.1.6 Load fluctuates greatly. 10.12.1.7 Opening indication of feedwater regulation valve doesn't match with actual opening. 10.12.1.8 Mistake close of feedwater electrical-driven valve or core of feedwater regulation valve fell out. 10.12.2 Handlings 10.12.2.1 When the water low level alarms, and boiler water pump functions properly, switch the feedwater regulation to manual immediately. Increase the boiler feed water supply, in order to make the water level back to normal. 10.12.2.2 Stop all the blowdown operations. 10.12.2.3 Pay attention to the change of main steam temperature during the water supply. 10.12.2.4 If the above-mentioned measures have been adopted, however the drum water level still decreases, till MFT activates, if MFT fails to activate, the following measures shall be adopted immediately: 10.12.2.5 Push the "emergency furnace shutdown" button 10.12.2.6 Stop the boiler water pump, and when the drum water level becomes lower 108
than visible level, fill the water into boiler. If the core of regulation valve falls out. The boiler water pump shall be stopped immediately, and seal the boiler. Notify the electrical staff to switch off the power supply to boiler water pump, at the same time, isolate the boiler water pump; and pay attention to the change of drum wall temperature. 10.12.2.7 Investigate and ascertain the cause to water shortage, and after proper handling and receipt of order from shift supervisor, restart the boiler. 10.12.2.8 The order for water filling time and rate under boiler shut down due to water shortage shall be given by the responsible plant manager. 10.13 Turbine trip 10.13.1 Handlings 10.13.1.1 Boiler load reduces to 70%MCR automatically, otherwise, reduce the load to 70%MCR manually. 10.13.1.2 High, low pressure by-pass valve shall be opened rapidly, otherwise open them manually. 10.13.1.3 Confirm the exhaust valve of reheater is opened automatically, otherwise, open it manually. 10.13.1.4 Before putting the oil gun into service, stable the load at more than 420T/H, in order to avoid the activation of MFT. 10.13.1.5 When more than 4 oil guns are put into service as per regulations, stop the pulverized fuel feeder which corresponds to the oil guns, which are not put into service, reduce the boiler load, in order to avoid the close of low pressure by-pass due to turbine low vacuum. 10.13.1.6 Reduce the set point of main steam pressure. 10.13.1.7 When the main steam pressure decreases, switch the high pressure by-pass into automatic position or manual control position, in order to avoid the close of high pressure by-pass, which results in boiler trip. 10.13.1.8 Pay attention to control of the drum water level, when the feedwater automatic control malfunctions, switch it to manual control mode immediately. 10.13.1.9 Maintain the superheating steam temperature and reheating steam temperature at more than 500, and confirm that the attemperation water shall be normal, otherwise, switch it to manual control mode. 10.13.1.10 If turbine trip can not be resumed rapidly, maintain the combustion of boiler, in order to avoid the MFT activation. 10.14 Loss of auxiliary power 10.14.1 Phenomena 109
10.14.1.1 Turbine trip, boiler MFT activation. 10.14.1.2 The entire running equipment trip. 10.14.1.3 All electrical-driven valves are kept as the same position as it was when the power lost. 10.14.1.4 Main steam pressure, temperature and flow decrease. 10.14.2 Handlings
10.14.2.1 Confirm that DC fan for flame scanners are in service; and confirm that DC motor for air preheater has started. 10.14.2.2 Confirm that television water level indicator furnace flame television is in service. 10.14.2.3 Check the three-way valve FV003 for drainage under boiler water pump accident has opened, and when the cavity temperature of boiler water pump continues to rise, close the outlet valve of boiler water pump immediately manually. 10.14.2.4 When the diesel generator is put into service, start the big-tooth wheeled seal fan. 10.14.2.5 If the auxiliary power interrupts during the sootblowing, the maintenance staff shall be notified of retreating the soot gun manually immediately. 10.14.2.6 After the power is resumed, following operations shall be performed. 10.14.2.7 Fill the water to drum up to -100mm. 10.14.2.8 Wait till the cooling water system resumes to normal condition, start the boiler water pump. 10.14.2.9 Start main motor of air preheater. 10.14.2.10 Start AC cooling fan for flame scanner, shut down the DC cooling fan, and put "interlock" into service. 10.14.2.11 Start the cooling fan for oil gun, and put "interlock" into service. 10.14.2.12 Check that electrical-driven valve and regulation valve for attemperation water is at close position, open the recirculation valve of economizer. 10.14.2.13 Start the lubricating oil system for coal mill. 10.14.2.14 When the close-loop cooling water system interrupts, confirm that accident water tank is provided following equipment with water. 10.14.2.15 Low pressure cooling water for boiler water pump. 10.14.2.16 Cooling water for upper and lower bearings in air preheater. 10.14.2.17 Cooling water for furnace flame television. 110
Volume C
Steam Turbine Operation
1 Equipment Definition and Working Principle

1.1 Equipment Definition and Working Principle Steam turbine is a kind of power machine, whose blades turn by the superheated stem generated from the power plant boiler to drive the steam turbine and the generator to generate the power. It is a prime mover of the power generation unit. The purpose of the steam turbine in the process of thermal electric generation: In the power plant, the energy is transmitted from one place to another. Most of these places are different. But for each place, they have the same important concept. If we can understand this concept clearly, then we can simplify the task of the power plant.
Energy Converting Place
Coal Yard
Boiler
Steam Turbine
Generator
111
Steam Turbine
English Boiler Steam Turbine Generator Chemical Energy(Fuel) Steam Thermal Energy Mechanical Energy Electric Energy
The thermal energy in the steam is converted to the mechanical energy by the steam turbine. Below is schematic diagram of steam turbine.
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English HP Cylinder IP Cylinder LP Cylinder Generator Condenser
Cooling Water From reheater Go to reheater Go to feed water heater
The steam is delivered to the steam turbine by the steam pipe (1) from the boiler. The steam passes through the shut-off valve (to shut off the steam in emergency) firstly, then passes through a governing valve (2). The governing valve can adjust the steam supply of turbine automatically. Both shut-off valve and governing valve are mounted in the steam chamber. The main shaft (4) of steam turbine drives the speed governor (3) to operate the governing valve to regulate the steam demanded. This entirely depends on the generated energy from the generator. The steam from the governing valve enters HP cylinder of steam turbine. The steam passes through one circle of stationary blade (5) on the cylinder wall (6). The stationary blade plays a role of nozzle, which leads the steam to one circle of moving blade (7). The moving blade is fixed on the disc of turbine shaft. The shaft is rotated by the moving blade under the work of steam force. The stationary blade and moving blade constitutes a stage of the steam turbine. In fact, many stages are needed. Therefore, there are a lot of circles of stationary blades in the cylinder, and there are moving blades between stationary blades. The steam passes through each stage till the end of HP cylinder. When the steam passes through each stage, part of thermal energy from steam is converted to mechanical energy. The steam leaving from HP cylinder returns to the boiler to be reheated (8), and backs to the IP cylinder by the other pipe (9). Then, the steam passes through another group of stationary blade and moving blade. At last, the steam enters the LP cylinder from the middle, and flows through the blade of steam turbine towards two contrary directions till the end of cylinder, which is called convection layout. When the steam generates the thermal energy to drive the steam turbine, the temperature and pressure of the steam will drop, so, the steam will expand accordingly. In order to adapt such expansion, more be close to the LP end of steam turbine, more big and long the blade will be. The speed of the turbine shaft is 3000rpm, which is decided by the frequency used in local electric system. The 2-pole generator could generate the alternating current with frequency of 50 cycles/second under such speed. The steam is exhausted into the condenser after its energy is extracted. The condenser is a huge big vessel, in which there is about 20000 pieces of tubes with cooling water passing. So, when the steam from the turbine flowing these tubes, it would be condensed and become water quickly. The water is condensate water. Condensate pump transports the condensate water to low-pressure feed water pump from the condenser. Then raise the water pressure to the boiler pressure by the feed 113
water pump of the boiler. The condensate water flows to other feed water heater and reaches economizer and boiler, then become the steam again.
1 Main steam valve; 2 Governing valve; 3 Steam turbine; 4 Condenser; 5 Steam ejector;6 Circulating water pump; 7 Condensate pump; 8 Low-pressure feed water heater; 9 Deaerator; 10 Feed water pump; 11 High-pressure feed water heater Composition of Steam Turbine 1.2 Working Principle The steam firstly converts the thermal energy to kinetic energy in the steam turbine, then mechanical energy. The steam turbine has different working principle for different mode to convert kinetic energy to mechanical energy. English Protection device Governing device Oil supply system Main steam To each bearing To steam generator From steam generator
114
1 Shaft ; 2 Impeller ; 3 Moving blade ; 4 Nozzle Working Principle Graph of Impulse Turbine In the steam turbine (as fig.), steam expands in the nozzle, the pressure drops and the speed increases, the thermal energy is converted to the kinetic energy. High-speed steam flows through the moving blade 3, due to the change of flow direction, a impulse force on the moving blade is generated, which drives the impeller 2 rotate to do work, thus, the kinetic energy of the steam is converted to mechanical energy of rotating shaft. Such principle to do work by impulse force is called impulse working principle. For reaction type turbine, the steam not only expands in the nozzle (i.e. stationary blade cascade), with pressure dropping from p0 to p1, speed raising from c0 to c1, a impulse force is generated on the moving blade by high-speed steam ; the steam but also expands in the moving cascade, with pressure dropping from p1 to p2, speed raising from w1 (inlet relative speed of moving blade) to w2 (outlet relative speed of moving blade), a reaction force must be generated on the moving blade by the steam due to speeding up, which make the rotor turn to do work under the action of both steam impulse and reaction forces.
1,2 Impeller; 3 Live steam pipe; 4,5 Turbine shaft; 6,7 Working blade;8 115
1 Hub2,3 Moving cascade4,5
Housing Radial Flow Multistage Reaction Turbine
Stationary cascade; 6 Cylinder Axial Flow Multistage Reaction Turbine English Axial thrust Flow to Condenser
2 Classification of Steam Turbine

2.1 Classification of Steam Turbine There are many types of steam turbines. In order to convenient the selection, the steam turbine is classified according to thermal process characteristic, working principle, live steam parameters, steam flowing direction, etc. 2.1.1 The steam turbine is divided into impulse turbine and reaction turbine by working principle. 2.1.2 By thermal engineering process, the steam turbine is divided into: Condensing steam turbine Back pressure turbine Governing steam extraction turbine Extraction back-pressure turbine Reheating type steam turbine 2.1.3 According to the live steam pressure, the steam turbine is divided into: Low pressure turbine: inlet pressure: 1.5MPa (a), temperature: 340 Intermediate pressure turbine: inlet pressure 3.4MPa (a), temperature 435 Sub-high pressure turbine: inlet pressure 5MPa (a), temperature 435~460 High pressure turbine: inlet pressure 8.83~9.5MPa (a), temperature 535 Ultra pressure turbine: inlet pressure 12~14MPa (a), temperature 535~538 Sub-critical pressure: inlet pressure 16~18MPa (a), temperature 535~565 Supercritical pressure turbine: inlet pressure 22.2MPa (a), temperature 535~565 Ultra-super critical pressure turbine: inlet pressure 28MPa (a), temperature 580 2.1.4 According to the shaft number, the steam turbine is divided into single-shaft turbine and double-shaft turbine. 2.1.5 According to the cooling mode of steam exhausted, the steam turbine is divided into water cooled turbine and air cooled turbine. 2.1.6 By thermal-dynamic cycle mode, it is divided into 116
Simple cycle type steam turbine Gas-steam combined-cycle turbine 2.1.7 It is divided into thermal electric steam turbine and nuclear electric turbine according to the fuel.
3 Model of Steam Turbine Made in China
Model of Steam Turbine Made in China The type of the steam turbine is expressed by Pinyin, like as the below: Code Type N Condensing B Back pressure C Extraction CC Two extractions CB Extraction back pressure H Vessel using Y Movable
Expression for Steam Parameters in Model of Steam Turbine Type of Steam Turbine Condensing steam turbine Reheating turbine type steam Expression of Steam Parameters Main steam pressure/main steam temperature Main steam pressure/main steam temperature/reheating temperature Main steam pressure/extraction pressure Main steam pressure/HP extraction pressure/LP extraction pressure Main steam pressure pressure/back Example N100-8.83/535 N300-16.7/538/538
Extraction steam with one extraction
turbine
C50-8.83/0.118 CC25-8.83/0.98/0.118
Extraction steam turbine with two extractions Back pressure turbine Extraction turbine back-pressure
B50-8.83/0.98 CB25-8.83/0.98/0.118
Main steam pressure/extraction pressure/back pressure 117
4 Major Components of Steam Turbine
The steam turbine is divided into two parts, i.e. steam turbine proper and auxiliaries. The steam turbine proper is composed of stationary part and rotating part. The stationary part includes the cylinder, nozzle box, diaphragm, diaphragm sleeve, stationary blade cascade, steam seal gland, bearing, pedestal, seat, sliding pin system and relevant fasteners, etc. While, the rotating part includes main shaft, impeller, moving blade cascade, coupling and their fasteners, etc. 4.1 Rotating Part a) Rotor Rotor is composed of main shaft, disc, moving blade and coupling. The rotor gathers all mechanical energy got from each stage moving cascade, and transmits it to the generator. The rotor is divided into assembling rotor, monoblock rotor, assembled rotor and welded rotor.
b) Moving Blade Moving blade is the blade rotating with the turbine rotor during the operation of the steam turbine, which also is called working blade. The moving blade converts the kinetic energy of steam to mechanical energy, to turn the rotor. The moving blade is mounted on the impeller or the rotating drum.
118
c) Coupling Coupling is an important part to connect the rotors of steam turbine and generator. It is used to transmit the torque and axial force.
Rigid Coupling
Semi-Flexible Coupling
119
d) Turning Gear When the steam turbine is without steam entering, the equipment drives the rotor turn at a certain speed is called turning gear. Before impulse starting or after shutdown, turn the rotor in a certain speed continuously, so as to assure uniform heating or cooling of the rotor, to avoid hot bending of the rotor. To turn the rotor before starting can check if there is any friction between the stationary and rotating parts, if the lubrication oil system operates normally, and if the bending of main shaft is too large, etc. It is an equipment to check if the steam turbine is with normal start-up conditions. e) Impeller The impeller is mounted on the main shaft or integrated with the main shaft. It is placed in the cylinder after assembling with the moving blades. The impeller on the assembling rotor is composed of rim, wheel body and hub. The impeller of monoblock rotor and welded rotor only has two parts, i.e. rim and body.
4.2 Stationary Part a) Cylinder and Sliding Pin System The cylinder isolates the flow part of steam turbine from atmosphere, to form a sealing space of steam energy conversion, to support the other stationary parts 120
(diaphragm, diaphragm sleeve, etc.) of steam turbine. The cylinder is divided into high pressure cylinder, intermediate pressure cylinder and low pressure cylinder.
Sliding pin system is a kind of device to assure freely directional expansion of cylinder and keep unchanged axis.
Sliding pin system keep the cylinder expand freely, to avoid deformation by over-large stress; It keep the alignment of the cylinder and rotor, to avoid centre change for expansion of turbine, which make vibration of the unit or friction between the moving and stationary parts. It makes the axial and radial clearances between the stationary parts and rotor is in accordance with the requirements. b) Diaphragm and Diaphragm Sleeve
121
The diaphragm is used to fix the stationary blade at each stage of steam turbine, and form a wall for each stage of turbine. It is composed of diaphragm body, stationary blade and diaphragm edge. The diaphragm either could be fixed on the cylinder directly, or the diaphragm sleeve. It is always made in horizontal half type. There is a key to mount the diaphragm seal in its inner hole. Diaphragm sleeve is used to fix the diaphragm. Usually, the diaphragms in adjacent stages are placed in the same diaphragm sleeve. Then the diaphragm sleeve is fixed on the cylinder. c) Steam Seal Gland In order to reduce the steam leakage in the stages and prevent the air from entering, a sealing device is needed at each stage clearance of turbine, which is called steam seal gland. It is mainly divided into flow part seal, diaphragm seal and shaft seal. The shaft seal is mounted on the shaft, which puts through both ends of the cylinder. The diaphragm seal is mounted on the corresponding place of diaphragm and rotating shaft. The flow part seal is mounted on the blade root and the top of the blade.
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Diaphragm Seal
Shaft Seal d) Nozzle and Nozzle Group The stage of the steam turbine includes stationary cascade and moving cascade except the small turbine with single nozzle. The stationary cascade is composed of many stationary blades (also named guide blades). The adjacent stationary blades form a nozzle, so the stationary blade is called nozzle in habit. 123
No matter nozzle adjustment or throttle adjustment is adopted for steam entering, the steam enters the nozzle box after entering the governing valve, then sprays out from the nozzle of nozzle box. One group of nozzle is mounted on one nozzle box. e) Bearing The bearing bears the rotor and locates the rotor at proper position in the cylinder. It is divided into supporting bearing and thrust bearing. The supporting bearing also is called radial bearing or main bearing. It supports the rotor and the centrifugal force resulted from unbalanced rotor mass, and locates the radial position of the rotor to keep its alignment with the cylinder. The thrust bearing bears the axial thrust of working rotor, and locates the axial position of the rotor, to keep its alignment with the cylinder and a certain axial clearance between the rotor and stationary part. The support bearing is at the end of each rotor of steam turbine. The thrust bearing is in the pedestal between HP, IP or IP, LP rotors of the turbine or front pedestal.
Vertical Section View of 300MW Subcritical Pressure Turbine (Two Cylinders/Two Exhaust)
5 SEC Fossil Turbine Introduction

5.1 Steam Turbine and Auxiliary Equipment Steam turbine and generator are in the turbine room. The pipes connect the boiler and the steam turbine to transport the steam to drive the steam turbine. Then the steam turbine drives the rotor of the generator. The steam becomes water in the condenser after passing through the turbine, which is condensate water. Several pumps between the boiler and the turbine return the condensate water back to the boiler. These pumps are called condensate pump and feed pump. The water back to boiler becomes steam again after heated. The condensate water is preheated by the heater before flowing into the boiler. The steam turbine drives the generator by a big coupling. 5.2 Structure of Steam Turbine 124
5.2.1 Rotor and Stationary Blade Steam turbine has two major components, i.e. rotor and cylinder. The rotor has a shaft supporting on the oil lubrication bearing. The turbine blades are fixed on the shaft, the blades at each place are different in length. The blade at the place where the high pressure steam enters the turbine is shortest, while the blade at the place where the steam leaves the turbine to enter the condenser is longest. The diaphragm is fixed on the cylinder of turbine. The diaphragm is assembled with fixed blade. The blade on different diaphragm is different too, so as to match with the rotor blade. The rotor stretches from the cylinder to the bearing. A sealing device is needed to avoid the steam leakage or air leakage. Such sealing device is called steam seal gland. But there would be steam leakage, so adjust the seal gland to control the leakage volume. 5.2.2 Rotor Blade High pressure steam is sprayed to the rotor blade by the nozzle, to turn the rotor. The steam firstly flows through the first line of moving blade, then the first line of stationary blade. Playing a role of nozzle, the stationary blade makes the steam act force on the second line of moving blade. Such acting would be continued along the length direction of the rotor. The pressure is loss when the steam flows through the blades. Till the last line of blade, the pressure nearly is dropped to zero. The steam would flow to the condenser at this stage and become water. In the steam turbine, each pair of moving and stationary blades is called a Stage. One set of turbine has several ten stages. 5.2.3 Extraction Point After passing through many stages, the pressure and temperature of steam drop. Extract part of steam from the turbine by the pipe. After passing through another stage again, extract the steam again. There are several such steam extractions along the blade line. The steam extracted is sent to the feed-water heater to heat the boiler water. 5.2.4 Coupling A coupling is mounted at the low pressure end of turbine rotor or condenser end, which is used to transmit the driving force of turbine rotor to the generator. 5.2.5 Speed Governor Speed governor controls the steam supplied to the steam turbine. It is a kind of hydraulic control system, which controls the steam inlet valve, in order to make the steam entering the turbine meet the demands. 5.2.6 Oil System The oil needed by the steam turbine is used to: 125
(a) (b)
Supply lubrication oil for the bearing. Supply oil to hydraulic control system of speed governor.
The turbine rotor drives the oil pump to pumps the oil from the oil tank. Prepare a motor driven auxiliary oil pump to supply the oil in startup and shutdown. The temperature of oil is very high when it leaves from the bearing because it plays a cooling role when it is supplied to the lubrication oil bearing. After cooling by lubrication oil, the oil temperature drops, then it could be delivered to the bearing again. The oil is cooled by the cooling water delivered from cooling water system in the cooler.
6 Start Up
6.1 Two Basic Operations to Start Units 1) 2) Cold start Hot start
Cold start means the time for the unit without load is very long, and the metal components are without residual heat any more, whose shrink has finished or close to finish. Before the unit recovers its working temperature and pressure, a long starting time is needed. If the time for the unit without load is short, and the metal components have a lot of residual heat, hot start is used at this time. Thus the unit can be started up in quick time, but the shrink will last a certain time. The purpose of hot start is to prevent the shrink ASAP. After the unit is started in short time, the metal components will gain the heat again quickly, so they will expand again later. Before the unit loading 30-40% of normal load, the shrink may not stop. Initial pressure rise for the boiler may be unnecessary in the hot start. Hence, the boiler keeps a certain pressure, maybe keeping the pressure to the next day. But the boiler steam temperature is dropped, which is lower than the metal temperature of the steam turbine. Before delivering the steam to the turbine, the boiler steam temperature must be raised above than the turbine metal temperature. 6.2 Typical start could be operated as following steps: 6.2.1 Start blower 6.2.2 Start feed water pump 6.2.3 Put burner into operation and have ignition 6.2.4 Speed up steam turbine 6.2.5 Start ball mill 6.2.6 Connect to power grid in synchronous 6.2.7 Increase load of steam turbine 6.2.8 Put the other auxiliary equipment of steam turbine into operation 126
6.2.9 Fully change the control from the manual to the automatic 6.3 The method of hot start and cold start is similar except the time. The following the procedure of start. 6.3.1 Check In order to ensure the safety of operators and avoid the damage of equipment, the below checks must be done. a) Check the position of each component, especially the component removed during the overhaul. Check the position of various covers, guards, etc. If any one of them is not at its place, check them and inquire the person concerned. Observe if the glass and instrument indicate. Check if the power is live, and if it is closed. Check if the valve is unlocked and in the operation position.
b)
c) d) e)
f) Check if the recorder and alarm system work normally g) Check if the foreign materials (all tools, pieces of insulation material, cloth piece, etc.) are removed from the operation area.
6.3.2 Preparations for Steam Turbine The preparations for the steam turbine and the boiler should be made at the same time. Check each auxiliary pump, bearing oil pump, oil pressure, flow, leakage. Then slowly turn the steam turbine by one set of motor, which is called turning gear. By this method, it is easy to control the initial rotating force. At this time, check the eccentricity of the shaft, and check if the rotation is smooth. Turbine shaft is a weight and long metal part. It would bowl slightly in stationary condition. Like a wooden board bridged on the creek, the board would be bowled when a person stand on the board. If the bending of the shaft is serious, there would be serious damage in the speed up of turbine. It is impossible to straighten the bending of such big metal part in short time. Such bending make the turbine shaft become soft in the high-speed rotation. The bearing may be damaged seriously due to the vibration generated. The vibration would become very serious at a certain speed. Such speed during speed up is called critical speed. Pay close attention to the bearing vibration under critical speed, and ensure to keep the vibration in specified limitation. Other possible reasons to cause vibration: unbalanced force resulted from over-large flow of steam at shaft seal or partial overheat of shaft for high temperature; resistance to the shaft by low-temperature and high-viscosity lubrication oil. These two conditions can be controlled by the operator. 127
Cooling water is needed, put the cooling water pump into operation. Put water feed system into operation, and start one set of condensate pump. Carefully check turbine extraction valve and deaerator. Main steam pipe means the pipe between the boiler and the turbine, which steam enters the pipe, but doesnt enter the turbine. The most important thing during the steam turbine startup is to drain water to steam pipe sufficiently. Usually, a governing valve is equipped on the draining pipe for present HP equipment. The valve is opened automatically when the turbine needs water drain, and closed automatically when the turbine doesnt need water drain. The sealing is needed at different point on turbine cylinder, so that the turbine wouldnt suck air during the operation. The method is to seal the sealing points in the steam seal gland. Pressurize the seal gland by steam, thus, the steam turbine sucked is the steam, instead of the air. When both steam pipe and seal gland are with pressure, put the air extraction equipment into operation to extract out all the air in the steam turbine, to form a vacuum in the internal of steam turbine finally. The vacuum rise of steam turbine would result in the problem relevant to the seal gland. The problem in the hot start and cold start is different. In general, for cold start, avoid the hot steam flows through the seal gland to contact the cold shaft; for hot start, dont let the cold air flow through the seal gland to contact the hot shaft. When the hot steam contacts the cold shaft, partial expansion will happen; when the cold air contacts the hot shaft, shrink will happen. The service life of the shaft will shorten due to big partial temperature different. Uneven expansion or shrink will make the shaft bowl, causing over-vibration of steam turbine in speed up. In order to avoid these problems, usually, pressurize the seal gland by steam before vacuum extraction. 6.3.3 Start Procedure for Steam Turbine The criteria to determine the start procedure is metal temperature of HP or IP turbine rotor before the steam entering the turbine. When the metal temperature of the HP or IP rotor is smaller than 204, have cold start. When the metal temperature of HP or IP rotor is 240 or above, has hot start. The hot start is divided into warm state, hot state and ultra hot state. The metal temperature of HP rotor is measured by the thermocouple in the high pressure inner cylinder. The metal temperature of intermediate pressure rotor is measured by the thermocouple on the stationary blade of intermediate pressure turbine. 6.3.4 Cold Start Procedure When the lowest superheat steam temperature is 56 and the total steam temperature is smaller than 427 at inlet of main steam valve, deliver the steam to the turbine. The inlet parameters of main steam valve, such as steam temperature, pressure, etc. should be in the range of curve Start Steam Parameters before Main Steam Valves. 128
These parameters assure the uniform heating and optimum differential expansion. At the same time, control the speed from main steam valve to governing valve, avoid the hot impact to steam chamber. The steam temperature before reheating valve should be in the range of curve Requirement for Start Reheating Steam Parameters. According to the request in the graph Suggestion for Turbine Warming up Speed, rise the speed of the unit in the rotor warming speed range. Keep enough long operation time for turbine at this speed, so that the HP/IP rotor is heated to brittle transition temperature (121) at least when it continues to speed up to synchronous speed. The purpose to keep the rotor heating is to avoid the brittle broken by limiting stress of rotor inner hole with temperature lower than 121. The duration of turbine warming up is decided by the graph Turbine Warming up Rules for Cold Start. when the steam temperature at the inlet of reheating valve is less than 260, dont heat. The important is not to shorten the heating time in the emergency. While, it is always that some operators still hope to synchronize the unit with the grid and put the unit into operation in short time. Heat the rotor according to the method mentioned above is practicable, reliable, economic when impulse starting. After keeping rotor heating, accelerate the turbine speed to synchronous speed. Then parallel the grid in synchronous and add the initial load according to instruction of adding load. Start Procedure before Turn Rotor OPER AUTO is a basic control mode for the turbine-generator unit. The unit always adopts such mode or remote auto mode except emergency operation of accident. Before reset the unit, the operators of steam turbine should monitor CRT displaying the normal operation. Precaution During the operation of turbine, if the door of DEH control cabinet is opened, dont operate portable radio equipment beside DEH controller except the door is closed. A radio transmitter with 5W may cause 10-15% position change of steam governing valve. After finish the preliminary checks and various operations, continue to do the followings: a) Select SPEED IN loop, which make the automatic controller trace the manual controller. Put the controller in the mode of OPER AUTO. Check Valve Position Limit Limiting. The reading shall be zero. Push the button of LATCH in two seconds. When the steam turbine is reset, the signal of TURBINE TRIPPED is disappeared. 129
b) c) d)
e)
Check valve graphic display, make sure RSV OPEN. For other valves status, please refer to the Suggestions for Start and Load Change.
f) Select the button of VPL RAISE, keep the valve be up to 120%. Fully (100%) open the steam governing valve. g) Operate the emergency governor by remote governing button or manual handle on the front bearing bracket, to govern the main steam valve, steam governing valve, reheating steam valve and governing valve. Make sure all valves closed automatically. Reset the unit according to the instruction in the step (4) mentioned above. Then, repeat the step (5) and (6). Over-speed protection controller (OPC) 1) Insert the key in the switch of OPC, turn the switch to the position of OPC TEST. Rapidly close the governing valve (GV) and intercept valve (IV) in 2 seconds. Close the check valve too. The air pilot valve isolates the air source, exhausts the air through steam extraction check valve to the atmosphere. Turn the key to the position of NORMAL. Open the governing valve (GV), intercept valve (IV) and check valve again. The air pilot valve pilots the air pressure to the steam extraction check valve. Take off the key and put it in a safe and reliable place. Do this test before starting the steam turbine by turning gear each time.
h)
i)
2)
3) 4) j)
Electrical monitor and stop of emergency governor system 1) The test procedure is completely in accordance with the description of Emergency Governor System. The test could be at the proper time thought by operator, either synchronizing the grid, or disconnect from the power grid.
k)
At this time, prepare to impulse starting by steam for the turbine. Please refer to the contents of Suggestions for Start and Load Change. The contents in adjacent chapter are suitable for Cold Start. If Hot Start is used, please refer to the contents of Hot Start, Impulse Starting by Steam.
Cold Start ----- Impulse Starting by Steam Refer to the chapter of Suggestions for Start and Load Change, to determine when adopt cold start. And according to operation request, determine when adopt Bypass Off procedure. Assume the operators clearly knowing the contents of DEH system. This material of training only gives general description for the concerned operations. Please refer to the relevant contents of DEH system for the details. Status before Steam Supply 130
a) b) c)
The steam turbine is turning by rotating device . Main steam valve is fully closed. Fully open the steam governing valve, intercept valve and reheating governing valve. The parameter of throttle steam is in accordance with the specification of graph Start Steam Parameters before Main Steam Valve. Vacuum break valve is closed. Open all drainage valves of steam turbine. The back pressure (absolute pressure) shall be as lower as possible, and which should not bigger than the reheating steam temperature provided by curve of full speed no load in graph of No Load and Low Load Operation Guide and the combined value of steam exhausting pressure at LP. When the biggest load ensured is 5%, the limitation for the reheating temperature and LP steam exhausting pressure also is in this graph.
d)
e) f) g)
Precaution: When the load exceeds 10% of rated load till 100% load, the maximum back pressure allowed for parallel operation is 0.0186MPa. a) When the load is low, or under full-speed no load, the low back pressure is requested. Such operation should meet the specification of graph No Load and Low Load Operation Guide. If the limit of back pressure is not complied with, the blade may be damaged, or the components and parts of steam turbine may be damaged seriously by the friction between moving and stationary parts.
Precaution The operator must assure when the speed of steam turbine is bigger than 3r/min, the water used for water-spray control valve of LP cylinder is in the state of standby. Impulse Starting by Steam a) After finish the operations described in the chapter of Starting Procedure before Steam Inlet, speed the steam turbine at acceleration of 100r/min till to given speed of 600r/min. When the operator push the button GO, bypass pilot valve in main steam valve is opened by DEH controller, several seconds later, the speed of the turbine begins to rise, up to 600r/min. The turning gear will uncouple automatically. Warning To avoid the damage, dont close to the control stem of turning gear which at uncouple under the force of compressed air. c) Keep the turbine operate in enough long time at the speed of 600r/min, so as to 131
b)
check if all monitor instruments of turbine are in good condition. Before raising the speed of turbine to exceed 600r/min, the stable value displayed by the eccentric recorder is smaller than 0.076mm. Monitor the vibration at the speed above 600r/min, the satisfied vibration reading shall be smaller than 0.076mm. Avoid Resonance of LP Steam Turbine Blade during Warming Up a) If warming up operation is needed during speed up, push the button (HOLD), the turbine stops speeding up to keep the warming up.
Precaution If the turbine warming up operation is needed due to the accident happened, please refer to the specification in graph of Suggestion for Turbine Warming Up Speed. It must be assured that the warming up speed is not in the range of resonance speed. If it happens to in this range, drop the speed below the resonance range. b) In order to continue routine speeding up procedure after a operation step of turbine warming up, a button ON needs to be pushed.
Process of Rotor Heating in Cold Start (Turbine Warming up at Medium Speed) Precaution In initial start, dont adopt the program of ATC during turbine warming up (if any). Adopt the curve in Turbine Warming up Rules for Cold Start. a) Input the target speed into Control device. The speed is in the range of Rotor Heating at Medium Speed which is shown on the graph of Suggestion for Turbine Warming up Speed. Push GO button. When the speed reaches the given speed, the steam turbine keeps medium speed warming up time specified in Turbine Warming up Rules at Cold Start. The medium speed warming up is begun when the steam temperature at inlet of intercept valve exceeds 260. Medium speed warming up is no longer needed when the metal temperature of IP rotor is bigger than 121. Turbine warming up is not needed for the HP/IP rotor without centre hole.
b)
Precaution When the operator requests to synchronize the unit to the power grid in short time, it is important not to shorten the turbine warming up time. c) During heating the rotor at medium speed warming up, the highest inlet temperature of main steam valve limited is 427. Keep the reheating inlet temperature be above 260. Refer to the graph of Starting Steam Parameters, to determine the main steam parameters before changing from main steam valve control to governing valve control. During the whole operation of steam turbine, keep the turbine steam, limit value of metal thermocouple and limit value of monitor instrument for turbine. 132
d)
Control from Main Steam Valve to Governing Valve a) Speed up the turbine at acceleration of 100r/min to suction valve exchanging speed shown on the graph of Suggestions for Turbine Warming up Speed. Before changing the control from main steam valve to governing valve, check if the inner wall temperature of steam chamber is equal to the saturated temperature of main steam throttle pressure. The graph of Starting Steam Parameters before Main Steam Valve shows when the temperature of steam chamber reaches the set value, usually, the relation met the request for main steam valve inlet pressure and temperature may happen. When the unit reaches the exchanging speed, and passes the first stage test, change the control from main steam valve to governing valve as follows:
b)
Push button TRANSFER TV-GV Observe the control change from main steam valve to governing valve by main control page on CRT. When the transfer is finished, the main steam valve is fully opened, the steam turbine is controlled by the governing valve. c) d) e) See the button of SINGLE VALVE SEQUENTIAL VALVE on the control panel. Raise the turbine speed to 3000r/min by the acceleration of 100r/min. As usual practice, after full speed is reached, the emergency governor is suggested to act, to check if the over-speed governing mechanism and steam valve work normally. Operate the over-speed governing mechanism by the button of Shut Down in the turbine control room or the manual governing handle on the front bearing pedestal. All main steam valves and intercept valves must be fully closed. After the emergency governor acted, the target value and set value of the speed return to zero. After the emergency governor acting, the control system is on TURBINE MANUAL position due to some reasons, recover it to OPER AUTO position. In order to latch the turbine operating in high speed, continuously operate as follows: 1) Push the button of LATCH several seconds. The target value and set value of the speed will be increased to the actual speed of turbine. Raise the acceleration from 100r/min to 200-250r/min. Input the speed exchanging valve (assume the turbine speed dropped is lower than this value) Push GO button. When the steam turbine reaches the exchanging speed, as what described above, the TV is exchanged to GV. Raise the speed of turbine unit to 3000r/min at the acceleration of 133
f)
g)
2) 3)
4)
5)
200-250r/min. h) i) Before synchronous operation, test the over-speed governing mechanism. Close the AC lubrication oil pump and seal oil standby pump. And put them on AUTO position. If necessary, deliver the water to oil cooler, and control the water volume, to keep the highest outlet oil temperature of the bearing is lower than 71. j) According to the detailed instruction in Instruction Manual for Generator, deliver the water to hydrogen cooler of the generator. Maintain the limiting condition of No Load expressed in the graph of No Load and Low Load Operation Guidance. Refer to the chapter of LP Steam Exhausting and LP Steam Exhausting Water Spray Device in Operation Limits and Precautions. Synchronize and Increase Initial Load a) Push the button of AUTO SYNC, the control for turbine speed is exchanged to automatic synchronous controller. At this time, inputting the contact closing signal of up/down, the automatic synchronizer makes the steam turbine in the synchronous speed and synchronizes the unit to parallel with the power grid. After the main switch of the generator is closed, the control of the unit will return to OPER AUTO automatically. Make it synchronize and rapidly increase the load to 5% of rated load. Stably operate at least 30 minutes under 5% load. During the stable operation, 1 minute operation time is increased if every 2 is changed for the inlet steam temperature of TV. After closing main switch of generator, power value in megawatt is displayed on DEH. It will automatically control the governing valve at the position of 5% load for existing steam throttle pressure. Push button IMP IN, put the first stage pressure feedback loop into operation. When it is in the mode of IMP OUT, the megawatt Setting Value displayed is different from the actual load displayed. When it is in the mode of MAP IN, the megawatt Setting Value displayed is basically the same as the actual megawatt value. Push button MW IN, put the MW feedback loop into operation. When it is in the mode o MW IN, the megawatt Setting Value displayed is adjusted precisely to the megawatt value of power generated. 1) The exchanges between IMP IN and IMP OUT, and between MW IN and MW OUT are stable, which dont affect the load value. When Setting Value is counting to Target Value, the exchange from MW OUT to MW IN, then MW OUT, will stop the Setting Value counting, and make the Target Value equal to Setting Value. 134
k)
b)
c)
d)
2)
3)
When MW OUT, the exchange from IMP IN to IMP OUT, or vice versa, will cause such conditions too.
6.3.4 Hot Start --- Impulse Starting by Steam Refer to the chapter of Suggestions for Start a Load Change, to determine when the hot start procedure is adopted. And according to the operation requirements, determine when the Bypass OFF procedure is adopted. Assume the operators clearly knowing the contents of DEH system. This material of training only gives general description for the concerned operations. Please refer to the relevant contents of DEH system for the details. When the lowest reheating temperature of steam is 56, deliver the steam to the turbine. The curve of Starting Steam Parameters before TC means the TV inlet steam temperature and pressure for speed control exchanging from TV to GV. The time for turbine speed from turning gear to synchronous speed is changed according to un-match condition of 1st stage steam chamber and initial temperature among metal. The reasonable acceleration time is decided by the graph of Suggestions for Hot Start. In order to shorten impulse starting time, TV steam parameters should be changed to the steam temperature of TV under 5% load, and the temperature of 1st stage steam chamber should be up to the range of rotor metal temperature (38) before impulse starting. Under such condition, the acceleration time advised is 10 minutes. If the temperature matches well, from the view of thermal stress, the rotor could be in the synchronous speed from beginning, which is entirely possible in the theory. But from the view of actual condition, it is better to select the minimum acceleration time of 10 minute. When the synchronous speed is reached, synchronize the turbine and parallel it into the power grid, and live it with initial load according to the specification of graph Suggestions for Hot Start. After the steam entering the turbine, the rotor will expand the cylinder quickly. There are two reasons. The first reason is the rotor mass is lighter than the cylinder; the second reason is the rotor is covered by the steam, while for the cylinder, only its inner wall contacts the steam. In order to avoid the collision between the branch blade and stationary blade caused by such expansion difference, at the same to turn the rotor by steam, heat the cylinder by steam. Thus, we are requested to control the speed up rate for turning rotor at different conditions. Status before Steam Supply a) b) c) The steam turbine is turning by rotating equipment. Fully close the main steam valve. Fully open the governing valve, reheating steam valve and reheating governing vale. Throttle steam parameters are in accordance with specifications in graph of Suggestions for Hot Start. 135
d)
e) f) g)
Close vacuum breaking valve. Open all drain valves of steam turbine. The back pressure (absolute pressure) shall be as lower as possible, and which should not bigger than the reheating steam temperature provided by curve of full speed no load in graph of No Load and Low Load Operation Guide and the combined value of steam exhausting pressure at LP. When the biggest load ensured is 5%, the limitation for the reheating temperature and LP steam exhausting pressure also is in this graph.
Precaution When the load exceeds 10% of rated load till 100% load, the maximum back pressure allowed for parallel operation is 0.0186MPa. a) When the load is low, or under full-speed no load, the low back pressure is requested. Such operation should meet the specification of graph No Load and Low Load Operation Guide. If the limit of back pressure is not complied with, the blade may be damaged, or the components and parts of steam turbine may be damaged seriously by the friction between moving and stationary parts.
Precaution The operator must make sure when the turbine speed is bigger than 3r/min, the water for LP water-spray control valve is in the standby status. Impulse Starting by Steam a) After finish the operation described in the chapter of Starting Procedure before Steam Inlet, decide the acceleration valve according to inlet steam data of TV before delivering the steam to the turbine. The various specifications in Suggestions for Hot Start mused be used. Raise the turbine speed to set speed 600r/min at the acceleration selected. When the operator push the button GO, bypass pilot valve in main steam valve is opened by DEH controller, several seconds later, the speed of the turbine begins to rise, up to 600r/min. The turning gear will uncouple automatically. Keep the turbine operate in enough long time at the speed of 600r/min, so as to check if all monitor instruments of turbine are in good condition. Before raising the speed of turbine to exceed 600r/min, the stable value displayed by the eccentric recorder is smaller than 0.076mm. Monitor the vibration at the speed above 600r/min, the satisfied vibration reading shall be smaller than 0.076mm.
b) c)
d)
Avoid resonance speed of LP turbine blade during the turbine warming up. Exchange the control from TV to GV Synchronize and raise initial load. 136
When start a reduced or rated main steam valve pressure, synchronize it according to the following sequence and take 5% of rated load immediately. The time to have stable operation under 5% load depends on the specification in the graph of Suggestions for Hot Start. If the steam parameters of main steam valve are under the precise match line in the graph of Suggestions for Hot Start for 1st stage steam temperature is lower than the metal temperature, thus, the stable operation time is not needed. According to the indication of the graph, give the lowest load by keyboard input. Further load increasing should be done according to the contents described in the chapter of Load Change. As usual practice, after full speed is reached, the emergency governor is suggested to act, to check if the over-speed governing mechanism and steam valve work normally. Operate the over-speed governing mechanism by the button of Shut Down in the turbine control room or the manual governing handle on the front bearing pedestal. All main steam valves and intercept valves must be fully closed. After the emergency governor acted, the target value and set value of the speed return to zero. Parallel the turbine with power grid in synchronous and increase the load slowing. It will take a little long time to increase the load, so that the turbine can expand uniformly after thermal absorption.
7 Operation
7.1 Check all conditions during the operation periodically, which is very important. Most of conditions are checked by the monitor and testing instruments. Pay close attention to the followings: a) b) c) d) Expansion at front of the steam turbine Differential expansion of steam turbine Rate of temperature rise or change Vibration of rotor
7.2 If any abnormal condition happened, we must take action and remove it: a) b) c) Keep the load or drop it Drop the temperature of main steam or reheating steam Check the oil pressure and temperature of the bearing, and the vacuum. If the vacuum is not enough, increase it. Check if the governing valve is stable. Adjust steam temperature of seal gland.
d) e)
7.3 Along with the increasing of unit load, even it is a little loss in the efficiency, it must be corrected as quickly as possible. This is very imported. Periodically check to assure there is no water loss for draining water or overflow of water tank. 137
7.4 Pay attention to the leakage at connection of pipes and valves. The leakage which could be treated under the unit with load must be solved as earlier as possible. Check the condenser to see if it is with optimal vacuum. Check if it necessary to operate two vacuum pumps to keep the vacuum. If necessary, find out the vacuum joint and sealing leakage, sealing them well. Check if the air pump is operated effectively. Check if the sealing of turbine seal gland is normal. For common-used cooling water supply, try to reduce the power for water pump without affecting the performance of condenser. 7.5 Suggestions for Load Change 7.5.1 General The load is changed along with the change of steam in the flow part. The thermal stress generated by the rotor depends on the load volume (heavy or light) and change rate of the load. If the purpose is to limit the stress reaching the value applicable to fatigue life selected, thus, the single change rate applicable for the turbine is not existed. During the stable operation without exceeding the limit, a small change could be completed instantaneously. Vice versa, the big change can be done in short time. In the whole load range, the biggest change of steam temperature happens at the first stage of high pressure steam turbine. The temperature of the first stage is changed along with the load. Moreover, the change degree of temperature depends on the operation mod of governing valve. The various possible modes for load change are: 1) Nozzle Control: under this mode, the governing valve is opened or closed in sequence according to instruction under the condition that the inlet steam parameter of main steam valve is changed or not changed; Throttle Control: under this mode, a group of governing valve is opened or closed at the same time to change the flow area of the valve; Variable-Pressure Control: in this mode, open a group of governing valve, at the same time, change the pressure at inlet of main steam valve, so as to reach the flow change.
2)
3)
The governing valve controls the steam flow of each nozzle box distributed along the circle, so that when all the valves are opened, it can deliver the steam to the first stage blade at 360. Thus, each governing valve deliver some steam to 360circle. Under Nozzle Control mode, along with the governing opening and closing in sequence, the steam is supplied to the blade by changing circular suction segmental arc. The degree of steam suction segmental arc could be expressed in percentage of circular steam suction segmental arc. Under Throttle Control mode, open all governing valves at the same time. When it supplies the steam to the circular 360steam suction segmental arc, change the flow by changing the opening degree of the valve. Under Variable- Pressure Control mode, each governing valve keeps fixed opening, it supplies the steam by unchanged segmental arc or percentage of steam suction. Under partial load, compared with the operation in the mode of Nozzle Control, if the 138
steam turbine operates in the mode of Throttle Control, the temperature for the governing stage is higher, which is good for the blade and rotor contact surface. The distribution of mechanical stress on the contact surface of the blade and the rotor could become uniform with time pass. Therefore, for the first six months operation, the steam turbine should be operated in the Throttle Control mode, then if the user assures that each measure point is regulated correctly, and all systems operate normally, thus, the operation mode could be changed to Nozzle Control. From the view of thermodynamics, under the low load, compared with Throttle Control and Variable-Pressure Control, Nozzle Control is a kind of effective operation mode. But, at the mode of Nozzle Control, the temperature of the first stage steam is changed a lot along with the load change. Therefore, a little long time is needed to finish the change of the load. At the mode of Variable-Pressure Control, all governing valve keep the position of full open, while, the main steam valve pressure is changed, which result in the minimum change for the first stage temperature, i.e., quick change rate for the load is allowed. But, the ability of operation at the mode of Variable-Pressure Control depends on the boiler and the control system of boiler and turbine. When change the load by Throttle Control, the change of the first temperature is smaller than that in Nozzle Control mode, but bigger than that in Variable-Pressure mode mentioned above. In the load range from 5% - 100%, the load change graph applicable for the turbine in various operation mode provides the guidance to the operator. It allows the operator to select the load change rate corresponding to circulation number of effective life. If all load changes begin from the mental temperature of the first stage initial stable condition, and finish under uniform change rate, thus, the stable turbine metal temperature and differential expansion, cylinder expansion, rotor position reading, prove the exist of stable conditions. Please refer to the information of instruments mentioned in Thermocouple for Measuring Steam and Metal Temperature and Monitor Instruments, all of them provide the information about this aspect. 7.5.2 Change the load by nozzle control or throttle control Determine the time to change the load according to the graph of Suggestions for Load Change (constant pressure operation), so as to determine a uniform change rate of the load. For the load change under low load, usually, it is reached by affecting the inlet steam pressure of the first stage temperature and changing the temperature. Due to the variability of the boiler under low load, the manufacturer of the steam turbine cant decide the unified standard for the operation in the range of low load. In order to select the change rate of the load which is complied with 10000 circulation index or other circulation life, the influence for the first stage temperature by inlet steam data must be considered. The fig. 1 and 2 in the graph of Suggestions for Load Change supply the necessary information for deciding the first stage temperature change of any combination of load and inlet steam data. The curve of Nozzle Control mode in Fig. 2 is suitable to a certain minimum degree of admission. Control each governing valve according to the opening sequence, so as to let the steam pass through the nozzle for the first stage blade in 139
enough big arc section to avoid the first stage blade heated. The curve of Throttle Control mode is suitable to 100% degree of admission. Open all governing valves at this time. In Fig. 2, determine the change of the first stage steam at the change of load. Project this temperature change to circulation index selected in Fig. 3, the operator can determine the time needed for load change. The time selected is suitable to load increasing and reducing. From the figures, we can find that the load change making the internal temperature change be lower than 70 could be finished in instantaneous. It wont exceed the stress for fatigue index 10000. It is like as the expression of the crossing point between the fatigue index 10000 line and axial line of zero time. But this doesnt mean that the series load changes could be finished in the short time as a certain sudden increment, at the same time, keep the first stage temperature be lower than 70. For example, if increase the load 40%, which makes the first stage temperature change 70, thus, 15 minutes later, dont increase another 40% load (70 temperature rise happen too). The working condition for stable temperature between two times of load change wont be reached in 15 minutes. Hence, the operator should decide the time or change rate separately. Finish the total load change according to each curve (which is 80% in this example). The allowed load change in Throttle Control mode is faster than that in Nozzle Control mode. From the Fig. 2, we can see that in the same load change range, the change range of first stage temperature in the mode of Throttle Control is narrower than that in the mode of Nozzle Control. During the operation, exchange the mode from Nozzle Control to Throttle Control by DEH controller, the steam temperature of the second stage would be increased immediately. Its increasing value is the difference of these two operation modes in the figure. 7.5.3 Change the load by the mode of pressure change and nozzle control (also called mix control) Refer to the graph of Suggestions for Load Change (variable-pressure operation), change the time of load and change rate by main steam pressure change. Although Fig.1 basically is suitable to the variable-pressure operation, it also includes the curve which is suitable to Throttle Control and Nozzle Control. In the example shown in the figure, these three kinds of modes for governing valve operation are used from 5% to 100% load increasing. The using of such mix mode is called mix control operation. Throttle control mode is used from 5% initial load, variable-pressure control is used in the load increasing when the main steam pressure changes to the rated pressure from the lowest under the governing valve is at a certain opening degree. Nozzle control is used when the load is increased to 100% with unchanged rated pressure of the main steam valve. In Fig.2, the temperature change of each stage steam between the highest and lowest temperature is determined during the load change. Such temperature change is based on unchanged temperature of main steam valve during load change. Therefore, the temperature change between two load values must be corrected by the temperature change line for temperature change of main steam turbine in Fig.2. By the project line of this temperature, mark it on the fatigue number line request, the operator can determine 140
the time to finish the load change according to it. From the figure, we can see the temperature change of the first stage when the governing valve operates at various modes. We can find that under the condition with unchanged rated pressure for main steam valve, firstly adopting Throttle Control mode, then Nozzle Control mode, to change the load, the temperature change of the first stage steam is bigger than that in Mix Control. Therefore, Mix Control mode allows faster load change.
8 Shutdown
8.1 Normal Shutdown The unloading rate of steam turbine in a certain operation condition shall comply with the specification range in Figure "Suggestions to load change. 8.1.1 Unloading 1) The recommended unloading time can be found in Figure "suggestions to load change (refer to Example 2 in the figure). The load change rate represented in the percentage of power per minute shall be determined. Convert the load change rate into MW/min Input the required load change rate MW/min Input the required load target. After the GO button is pressed, the load setpoint will be changing towards the target at the selected load change rate, while the load will be shown decreasing on screen. The HOLD button can be pressed if a stable load is required during unloading process and the load will stop decreasing. The GO button can be pressed again if required to continue the unloading process at the load change rate selected before. The unloading is complete when the load setpoint equals the load target. Ensure all drain valves of steam turbine are open at 20% load. These drain valves, controlled automatically in normal conditions, still need to be operated manually by operators if required. When the load decreases to zero the unit will be tripped by the overspeed governor. The main stop and control valves and reheat stop and control valves are fully closed at the same time.
2) 3) 4) 5)
6)
7) 8)
9)
8.1.2 According to the operation practice the vacuum breaker valve can not be opened until the steam turbine coasts down to the speed of 400r/min or the turning gear is engaged with the rotor. The vacuum breaker valve shall not be opened immediately upon the actuation of the emergency governor, which will lead to the damage of blades because of the braking effect caused by the thick exhaust steam, unless for 141
the purpose of shortening the coast down time in case of emergency. The vacuum shall be broken before shutting off the gland seal steam. 8.1.3 Ensure the bearing lube oil pump is started when the lube oil pressure decreases to a certain setpoint. 8.1.4 Ensure the select switch of the lift oil pump at the AUTO position. 8.1.5 Close the motor operated steam extraction valve. 8.1.6 Shut off the cooling water supply to the hydrogen cooler of the generator according to the specification of the generator. 8.1.7 Shut off the gland seal steam and stop the blower of gland seal condenser and the condensate pumps when the vacuum is at zero. 8.1.8 Ensure the control switch of the turning gear is at AUTO position for the auto engagement. 8.1.9 Stop the circulating water pumps. 8.1.10 Control the temperature at the outlet of the oil cooler at the range of 35 to 38 by modulating the cooling water supply to the oil cooler. 8.2 Emergency Shutdown 8.2.1 Load upon Being Tripped from the Grid In case of losing the whole or part load the energy of the remaining steam can lead to the acceleration of the rotor in a rate proportional to the load at the time the unit is tripped from the grid. 1) The OPC, which is included in the DEH control system ,can perform the following functions: a) "OPC" unloading. The function of the load decreasing prediction, which is active when the load is greater than 30% of the rated load or the generator breaker is tripped, is to detect the whole load rejection process and closes all main control valves and reheat control valves to prevent overspeed of steam turbine, When the generator breaker is tripped the speed setpoint in the DEH control system will be reset to the rated speed and will be at OPER AUTO mode. In the operation mode without bypass, the main control valves and reheat control valves will be closed after the generator breaker is tripped. The auxiliary controller will be cutoff and the reheat control valves will be allowed to open slowly when the speed decreases below the setpoint of the auxiliary controller after certain time. The remaining steam in the reheat system will lead to the speed acceleration. At the same time the auxiliary control valves will be put into operation and the 142
reheat control valves will be closed again. This control mode will continue until all the remaining steam disappears by controlling the reheat control valves. The main control valve will be kept closed when the speed is greater than the rated speed because of the speed error. The reheat control valves will be kept on open position and the speed will decrease towards the rated speed after the remaining steam in the reheat system disappears. At rated speed the main control valve will assume the control of steam turbine while maintaining the speed at rated value. In the operation mode with bypass, the main control valves and reheat control valves will be closed and the exhaust valve of HP casing will be opened quickly ,which makes the HP casing connected with the condenser and depressurized to vacuum after the generator breaker is tripped. The auxiliary controller will be cutoff when the speed decreases below the setpoint of the auxiliary controller after certain time, while the main control valves and reheat control valves will be allowed to open slowly. The reheat control valves will be opened to the position recorded when the speed is at 2900r/min and the rated speed of unit will be maintained by the main control valve. b) The function of OPC is to detect the steam turbine overspeed automatically and close all the main control valves and reheat control valves when the speed is greater than 103%.The function of OPC is to control the main control valves and the reheat control valves in the same operation mode for the convenience of eliminating the steam remained in the reheater and to take the unit to synchronous speed. Quick valve control function in OPC Part load rejection will be detected by comparing the input power of the steam turbine (IP exhaust pressure) and output power of the generator(measured by the power transmitter).When the input power of the steam turbine exceeds the output power of the generator by 60%-80%, quick valve control logic will close the reheat control valve only in a quick way. The instantaneous closure of the reheat control valves will reduce the input power of the steam turbine. As a result the output power of the generator will decrease instantaneously allowing the unit keeping synchronized with the grid system. 2) The unit can be resynchronized and loaded according to the following description after load prediction or OPC control is actuated a) The unit can be loaded to the previous load as quick as possible if it is synchronized again within 15 minutes after tripping from the grid. After that the loading shall comply with the specification in Figure suggestions to load change. The loading shall comply with the specification in Figure suggestions to load 143
c)
b)
change if the delay for resynchronization is more than 15 minutes. c) The normal shutdown procedure described above shall be complied if the unit will not resynchronized with the grid.
3)
The steam turbine and the boiler shall be shutdown automatically in accordance with the operating procedure in section of loss of pressure or temperature after specified delay if the root cause of load rejection can not be found and resynchronization with the grid is delayed.
8.2.2 Loss of Pressure or Temperature The operation of main steam pressure limiting (TPL): DEH controller includes the main steam pressure limiting logic. The setpoint of "TPL" is a variable which can be input by the operator through keyboard. The "TPL" function can be enabled or disabled by operators through keyboard. The control system shall be in automatic mode. Operators shall verify that the actual main steam pressure shall exceed the setpoint of "TPL". The "TPL" function will not be active if it is disabled when the control system switches between auto mode and manual mode. The "TPL" function will be disabled, if enabled under auto mode, when the control system switches into manual mode and kept disabled during manual mode of operation. If the main steam pressure decreases when the "TPL" function is being enabled, then the following conditions will occur: a) The "TPL" function will be active if any of the main steam pressure deceased below the "TPL" setpoint. The load will decrease continuously until the main steam pressure is recovered to its setpoint or the main control valves reach the minimum 20% position. Operators shall decide whether the operation pressure or temperature can be maintained when the main control valves are being closed to their minimum 20% position because of any main steam pressure loss. If can not, the steam turbine must be shutdown. Operators can increase the load to the previous value recorded when the loss of pressure occurs if the boiler pressure is high enough. Operators can disable the "TPL" function if it is active.
b)
c)
d)
The following procedures shall be complied when the actual main steam pressure decreases in a uncontrollable way if the "TPL" function is disabled: a) Operators shall decrease the load and maintain the pressure above the 95% of the rated value. The unit shall be unloaded and shutdown if the pressure decreases below the 90% of the rated value. If the load decreases to the 20% of the rated value, then 144
b)
check the drain valves of the steam turbine and the bypass valves on drain pipelines of the steam extraction heaters. Put the unit onto the turning gear and check the rubbing .If everything is ok then the unit will be accelerated and synchronized according to the applicable procedure in warm start or cold start. c) The unit can be loaded in the normal ways after the temperature and pressure are recovered to normal values when the pressure can be maintained above the 90% of the rated value.
8.2.3 The function of the emergency trip system The unit is equipped with the emergency trip systems (emergency governor) which will shutdown the steam turbine in case of emergency. 1) After the steam turbine is shutdown in accordance to the description above, the unit can be reset and resynchronized if the detected failure is already eliminated and the vacuum is maintained. The rotor will be stopped slowly in accordance to the normal shutdown procedure if the vacuum is broken after the steam turbine is shutdown. The unit can be startup again in accordance to the warm start or cold start procedure after the failure is eliminated.
2)
8.3 Operation of Turning Gear During Shutdown Period The turbine-generator shaft can be rotated by the single speed turning gear at 3r/min for the unit with the rated speed of 3000rpm. The turning gear of the turbine-generator will automatically be engaged after the rotor coasts to a stop. Operators shall check whether the turning gear is on continuous operation when the steam turbine becomes cooler, which will prevent bowing of the rotor caused by the steam leakage into the turbine so as to maintain the eccentricity within the allowed range for startup. After shutdown the unit shall normally be kept on turning gear operation until the rotor is cooled down. It may take 10 to 15 days depends the temperature of the inner parts of the turbine. The time will be shortened greatly using steam cooling method before shutdown. The operation of the turning gear during shutdown period will prevent the rotor from bowing and ensure the startup of the unit without delay. The normal lube oil circulation around the journal bearing is sufficient to maintain the cooling of the journal bearing regardless the unit is stopped or on turning gear operation because of the low thermal conduction rate from the gland seal of the rotor to the journal bearing. The journal bearing temperature increases depending on the temperature ramp rate of the inner parts of the steam turbine if the lube oil is shut off. The bearing Babbitt metal may be damaged when the lube oil circulation is lost and the journal bearing temperature exceeds 149. The metal temperature shall be monitored closely during this period, and the lube oil shall be recirculated if the temperature is too high. 145
The lube oil supply can be shut off for 2 to 3 hours before the journal bearing temperature becomes too high if the unit can not be turned for some reason at warm condition (the temperature of inner parts above 204, but not exceeding 454). The lube oil supply can be shut off for about 10 hours if the steam turbine is allowed to cool down to 204. After shutdown the turning gear and lube oil circulation system shall be kept on operation for at least 48 hours if not affecting the work schedule. The turning gear shall be restarted and kept on operation for sufficient time to maintain the eccentricity of the rotor within the allowed range before steam admission into the turbine if the unit can not be rotated continuously during shutdown. The following suggestions can be applied when the operation suggestions for shutdown can not be followed practically if the steam turbine plans to maintenance. 8.3.1 Steam Turbine Planning To Disassemble The turning gear shall be kept on operation until the disassembly schedule demands it to a stop. It must be realized clearly that the rotor may be distorted severely if the turning gear is turned off in case of emergency. After shutdown the lube oil circulation time shall be at least 24 hours to prevent overheating of bearings. During this period the oil temperature at the outlet of the oil cooler shall be controlled within the range of 21 to 35 if possible. 8.3.2 Shutdown for Overhaul The turning gear and bearing lube oil circulation system can be turned off after being kept on operation for at least 24 hours. The oil temperature at the outlet of the oil cooler shall be controlled within the range of 21 to 35 if possible. The unit shall be on turning gear operation prior to opening of gland seal steam and establishment of vacuum. Steam can be admitted for acceleration when the eccentricity of rotor is within the allowable range. These suggestions are also applicable when the lube oil circulation must be shut off for the check or maintenance of bearings. During this period the metal temperature of all bearings shall be monitored. The lube oil shall be recirculated as soon as possible to prevent overheating of bearings. 8.3.3 Shutdown for Maintenance The following procedures can be adopted according to work condition: 1) The turning gear and lube oil circulation system can be shut off for a while, but not exceeding 15 minutes ,after they are kept on operation for at least 3 hours. The lube oil shall be circulated continuously if practical. After 15 minutes of shutoff time specified in (1), the steam turbine will be rotated by the turning gear for 2 hours, or until a stable eccentricity is within allowable range, whatever occurs first. After that the turning gear and lube oil circulation system can be shut off for a while, but not exceeding 30 minutes. The rotor is 146
2)
turned 180by the turning gear after 15 minutes at same time the lube oil circulation shall be started for the lubrication of bearings. 3) After 30 minutes of shutoff time specified in (2), the steam turbine will be rotated again by the turning gear for 2 hours, or until a stable eccentricity is within allowable range, whatever occurs first. The turning gear and lube oil circulation system can be shut off for a extended time as long as the rotor is turned 180every 30 minutes in the following 6 hours while the lube oil circulation shall be started for the lubrication of bearings.
8.3.4 Emergency Operation of Turning Gear The unit shall be on turning gear operation immediately if for any reason the steam turbine is shutdown and the rotor stops rotating. If the turning gear can not be put into operation because of the rubbing between the rotating and stationary parts caused by distortion resulted from thermal impingement, then try to engage it after an hour. If not successful, then repeat the engagement after another hour. If the second attempt still failed the rotor (or blade ring) may be bowing or the distortion of stationary parts is so severe that the unit in stationary condition shall be insulated for 1 or 2 days before the next attempt of engagement of the turning gear. Warning:Never attempt to rotate the shaft by supplying steam to the turbine or using a crane, which may lead to a fatal failure, e.g. increasing clearance between blades and gland seal teeth, scratch on shroud or shaft and broken blades etc. The rotor may be bowing if the power of the turning gear is too small to rotate the rotor. Experience shows the rotor can be straightened by turning for 1 to 2 hours before startup. The extent of bowing can be reduced by turning the rotor 180from its previous position every 15 to 20 minutes as a result the turning gear operation time will be shortened before startup. However no attempt should be made to turn on the turning gear to rotate the stuck parts when the rotor and casing may be distorted in case of water induction to the steam turbine as an example. 8.3.5 Operation of Turing Gear When One or Several Jacking Devices not Working The lift oil system will be put into operation when the speed decreases to the preslected value during steam turbine coasting down period. The unit can be turned continuously on turning gear even one or several jacking devices not working, which may lead to crawling. The following work can be done until the jacking devices return to operation again if crawling has already happened. 1) Start the DC emergency lube oil pump to supplement the oil supply and reduce the oil temperature as much as possible but not lower than 21. Wait a minute. If crawling happens again, then turn off the turning gear and restart it 15 seconds later. If crawling still happens, then turn off the turning gear again. Turn the rotor 180every 10 minutes to keep the rotor at straight condition. Repeat the procedure until the rotor can be engaged with turning gear without crawling 147
2)
3)
again. 8.3.6 Typical Cooling down Time for HP Steam turbine The information about the cool down of HP steam turbine can be found in Curve typical cooling down time for HP steam turbine (refer to the attached figure) when the unit is on turning gear operation after load rejection. This curve is helpful to the development of warm up scheme, warm start procedure or maintenance schedule. User can refer to this curve which is based on the operation data before user finish the actual temperature decreasing curve for his own unit according to the operation experience. 8.3.7 Operation with Steam Cooling The unit can be unloaded and operated at low load to steam cool the metal before shutdown in order to expedite the cooling process of the steam turbine parts for quick maintenance. Decreasing the main steam and reheat steam temperatures are also helpful to lower the temperatures inside the steam turbine. At low load the temperature of HP steam turbine parts is lower when the control valves are in nozzle governing mode than that in throttle governing mode for coal fired unit with control valves. The chart "suggestions to load change and other temperature change limits are still applicable during shutdown period. 8.3.8 Remove Insulation The insulation of the casing can not be removed until the unit is cooled for 24 hours or longer period. It is necessary to prolong the cooling time to prevent the thermal stress of casing, partial cooling and distortion of the casing and temperature differential between casing parts and rotor from exceeding allowable limits.
9 Periodic Function Tests

It is necessary to carry out the function tests for equipments periodically to ensure the maximum reliability of operation besides the tests at startup period. The function of equipments can be tested more often than the recommended requirement if operation experience shows that it is reasonable. 9.1 Weekly Test 9.1.1 Main Steam Admission Valves and Reheat Steam Admission valves The function test of steam admission valves of the turbine shall be carried out weekly when the unit is loaded without bypass operation. The purpose of the test is to ensure the normal operation of main stop valve, main control valves, reheat stop valve and reheat control valves, otherwise these very important devices may not change positions for long time. Operators shall observe the operation of these valves locally during test. These valves shall be moving smoothly and freely. Interrupted movement shows that dusts may be accumulated on valve stem. The repair work must be done if any failure shows during test 148
because the normal operations of these valves are very important. 1) Main steam admission valves Main stop valve and main control valve should be tested when load control function is enabled (MW IN) and first stage pressure control function is disabled(IMP OUT).The control valves that are not on test mode can be modulated to pass the steam flow cut off by the control valve on test mode so that the stable load can be maintained during test. Caution The control valves shall be preferably in single-valve control mode during the test because the blades of regulating stages may be subjected to excess stress if in sequence-valve control mode. It is suggested that he main steam admission valves can only be tested when the load is within the range shown in the attached figure for the safe and reliable operation of the steam turbine. The load at test time should be above the minimum value if the control valves are in single-valve mode operation to prevent the reverse power of the turbine while the load should be above the minimum value corresponding to admission pressure when tested in sequence-valve mode to prevent the blades of regulating stage from excess stress. If the load during the test exceeds the maximum recommended value specified in the figure then the load will be lowered to the value corresponding to the maximum flow that all control valves in one steam chamber can pass. The movement test of valve stem shall be carried out weekly according to following procedure: a) Press the VALVE TEST button to initiate the test sequence for the #1 main stop valve and corresponding control valves Select TV1 and press ENTER The position of main stop valve (in percentage of travel) will be shown. Then press CLOSE button. The main stop valve in left side will be closed after the control valve is closed. Open the main stop valve. Press OPEN button and the control valve will return to the previous position.
b) c)
d) e) f)
149
% g) h)
English Rated pressure of admission steam Recommended load range during valve test Load may decrease when tested in this range Blades at regulation stage may be subjected to excess stress when tested in this range Rated load% Single valve mode sequential valve mode Recommended load range for main steam valve test
Repeat the test above for #2 main stop valve and corresponding control valve. The electrical circuit is interlocked so that two control valves can not be tested at the same time
Fast load feedback can not be achieved in a certain time if the valve is being tested when the load control function is disabled (MW OUT) so that a stable load can not be maintained by auto regulation of control valves, which means that the load may be decreased greatly. Operator shall adhere to the recommended load range shown in the attached figure in order to prevent great decrease in load during test. 2) Reheat steam admission valve The test can be carried out at any load below the maximum value, which decreases about less than 2% during test. 150
The movement test of valve stem shall be carried out weekly according to following procedure: a) The reheat stop valve and control valve will be closed after the TEST button corresponding to the testing valve is pressed. The procedure is the same as that of the main steam valve. The reheat stop valve will be opened first followed by the reheat control valve after OPEN button is pressed. Test the other group of valves after the two valves in first group are shown open. The electrical circuit is interlocked so that the reheat stop valve and reheat control valve at the other side of turbine can not be tested when the valves at this side are not open.
b)
c) d)
9.1.2 Auxiliary Oil Pump and Controller During normal operation the lube oil is supplied by the main pump as a result the pump test is different when the turbine is at synchronous speed from that when the turbine is on turning gear operation. During normal operation the oil pump can be test according to the following description. The oil pressure will decrease as a result the pressure switch will be actuated after the test solenoid equipped on the bearing oil line is energized when the oil pump is tested in remote mode. 1) AC bearing lube oil pump The oil pressure will decrease as a result the pressure switch will be actuated after the test solenoid is energized. The solenoid will be de-energized after the auxiliary pump is started. 2) DC emergency pump The description for AC lube oil pump can be followed during the test of DC emergency pump. Verify the DC emergency pump is running and record the output pressure shown on the pressure gauge which is equipped on the pressure measurement joint at the outlet of the pump on the lube oil tank after the pressure switch is actuated. Compare the pressure at the outlet of the pump with the value recorded at the initial start of steam turbine. Note The oil pressure at the outlet of the auxiliary pump during normal operation is greater slightly than that measured when the unit in on turning gear operation. 9.1.3 EH Oil System 1) The EH standby pump shall be started at least once a week. 151
2) Monitor the differential pressure between the two sides of the filter at the outlet of the pump. The filter should be replaced if the differential pressure switch actuates. 3) Monitor the differential pressure between the two sides of the filter at the drain port of the pump. The switch valve on the oil tank should be turned to the position of replacing the filter and heat exchange when an alarm shows excess differential pressure. 4) Check the pressure of the accumulator once a week 9.1.4 Extraction Check Valve It is suggested that the extraction check valve be tested once a week when the load is below 10%.The valve must be tested at low load with low flow and low density of steam. Turn the shaft of the valve to a certain degree so that operator can observe. During test the valve is closed slightly by the lockout valve The test is complete when the lockout valve is reset to its normal operation position and the extraction valve is verified to be fully open. 9.2 Monthly Test 1) Electrical overspeed trip 2) Check of oil pressure of the overspeed trip system 3) Low vacuum trip 4) Low lube oil pressure trip 5) Low EH oil pressure trip 6) High metal temperature of thrust bearing trip 7) Remote shutdown 8) Check the setpoint of pressure switch used to start the auxiliary lube oil pump by comparing the oil pressure at which the pressure switch actuates with the setpoint shown in the document of steam turbine control setpoint. 9) Lift oil pump test 9.3 Half-Yearly Test 9.3.1 Overspeed Trip DeviceOverspeed Trip Test The setpoint of the spring on the protection bolt should be calibrated half-yearly at a minimum by actual overspeed test during the service period of the steam turbine. The calibration should be done before initial startup or after overhaul and maintenance of front standard that may affect the setpoint. The unit should be heated evenly to achieve a stable rotor temperature before the overspeed trip device is actuated.T he procedure must be followed to prevent the thermal stress caused by the un-uniform temperature distribution of the rotor ,which will lead to a 152
very high centrifugal stress on the rotor bore during overspeed. The back pressure should be kept stable and should not exceed the limit specified in full speed no load condition during the test to prevent overheating of the LP exhaust section (1) The overspeed trip device is checked by the overspeed operation on steam turbine during the initial startup after installation or overhaul. Following the procedure of acceleration to rated speed, synchronization and initial loading to 5%, the unit should be continuously loaded to 10% of the rated load and kept operation under this condition for at least 4 hours before overspeed test. The energy, flow and temperature of steam is sufficient to achieve an uniform temperature distribution as a result the turbine is heated evenly at 10% of the rated load The damage can be reduced to a minimum extent at 10% of rated load if the main and reheat steam valves can not be closed by the emergency trip system which is not calibrated yet upon load rejection and shutdown of the turbine. The possibility of property loss and the danger of human injure and death will be definitely increased when the unit is even-heated at higher load, in fact the steam supply at 25% of rated load can drive the unit to a destructive overspeed condition for some kinds of turbines. As a result it is suggested that the load not exceed 10% and 15% of the rated load be the maximum value for even-heating when absolute necessary before the overspeed test. The stableness of the load, main steam temperature and pressure, reheat steam temperature, back pressure (exhaust pressure of LP casing) and circulation is important during the even-heating period. The unit is unloaded to 5% of the rated load in less than 5 minutes after the even-heating condition is achieved. Then shutdown the unit and finish the overspeed test in 15 minutes so as to reduce the effect of sudden cooling of the rotor to a minimum level. The overspeed test should be done in 2 hours after the unit is shut down. The unit should be put into operation again for several hours at 10% load in the case of longer shutdown period so as to achieve a stable temperature distribution before the overspeed test. (2) Half-yearly test Before the overspeed test the unit should be heated evenly at a load not less 10% of rated load and not greater than that can be reduced to 5% in 5 minutes while within the limit specified in curve suggestions to load change so that the test can be finished in 15 minutes after the unit is shutdown. The above procedure must be followed to prevent sudden cooling of the rotor.
10 Operation Curve and Figure

10.1 Suggestions to Speed during Warm up Period Never attempt to hold speed during warm up period in the resonance range. Decrease the speed to a value that is out of the resonance range if necessary before it is stable.The shadow area represents the resonance range that should be avoided by the LP blades. The speed should be hold within the range of medium-speed warm up of the turbine 153
shown in the figure for cold start. The warm up time is determined by the curve warm up specification for cold start.
/ 10.2 Warm up Specification for Cold Start
English Check supervisory instruments at this speed Speed range for mediate speed warm up Speed during transfer of steam admission valves rpm
This specification includes the procedure of acceleration to the speed specified in figure suggestions to warm up speed of steam turbine and warm up time determined by the curve below. Before the initial startup of the steam turbine the warm up time is determined according to the figure below using the metal temperature of first stage and temperature of IP blade ring, whatever is lower. Warm up of the turbine begins when the temperature of IP admission steam reaches at least 260.
154
English Rotor warm up time, hour
10.3 Suggestions for Warm Start-Acceleration and Minimum Load (Regulation Stage) 1) For instance: Determine the time for the following process, e.g. accelerating to rated speed, synchronization and warming up with a minimum load: The parameter of main steam is 6.86MPa(a)-426 from disengagement speed of the turning gear to full speed no load, The metal temperature of HP second stage is 260 before acceleration, The parameter of main steam is increase to 10.3MPa(a)-510 at minimum load. The turbine is in throttle control mode at synchronous speed and at minimum load. 155
2) Procedure Find the point where the main steam parameter is 6.86MPa(a)-426 in Figure 1, to Figure 2 crossing the Curve 5% load in throttle control mode.The steam temperature at first stage corresponding to this main steam parameters is 360. Project this point to Figure 3 crossing the first stage metal temperature curve of 260 to determine the mismatch temperature between steam and metal is 100.Project this point to Figure 4 crossing the Curve acceleration time to get the time to synchronous speed is 22 minutes. Project the point of 100 in mismatch temperature curve to Figure 5 crossing the Curve "0"increase of steam temperature at first stage during warm up. This intersection point shows that the minimum 5% load should be kept for 6 minutes if steam temperature at first stage during warm up does not change. However in this example the parameter of main steam is increased at minimum load as a result the warm up time should be longer. Determine the whole warm up time at 5% minimum load according to the following procedures: project the point where the parameter of steam is 10.3MPa (a)-510 in Figure 1, which will be achieved at the end of warm up, to Figure 2 crossing the Curve throttle control to get a 72 (432-360) increase of steam temperature at first stage. Prolong the previous curve of 100 crossing the Curve 72 increase of steam temperature at first stage to get the whole warm up time at minimum load is 45 minutes. 3) Note a) The unit should be accelerated to rated speed, synchronized and loaded with the minimum load, as shown in the figure above, in 10 minutes if main steam parameter causes the steam temperature at first stage is less than the metal temperature at the shadow area below the accurate match curve in Figure 3.It is not necessary to guarantee the warm up time at the minimum load. Extended acceleration and loading time will lead to the forced cooling of turbine metal. Figure 3 can be used to guide the selection of main steam parameters to match with the metal temperature at first stage before acceleration so that the thermal stress and start up time will be reduced to a minimum level.
b)
156
10.4 Steam Conditions during Startup Curve 1 shows the relationship between the steam pressure, steam temperature before main stop valve and the requirement of metal temperature at the inner casing of steam chamber before the control is transferred from the stop valve to control valve. Curve 2 shows the relationship between the steam pressure and steam temperature before the reheat stop valve and the maximum and minimum reheat temperature. The guide valve of main stop valve continues to control the speed when the metal temperature is less than the saturated temperature corresponding to the pressure at the 157
inlet of main stop valve at present. The steam temperature here should be equal with or greater than the minimum temperature at the inlet of main stop valve, as shown in the figure. The control will not be transferred to main control valve until the metal temperature of steam chamber is equal with the saturated temperature. The steam parameters before the main stop valve should be within the range of cold start as shown in figure below before the control is transferred from main stop valve to control valve during cold start of steam turbine. The steam parameters before the main stop valve should be above the Curve minimum steam temperature at the inlet of the main stop valve at transfer speed before the control is transferred from main stop valve to control valve during warm start of steam turbine.
English Steam parameters before main stop valve Temperature
158
56 Mpa - - 159
English Steam parameters before reheat stop valve Maximum temperature of reheat steam during start up (cold start) minimum temperature of reheat steam during start up (56 superheat) temperature of reheat steam Pressure of reheat steam Mpa Operation guideline at no load and low load Overspeed test according to the full speed no load curve with a stable back pressure Temperature of reheat steam at the inlet of steam turbine Full speed no load
5%
5% of maximum guaranteed power Operation limit recommended for reheat steam turbine Pressure of LP steam
10.5 Suggestions to Load Change (Fixed Pressure Operation) The controllable minimum steam flow is designed at 50% for steam turbine of 50Hz(16.7MPa(a)-538/538). 10.5.1 Example 1 Determine the time and load change rate if the unit will be loaded from 50% when the steam parameter is 1 0.3MPa(a)/425 to 100% at rated conditions, supposing the fatigue index is 10000. Project the point where the main steam parameter is 10.3MPa(a)-425 in Figure 1 to Figure 2 crossing the curve of 50% load to get the steam temperature at first stage is 374. Project the point where the main steam parameter is 16.7MPa(a)-538 in Figure 1 to Figure 2 crossing the curve of 100% load to get the steam temperature at first stage at 100% load is 490.So the steam temperature increase at first stage from 50% load to 100% load is 116(490-374=116).Project the point where the temperature increase is 116 in Figure 3 crossing the curve of fatigue index at 10000 to get the time for load/main steam change is 57 minutes. So according to the procedures described above the unit can be loaded from 50% to 100% load at a fixed change rate of 0.877%/min (50%/57min) in 57 minutes supposing the fatigue index is 10000. 10.5.2 Example 2: Unloading Determine the time and load change rate if the unit will be unloaded from 100% to 5%, supposing the fatigue index is 10000. Project the point where the main steam parameter is 16.7MPa(a)-538 in Figure 1 to Figure 2 crossing the curve of 5% load to get the steam temperature at first stage is 380. The steam temperature at first stage at 100% load is 490 (refer to Example 1).So the steam temperature increase at first stage from 100% load to 5% load is 110(490-380=110).Project the point where the temperature increase is 110 in Figure 3 crossing the curve of fatigue index at 10000 to get the time for load/main steam change is 52 minutes.
11 Safety and Incident

11.1 Periodic Test of Protection Devices Almost all equipments are equipped with instrument & control or electrical protection to avoid serious incidents that may happen. Equipment will be tripped automatically if any of the serious conditions occurs. The unit will be shutdown by protection devices if serious incident happens, however operators still need to monitor the shutdown process, steam pressure and temperature, bearing lube oil pressure and temperature and supervisory devices carefully. In addition there are many annunciators and instruments to warn 160
operators to pay attention to the abnormal or serious conditions. It is very important to test these annunciators, backup equipments and protection devices periodically at the frequency of once a week (once a shift if not sure about some equipment)and after maintenance of equipments. All operators should be informed with the test that will be done before the start of test. The periodic tests should be recorded carefully. Make sure to put the isolated protection devices into operation again after the test finishes. 11.2 Dangers and Observations 11.2.1 Continuous observation can prevent many incidents from happening because normally incidents do not happen suddenly but show some signs which can be noticed before developing to dangerous period. So with careful observation operator can shut down the unit in an orderly way without hurry. 11.2.2 Dangers Most Likely To Happen: Steam leakage and explosion--- pressurized vessels and pipes Fire---electrical equipment on fire and oil leakage Gas leakage---hydrogen cooling generator and chlorine in water treatment unit Operators should be clearly that which places dangers described above may happen and be familiar with the procedures and specification about dealing with these conditions. 11.2.3 Taking correct action can prevent expensive equipments from being damaged and some unnecessary shutdown at suitable time. Incidents mean that the units with lower efficiency and higher operation costs will be put into operation during incidents. In addition sudden shutdown will lead to a severe distortion so as to damage equipments. 11.2.4 Abnormal circumstances 11.2.4.1 Load Failure Load failure may most probably result from disconnection between turbine-generator and electric power system. One fault in substation may result in trip of generator breaker. Fault may also disconnect load export line from substation. What is more serious is that mechanical fault in generator coupling may commit load throw-off. Fortunately, this kind of emergency seldom occurs. In case of load failure, the heat energy inside the turbine could not be utilized to generate electric power while the boiler continues to supply steam to turbine. At this moment, the turbine will reserve the energy in its mass. Moreover, kinetic energy is also related to mass and velocity. As the mass of turbine remains unchanged, its speed will definitely increase rapidly. This is an extraordinary serious situation. If the protection devices fail or are not put in service, the bearing and its seat are not able to withstand such high speed. Once the bearing and its seat are damaged, the turbine or generator will be launched like a rocket. This kind of accident will obviously bring extreme hazards to staff and public. Protection devices are helpful in handling unexpected load throw-off and 161
it will stop the boiler and exhaust the excess steam to atmosphere or to condenser through bypass. Sometimes, load failure does not occur unexpectedly. It may be because of re-dispatching of electric power system. It requires system control center to redistribute load. Staff in power plant control room shall attach considerable importance to the proceeding of redistribution. If there is no load, they must reduce steam supply to turbine. 11.2.4.2 Overload If two turbines are running for power supply and one of them is stopped due to emergency, the other turbine shall immediately take up the load of the stopped one. Suppose two turbines were running at full load before emergency, then the running one will be overloaded after emergency stop of one turbine. At this moment, the remaining turbine requires more energy than that boiler is able to supply. It is like driving a car by treading on both accelerator pedal and brake at the same time. The car has to proceed with both engine and brake on. it could not overcome the brake force and will slow down instead of maintaining the speed. It is the same situation for turbine. Additional load is the brake power existing in the coupling between turbine and generator. Finally, turbine speed has to slow down. If overload happens to one turbine, stress will be produced while the turbine is overcoming the brake force, which is very bad. However, the unit is able to run with higher load than designed load. At that moment, the boiler should perform combustion at high rate to supply extra energy required. This is also called overload sometimes. But it should not be mixed with unexpected overload. Ordinary overload will not produce above mentioned stress if the load does not exceed too much (within reasonable limit). 11.2.4.3 Stop of steam supply Generator is as same rotating machine as motor. Generator also has rotor and stator as motor does. Rotor is driven by turbine and generates power in stator winding. Electric motor is to provide power supply for the stator to generate magnetic field that enables the rotor to rotate. Therefore, electric motor is a generator running in converse mode. Input of generator is mechanical energy while output is electric power. Input of electric motor is electric power while output is Mechanical Energy. It is obvious that no energy will be supplied to generator if we stop steam supply to turbine. The generator could not deliver any output without obtaining input. In this case, the generator will obtain energy from electric power system and rotate like electric motor. Besides, electric power system is still charged as a lot of running generators are connected to it. Then the generator will transfer the energy to turbine and the turbine will reserve the energy in its rotating mass. 162
Stop of steam supply will also bring serious consequences. Therefore, similar protective devices shall also be applied. And electrical breaker shall be opened to cut off the power supply from the grid. 11.2.4.4 Turbine Malfunction Some malfunctions of turbine will result in immediate stop of turbine by protection devices. But if the operator is aware that the turbine will finally come to stop due to malfunction, he should stop the turbine under proper control to minimize the shrink rate. 11.2.4.5 Failure of cooling water This kind of emergency can be temporarily handled by shedding load according to the turbine vacuum. If cooling water totally fails and could not be recovered in a short time, load of the unit shall be completely reduced. 11.2.4.6 Vacuum depression Measures should be taken based on actual situations. If one air pump fails while the other one is available, start it immediately. Another way is to reduce load as mentioned above. If low vacuum results from air leakage into the casing, shutdown of the unit is probably required for maintenance. The key point is that the cause shall be identified immediately and then corresponding measures should be taken. For emergency resulting from failure of one auxiliary equipment, measures to be taken depend on availability of spare equipment and applicability of load shedding and maintenance. In addition, it also depends on whether the spare equipment can be used in a short time. 11.2.4.7 Failure of turbine oil Lubrication of turbine shaft is very critical. If any serious unstoppable oil leakage occurs, the turbine should be shutdown by pressing manual emergency stop button. Measures should also be taken to prevent fire accident. 11.2.4.8 Water influent into turbine a) Running
Once there is water influent into turbine, it is impossible to avoid damages. Damages to turbine committed by water includes but not limited to : damage of vanes and shrouding, damage of thrust bearing, rupture of rotor, rupture of supporting ring, long-time bent of the rotor, permanent deformation of fixed parts and fracture of steam seal teeth (vane and steam seal). Extent of damage shall refer to various factors, including position of water influent, volume of water, duration of influent, temperature of turbine, running speed and/or load of the unit, steam flow, corresponding positions of rotor and fixed parts and measures taken by operators. With involvement of so many factors, no complete operation instruction is available for every emergency. However, we compile operation instructions for unit of each kind and train operators with these details to minimize the damage during water influent emergency. Therefore, the following details are advised. 163
General rules 1) 2) Operators to handle emergency resulting from water influent. Whenever alarm comes, instrument shows water influent into the unit or water is about to enter the unit, operators should follow specified procedures. Take immediate actions whenever water influent indicated. Alarm devices are to be fixed on all thermocouples monitoring water influent in thermal circulation in control room and recording instrument is to be adopted. When alarm unit sounds, control valves remotely and observe them visually to confirm their correct position instead of depending on automatic operation of these valves. If protection device is installed with combination to water supply system, then isolate water supply system from the turbine and adjust operation conditions as per the requirements, considering absence of this protection device. In case of water influent emergency, careful analysis shall be made on the emergency and necessary rectification should be one to the equipment not only in affected area but also in other areas where the same emergency has easy access. If rectification is required, the same should be made on operation procedures and deficiency of operators. If the heater shows the last high water level or abnormality, if transmitter monitoring water influent on extraction line indicates existence of water or if any couple of thermocouple monitoring water influent indicates the temperature difference between upper and lower casing is 42 (lower casing is cooler than upper casing) or more, it is deemed as water influent is in process. If the temperature difference is more than 56, the unit must be shut down. If the temperature difference does not exceed 56 and no indication of instrument or other emergency signal shows shutdown of the unit, the unit can remain running after isolation and treatment of water. If there is vibration or swaying in pipes which does not exists before and there is no acceptable explanation for the situation, it is deemed as water influent is in process. There may be certain situations that can be identified easily. Operators should deem that water influent is in process and necessary protective measures should be taken immediately. In case of occurrence of any situation, emergency operation procedures must be executed immediately. Although we implement monitoring, isolation and discharge of water in running turbine, experience indicates that the unit must be shut down in case of emergency that influent water exceeds allowed operating limit once water enters hot turbine. Therefore, turbine operators must be trained for capable of controlling accidents. The recommended automatic protection system is essential to maintain the temperature difference between turbine upper and lower casing within 56. 164
3) 4)
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7)
8)
9)
Operation instruction is made based on automatic operation of drain valves and shutoff valves and at precondition of remote or automatic control These descriptions are applicable to manual valves as they will not operate within available time. To minimize loss, quick action is extremely essential. If valves are controlled automatically, operation procedures should be followed up step by step and preparation should be done for malfunction that may occur. To avoid repeating of basic method in particular instruction book, basic isolation method is provided as follows as most of emergencies are related to the heater. Quick implementation of these procedures is extremely essential. Basic isolation method of heater: a) b) c) A Close stop valves on extraction line B Open all drain valves on extraction line and in affected area of turbine. C Visually check all stop valves and discharge valves if they are in correct position D Reduce heater's water level to normal level E Confirm and rectify the cause to emergency F If the emergency cause can not be rectified in time, the unit can continue to run in following conditions: 1) All influent water is drained from turbine and gave evidence indicates that the temperature difference between turbine upper and lower casing is less than 42. 2) All water is drained from extraction line, 3) The unit can continue to run safely with absence of defective component, i.e. defective component is completed isolated and emergency will not occur again. 4) All indications, especially for metal temperature, eccentricity, vibration and expansion difference, shows that the unit is running satisfactorily. 5) All drain valves on extraction line and stop valves at heat regenerator side of turbine remain open. 6) No indication of damage or emergency and no indication of dismantling components for maintenance in past and at present.
d) e) f)
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Volume D
1 General Introduction of Generator 1.1 Definition
Electrical Operation
Generator is a machine driven by prime mover by which mechanical energy is changed into electrical energy. Alternating current will be generated when armature winding cuts flux field. Rotor: excitation field is produced when excitation current flows through the rotor windings. Stator: current is induced in the stator windings as per electromagnetic theory, and mechanical energy is transferred to electrical energy. 1.2 Classification of Generator The main components of a generator required to be cooled include stator winding, rotor winding and stator core. Based on cooling method, generator can be classified into the following types: Cooling method Air cooled generator Dual internal water cooled generator Water-hydrogen cooled generator Hydrogen Cooled generator 1.3 Main Systems of Generator 1.3.1 Body Stator winding Air cooling Water cooling Water cooling Hydrogen cooling Rotor winding Air cooling Water cooling Hydrogen cooling Hydrogen cooling
Outside View of Generator Body Sectional View of Steam Turbine Generator
166
1.3.1.1 Stator a) Stator housing: it is used for securing, supporting and protecting stator core and stator winding, and it has to be used for completing the air circulating loop of the generator. It also bears the rotor for hydrogen cooled generator with a structure of end-shield bearing and it should have the functions of seal and explosion protection under air pressure. Stator housing (external) is an airtight, pressure resisting and steel welded component.
b)
Stator Core Stator core is used to form a magnetic circuit for the general magnetic flux with a low magnetic resistance and used to secure the stator winding. Hysteresis loss and eddy current loss will be produced in the core when magnetic flux rotates in the stator with the rotor winding. Hysteresis loss is determined by the performance of armature plate and the density of flux passing through armature plate, and it keeps exist during excitation. 167
Core is formed by overlapping insulated low-loss silicon steel laminations. Slot on the core is used for locating stator winding bar. Supporting and locating slot is located on the external surface of the core for guiding the silicon steel laminations during installation. Core is secured axially. There currently are two kinds of structure in the world for securing, which are clamping bolt passing through core and junk ring. Normally, core has radial air path and has axial air path in case of hydrogen cooled generator. For generator with large capacity, magnetic shield and copper shield are adopted for its end, or silicon steel lamination clamping ring and aluminum clamping plate are used, which are made by diamagnetic materials to reduce loss and heat.
c)
Stator Winding Stator winding is located in the slots of the internal wall. It will induce high voltage/current to the grid when it is in a rotating magnetic field. Therefore, it is a key component in the generator for energy transferring and electric energy outputting. Sufficient insulation shall be adopted outside conductor. Insulation of high voltage (HV) winding is the most important aspect of a generator. Anti-corona measures also should be considered for HV winding. Excellent and reliable insulation system is adopted for stator bar. Vacuum-pressure impregnated (VPI) technology endures real seamless HV insulation, and makes the bar have sound electrical, mechanical and heat performance as well as waterproof and oilproof.
168
1. Transposing strip - mica sheet 2. Molding strip - mica sheet 3. Cooling pipe - austenic steel 4. Row insulation - epoxy resin 5. MICALASTIC insulation - mica tape soaked by vacuum epoxy resin 6. External anticorona coating - conductive polyester type 7. Internal potential control - semi- conducting tape 8. Insulation strand - insulation layer weaved by fiberglass
The high voltage of the stator makes the current and electromagnetic force low. Design of anticorona coating is reliable. Stator winding is shunt winding with two layers and two branches Bar can be transposed within 540 degree effectively reducing the additional loss of stator winding. Side corrugated plate and wedge corrugated plate are used for securing stator bar in the slots preventing the bar from becoming loose in any direction
1.3.1.2 Rotor The function of the rotor is to transfer the load torque provided by the steam turbine. Meanwhile, because rotor winding is fixed on the rotor body, a strong magnetic field will be produced in the rotor body when excitation current passes through rotor winding. The main part of the rotating magnetic field forms a closed loop by passing through rotor core, air gap and stator core which is called main magnetic flux. The other part forms rotor leakage flux by passing through rotor body and air gap. Two parts of flux works on the stator winding and stator core with a fixed flux value and direction along with the rotating rotor.
Internal arrangement of Generator Slot
Strip, material
semi-conductive
Side corrugated plate, semi-conductive material
Layer strip and temperature meter

Side corrugated plate, semi-conductive material Strip, adhesive tape Strip, adhesive tape Double layers corrugated plate Strip with sliding layer
Wedge
169
Rotor shaft is made of high quality forged NiCrMoV steel alloy; Rotor disc is composed of high strength diamagnetic Mn18Cr18 steel alloy with excellent anti-corrosion performance.
1.3.2 Excitation System Excitation system refers to the system providing excitation power supply for the synchronous generator in accordance with specified law. The system mainly include synchronous generator (G), excitation power supply(ED), Automatic voltage regulator (AVR), manual voltage regulator (MVR) and deexcitation device (DM). 1.3.2.1 Brushless Excitation 1.3.2.2 Static Excitation
Collector Ring of Static Excitation System 2 Operation of Generator 2.1 Inspection and Preparation before Start Up 2.1.1 All works on generator circuit shall have completed. All work sheets shall be ended. Safety measures such as grounding wire, sign, fence equipped for maintenance shall have been completely removed. Shade and railing as well as normal signs shall have been recovered. 2.1.2 Check the static excitation devices operate correctly without abnormal signals. 170
2.1.3 Check all signals of generator system in normal condition. 2.1.4 Check primary circuit and secondary circuit of generator are complete and in accordance with operation conditions. 2.1.5 Relay protection system and automatic control devices of generator have been put into operation and shut down as per specified rules and operate correctly. 2.1.6 Pressurizing device for enclosed busbar of generator has been put into operation and in correct condition. 2.1.7 Check hydrogen charging for generator has finished with normal pressure, purity, humidity and temperature. No internal cooling water leakage exists. Cooling water is qualified. 2.1.8 Verify the Following Parameters and Tests: 2.1.8.1 Insulation resistance to earth of stator winding (dry) 500M(2500V Volt megger at a temperature close to operation temperature; Insulation resistance 20M (2500V Volt megger) and absorption ratio 1.3 in case of the electrical equipments connected in the stator circuit which cannot be disconnected by switch. If the value is only 1/3 to 1/ 5 of the two formal measured results (considering the changes of temperature and humidity), causes shall be found out. 2.8.1.2 Insulation resistance of rotor winding 10M (500V Volt megger), rotor winding in clod state of 20 C. 2.8.1.3 Insulation resistance of internal and external oil baffle plates of bearing seal at excitation end 1M (500V Volt megger). 2.8.1.4 Insulation resistance of brush holder conducting ring 10M (500V Volt megger). 2.8.1.5 Insulation resistance of excitation transformer 6M (2500V megger), absorption ratio 1.3. 2.2 Generator startup and synchronization 2.2.1 In case of any of the following conditions, startup or synchronization shall be forbidden: 2.2.1.1 Main protection system of the unit fails, or any of the tripping protection is abnormal; 2.2.1.2 DCS fails; 2.2.1.3 Excitation system of generator fails; 2.2.1.4 Stator cooling water system of generator is abnormal or water quality is unqualified; 2.2.1.5 Purity of hydrogen inside generator is below 90; hydrogen pressure is lower than 0.14Pa; 2.2.1.6 Synchronizing device of generator fails. 2.2.2 Energization for Auxiliary power system 2.2.2.1 500KV or 220KV system energizing 6KV busbar: verify that: all maintenance 171
works on section A and B of 6KV in the auxiliary power system have been completed; all work sheets are ended. Safety measures such as grounding wire, sign, fence equipped for maintenance have been completely removed. Shade and railing as well as normal signs have been recovered; the circuits of main transformer, HV auxiliary power transformer and related electrical equipment are complete and satisfying the operation conditions; protection devices are correctly put into operation. 6KV busbar energization: Change the state of circuits of section A and B of 6KV busbar and their feeding circuits from maintenance to cold standby (insulation of busbar is checked qualified). No.1, No.2 main transformer and HV auxiliary power transformer are normally charged. Energize the 6KV busbar by switches of operation power of section A and B (before energization, PT shall be put into operation). 2.2.2.2 110KV system energizing 6KVbusbar: verify that: all maintenance works on startup/standby transformer as well as section A and B of 6KV in the auxiliary power system have been completed; all work sheets are ended; safety measures such as grounding wire, sign, fence equipped for maintenance have been completely removed; shade and railing as well as normal signs have been recovered; the circuits of startup/standby transformer and related electrical equipment are complete and satisfying the operation conditions; Protection devices are correctly put into operation. 6KV busbar energization: Change the state of circuits of section A and B of 6KV busbar and their feeding circuits from maintenance to cold standby (insulation of busbar is checked qualified). Close the 110KV switch of NO.1startup/standby transformer; correctly charge the NO.1startup/standby transformer. Energize the 6KV busbar by switches of standby power of section A and B (before energization, PT shall be put into operation). 2.2.2.3 380V auxiliary power system: verify that: all maintenance works on 380KV auxiliary power system have been completed; all work sheets are ended; safety measures such as grounding wire, sign, fence equipped for maintenance have been completely removed; shade and railing as well as normal signs have been recovered; circuits of related electrical equipments are complete and satisfying the operation conditions; Protection devices are correctly put into operation. Energize the 380V steam turbine PC section A and boiler PC section B with steam turbine transformer. Energize the 380V boiler PC section A and boiler PC section B with boiler transformer; energize busbar of emergency power source PC section A and PC section B respectively with 380 KV boiler PC section A and B . 172
Energize common PC section busbar with common transformer. Energize lighting PC section busbar with lighting transformer. Energize ESP PC section busbar with ESP transformer. Energize administrative zone PC section busbar with administrative zone transformer. Energize water supply system PC section busbar with water supply transformer. Energize ash handling PC section busbar with ash handling transformer. Energize coal handling PC section busbar with coal handling transformer. Energize circulating water system PC section busbar with circulating water transformer. Energize chemical water treatment system PC section busbar with Chemical water treatment transformer. Energize ash yard PC section busbar with ash yard transformer. 2.2.2.4 Recover diesel-engine generator to hot standby state. 2.2.2.5 Verify that MCC, power control box, power and load of distribution board for main building and auxiliary buildings are in normal conditions. 2.2.3 Pre-startup Test 2.2.3.1 Required Tests after Overhaul a) b) c) d) e) a) b) c) d) Tripping and closing test as well as drive test of relay protection for generator outlet switch, excitation Switch, switch of 6KVoperation power supply. Excitation system test (including switching test of operation and standby fans in the excitation rectifier cabinet). Switching test of diesel-engine generator and Emergency power source. Quick switching test of 6KV auxiliary power supply. UPS power switching test Generator quasi-synchronization test. Generator no-load test. Generator short circuit test. Other tests determined by maintenance items.
2.2.3.2 Optional tests after Overhaul
2.2.4 Preparation before Generator Synchronization (before speed of steam turbine is stable) 2.2.4.1 Close operation and signal power switches (I, II) for generator outlet switch. 2.2.4.2 Close DC power switch of generator protection cabinet and check it operate correctly. 2.2.4.3 Check protection plates of generator protection cabinet A are correctly put into operation (lockup plate for main steam valve is to be put into operation after synchronization while protection plates for accidental energizing or sudden voltage applying shall be out of service) 173
2.2.4.4 Check protection plates of generator protection cabinet B are correctly put into operation (lockup plate for main steam valve is to be put into operation after synchronization while protection plates for accidental energizing or sudden voltage applying shall be out of service) 2.2.4.5 Check protection plates of generator protection cabinet B are correctly put into operation (lockup plate for main steam valve is to be put into operation after generator synchronization). 2.2.4.6 Check AC power switch for excitation startup on MCC board is correctly put into operation. 2.2.4.7 Close DC power switch for Trip 2 control in the excitation device. 2.2.4.8 Close DC power switch for switch control in the excitation device. 2.2.4.9 Close 24V DC control power switch in the excitation device. 2.2.4.10 Close the power switch of cooling fan in the thyristor rectifier power cabinet and check it works normally. 2.2.4.11 Close the power switch in the excitation device. 2.2.4.12 Close the AC power switch for 24V DC rectifier. 2.2.4.13 Check no alarm or fault information is displayed on the local excitation control panel and DCS HMI. 2.2.4.14 Change the Local/Remote control to "Remote" mode from local excitation control panel. 2.2.4.15 Change the excitation channel to "automatic channel" from the local excitation control panel. 2.2.4.16 Check F1~F6 power fuses in the excitation power cabinet are in position without any fusing signal. 2.2.4.17 Select the mode "Channel 1 Operation" at the local excitation control panel. 2.2.4.18 Check MK is at open position. 2.2.4.19 Check HV fuse of PT at generator outlet is in position with sound contact. 2.2.4.20 Push the trolleys of outlet TV and LA to operation position. 2.2.4.21 Close the LV secondary airbreak switch of generator outlet TV 2.2.4.22 Check the Local/ Remote control switch of outlet switch is switched to the position of "Remote Control" 2.2.4.23 Check the indication of the 3 phases SF6 pressure meter of the outlet switch is in normal condition. 2.2.4.24 Check indication of spring energy storage of outlet switch is in normal condition. 2.2.4.25 Check the outlet switch is at open position 2.2.4.26 Check the blade of the outlet switch is at open position. 2.2.5 Generator Synchronization 2.2.5.1 Requirement and precaution for step-up synchronization operation The operation of synchronization should be started under the command of the shift supervisor after verify that steam turbine, generator and related devices are ready for 174
synchronization with any alarm signal. Completely check the CRT screen for synchronization operation ensuring related signal indication correct and the positions of operating switch and changeover switch as well as synchronization switch are correct. The step-up operation normally is performed by the automatic voltage regulator (AVR) via DCS screen. Conditions for synchronization: a) b) c) d) Generator voltage equals to that of grid with a maximum error within 10%. Generator frequency equals to that of grid. Voltage phase of generator equals to that of grid. Phase sequence of generator equals to that of grid.
Automatic quasi synchronizing method is adopted for generator synchronization operation: Caution: a) Excitation switch should be kept open during generator run-up until generator reaches the rated speed and satisfies the synchronization conditions. Then, start initial excitation switch and raise the voltage of generator to the excitation value determined during commissioning. Slowly increase the excitation in accordance with the terminal voltage of generator. During run-up, voltages of three phases of the stator should be balanced, and the current of three phases should equals to the no-load current of main transformer. The voltage of generator and excitation current should not exceed the rated values for no load operation, otherwise, the voltage should be lowered down until fault is eliminated. In no case should the generator excitation be loaded before water feeding and hydrogen charging for the generator. No matter which method is adopted for synchronization, synchronizing block circuit should not be released. After the synchronizing device is put into operation, the generator should not be synchronized when the synchronization meter of the synchronizing device rotates unevenly or stops/jumps. During automatic quasi synchronization, if the device is abnormal, it has to be maintained by electrical maintaining staff. Before the next synchronization operation, the automatic quasi synchronizing device should be tested. Non-synchronous switch-on should be avoided. If the CT circuit is maintained during outage, the differential protection for generator should be stopped until the differential current is qualified or confirmed by maintaining staff.
b) c)
d)
e)
2.2.5.2 Automatic quasi synchronizing: Close the operation power of the outlet switch. Close the outlet switch. Check the three phases of the outlet switch are well closed. Open the operation power of the outlet switch. 175
Close switch I of operation power of the outlet switch. Close switch II of operation power of the outlet switch. Close the DC power switch of synchronization device. Check the speed of steam turbine is stable. Verify no abnormal signal is displayed on the DCS screen. Change the excitation state on DCS to "Auto" position. Set the operation state of excitation system on DCS to "operation" position, and click "operation" function. Check excitation switch is well closed and excitation is initiated correctly. Check outlet voltage runs up to rating value, and no-load excitation voltage and current are normal. Check voltages of three phases at outlet are balanced. Notify operators of generator and steam turbine to synchronize in mode of "auto synchronization" and satisfy conditions. Click the function button of "Run" in the "Synchronization Control" function of the generator DCS. Click the function button of "Operate" (gray to red) in the "Synchronization Control" function of the generator DCS. Click the function button of "Reset" in the "Synchronization Control" function of the generator DCS. Check the "ACT" function block of the "Synchronization Control" change from gray to red. Check generator switch is well closed. Check currents of three phases of the stator are balanced and add initial load. Click "General Reset" button of the DCS "Synchronization Control". Stop accidental energizing protection pressure plate in protection cabinet A. Stop accidental energizing protection pressure plate in protection cabinet B. Put the pressure plate of "Close Main Steam Valve" in protection cabinet A into operation when it is checked no voltage on its both ends Put the pressure plate of "Close Main Steam Valve" in protection cabinet B into operation when it is checked no voltage on its both ends. Put the pressure plate of "Close Main Steam Valve" in protection cabinet C into operation when it is checked no voltage on its both ends. 176
Open DC power switch of the synchronization device. 2.2.5.3 Check 3 phases current of stator is balanced and 5% (around 15MW) of initial load is carried. 2.2.6 Maintenance and Inspection of Generator 2.2.6.1 Routine work for generator system: a) Strictly monitor the operation of generator and timely adjust operating parameters within specified value. The increase and decrease of the generator active load normally is controlled as per unit condition or by shift operator. Meanwhile, reactive power shall be monitored and adjusted to strictly keep the voltage and current below specified values. During normal operation, operating parameters shall be recorded hourly, and compared to the printed sheet. If difference exists, cause shall be found out by analysis. If the temperature of a certain temperature measure point is abnormal, the monitoring of this part shall be strengthened and recording interval shall be shortened while report to related department. During generator operation, the grounding detecting device for excitation circuit should be put into "Auto" mode and calibrated regularly, keeping it in normal condition. Every shift should completely check the generator, AVR and relay protection devices. Timely report, treat and record in case of abnormal condition.
b)
c)
d)
e)
2.2.6.2 Main inspection items during generator operation a) Inspection items for central control building and protection room: 1) Indication values of parameters on DCS should not exceed allowable values. 2) Light indicators work normally; positions of control switches are consistent with actual positions; displays on CRT screen are correct. 3) No abnormal condition exists in the relay or automation devices, such as loose contact, open weld, overheat and smoke. 4) Positions of protection pressure-plates are correct and consistent with operation situation. 5) Record carefully. Strengthen monitoring and shorten recording interval in abnormal condition. 6) Check the shell temperature of enclosed busbar of generator is normal. b) Inspection of generator body: 1) Sound from generator is normal without friction or crashing as well as vibration. 177
2) Pressure of seal oil at two ends is normal; flow of lube oil is correct and temperature of return oil is no higher than specified value. 3) Surrounding is clean; no oil leakage or condensation. 4) Check temperature-rise of generator parts is not higher than specified value and no overheat phenomenon. 5) Completely check the switches, breakers, PT and CT. 6) Check the shell temperature of the outlet enclosed busbar is below 70C. c) Inspection and maintenance of stator cooling water system: 1) During operation, the hydrogen pressure should be higher than that of stator winding cooling water. It will alarm when their pressure difference is lower than 0.035MPa. 2) Water quality should be qualified. Otherwise, an ion exchanger should be put into operation. 3) Check the flow of stator cooling water is correct. Otherwise, the pressure difference between water filter should be inspected. It will alarm when pressure difference is higher than 0.2MPa. A standby filter should be put into operation. 4) Check the temperature of stator cooling water is normal. 5) Check water paths are clear; no vibration and leakage of water pipe. d) Inspection of hydrogen system: 1) Check the hydrogen pressure in the generator in within a specified range. 2) Check the purity of hydrogen inside generator is higher than 96%, and its humidity is in a normal range. 3) Check the temperature of hydrogen is in a allowable range and hydrogen cooler runs correctly. e) For inspection of excitation system, please refer to relative sections in the excitation system procedures.
2.2.6.3 Specifications for the operation of overheat monitoring device for generator insulation: Only for maintenance and commissioning, the adjustable knob on the panel should not be touched with permit. Once the device is put into operation, except outages for overhaul or routine maintenance, or gas replacement, the device can keep running; the device should be put into operation after the speed of unit is stable. Startup operation: close the power switch of the device when the pointer of ammeter points zero. Slowly open inlet valve and then open outlet valve. Verify the 178
monitoring flow of device is around 2L/min and indication of ammeter is higher than 75. Shutdown operation: close outlet valve; then close inlet valve; finally switch off power (unnecessary for temporary outage). Verify the detecting part and remote control part of the device is normal at least four times for each shift. 2.3 Generator Step-out 2.3.1 Step-out Operation 2.3.1.1 Check the active load of generator is reduced to minimum and the reactive load is near to zero. 2.3.1.2 Open the outlet switch. 2.3.1.3 Check the outlet switch is at open position. 2.3.1.4 Check 3 phase current of stator is zero. 2.3.1.5 Change the operation state of excitation system on the DCS screen to "Shutdown". 2.3.1.6 Check excitation switch MK is well opened. 2.3.1.7 Open the outlet breaker. 2.3.1.8 Check the breaker is at open position. 2.3.1.9 Open the operating power of outlet breaker. 2.3.1.10 Put the protection pressure plate into operation for accidental energizing (sudden voltage applying). 2.3.1.11 Shutdown protection pressure plate for lockout main steam valve. 2.3.1.12 Open operating power I, II switch for outlet switch. 2.3.1.13 Report to shift supervisor that unit is stepped out. 2.3.1.14 After step-out, if the unit is required to change to cold standby state by the shift supervisor, the following operation should be carried out: f) g) Change the PT circuit to cold standby state. Change the AVR to cold standby state.
2.3.1.15 If the generator is required to be maintained, safety measures such as equipping grounding wires should be prepared as per work sheet making the generator ready for maintenance. 2.4 Failure and Abnormal Situation Treatment for Generator 2.4.1 Reverse power operation 179
2.4.1.1 Fault Indication: a) Active power meter displays negative value on the DCS screen, and electric meter reverses; Alarm message of "Main Steam Valve Close" is shown on DCS screen together with sound failure alarm; Indication value on the reactive power meter increases and the value of stator current decreases; indication of meters for voltage of stator and excitation circuit are normal; System cycle decreases.
b)
c)
d)
2.4.1.2 Treatment: During reverse power operation, if the protection trips, it should be treated as a failure trip. Otherwise, manually step the generator out of grid immediately. 2.4.2 Two Points of Rotor Grounding 2.4.2.1 Fault Indication: a) Excitation current increases; excitation voltage decreases; indication of reactive power decreases; Unit significantly vibrates; Generator trips when two points grounding protection of rotor is put into operation.
b) c)
2.4.2.2 Treatment: a) Before protection acts, immediately step the unit out of the grid and discharge field. Measure the insulation of rotor at different speeds; Unit should be shutdown after confirm rotor two points grounding.
b) c)
2.4.3 Loss of Excitation 2.4.3.1 Fault Indication: a) Alarm message of "Generator Underexcitation " is shown on DCS screen with sound alarm; indicated value of excitation current is near or equal to zero; Indicated value of generator reactive power is negative; Indicated value of generator active power decreases; stator voltage drops down; stator current increases, swinging periodically; Busbar voltage is lower than normal value.
b) c)
d)
2.4.3.2 Treatment: a) During loss of excitation if the protection of loss of excitation trips, it should be 180
treated as a failure trip. Otherwise, step the generator out of grid, report to shift supervisor and find out the cause as well as eliminate the fault. b) Load of generator should decrease to 60% of rating load within 60 seconds since loss of excitation and decrease to 40% within 150 seconds. The total allowable time of asynchronous operation without excitation should not exceed 15 minutes.
2.4.4 Stator Grounding 2.4.4.1 Fault Indication Protection of stator grounding (3U0) might trip; outlet switch and deexcitation switch trip; main steam valve closes; indication of relative parameters reduces to zero, which reflect operation of generator such as stator voltage, stator current, active power, reactive power, rotor voltage and current. Indicators of "Electrical Forecast" and "Electrical Trip" shines and send signal of "Stator Grounding" with buzzer ringing Zero sequence voltage meter in protection cabinet has an indication value even higher than 100V; Zero sequence voltage meter of generator has an indication; 2.4.4.2 Cause Complete or partly grounding exist in stator circuit and system. 2.4.4.3 Treatment When stator grounding protection trips: If protection trips, treat it as outage; Check generator for any fault. In case of no fault, run up generator from voltage of 0 and synchronize again. When protection of stator grounding alarms: Shut down unit if water leakage alarm also exists; If the measured zero sequence voltage is below 10V, treat it as the following: Check whether the generator circuit is grounded; Check the low voltage switch of the neutral point is intact or not, or contact is normal; If find internal fault or can not find external fault, report to the shift supervisor and shutdown the unit for maintenance. 2.4.5 Unsymmetrical Operation 2.4.5.1 Fault Indication The indicated value of three-phase ammeter of generator stator is wrong and the 181
negative sequence ammeter has indication. 2.4.5.2 Cause a) b) c) Parameters of stator current circuit is not balanced; Meter is inaccurate; Load of three phases is unsymmetrical.
2.4.5.3 Treatment a) The difference between the currents of three phases should be lower than 8% of the rated current. When the current of any of three phases is less than rated value, the unit could keep continuous running. Otherwise, the operator should lower the load of generator to satisfy the requirement above mentioned. When the unsymmetrical value is above the value mentioned, cause should be found out and eliminated. Otherwise report to chief engineer for decision. Unsymmetrical overload protection might trip.
b)
c)
3 Transformer
3.1 Transformer Operation Mode 3.1.1 Rated Operation Mode 3.1.1.1 Transformer should run as per rated parameters by manufacture. Under rated operation conditions, transformer could operate in accordance with rating capacity all year. 3.1.1.2 The allowed operation temperature of transformer is determined by monitoring temperature of upper layer oil. The temperature of upper layer oil decreases as the temperature of coolant drops Temperature of upper layer oil should not exceed 95C. To avoid accelerating deterioration transformer oil, the temperature is not recommended to exceed 85C frequently. Temperature and temperature rise of upper layer oil of oil filled transformers adopting different cooling methods should not exceed the values specified in the table below. Temperature Rise of Upper Layer Oil C 55 Highest Temperature of Upper Layer Oil C 95 Normal Temperature of Upper Layer Oil C 85
Cooling Method Oil Immersed Self Cooling, Air Cooling Forced Oil Circulating and
45 182
85
75
Air Cooling 3.1.1.3 The temperature rise of HV and LV windings of dry-type transformer (F class insulation) should not exceed 100C. During operation, the monitoring on signal thermometer should be emphasized for it is the protection system of a dry-type transformer. Ratings of dry-type transformer in the main building are listed as below: Description Temperature T1 (fan shutdown ) Temperature T2 (fan running) Temperature T3 of temperature excursion alarm Temperature T4 of temperature excursion trip Note: setting principle: T1<T2<T3<T4 3.1.1.4 The applied primary voltage could be higher than rating value, but it normally is no higher than 105% of the rated voltage of relative tap changer. No matter where the tap changer is, the secondary side of transformer could run with rated current if the applied primary voltage is not higher than 105% of relative rating value. 3.1.1.5 The rated capacity of no-load voltage regulating transformer at individual tap changers should be in accordance with specifications of manufacture. The rated capacity will not change when change the position of tap changer within a range of 5% of rated voltage. The rated capacity of on-load voltage regulating transformer at individual tap changers should be in accordance with specifications of manufacture. 3.1.2 Permit Overload Operation Mode 3.1.2.1 Transformer can operate under situations of normal overload and emergency overload. The normal overload operation mode can be often used. The permit value is determined by transformer load curve, coolant temperature and the load of transformer before overload. The operation mode only can be applied in case of emergency. Overload operation is forbidden when transformer has significant defect (e.g. abnormal cooling system, serious oil leakage and abnormal Chromatographic analyses result). 3.1.2.2 During transformer overload operation, all cooling devices should be put into operation. Monitoring, inspection and recording should be emphasized. Temperature of upper layer oil should be strictly kept below allowable value. The normal overload and emergency overload operation modes should be in accordance with manufacture's specifications. The capability of emergency overload operation is listed in the table below: Over Current Multiple 1.2 183 1.3 1.45 1.6 1.75 2.0 Rating Value (C) 80 100 130 150 Adjusting Range (C) 60-100 80-120 110-150 130-170
Permit operation time (minute)
60
45
24
The capability of normal overload and emergency overload operation of oil filled transformer also should follow the specifications of manufacture. In case of no specification, the permit time of emergency overload operation of oil filled transformer could be referred to the table below as per cooling method and ambient temperature: Permit time of emergency overload operation of oil immersed self cooling transformer (hour: minute): Times of Overload 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 Ambient Temperature (C) 0 24:00 24:00 23:00 8:30 4:45 3:00 2:05 1:30 1:00 0:40 10 24:00 24:00 10:00 5:10 3:10 2:05 1:25 1:00 0:35 0:22 20 24:00 13:00 5:30 3:10 2:00 1:20 0:55 0:30 0:18 0:11 30 19:00 5:50 3:00 1:45 1:10 0:45 0:25 0:13 0:09 0:06 40 7:00 2:45 1:30 0:55 0:35 0:18 0:09 0:06 0:05
Permit time of emergency overload operation of forced oil circulating cooling transformer (hour: minute): Overload Multiple 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Ambient Temperature (C) 0 24:00 24:00 11:00 3:40 1:50 1:00 0:30 10 24:00 21:00 5:10 2:10 1:10 0:35 0:15 20 24:00 8:00 2:45 1:20 0:40 0:16 0:09 30 14:30 3:30 1:30 0:45 1:16 0:08 0:05 40 5:10 1:35 0:45 0:15 0:07 0:05
3.1.3 Operation Mode of Cooling System 3.1.3.1 The cooling devices should be reliably put into operation before and during transformer operation. 3.1.3.2 There are two power supply circuits for the forced oil circulating air cooling device for the main transformer. During normal operation, both circuits could ensure reliable power supply and interlock and standby for each other as per selected operation mode. The operation of control circuit of cooling device should be in accordance with: 1) Switch the changeover switch of power supply to selected position, for 184
example "Circuit I Standby, Circuit II Run " or " Circuit I Run, Circuit II Standby ". 2) During normal operation, both switch 1K of automatic startup control circuit and switch 2K of signal circuit of cooler should be changed to position "Run". Automatic switch 1ZK ~ 4ZK of cooler groups should be closed. The positions of selection switch 1KK ~ 4KK of cooler are determined operation mode. Selection switch has four positions: Run - cooler is put into operation. Assistant - when transformer load rises to 75% of rated value or temperature of upper layer oil reaches 55C, the cooler starts up automatically and shut down when load or temperature mentioned above is lower than the values. Standby - when the operating cooler or automatically running assistant cooler trips, the standby cooler will start up. Stop - cooler is out of service.
3)
4) 5)
6)
7)
3.1.3.3 Operation Method of Main Transformer Cooler: 1) There are four groups of transformer cooler, three of which could satisfy the requirement of rated load operation of transformer. For even cooling of transformer, operation cooler and assistant cooler should be started up alternatively along oil tank. During normal operation, two cooler groups are put into operation while one group is in assistant state and the other is standby. When ambient temperature changes significantly, the operation mode of cooler could be changed as per the temperature of upper layer oil; When the ambient temperature is high in summer, three groups of cooler could be put into operation according to the temperature of upper layer oil with the other group for standby; When the ambient temperature is low in winter, one cooler group could be put into standby according to the temperature of upper layer oil, i.e. two for operation and two for standby (the temperature of upper layer oil is no lower than 75C).
2)
3)
4)
5)
6)
3.1.3.4 When all coolers are shut down because of fault (all fans of oil pump are shutdown): 1) When the temperature of transformer upper layer oil reaches 75C and lasts for 20 minutes, the outlet protection will trip; 2) It is 60 minutes for transformer to run under rated overload. The outlet protection will trip if the period is longer than 60 minutes; 185
3.1.3.5 Insulation Monitoring 1) Before transformer starts up after maintenance or outage, insulation resistances of both sides of transformer should be measured with disconnecting PT in the transformer circuit. 2) During measurement of insulation resistance of transformer windings, 2500 V megger should be used for those with a voltage above 10KV and 500V megger for those below 500V. 3) Discharge the windings by grounding before measurement. The values for R15 and R60 should be measured. Calculate the absorption ratio of R60/R15. Discharge to earth after measurement. 4) Normally no requirement is specified for insulation resistance and absorption ratio of dry-type transformer. 5) The insulation resistance of oil filled transformer should be in accordance with the following standards: For transformers with a rated voltage above and below 20KV, the absorption ratio at 10C ~ 30C should be no lower than 1.3 and 1.2. The insulation resistance should be no lower than the values listed in the table below. Permit insulation resistance (M) of oil filled transformer: Temperature HV Winding Voltage 310KV 2035KV 60500KV
10 450 600 1200
20 300 400 800
30 200 270 540
40 130 180 360
50 90 120 240
60 60 80 160
70 40 50 100
80 25 35 70
Note: for a certain transformer, the insulation resistance standards for the LV and MV windings are identical to those for HV windings. If measured insulation resistance is unqualified, report to the shift supervisor immediately and request maintenance staff to find out cause and eliminate the fault. After that, recover the transformer to standby state waiting for operation order. 3.2 Operation and Maintenance of Transformer 3.2.1 Preparation for Transformer Startup Before startup of transformer, take back work sheets related to electrical connection of transformer and remove grounding wire and short-circuit wire. Verify that transformer and its circuit are in correct condition for operation. In addition, complete the following steps: a) Measure the transformer insulation resistance (for maintained equipment, check 186
the maintenance record); b) Check the position of tap changer, oil color and level. Make sure no oil leakage of transformer; Valve of gas relay should be opened and filled with oil without gas inside and it cover should be intact; Verify the valves of cooler are open and the cooling devices are intact (valves are to opened by maintenance staff after maintenance); the interlock and test run of motor should be normal. Check the color of the breather silica gel. The pressure relief valve should be intact and at reset position. The grounding wires of transformer parts are solid and reliable. Check the termination of transformer thermometer are complete and the temperature calibrated is in accordance with requirements; Check the secondary circuit (control, meters and protection) are intact. Protection system for normal transformer operation should be started correctly.
c)
d)
e)
f)
g)
3.2.2 Operation a) Beside of related specifications for electrical operation and emergency, the operation of energization and shutdown of transformer should also follow the requirements below: 1) Transformer should be charged by the power side with protection devices. During shutdown, the switch of power side with protection devices should be finally opened. 2) Breaker should be used for transformer startup or shutdown rather than knife switch. 3) Cooler should be put into operation before the startup of forced oil circulation air cooling transformer. The cooler could be stopped after transformer shutdown. b) After the maintenance of main transformer and HV auxiliary power transformer with changing windings, the transformer could not be put into operation before generator zero-initial voltage boosting and verification of phase sequence. After maintenance, the startup/standby transformer and LV transformer should to be put into operation after phase verification and power charging. The position adjusting operation of tap changer of no-load voltage regulating transformer should be performed after the transformer is shutdown and protection measures are finished. The equality of phases DC resistance should also be measured. Carefully the record changing of the tap changer. The tap changer of on-load voltage regulation transformer could be regulated 187
c)
d)
under normal operation of transformer. The following aspects should be paid attention to: 1) During changeover, the indication of the position of tap changer, transformer current and voltage of sides should be monitored; 2) In principle, only one span could be changed for the tap changer. The regulation for next span should be performed after an interval; 3) Frequent operation of tap changer is prohibited during transformer overload operation; 4) Normally the on-load voltage regulation tap changer is electrically operated. In case of failure of electrical operation, necessary safety measures should be taken. 3.2.3 For on-load voltage regulation tap changer, each 33 circles turned manually refers to a tap changer. Clockwise direction is for voltage increase and the counterclockwise direction is for decrease. The steps are: take off connection sleeve; shutdown the power of electrical mechanism; install the crank to the worm shaft and begin to operate; after changeover, verify the crank is just vertically up and the value indication is right located in the middle of the gap; finally recover the connection sleeve. 3.2.4 The on-load tap changer should be maintained and inspected as per the following requirements: a) Regularly check the cleanness and loss of oil inside the insulation cylinder of the changeover switch. Normally, an oil sample examination should be performed every 1000 switching operations under rated current. The withstanding voltage should be no lower than 30KV. Oil should be replaced when the withstanding voltage is lower than 30KV, and should be replaced every year even withstanding voltage is higher than30KV. The electrical magnesium should be kept intact. Gas protection and explosion proof device of the tap changer should be in normal condition. Cause should be found out after protection acts.
b) c)
3.2.5 For transformer in operation or hot standby state, Gas protection should be at the position of "Trip" and that of transformer in cold standby state could at the position of "Signal" for monitoring the oil level of transformer. 3.2.6 When the indication of the oil level meter is abnormally high, the cause of oil level rising should be found out. Plugs for releasing gas or draining oil should be kept closed and cleaning of moisture absorber as well as other works are prohibited before release the trip pressure plate of gas protection to avoid its malfunction trip. 3.2.7 Heavy gas protection pressure plate should be changed to "Signal" from "Trip" when the following works are carried. The gas protection should be recovered to "Trip" 188
when works are finished. a) b) Oil filling, filtering and changing submersible pump; Cleaning the meshes of breather; opening valves for air ventilation, oil drainage and oil feeding (not including taking oil sample and gas release of gas relay); Gas protection working on the secondary circuit; The above works, changeover of the state of gas protection (to trip or signal) should be permitted by the shift supervisor.
c) d)
3.2.8 Operation and maintenance of forced oil circulation air cooling device of transformer a) Before and during operation of the forced oil circulation air cooling device, the following items should be checked: 1) Verify the valves of intake and outlet oil header of the cooler are open, the air path of the heat exchanger is clear and the inlet is clean. 2) Start cooler group by group: Verify the direction of submersible pump is correct without noise and obvious vibration during operation ; Verify the rotating direction of the fan motor is correct; no friction of the blade exists; Switches in the control box of the cooler are well closed with vibration and abnormal noise; No oil leakage of the cooler exists. 3.2.9 Inspection of the transformer a) During transformer operation, shift operator should monitor the operation of the transformer via the indication of meters and record related parameters hourly. When transformer is overload operation or other abnormal condition, strengthen the monitoring of transformer load, temperature of upper layer oil and temperature of windings, and shorten the recording intervals. Inspection of oil filled transformer in operation: 1) Verify the positions of conservator and bushing as well as the oil color are correct; no oil leakage exists; 2) Verify the external of bushing is clean without crack, discharge mark and other abnormal sign; 3) Verify the sound of transformer parts are normal; 4) Verify the temperature of transformer parts are normal, the valves of oil system are in correct positions, and the operation of fans and oil pump are normal; 189
b)
5) Verify the contacts of connectors of the primary circuit are normal and not heated; 6) Verify the pressure relief valve and explosion proof cylinder are intact and the pressure relief valve is at reset position; 7) Verify no gas in the gas relay; verify the valve between gas relay to conservator is open; 8) Verify that the door and windows of transformer room are intact. No water leakage or water logging in the room; lighting and ventilation are good. 9) Verify the grounding resistor of the neutral point is not overheated; 10) Verify the position of on-load tap changer and power indication are correct; 11) Check items of the grounding resistor of the neutral point are: Check no debris in the resistor; clean dust in it; Check the connection between resistor elements is qualified; Check the condition of insulation support is proper. Before operation of the resistor after system failure, it should be carefully checked to eliminate potential risk. 3.2.10 Inspection of dry-type transformer in operation: a) Verify the temperatures of transformer parts are normal; verify the thermometer is lean and intact; Verify no abnormal noise , empyreumatic smell and obvious vibration; Verify that no water logging or leakage is around transformer and the shell of transformer is clean; Verify the door of transformer cabinet is well locked; Verify the ventilation system of the transformer is in good condition and the fan works well;
b) c)
d) e)
3.2.11 Special inspection of transformer: a) It should be checked after the action of gas protection and differential protection. Inspection times should be increased in case of abnormal condition; In the rainy, snowy and foggy days, check whether there is evaporation, melting at the transformer connectors, whether the flashover is serious. Verify no crack or burned marks on the sleeve, no ice column on the insulators, which would cause flashover; During windy weather, verify the upper leads of transformer do not swing tempestuously and are not loose; verify no debris on the cover or around; 190
b)
c)
d)
When the air temperature suddenly changes, check the oil level, operation of coolers for any overheating or freezing; In case of overload operation, monitor the change of load, oil temperature and oil level; verify the contact of connector is proper without overheating and the cooling system operates well. After short-circuit failure, check tap changers for any distortion, oil ejection and check the neutral point or discharging gap for any burned marks.
e)
f)
3.3 Treatment of transformer abnormal operation and failure 3.3.1 Treatment of transformer abnormal operation Any abnormal condition found during operation (oil leaking, low oil level of oil conservator, overheating, abnormal noise, etc.) should be eliminated as soon as possible and reported to related department. If the transformer has to be shut down for fault eliminating and the fault may threaten the safety of device and system, the transformer should be shut down immediately and put the standby transformer into operation as soon as possible. In case of the following conditions, report before transformer shutdown: 1) Crack, oil penetration, discharging phenomenon and marks are found; 2) Falling matters on the transformer threatening safety and requiring for power off; 3) Serious oil leakage; 4) Temperature of transformer is abnormally high while the load, ambient temperature and cooling conditions are correct; 5) Oil color changes suddenly; the oil color is dark and feculent with higher viscosity; result of regular oil inspection is not qualified; 6) Abnormal noise with sound of discharging; 7) Termination lead becomes loose and hot, and its color changes; 8) On-load tap changer fails and can not be regulated manually; 9) All protections are out of service; 10) In case of conditions above mentioned, standby transformer should be put into operation. If no standby transformer, stop the operation transformer as soon as possible. Transformer should be ceased in any case of the following: 1) Noise inside the transformer is loud, uneven and with crepitation ; 2) The temperature of transformer is abnormal and keeps rising under normal load and cooling operation condition; 191
3) Oil conservator or pressure relief valve eject oil; 4) Oil quality deteriorates with carbonization inside; 5) Bushing is seriously damaged with discharging; 6) Oil level drops below the range of oil level meter because of oil leakage; 7) Transformer fires. If the oil temperature is higher than permitted value during transformer operation, the cause should be found out and measures should be taken to lower the temperature together with the following works: 1) Check the load and coolant temperature; verify the supposed load and coolant temperature; 2) Verify the indicated temperature of remote and local thermometers; 3) Check the ventilation and cooling device is normal. If cause of the temperature rising is abnormal condition of cooling system, try to keep the transformer in normal operation. If the abnormal condition can not be eliminated, change the load of transformer to a relative capacity as per this specification until transformer outage. If no cause is found out and the temperature is 10 C higher than that of normal operation, or the oil temperature keep rising under normal load operation, the transformer should be ceased considering that there is internal failure of transformer. Abnormal transformer oil level 1) If the oil level is much lower than the level the temperature at that moment corresponding to, oil should be filled immediately. During oil filling, related procedures in this specification should be followed. If the oil level quickly drops because of oil leakage, the gas relay protection is prohibited to set as only for signal, and measures for preventing oil from leakage should be taken at once. If the oil leakage can not be stopped, shut down the transformer when oil level reaches lower limits. If the oil level drops because of too low temperature, change the operation method of the coolers according to the transformer load, so as to control the oil level and oil temperature within a specified range. 2) When the oil level increases because of temperature rising and higher than oil level meter, drain oil to control the oil level to an appropriate level. If the oil level is much higher because of blockage of seal system of breather, or oil overflow from breather, immediately inform the maintenance staff and report to related department to solve the problem. The indication of the oil level meter is fault during abnormal conditions mentioned above. Oil drainage without permit is prohibited until breather is recovered. 192
3) Under abnormal oil level condition, carefully monitor the oil level and temperature and report to related management personnel timely. 3.3.2 Treatment of transformer failure 3.3.2.1 When the gas relay protection system sends signal, check the transformer immediately for the cause, such as air invasion to the transformer, low oil level, or fault of the secondary circuit. If there is no failure sign outside of transformer, take gas example from gas relay for examination. If the gas is combustible and the result of chromatographic analysis is abnormal, shut down the transformer for maintenance. During treatment of failures above, pay attention to the interval between gas signals. If the interval becomes shorter and shorter, the transformer will trip. Do not change the gas relay protection to Signal state, put the standby transformer in to operation and report to relative management personnel for transformer shutdown. 3.3.2.2 If the transformer trips because of action of gas relay protection, completely check the transformer and take gas example for examination. Do not start up the transformer again until results of inspection and examination are qualified. 3.3.2.3 If the gas relay protection send signal while transformer does not trip, the cause of fault may be: Air enters the transformer because of oil filtering, oil filling or unsealed cooling system; Oil level drops because of low temperature or oil leakage; Negative pressure caused by blockage of breather system; gas produced by transformer failure; Short circuit through fault.
3.3.2.4 Manually reset the mechanical and electrical signal of relief valve after the action of pressure relief valve. 3.3.2.5 Trip of transformer Standby transformer (if any) should start up as soon as operation transformer trips. Find out the trip reason based on the action of protection and external situation (external short circuit, transformer overload)of the transformer at the moment of trip; If the main protection of transformer acts (gas or differential protection), check devices in the range of main protection for any internal or external sign. Measure the insulation resistance of windings. If there is any internal fault sign, perform internal inspection. If it is found that trip is caused by over current protection of external fault or by 193
fault of secondary circuit, the transformer could be put into operation without raising voltage from zero or impulse closing test 3.3.2.6 Treatment of transformer firing: Shutdown power supply; put out the fire by dry-chemical fire extinguisher, carbon dioxide fire extinguisher and 1211 fire extinguisher and inform the fire fight department. No liquid can be used for fire fighting before power is switch off. Stop cooling devices; If the cover of transformer fires, open the oil draining valve to lower the oil level below firing point. Oil draining should be precipitated for internal failure of transformer to avoid transformer explosion.
4 Electrical System
4.1 Switching operation of electrical system 4.1.1 Requirements a) Switching operation and changing of operation method for 500KV and 220KV system should be performed under the command of dispatching personnel and shift supervisor. Operation on auxiliary power system and changing operation method should be under the command of shift supervisor and relative personnel should be informed. Before execute the work sheet, verify it on the DCS or electrical system drawing; After equipment maintenance, the responsible maintenance person should notify on the maintenance deliver sheet with signature whether the equipment is ready for operation. Then operator could perform switching operation; Before equipment energization, take back all work sheet, remove safety facilities for maintenance, recover shade and railing as well as warning sings and completely check equipment and their circuits ensuring the circuits are ready for operation; All switching operation should be in accordance with the requirements specified in [Working Regulation of Power Safety] and Management System of Electrical Switching Operation; Normal switching operation should be avoided between shifts (operation such as failure treatment could be performed as per actual situation).
b) c)
d)
e)
f)
4.1.2 Principles for switching operation: a) For power switching operation between unit 1startup/standby transformer and unit 1(2)HV auxiliary power transformer, only series switching mode (power switching off)is permitted ; For power switching operation between 6KVbusbar and 400V busbar, if they are 194
b)
in synchronous operation, short time parallel switching is allowed, meanwhile, the working transformer supports these sections should be overloaded. c) For special panel, power supplies of which come from the same 400V busbar, parallel switching at panel side is allowed during switching operation; for panel using power supplies from different busbar of 400V, parallel switching is prohibited. If power switching operation is required, notify the operators of steam turbine and boiler to adopt the method of instant power-off. For circuits installing SF6 breaker, vacuum switch and air switch, switching operation should be performed by these switches to cut or connect load current rather than knife-switch. The operation of shut down power should be performed from switch, to knife-switch on load side, and to knife-switch on busbar side. For energization, the sequence should reverse. Before close the knife-switch, make sure that switch of this circuit is at open position (except busbar changeover operation). The open/close position of the switch should not only be judged just from the indications from DCS and meters, but also from the actual switch position. Normally the 6KV vacuum switch is prohibited to trip manually; The synchronization and step-out of loop system should be performed by switch rather than knife-switch; For switching operation, the overload possibility of parallel circuit and transformer should be considered as well as reliability of operation and treatment of failure; For newly installed transformer and busbar or those phase sequence and phase may be changed, check their phase before energization; During operation of switch, pay attention to indicator, meter and related signals ensuring the correctness of switching action; During switching operation, the application of relay protection and AVR should be in accordance with [Rules for the Operation of Relay Protection]; For switch with synchronous close function, it only can be closed after the synchronous function starts. When only the switch side has voltage, the synchronous lockout function could be released only with the shift supervisor's permit; Power on/off operation: 1) The switch should be at open position before close/open knife-switch and vacuum switch to supply or shutdown power; 2) Close/open knife-switch with load is forbidden. Electrical and mechanical (anti- malfunction) lockout devices could not be shutdown without permit; 3) To shutdown power, open the switch, then open the knife-switch on load side and finally open the knife-switch on busbar side. To supply power, operate in 195
d)
e)
f)
g)
h)
i)
j)
k)
reverse order; 4) During operation, if knife-switch is closed or opened by error, do not open or close it before taking safe measures. n) Loop Closing operation 1) System loop closing operation should satisfy the following conditions: identical phase, identical phase sequence, identical frequency and identical voltage, etc.; 2) During loop closing operation, for switch with synchronous identification function should be identified before loop closing. For switch without the function, verify the loop is at the loop network state before loop closing. 3) Before looping-off/looping-in, the change of voltage should not exceed specified value. The power flow and overload of electrical elements should be paid attention to. o) Impulse closing operation: 1) Full-voltage impulse should be performed for newly installed or maintained equipment such as transformer, busbar, etc. as per relative rules. If possible, adopt the method of raising voltage from zero to charge equipment; 2) After the emergency trip of transformer and busbar, full-voltage impulse could be performed as per relative rules. If possible, adopt the method of raising voltage from zero to charge equipment; 3) During impulse closing operation, the following aspects should be considered: the switch for impulse closing should have sufficient breaking capacity and the times of emergency trip is within specified limit; protection device for impulse closing switch should be intact and put into operation. The automatic closing function should be forbidden. If necessary, reduce the setting of protection device before impulse closing; choose the power supply with less impact to stable operation as the impulse closing power supply. If necessary, check and regulate the power flow of tie lines; when perform impulse on the transformer of the neutral point grounding system, its neutral point should be grounded. p) Precaution for operation of raising voltage from zero 1) The equipment to be operated should have complete protection system. 2) During operation of raising the voltage of generator, manual mode should be applied and strong exciting devices should be stopped; 3) During operation of raising the voltage of the transformer of neutral point grounding system, the neutral point of the transformer should be grounded. q) Operation could be performed by knife-switch: 196
1) Operation of closing and opening for no-load busbar without fault; operation of connecting the capacitor current from equipment connected to the busbar; 2) Closing and opening for PT in normal condition; 3) Closing and opening the shunt branch without impedance according to equipotential principle; 4) Closing and opening for the loop equalizing current no higher than 70A in the system with a voltage no higher than 10KV; 5) Closing and opening the neutral point grounding knife-switch of the transformer when the system has no grounding fault; 6) Closing and opening the no-load transformer with a excitation current less than 2A, and the no-load circuit with a current less than 5A. r) No parallel operation is permitted between the two power supplies of the MCC, power Switchboard, I &C power distribution panel. Temporary parallel operation is allowed only for those in the same power system during switching; The operation mode of short time parallel for switching auxiliary power should satisfy the following: 1) Voltage difference between 6KV auxiliary power systems to be switched should be no higher than 10%; 2) During auxiliary power switching, Non-synchronous parallel should be avoided; 3) Startup and shutdown of automatic switching device of the standby power in the auxiliary power system: when the standby power supply is in hot standby state, the switch should be at the position of startup; the switching device should be set at the shutdown position when the standby power is in the state before manual closing or after automatic closing, or before quitting standby. When the 6KV system is in normal condition, the button of startup mode for the quick switching device should be switched to the position of unblocked; when there is no standby power supply, the startup mode should be switched to Blocked t) Startup and shutdown operation of the PT for 6KV busbar: during power failure, change the button of quick switching device for the auxiliary power busbar to Blocked, open the LV DC protection switch on the busbar where the PT to be shutdown is located; open the relative LV AC protection switch; pull the dolly of PT to the test or maintenance position. The startup sequence is reverse. Shutdown operation of the PT for 400V busbar: open the LV DC protection switch of the busbar, open the Switch cabinet where PT is located; open the secondary switch of the PT to be shutdown; and take off the fuse for the primary side. Startup sequence is reverse 197
s)
u)
v)
To run the generator and network, or two systems out synchronization by opening breaker, load dispatching should be checked, and regulate the active and reactive power to or close to zero;
w) Before shutdown any circuit of a double circuit system by breaker, check the other circuit is not overload; x) To synchronizing the generator to the network, or one system to another, the synchronizing device should be put into operation. Before close the breaker, check synchronization or no voltage exists in the system to be connected. Closing sequence of the disconnector on both sides of the breaker: to shutdown, open the breaker, then open the disconnector on the load side, finally open the disconnector on the power supply side. The startup sequence is reverse; Before closing disconnector of unit circuit, verify the breaker is at open position. Check the actual results after opening or closing a disconnector;
y)
z)
aa) Operation of closing disconnector should be quick: when a disconnector is closed by error (e.g. in the circuit with short circuit fault or shortened line, or connecting two system not synchronous), in no case the disconnector could be opened before the circuit is disconnected with breaker or it is crossed over; bb) When manually open the disconnector, be careful and slow, especially when the contacts are just opened. If strong arc is produced, operate in reverse direction to close the disconnector and find out the cause. If the arc is produced by cutting the on-load current of the no-load line, no-load busbar small capacity no-load transformer, or the capacitor current of low capacity capacitor, quickly open the disconnector. cc) 500KV, and 220KV disconnector for normal power outage could only be closed during operation and should be opened after switching; dd) Operation sequence of control power switch: for shutdown, open the switch after the breaker and disconnector are open. For startup, close the switch before the breaker and disconnector are closed; ee) For circuit only with fuse and disconnector, locate the fuse and close disconnector before startup; the sequence for shutdown is reverse; ff) Startup and shutdown of relay protection pressure plate: verify relative pressure plates are put into operation before startup equipment to standby state or close breaker for energization. After the equipment (circuit) step out of standby state, the protection pressure plate should quit service as per [Rules for Operation of Relay Protection and Automatic Device]. Normally, it should not quit service if no definite specification;
gg) To shutdown the transformer because of fault or to take off LV fuse on the secondary side (or open the secondary switch), it should be approved by the shift supervisor (except the situation requiring to shutdown equipment immediately). If 198
collapse of voltage may be caused by the power failure of the transformer, shutdown the LV protection and automatic devices (such as LV, LV over current, distance protection, strong excitation devices, etc.) supplied by the transformer before shutdown the transformer. Startup the protection system and devices mention above after the operation of transformer is recovered. hh) If the generator changes to hot standby after step-out synchronization and shutdown, open the outlet switch, excitation switch, and outlet disconnector; if to cold standby state, change the state of transformer to maintenance, open the LV switch and disconnect the excitation power supply ii) The switching operation of HV auxiliary power supply should be performed by quick switching device. If the quick switching device is out of service because of fault, perform the operation as follows: if the operating UAT is synchronous with the standby one, close the switch and open it; if not synchronous, open it and then close (synchronous id preferred). During voltage regulation, to decrease the influence of ring current, the function of on-load voltage regulation of startup/standby transformer should be considered. Installation and removing sequence of grounding wire (including grounding disconnector): installation should be performed after switching operations are finished and verify no voltage exists; before startup of maintenance equipment (or before standby), verify that no shorten grounding wire after remove safety measures.To close the grounding disconnector of the line, command from provincial power dispatching center is required;
jj)
kk) When switching power supply of MCC power dispatching cabinet with two power supplies, the power should be shutdown and parallel operation is prohibited to avoid arc short-circuit caused by disconnector cutting ring current. Meanwhile, switch opening and closing during on-load operation of is prevented. 4.2 Electrical System Abnormalities and Countermeasures 4.2.1 General Rules on Events Dealing a) Main task of events dealing: 1) Prevent the development of events as soon as possible, eliminate the root of events, and get rid of the danger to equipment and human. Try to ensure the normal operation of service power and major machine, so as to prevent the expansion of events. Adopt all possible methods to keep the operation of machine, in order to ensure the normal power supply to customers. Recover the power supply to out-of-power customers as soon as possible. Adjust the operation mode reasonably, and make the system to normal state, when the event condition is under control and tend to be stable. 199
2)
3)
4) 5)
b)
During the dealing of events, the chief operator is the director of event dealing, leading all attendants to carry out the event treatment and operation. When events occurred to the Electrical system, the attendant should judge and treat with according to the following sequence: 1) Judge the nature of event according to meters and CRT display, warn signal of alarm window, impacting/swing situation exists or not, the operation of relay and auto-protective equipment, printed records of computer and outside evidence of equipment. Judge the event site and range through complete check and test on equipment. If fault threatens human and machine, measures should be taken to eliminate the threat, and stop the machine if necessary; if there is not threat to human and machine, try to keep or recover the normal operation of machine. Ensure the safe operation of no-fault equipment. Specially, pay attention to separate the equipment without receiving direct affection. Start the standby machine, when necessary. After the fault nature and range is judged, the attendant should implement site safety measures to faulted equipment, so that maintenance operator can repair them conveniently. To prevent the spread of event and avoid the disorder during the treatment, each period of event treatment should be actively and precisely reported to shift chief operator or leader in time.
c)
2)
3)
4)
5)
6)
d)
To prevent the spread of event and deal with the event quickly, the attendant can report to shift chief operator after implementation of the following operation, when under the emergency. 1) De-energize the broken equipment or the one threaten to human and equipment. Separate the operating equipment when it tends to threaten. Open the busbar connection switch when its voltage disappears. Restore its supply when the service power partially or totally in outage.
2) 3) 4) e)
After the fault of bus, the step-up or impulse test is permitted only after the inspection of busbar and open of all switches connected to it. If someone is work on distribution devices, be to inform him to leave before the step-up or impulse tests. The quick and precise treatment is necessary for event. But the disorderly, hasted or indeliberate treatment should be avoided. Otherwise, it will spread the 200
f)
events. g) The attendant should iterate the order to the order issuer when he receives the event treatment order. The attendant should make clear of the order, if he do not understand it or its objection. The attendant can execute the order only after he received the order from acquainted leader. After the execution, he should report to order issuer immediately. Order issuer must be acquainted with the order receiver, and ask him to repeat the order. If the next event order must be decided in accordance with the former order, then wait the personal report of order receiver. Delivery through the third person is prohibited, and to judge the execution situation according to indication of meter is not permitted either. The indication of meters and signals must be monitored during the events. Among the attendants in the main control room, someone must be responsible for recording the execution time of each operation (esp. the operating sequence) and phenomena concerned events. If the event occurred during the shift handover, the handover person should stay at his duty post. The duty succession person must cooperate with the event treatment under the united direction of handover shift chief-operator and chief operator. After periodic event treatment, the machine recovered to normal operation, the shift handover may be carried out all together under the order of shift chief-operator or leader of department. After the event treatment, the duty principal should fill the observed things and matter in the duty record book actually, in order to facilitate the event analysis and cause finding. Pay attention to the following items when forced line energization to be implemented manually after the trip: 1) When conducting the forced line energization, observe the conditions of voltage, current and system impulse, in order to identify the fault. If fault exists, the forced switch must be open immediately. If faults, such as smoke, fire and arc etc. are found, the forced line energization must be prohibited. When forced energization of trip switch is conducted, the event of over-stage trip may be considered. During the event treatment, the principle of dealing with above events should be put into effect according the site event nature and actual situation.
h)
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4.2.2 Treatment of Faults and Abnormalities of 6KV Service Power System a) The power supply switch of 6KV service bus bar tripped, the switch of standby power supply automatic close succeeded 201
1)
Check the voltage indication of 6KV service bus bar- it should be in nature. Reset flash switch and sound signal, cut off the high-speed switching device of that section of bus bar. Check the operation of protective devices, find the cause of fault. And conduct necessary inspection on tripping switch. If resulting from the mis-operation, recover the normal operation mode after making clear of the cause of mis-operation.
2)
b)
Treatment of 6KV service bus bar voltage failure 1) Check the cause of switch trip and operation of protective devices promptly, and report to shift chief-operator and chief operator. Regulate the unit load according to actual situation. When the work power supply switch tripped, failed automatic close, no branch quick cut off and zero sequence overcurrent blocking signal, the standby supply switch should be closed immediately. Under the condition of without gas or differential protective operation, if there is no standby power supply or the power supply switch tripped, once forced line energization of current power supply switch is permitted. Otherwise it can be dealed with as the bus bar power off until outage. If the switch trip again after the automatic close or forced energization, another forced line energization is forbidden. The faulty bus bar and its circuit should be inspected and the insulation of bus bar and related circuit should be measured. Where exists apparent faulty point, try to eliminate the point, recover the bus bar power, and notify maintenance person to rush to repair faulty equipment. Where no apparent faulty point exists, open all load switches on the faulty bus bar, try to energize with standby supply. After the success of trial energization, energize the outage load line to line. While certain circuit switch is closed, the standby power supply trip again, the circuit should be de-energized and put into maintenance. Recover the operation mode to the one before the event of 6 KV bus bar. 5) When the 6 KV bus bar voltage failed, the treatment of 400 V service bus bar may be implemented according to requirements of 400 V bus bar voltage failure treatment. During the treatment, be to report in time and make good records.
2)
3)
4)
c)
6 KV bus bar single phase grounded 1) When the HVT operates connecting with certain section of 6 KV bus bar, the 6 KV single phase of the bus bar happen to ground, after 1.5 second the 202
switch of working power supply for 6KV1A(2A) or 1B(2B) section bus bar trips, and block the service high-speed switching device of corresponding section. Meanwhile, the single-phase grounded 6 KV bus bar will be de-energized. The event treatment can be carried out according to the case of 6 KV bus bar voltage failure. 2) When the No. 01 startup/standby transformer operates connecting with 6 KV bus bar, the 6 KV single phase of the bus bar happen to ground; after 3.0 seconds, trip the branch, i.e. the switch of 6KV1A(1B) standby power supply or standby power supply switch of 6 KV2A(2B) section bus bar; after 3.5 seconds trip all switches, i.e. the switch of HV side of No. 01 startup/standby transformer, switch of standby power supply of 6 KV1A(1B) section bus bar or switch of standby power supply of 6KV2A(2B) section bus bar. Now, if the No. 01 startup/standby transformer operates with certain machine, the result will be that all the 6 KV service power of the machine fail. If the low voltage branch of No. 01 startup/standby transformer operate after zero sequence of 3.0 second, the following treatment measures may be taken: after isolating the faulty 6 KV bus bar section, provide power supply with another bus bar to ensure the service power; if the low voltage branch of No. 01 startup/standby transformer operate after 3.5 seconds, the following measure may be taken: using the diesel generator to provide standby power supply for safety PC section.
4.2.3 Event Treatment of 400 V Service Power Busbar a) Treatment of 400 V service busbar voltage failure 1) Check for the cause of switch trip and operation of protective devices, and report them to the shift chief-operator and chief operator. Regulate the unit load according to actual situation of site. 2) If the trip is due to the misoperation, recover the power of outage busbar promptly. 3) If the voltage failure of 400 V busbar is due to 6 KV busbar voltage failure or operation of house service transformer, close the 400 V busbar tie switch to recover the power of outage busbar after inspection and open the switch of working power supply of busbar. 4) Check the voltage failure busbar and related circuit. If no apparent faulty point is found, open all load switches on the busbar. After identifying the normality of busbar insulation, try the line energization of busbar with low voltage service transformer. When being normal, ensure the qualification of the insulation of each branch through measurement. Recover power supply to branch load. If apparent faulty point exists, isolate it in no time, and recover the normal operation manner of voltage failed busbar. Also inform the maintenance personnel to repair. 203
5) If it is busbar fault and failed to recover, another busbar supply may be shifted to the MCCs and switch pannels (At first, cut off normal power supply circuit, then close the standby circuit). 6) When the voltage of PC section busbar for 400 V boiler failed, pay attention to the operation of 400 V safety section busbar.
5 DC System
5.1 Outline of DC System 5.1.1 Two packs of 220 V batteries, which are installed in electric building, are equipped for each unit. A common 220 V battery pack is installed in central control building. The battery is valve-control lead-acid one. 220 V battery packs supply power for the loads of control and automatic, electric control, signaling, power and emergency lighting, UPS system, protective relay and automatic devices of proper unit. The common 220 V battery pact supply the load of common relay room etc.. 5.1.2 The 220 V DC system of each #1, 2 units is provided with two high-frequency switching power source charging devices. 220 V common DC system for each of #1, 2 units is providedwith one high-frequency switching power source charging device. There are tie lines between two 220 V DC systems of each unit and two 220V common DC systems of two units. The switching operation of power supply mode can be conducted via the tie switches. 5.1.3 In the 220V DC system, DC diverging panel is provided in the load intensive position. The bus of diverging panel is fed via double circuits of main bus for DC panel. Other DC loads are fed via radial feeder from DC panel. 5.1.4 #1, 2 units 220V batteries are valve-control enclosed lead-acid ones, which operate with floating charging manner. Each pack of each unit have 104 cells, with capacity of 1500Ah; the 220V common battery pack has 104 cells, with capacity of 400 Ah. 5.2 Operation and Maintenance of DC System 5.2.1 Operation Rules of DC System a) b) c) The power DC network feeds through radial net. The control DC network feeds through loop net. Under normal manner, all tie switches of control DC network must be able to switching. When the power supply switch of a side opened due to fault, the power can be fed through tie switch on the other side. When any bus charging device stop working due to certain reason, the battery can feed by itself in short time. If last for a long period, the charging device in another bus can be put into operation instead, which feeds the load on that bus and floatingly charges the battery. When the DC control buses operate individually, the loads which do not share 204
d)
e)
one bus are inhibited to parallelly operate at load side. f) If the busbar need power supply switching, try to avoid the method of short time outage. When the DC system operates, the insulation monitoring device should be put into operation. Before the startup of DC oil pump, check the voltage of bus within permitted range; after DC oil pump stop, check the voltage of bus within permitted range. DC busbar is not allowed to operate by itself that disengage from battery. When the high-frequency supply switch-type charging device failed during the operation, the battery can be used to provide short period load power. But the high-frequency supply switch-type charging device should be recovered to normal operation as soon as possible. If the faulty high-frequency supply switch-type charging device can not be recovered to operation in short period, the charging device on another bus may be put into operation instead, which feeds the load on that bus and floatingly charges the battery. As to the load which has double-circuit feeding, it should open-loop operate wherever the power supply side in the same busbar or not, it is fed individually, parallel operation is inhibited. Any parallel operation of DC system can be carried out only after the polarity of parallel point being checked for sure and the voltage difference satisfy the condition.
g)
h)
i) j)
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m) The permitted fluctuating range of 220V DC bus voltage is usually within 5 of rated value. n) With the battery pact under the condition of floating charge operation, the voltage of each battery should be kept between 2.15 to 2.20V. Monitoring and inspection of DC system operation: 1) In normal operation, the voltage of DC busbar should keep within the range of 225 to 235V. 2) The input voltage of high-frequency power supply switch adopts 38010, 50 Hz0.5 Hz. The output of charging device should meet the requirements of busbar voltage and floating charging current. 3) The work that periodic charge/discharge of battery and maintenance will be conducted by special maintenance person. 4) Each DC busbar has a insulation check device, used to monitor the insulation of busbar to ground. When the insulation reduced below certain value, the signal DC busbar insulation reducing giving out. Meanwhile, check the cause in time. 205
o)
p)
The attendant should give the battery two outside inspection during each shift. When the weather changes, the inspection should be enhanced from time to time. The inspection content is as follows: 1) The temperature, ventilation and lighting inside the house should be in normal. 2) The outside of battery is clean, ends, enclosure and cover has no evidence of breaking, overheating. 3) The battery room is clean, without foreign matters. 4) Naked flame is forbidden in the battery room. 5) If the acid smell inside the battery room is relatively thick, start the house ventilation fan until the air recover to normal.
q)
Inspection of high-frequency power supply switch-type charging device, DC panel and insulation monitoring device 1) Check the normality of meters and signal indication in the DC panel. 2) Measure the positive and negative polar to ground voltage, the insulation should be qualified. 3) Knife switches, switches, press buttons on the DC panel should correspond to operation condition. 4) Check the joints for loose connection, overheat phenomena. Ensure the sound of fuse. 5) The voltage and floating charging current of DC busbar should be normal. 6) Elements of thyristor rectifying device have no overheat phenomenon. 7) The insulation monitoring device operate normally, without exception alarm.
r)
Inspections during the operation of busbar of DC system 1) The insulation of system is well without grounding and busbar voltage is normal. 2) Every meter on the DC panel indicates well. 3) Switches, signal devices are well contained. 4) The system equipment is good, parts are clean, no leakage, no overheating phenomenon in joints.
6 UPS Power Supply Outline of UPS System 6.1 The work power source of control and automatic device protection, monitoring instruments, computers etc. used for 2300 MW units require single phase 220V AC 206
UPS. Thus, a suit of inverter-type uninterrupted power supply (briefly as UPS, type: BORRI E2001). 6.2 In the UPS system, the equipment includes: rectifier, inverter, static switch, bypass maintenance switch, load distribution switch and control device etc.. These devices are installed individually in four cabinets, i.e., rectifier cabinet, inverter cabinet, bypass cabinet and load control panel cabinet. a) Main Power Supply: The main power supply, i.e. working power supply, is fed to rectifier cabinet. After the conversion of rectifier (3-phase thyristor rectifier bridge), the 3-phase AC voltage is transformed to constant voltage, and output with DC current. The DC voltage output of rectifier can be divided into two branches, one of them used for charging of battery, the other one serve as input of inverter, feeding DC current to it. To avoid affecting the normal charging from thyristor rectifier to battery of 220V DC system of unit, a isolating diode is equipped in the line of DC voltage output that is from rectifier to battery. When fault occurred to the working power supply or rectifier, or the 220V DC system voltage of unit is higher than the DC output voltage of rectifier, the 220v DC system of the unit will feed the inverter with DC input power supply. The DC voltage output of rectifier or the DC power supply provided by 220V DC system of unit is fed to inverter cabinet, acting as the input of inverter. The inverter control circuit converts the DC voltage into a series of sine impulse width square wave for output. After the filer circuit filter out the high order harmonic wave, it converts to single-phase AC voltage. Then it flows to bypass cabinet via static switch, goes through the bypass switch, at last to the load control panel. b) Standby Power Supply: The standby power supply is fed to bypass cabinet via 380/220V isolation transformer and automatic voltage stabilizer, then to the load control cabinet via static switch, bypass switch. c) Power Supply Switching: Both working power supply and standby power supply are fed to bypass cabinet, then through the bypass switch QIBY to the load control panel, where it is distributed to loads. The working power supply and standby power supply have such switching styles as follows: 1) Switching power supply by the bypass switch QIBY The bypass switch has three position states, i.e., normal (I), test (I + II), bypass (II). When the bypass switch shifts from one state to another, the contacts of switch transfer according to the sequence of close first open afterwards. When the working power supply feed to the load of UPS system and standby 207
power supply is in normal state, while switch the bypass switch QIBY from normal position (I) to position of test (I + II) and bypass (II), the load power supply will uninterruptedly switch to standby power supply; when the working power supply is normal, change the bypass switch from bypass (II) or test (I+II) position to normal position (I), the UPS load power supply will also uninterruptedly change the standby power supply to working power supply. 2) Switching through turning on/off of static switch When the bypass switch QIBY in normal (I) position, turning on/off control static switch can be used to the transfer of power supply of UPS system load. When the inverter stop operation due to fault or the MANUAL TRANSFER button, i.e. button of power supply manual transfer is pressed, the working power supply transfer to standby power supply, feeding to load of UPS system; After the rectifier, inverter etc. recover to normal operation, press RESET button, the standby power supply will transfer to working power supply, which feeds to load of UPS system (the rectifier, inverter operation stop was not due to manual action, if the cause of operation stop were eliminated, they will start automatically. If the MANUAL TRANSFER button was not pressed, the UPS system load power supply will automatically transfer standby power supply to working power supply, without pressing the RESET button). Such transfer procedure is interrupted, but the interrupted period is short, which fulfill the need of customer. d) Power Supply Track: This device is provided with synchronizer to enable the AC voltage output by inverter track the frequency of standby power supply. Thus ensure that the interrupted period will not increase because the asynchronous transfer of working power supply and standby power supply, when transfer them to feed the load of UPS system. When the standby power supply failed, the synchronizer disarm the track, the working power supply continues to operate with self-excited oscillation frequency of 50 Hz. 6.3 Operating condition: a) Normal condition: power supplied by main power supply, UPS provides stable AC 220V, 50 Hz sine wave power to load; Faulty condition: when the main power supply failed, the inverter automatically transfers the power supply to DC system battery of unit. UPS system provides stable AC 220V, 50 Hz sine wave power to load. When the DC battery system discharges to the limit, UPS inverter will automatically turn off. When the main power supply recover, the inverter will automatically resume the rectifier power supply; Bypass (automatic/ manual) states: if the output voltage of inverter is abnormal due to internal fault etc., the static switch can automatically transfer the load to 208
b)
c)
the standby power supply for bypass system. If the cause is maintenance etc., the load can be transferred to the standby power supply of bypass system through manual switching of bypass switch, and be insulated from other equipment completely. When return to main supply, the power of load is also uninterrupted. 6.4 The local main cabinet panel of UPS has the following signals: a) b) c) d) e) f) g) h) i) j) k) l) Under-voltage alarm of rectifier input Under-voltage alarm of DC input. Under-voltage alarm of bypass AC power supply. Excess high/ low voltage alarm of rectifier input. UPS output alarm: high/low voltage, high/low frequency. Input voltage of rectifier. Input voltage of inverter. Output voltage of inverter. Output frequency of inverter. AC power supply voltage of bypass circuit. Output current of inverter. Alarm of static fast diverter-switch (close on bypass position).
m) Alarm of battery operation. 6.5 Meaning of UPS Alarm Signals: a) Input fault of main power supply: its voltage or frequency beyond the normal range; Battery discharge: battery is in the discharging state (red light flash); when the discharge stop, red light keeps on. Inverter fault: the input voltage of inverter exceeds the normal range. The general fault signal, battery operation, and bypass operation signal can display on the DCS screen of unit. 7 Diesel Generator and Safety Power Supply Outline of Interlock Logic of Diesel Generator and Safety Power Supply Automatic Start Besides the automatic control, the machine also has two manual control manners of local cabinet control and remote control by central control room. 209
b)
c)
The normal switching of power supply is conducted through the interlock of feeder CB of machine and working power supply incoming line CB of the AC safety busbar section. When the safety busbar section voltage fails, after a delay of 3 to 6 seconds (avoid the outage protection and standby power supply automatically close time), the diesel generator auto-starts through the inter-operation of voltage monitoring relay and secondary relay on the safety busbar section. When the frequency and voltage of diesel generator attained certain value, close the trip switch of diesel generator unit, interlock the trip of incoming CB of safety section working power supply and the trip of feeder CB of safety sectional diesel generator unit, then the unit begins to feed the safety section busbar. When the safety sectional working power supply recovered, manually give the shutdown order according to procedures, then the unit trips and shut down automatically. During the normal standby, the safety sections (A, B) busbar voltages should be monitored in-line at real-time. When the busbar voltage is lower than set value and after certain delay (can be set), if the start order is not received or the unit does not start after receiving the order, such case should be alarmed to operation person in the central control room immediately, allow the operator issue order of start through the emergency button on the console. That order channel should be independent of the channel of normal starting procedure, i.e., the start procedure of unit should adopt two channels. The shutdown use local manual operation. After shutdown, trip CB is automatically cut off, and two on/off values are output to safety power supply CB of safety section of A, B to break them. Further, local emergency shutdown button should be equipped. The local control is used for commissioning and normal maintenance of unit, when the unit has no load in general. When unit needs on-load test, the start procedure is same to that of auto-start. Only that the start order is delivered from local manually. Meanwhile, the unit and service power supply have temporary parallel operation, then switch to unit feeding; when the test ends, the unit also has temporary parallel operation with service power supply, and is switched to service power supply at last. The automatic regulation devices should ensure the stable switching of load power supply. If the diesel generator auto-start fails for three times, it gives out shut-down signal, meanwhile lockout auto-start circuit. 8 Relaying Protection and Automatic Devices
8.1 Manage Rules of Operation Principle of Relaying Protection and Automatic Devices 8.1.1 Operation Principle of Relaying Protection and Automatic Devices a) In usual cases, electric equipment is not allowed to operate without relaying protection. If necessary, some protection devices may be shutdown after approval procedures, however, the main protection device is inhibited to stop at the same time. During the operation, the cabinet door is forbidden to open. In the relaying protection chamber of central control room, the mobile phone or other 210
devices having the function of radio emitting is not allowed to use. b) The repair and test of relaying protection and automatic devices should be performed cooperating with outage of primary equipment. Only during the following cases, the relaying protection and automatic devices of the energized equipment can be shutdown for above mentioned work: More than two kinds of main protection devices; When special main protection device is operating, short time shutdown of reserve protection device is permitted; If condition permitted, temporarily put into effect some standby protection device to replace the outage protection device; The gas and differential protection relays for transformer, one of them is allowed to shutdown for a short while; The relaying protection and automatic devices agreed by the provincial grid dispatching organization to get out of service. c) The load current must be used to check the correctness of connection. When appropriate measured are taken and the weather permitting, relaying protection devices is allowed to shutdown for short period. In any cases, strict precautions should be taken against second open circuit of current transformer (CT), second short-circuit of potential transformer (PT). The put-in or shutdown of relaying protection and automatic devices of operating equipment and the change of operation manner must be granted by the order of provincial grid dispatching organization or shift chief-operator, and performed according to written order of shift chief-operator. Such detailed operation will be logged in the Central Control Operation Log. When the relaying protection and automatic devices are ascertained to have the risk of misoperation, the attendant has the right to disengage the relaying protection equipment and report the case grade by grade. The AC power of protection equipment usually comes from itself or the TV which share same circuit with protection equipment. The outage of TV will cooperate with the maintenance or standby state of primary equipment (circuit). As to the single bus PT, only when it does not affect the normal operation of protection equipment, can the PT be permitted to shut down. Never shutdown DC power supply of protection devices. If the shutdown of DC power supply is necessary due to fault treatment, it must be approved by General Engineer, and corresponding safety measures and accidental envision must be made.
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8.1.2 Work Regulations on Relaying Protection Circuit 211
a)
Maintenance work regulations of secondary circuit: When conducting equipment maintenance, the attendant should responsible for the correctness and perfect of safety measures for relaying protection written on worksheet; During the maintenance of relaying protection and automatic devices, the label of working here should be hung on the front/back of protective panel, and red symbol tape will be used to distinguish the limit and range of maintenance and operating equipment. After the maintenance work on relaying protection and automatic devices complete, maintenance personnel must recover all equipment to normal operation state. After the site cleanup, he should hand over the site to operator combining with the worksheet, and take down the maintenance matters into relaying protection work notebook. The content requiring record includes: variation of setting, variation report, changing of secondary wiring, questions and defects settled and unsettled, operating cautions and the put-in of equipment. The operating attendant should check and accept carefully. Both work shift parties should sign on the relaying protection work notebook. To prevent the misoperation of protection devices of operating equipment, the large vibrating work such as drilling is prohibited on or near the operating panel and protective panel. If necessary, appropriate measures should be taken or shut down some protection devices. Tests and other measuring work is not allowed on protection devices that were not shut down. Under such case, test of trial button of devices is not permitted either.
b)
Operation Rules Related to Secondary Circuit: When change the operation manner of primary equipment, the cooperation of secondary equipment and relaying protection devices should be considered in the same time, i.e., when draft the operation sheet for primary equipment, the regulation action to relaying protection and secondary circuit should be included in. When working on the operating PT or secondary circuit of CT, prevent the short-circuit of secondary circuit of PT and open of CT secondary circuit. Detailed regulation requirements should be given to all the protection equipment to be regulate with operation by the electric maintenance person; When adjust the relaying protection setting or change the operation manner of secondary equipment due to the variation of operation manner, those changes that only vary the operation manner of relaying protection or automatic devices through clamp, switch, can be implemented by operation 212
person, other changes to be carried out by maintenance person. The operation attendant should hand over such situation to duty receiving attendant; When conducting the terminal switching of secondary circuit of CT, the method of make-before-break will be used, if adopting double clamps; the switching must be conducted during the outage of corresponding primary equipment, if adopting single-layer clamp. During the operation, cotton glove should be worn.
c)
Changing the setting during the operation should be performed according to the following procedures: Verify the dispatching order or the origin value on the adjusting notice sheet with the actual value. Break the clamp, adjust under custody and reexamine; When the voltages of both ends of measuring clamp disappear, close the clamp. After change of setting, record should be taken down.
8.2 Inspection of Relaying Protection Device 8.2.1 Inspection Items before Putting Into Operation: Written notice of can be put into operation by the relaying protection person exists; Relay elements, clamp and test parts should be in correct position, setting should correspond to the adjusting notice sheet or dispatching order; The clamp can be closed after making sure the ends of clamp in the trip loop having no voltage using high internal resistance voltmeter or multimeter.
8.2.2 Inspection Items during Operation: The switches, knife-boards, safety part, plugs of test part, clamps that the equipment affiliated can be switched smoothly, and have correct position. The attendants should clean the relaying protection panel regularly. During the clean, pay attention to not shake the relay to avoid its misoperation. Water and wet cloth is prevented to use for brush the devices on the relaying protection panel. Attendants should routinely inspect the relaying protection equipment each shift for at least one time. The content of inspection includes: power supply of protection device, signal indications, joint position, clamp position, axis pulling off of relay or not, temperature rising of heating elements, abnormalities of rotating elements, exceptional evidences of resistor or coil (i.e., burnout, color change, smoke, apparent wire break), the doors of protection device panel for operating 213
equipment should be closed. Attendants should regularly check the operation of signal devices, such as emergency sound, alarm bell, light, and check the DC to ground insulation, DC voltage etc..
8.3 Treatment of Operation of Relaying Protection and Automatic Devices 8.3.1 Record the on/off operation (trip, auto-close etc.), protection signal drop or display, time and sequence of operation order. Check the operation of fault wave recorder. Relaying protection device operates or trip, should be reported to shift chief-operator or provincial grid dispatching organization timely. The protective operation signal is allowed to reset only after the review by second person. When the protective operation tripped switch, the protective operation signal should be reset if the forced energization or trial energization is needed. If misoperation occurred to protection device, try to keep things as they are, and notify the relay person to deal with them. When break the PT or deal with the fault of PT circuit, the employment of PT as power supply protection or its function as trip or self-motion of automatic devices should be disarmed. Do not rely on automatic lockout function of some elements without corresponding measures.
8.3.2 8.3.3
8.3.4
8.3.5
8.3.6
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Volume E
1 General
Chemical Operation
This teaching material is applicable for technical education of staff engaging in chemical operation of Quang Ninh 2X300MW Thermal Power Plant in Vietnam, including the operation principle, start-up, shut-down, operation and maintenance, control and adjustment, accident disposal of dematerialized water system, water-stem sampling and dosing system, hydrogen generation system and waste water treatment system, as well as the principle, method and procedures for chemical supervision of water-steam-hydrogen of this thermal power plant.
2 Codes and Specifications Used as Referents

DL/T 543-1994 DL/T 561-1995 DL/T 794-2001 DL/T 5068-1996 SD 223-1987 DL434-1991 GB12145-1989 Quality Inspection Standard for Water Treatment Equipment Used in Power Plant Guide for Chemical Supervision of Water and Steam in Thermal Power Plant Guide for Chemical Cleaning of Boiler in Thermal Power Plant Technical Code for Chemical Design of Thermal Power Plant Guideline for Lay-up of Thermal Power Equipment in Fossil Fuel Plant Regulations for Implementation of Legal Metering Unit in Chemical Water Discipline of Power Plant Quality Criterion for Water and Steam of Steam Power Equipment and Thermal Power Unit
3 Basic Chemical Knowledge

3.1 Chemical Reaction 3.1.1 Chemical Reaction Rate and Chemical Balance 1) Chemical Reaction Rate: refers to whether the chemical reaction under certain conditions is quick or slow. In the process of chemical reaction, the reactant concentration will become lower as the reaction going on and the resultant concentration will become higher, usually, the rate of chemical reaction is denoted by variance of reactor concentration or of reaction resultant concentration in unit time.
Chemical Reaction Rate
v=
Varianceof Concentrat ion ( mol / L ) TimeforVar iance ( s / min)
2)
Factors influencing chemical reaction rate: concentration, pressure, temperature and activator. Chemical Equilibrium: chemical reaction has two cases, one is that the reactant can be completely changed to be resultant, such as acid-base neutralization 215
3)
reaction: NaOH HCl = NaCl H2O The other one is, if one reaction can proceed toward one direction but also can proceed toward the opposite direction under the same condition or some certain condition, this reaction is called reversible reaction. Reversible reaction is unable to keep on to the end, which means the reactant is unable to be completely converted to be resultant. CO H2O CO2 H2 If the external conditions changes, the chemical equilibrium that has been reached will be damaged and new equilibrium will be established again under new conditions. 4) Main Types of Chemical Reaction: (a) Neutralization reaction: a kind of reaction in which the salt and water will be generated by interaction of acid and alkali. Neutralization reaction of strong acid and strong alkali is actually the reaction in which the water molecule was generated, which is difficult to be ionized, from combination of H+ in acid molecule and OH- in alkali molecule, e.g.: H+ OH- = H2O (b) Precipitation reaction: a kind of reaction in which the deposit will be generated, e.g.: SO4- Ba2+ = Ba SO4
(c) Oxidation-reduction reaction: a kind of reaction in which the electron transfer is occurred and the ion and the ion valency will be changed, e.g.: 2KMnO4 5Na2C2O4 8H2SO4 = 5Na2CO4 K2SO4 2MnSO4 10CO2 8H2O (d) Complexation reaction:a kind of reaction in which the complicated ion or molecule is formed by combination of an electropositive ion or atom with a certain number of neutral molecule or negative ion with coordination bond, e.g.: Cu2+ 4NH3 = [Cu(NH3)4]2+ 3.2 Solutions 3.2.1 Electrolyte and non-electrolyte: the compound that is conductive in solution where it is dissolved or in melting condition is called electrolyte, and the compound that is not conductive in solution where it is dissolved or in melting condition is called non-electrolyte. Both of electrolyte and non-electrolyte are referred to compound. The opinion that all material except for the electrolyte belong to non-electrolyte is wrong (simple substance not involved in non-electrolyte). Only one condition, either being conductive in water or in melting condition, is satisfied that the substances can be judged as electrolyte, but not both of them. However, if a 216
compound can not be directly ionized to be the ions freely moving under the effect of water molecule or in the melting condition by heating, it is not the electrolyte. For example, water solution of NH3 and SO2 is conductive but they are not the electrolyte, because the weak electrolyte of NH3.H2O and H2SO3 will be generated in the reaction of NH3 and SO2 with water when it is dissolved in the water, it is from ionization of NH3.H2O and H2SO3 that freely moving ions comes but not direction from that of NH3 and SO2 themselves, so NH3 and SO2 can not be called electrolyte. 3.2.2 Ionization of electrolyte: in water, the attraction between positive ion and negative ion will be weakened under the impact of water molecule, and the electrolyte is therefore ionized to be the ion in free moving condition; when in heating, the attraction among ions bringing different electric charges will be overcome when the crystal becomes melting as a result of the crystal ion movement become faster as the temperature climbing up in the heating, and the electrolyte is therefore ionized to be the ion freely moving. When the electrode connected with DC power is inserted into this kind of solution or melting liquid, the ion bringing the positive charge will move to the cathode and the ion bringing the negative charge will flow to the anode, and the solution or the melting liquid is therefore be able to conduct the electricity. Ionization of water and pH value of solution: the delicate electricity conductivity of pure water can be measured by use of precision instrument, this means the water is a kind of electrolyte that extremely weak. The molecule of pure water can be partly ionized to be H+ and OH- : H2O = H+ OHNegative common logarithm value of concentration of hydrogen ion in the solution is jus the pH value of this solution, namely: pH = lg[H+] the said means the smaller the pH value, the higher the Molar concentration of H+ and the higher the acidity in the solution, and vice versa. Also, the negative common logarithm value indicating the Molar concentration of hydroxyl in the water is just the pOH value of the solution. Because the multiplication of water ions comes out as a constant: [H ][OH ] = 10-14

3.2.3
So pH pOH = 14, namely the sum of pH value and pOH value of any water solution will be 14 in normal temperature. 3.3 Methods for Water Quality Analysis 3.3.1 Weight Analysis Method: a method by which the content of tested component is determined through weighting certain reaction resultant. It includes three ways as per different separation techniques: precipitation, volatilization and electrolytic analysis. 217
3.3.2
Volumetric Analysis Method: titrimetry analysis also, it is a method in which the content of tested substances can be decided as per concentration of titration liquid and volume consumed, in the way of adding a titration liquid, whose exact concentration has been already known, into the solution of tested substance until they are completely reacted with each other. It can be separated into, in accordance with different types of chemical reaction of titration liquid with tested substances, measures of acid-base titration, precipitation titration, compleximetry and oxidation-reduction titration. Most of titration reactions can proceed in water solution, and for those tested substances that are not dissolved in the water or the water can not be used as solvent for other reasons, the nonaqueous solvent can be used as titration media. Colorimetric and Spectrophotometric Analysis: the color developing agent will be added into the tested sample to bring out the color reaction in which the ion concentration of the analyzed will be in direct ratio with the color depth already developed, and then the spectrophotometer will be used to measure the degree of color depth. Two points has to be noticed when using the spectrophotometer: (1) suitable color developing agent shall be selected, generally, the agent shall have high capability for color developing, the color it develops being stable, only reacting with ions to be tested, easily obtained and with stable performance. (2)Specified operation sequence for analysis must be strictly and correctly followed when in color developing, or else the testing precision will be influenced. Conductometric and Potentiometry Analysis: it is an electrochemistry analysis method to test the material activity (concentration) by use of electrode potential, including direct electric potential method and potentiometric titration method. Direct electric potential method is to use special electrode to transfer the activity of tested ions to be the electrode potential before testing, such as to use glass electrode to test the activity of hydrogen ions in the solution, and to use fluorin selective electrode to test the activity of fluorin ion in the solution. The potential titration method is to use the abrupt change of indicator electrode potential to indicate the titration end point. The difference of these two methods is: direct potential method is only applicable for measuring the free ions already existed in the tested solution without damaging various equilibriums in the solution, while the potential titration method is applicable for measuring the total concentration of tested ions. The potential titration method can be directly employed for titration of colored and turbid solution, and in acid-base titration, it is applicable for titration of weak acid with K smaller than 510-9 that unfit for use of indicator, moreover, in precipitation and oxygen-reduction titration, it is applicable for use in extensive field where the indicator is lack of. Potential titration can be implemented in a continuous and automatic way.
3.3.3
3.3.4
4 Water Purification Station

4.1 General Description and Equipment Operation Principle 4.1.1 General Description 218
The water purification station system is designed on basis of 4300MW unit capacity, and the equipments will be erected in stages. The water amount treated within the capacity of 4300MW Power Unit is about 350 m3/h and the equivalent in this 2 300MW project will be approx. 200 m3/h. The mechanical acceleration clarifier will be arranged in accordance with capacity of 4300MW unit, Two sets of mechanical acceleration clarifier and two sets of filter tank with 200% capacity will be established for this 2300MW project, and matched with dosing systems of coagulant, coagulant and sodium hypochlorite. 4.1.2 Operation Principle of Water Purification Equipment There are various impurities in the natural water, and their categories can be separated into the followings in accordance with the particle size: (a) The particles with diameter over 10-4mm is called suspended substances, which is unstable in the water and can be eliminated by means of natural precipitation, coagulation and filtration; (b) The particle with diameter between 10-6 and 10-4mm is called colloid, which is the aggregate of much molecule and ion. The colloid has large specific surface area due to the relatively incompact bonding among the said molecule and ion, and it often brings electric charges for absorbing mass of ion. The colloid of same kind will repel each other as they bring the like charge, therefore they will be stabilized as tiny colloid particle and not easily to be precipitated in the solution. The colloid can be eliminated by means of coagulation and filtration. (c) When the particles diameter is under 10-6mm, the impurities will be existed as soluble substances (in ion status) and soluble gas (in molecule status) in the water. The ion can be eliminated by means of cation and anion exchange resin. An extremely large part of soluble gas in the water such as N2, O2 and CO2 , etc., can be eliminated by decarbonization device on the one hand, and one part of gas dissociated in the water can be eliminated by means of ion exchange on the other hand. (d) In addition, there are plentifully various organic substances in the raw water, which will easily contaminate the resin, especially anion resin. The organic substances entering into the boiler will be decomposed to be low-molecule acid, which will bring down the pH value of boiler water and result in the corrosion on one hand and will easily converted to be deposit in the boiler on the other hand. The coagulation treatment can remove extremely a large number of organic that existed as colloid and suspended substances in the water, and the activated carbon filterer will be used to absorb the remaining organic and residual chloride. Part of organic materials will be eliminated when it comes through the anion resin, and the content of organic substance in the make-up water is therefore reduced to a very low degree. 4.1.3 Operation Principle of Mechanical Agitation Clarifier Mechanical agitation clarifier is applied to remove the suspended substances and 219
colloids in the water in the principle of coagulation treatment. The coagulation treatment includes the processes of coagulation and flocculation: - Coagulation includes the process to make the colloid loss stability and the process to make the colloid having lost stability coagulated to be small floccules in the Brownian Movement; the colloid losing stability is the process of colloid will loss its stability due to reduce ofpotential or other reasons. Applicable methods: apply the electrolyte bringing high-valency counter-ion to the water; apply colloid bringing unlike charge with that of colloid in natural water; apply macromolecule flocculants, etc. - The flocculation process is the process in which the tiny floccules bumping into the large ones under the fluid dynamic effect. The coagulant will be added into the raw water after the water entering into the feed pipe, then the fluid will flow into the circulating feed gutter in triangle shape, and evenly flow into the first reaction chamber through the lower outlet hole of the gutter, in which the water, plentiful return slurry and the coagulant will be evenly mixed as the rotating of upper impeller of agitator, after that the mixing water will be lifted to the second reaction chamber by agitator turbine. When the water is entering into the second reaction chamber, the coagulant in the water has finished the process of ionization, hydrolyze and core-forming, and starts to come into being the tiny floccules, and after the water has entered the second reaction chamber and guide chamber, the floccules can gradually grow up in the stable low-speed water because the water flowing cross-section become larger and the disturbance of water flow is overcome by the guide plate. After all of that, the water will enter the separation chamber again, here the water flow will be more slower due to the flowing cross-section be much larger, so the floccules will be precipitated in the water under its gravity effect and therefore be disassociated with the water. The clean water coming from the separation chamber will flow into the water collection gutter, and then flow into the filter tank via outlet pipe, and the sludge inclusion will return for circulation or enter into the condensation chamber for periodic discharge. 1 - Inlet Pipe 2 - Inlet Gutter 3 - 1st Reaction Chamber (mixing chamber) Inlet Water 4 2nd Reaction Chamber 5 Guide Plate 6 Separation Chamber 7 Water Collection Gutter 8 Sludge Condensation Chamber 9 Chemical Dosing Pipe 10 Mechanical Agitator 11 Guide Plate 12 Umbrellar Plate
Outlet Water
Waste Discharge
Waste Discharge
4.1.4
Operation Principle of Gravity Air Filter Tank 220
V1: Electric Butterfly Valve for Water Feed V2: Electric Butterfly Valve for back-washing water discharge V3 (1): Inter-connection Electronic Butterfly Valve V3 (2): Inter-connection Electronic Butterfly Valve V5: Discharge Electric Butterfly Valve after back-washing and before operation commence V7: Compressed Air Inlet Valve V8: Bypass Exhaust Valve V9: Outlet Valve of Rose Fan V10: Discharge Valve of Compressed Air The fundamental principle of using the granule media for filtering of coagulation treated water is based on the bonding capacity between suspended grains and filtering media, being similar to the contact coagulation during clarification, in which the filtering media has surface activity, and the contact coagulation will be occurred when the suspended impurities approaching the surface of filtering media under the water force. The suspended impurities has more chances to contact the filtering media when the water circuitously flowing through the interspaces of filtering layer, for the filtering media is much densely arranged than the active sludge are in the clarifying equipments. During the filtration, the water flowing through the filtering media layer will receive more and more resistance as the suspended substances filtered out accumulate little by little in the pore among granule filtering media and on the surface of filtering media, resulted in the water head loss gradually increased in the filtering process, therefore, the air scrubbing and back washing for filtering media cleaning will be necessary when the said head loss has been up to certain level. The water used in back washing is the water stored in the back-washing water box over the filter tank. In each back washing, the dirty 221
in the filtering layer must be completely removed or else their accumulation will make the filtering media particles bond together and the normal operation of filter tank will be therefore impacted. 4.2 Operation of Clarification Station Equipments 4.2.1 Control of Operation Parameters Control Requirement 10-20% 10 5 0.1 0.05
Water Samples
Test Item Basicity
Unit mmol/l mg/l s/cm 5min% mg/l mg/l mg/l MPa
Interval 8h 8h 8h 4h 4h 4h 4 4
Remark
Raw Water
Turbidity Conductivity Settling Rate Turbidity Turbidity
Outlet Water from Clarifier
Outlet Water of Gravity Filter Tank 4.2.2
Residual Chloride Pressure Difference
Maintenance of Chemical Clarifier and Points for Attention
4.2.2.1 The quality of outer water from clarifier shall be tested in accordance with specified supervision items and in specified interval, and the test results will be recorded on the operation report. 4.2.2.2 Amount of chemical dosing will be supervised and adjusted based on the quality of outlet water that observed. 4.2.2.3 The settling rate of sludge in the 2nd (second) reaction chamber will be controlled on 10~20% (5min). 4.2.2.4 The internal of waste discharge (once every 8h for continuity of 2min) will be decided in accordance with the settling rate of sludge in the 2nd reaction chamber. Attention shall be paid for prevention of sludge escape or losing during waste discharge, one bottom blow-down in day time shift every day, and the amount of blow-down will depend on the quality of outlet water from clarifier and the sludge thickness. 4.2.2.5 The stable operation of settling tank shall be guaranteed, and the range of flow rate change normally does not exceed 10% of original flow rate for every 10 minutes. 4.2.2.6 Oil level of agitator shall be strictly controlled. The highest level shall not be over when in oil filling and the lowest level not be exceeded when in operation, neither. 222
4.2.3
Points for attention during operation of mixing machine:
4.2.3.1 No abnormal fluctuation of current. 4.2.3.2 Smooth equipment running without abnormal vibration and noise. 4.2.3.3 Oil temperature of speed reducer not greater than 30in usual condition. 4.2.3.4 No visual seepage in seal Joint. 4.2.3.5 The operation height of agitator impeller shall be strictly controlled within upper and lower stop limit and the screw nut must be fastened when in adjustment. 4.2.4 Maintenance of Gravity Filter Tank and Points for Attention.
4.2.4.1 Air scrubbing in 20h continuous operation of filer tank. 4.2.4.2 Air scrubbing as soon as the obvious deterioration of outlet water from filter tank is observed. 4.2.4.3 Air scrubbing as soon as the rate of outlet water flow from filter tank is going down. 4.2.4.4 Air scrubbing as soon as the quality of outlet water from filter tank exceeding the standard limit is observed 4.3 Maitenance of Chemical Dosing System and Points for Attention 4.3.1 The tank level of coagulant and coagulant aid solution shall be above 20cm, if not, the chemical dosing is necessary. Adequate chemical in storage chamber in sodium hypochlorite dosing system shall be guaranteed and the level of metering tank shall be over 20cm. Normal operation of sodium hypochlorite generator shall be guaranteed. Outlet pressure of metering pump shall be greater than water pressure of dosing point, and the hand of pressure meter working well. No seepage in the joint of pipe and flange connection. Metering pump and motor body shall be checked in accordance with guide rules. Back-up metering pump will be switched on by system transferring in case of working one being failed.
4.3.2
4.3.3 4.3.4
4.3.5 4.3.6
4.4 Common Faults, Judgment and Disposal 4.4.1 Causes and Disposal of Deteriorated Outlet Water from Clarifier No. 1 Reasons Inadequate or Excessive Chemical Dosing Sludge getting more thicker for not discharged timely 223 Disposal Stop filter tank, drain clarifier water, and adjust the amount of chemical dosing at once Stop filter tank, drain clarifier water, and discharge the waste at once
Excessive flow volume of clarifier, and the clarifier load changing rate being greater than 50t/h. Quick temperature rise of raw water, approx. 1~2/h. Sludge settled in the bottom resulted from clarifier long-time running Air entrained in inlet water
Stop filter tank, drain clarifier water, and reduce the flow volume Stop clarifier and drain the water, adjust the system, stabilize the temperature and flow volume Empty and flush the clarifier Clean the pump filtering mesh in time, and prevent the air leakage from pump flange. Clean the clarifier in a periodic time
5 6
No periodic cleaning of clarifier
4.4.2 Entire Trip of Pretreatment Rotating Equipments Possible Causes: MCC Cabinet Power Source Failure, Transformer of Chemical Water Failure Disposal: a) To report the incident to the shift-chief operator and specific engineer, and prepare the record. To check and dispose the failure through contact by shift-chief operator with staff working on central control system. To locate the operation switch of power-off equipment to the off position To start original operation system again after the power supply regained
b)
c) d)
4.4.3 Poor sludge Circulation in Clarifier, Drift of Sludge and Bottom Sludge Confusion No. 1 Reasons Abnormal circulating due to impropriate rotating of agitator Disposal To reduce the rotating speed temporarily for 1~2hs, and restore it after water clarified. If the water quality is getting worse, the possible reasons may be rotating speed being too high or too low. To adjust the rotating speed, and remove the slurry below the concentration chamber and cladding periphery (waste discharge).
Accumulation of circulating slurry resulted from low rotating speed of impeller due to high turbidity of raw water.
4.4.4 Large Volume of Outlet Water from Clarifier Resulted in Water Level Lowering No. 1 Caused by Blowdown valve being not closed or serious leakage being occurred Abnormal operation of raw Disposal To close the blowdown valve or to examine and repair To check and guarantee the normal current of 224
water booster pump 4.4.5 Whitening Water in Clarifier No. 1 2 Reasons Excessive Chemical Dosing Excessive Slurry Discharge
raw water booster pump under control
Disposal To adjust the quantity of chemical dosing To control the quantity of slurry discharged
4.4.6 Alum Coagulation Floating in Clarifier No. 1 2 3 4 5 6 7 Reasons Initial flow rate being too high Water load increased suddenly during Operation Excessive chemical dosing Agitator rotating too quick Sudden drop of temperature Slow discharge of slurry Sludge flushing valve not closed Disposal To reduce the flow rate To smoothly regulate the load To control the amount of chemical dosing To adjust the agitator rotating speed To reduce the working output To maintain the normal rate of slurry discharge To close the sludge flushing valve
4.4.7 Unsatisfied Turbidity of Outlet Water from Filter Tank No. 1 2 3 4 5 Over-load Long-time operation Incomplete back-washing Drift of filtering media and strainer broken Reasons High turbidity of inlet water To reduce the load To carry out back-washing and reinforce the air scrubbing To fully carry out the back-washing To examine and repair Disposal To improve the water quality in clarifier
5 DM system
5.1 General Description of DM System & Equipments Operation Principle 5.1.1 General Description The rated and maximum capabilities for equipment of boiler make-up water system are 240t/h and 290t/h respectively. The boiler make-up water treatment system will consist of two(2) trains of unit primary demineralized system (2 sets of 60t/h activated carbon filters 1 set of 120t/h counter flow type cation exchanger 1 set of 120t/h decarburization device 10m3 Intermediate water tank counter flow type anion exchanger) 2 sets of mixed bed 5.1.2 The Operation Principle of Demineralization System Equipments 5.1.2.1 Operation Principle of Activated Carbon Filter Same as the charcoal, carbon black and coke, activated carbon is a kind of amorphous carbon which the structure is similar to graphite. Activated carbon has an absorptive capacity due to its large number of pores provide the surface area of 500-1700m2/g 225
approximately. Activated carbon mainly absorb the organic substance in the water, it can remove about 80% organic substance which express by COD or TOD as well as the reek, coloring matter, free chlorine, oil stain and surfactant etc. But attention shall be paid to the following items: a) The impurity such as suspended matter and colloid shall be removed in advance (if any), or the mesh and granular layer of activated carbon is easy to be plugged up. Therefore, output water quality from clarifiers and filter tank shall be ensured to meet the standard requirement. Insufficiency raw water coagulation filtration will cause large numbers of suspended matter accumulated in the activated carbon that will result in activated carbon agglomeration and accordingly increase the flow resistance. Therefore, back wash or air cleaning shall be carried out to the activated carbon in bed termly to keep a cleanly bed. The adsorption effect will also be affected by the water temperature and pH value of intake water.
b)
c)
5.1.2.2 Anion Exchanger (Anion Bed), Cation Exchanger (Cation Bed)
1- Water intake device 2- Middle drainage device 3-Cation resin layer 4-Quartz sand bedding 5-Arc polyporous plate 6-Resin-packed layer
Ion exchange treatment is carried out by ion-exchange agent. When contacted with water, the ion of ion exchanger agent will exchange with the same ion in the water, e.g.: the following exchange reaction will happen when Na ion-exchanger contact with the water which contained Ca ions: Ca2+ 2RNa R2Ca 2Na+ In the reaction, RNa is ion-exchange agent, the Ca2+ in the water will be absorbed on the exchanger. Na ion-exchanger is changed to Ca, and the original Na was exchanged from the ion-exchanger to the water. Thus the Ca2+ in the water can be removed. The cation exchange resin we used can be expressed as RH, anion exchange resin can be expressed as ROH; the exchange capabilities of RH for usual mental cations in the water can be concluded as follows: 226
Fe3+ Al3+ Ca2+ Mg2+ K+ NH4- Na+ Li+ The exchange selectivity of ROH is as follows: PO43- SO42- NO3- Cl- OH- F- HCO3- HSiO3The resins in the exchanger are divided into resin-packed layer, dead layer, operating layer and protective layer. The ion exchange resin is out of service if protective layer lost, and then regeneration treatment shall be carried out to the ion-exchanger. Hydrochloric acid will be applied to cation exchange agent regeneration and sodium hydroxide will be applied to anion exchange agent regeneration. The principle of regeneration is as follows: 2H+ R2Ca 2RH Ca2+ H+ RNa RH Na+ 2OH- R2 SO4 2ROH SO42OH- R Cl ROH ClFor the unit system, the anion resins in the anion exchanger are 10% more than the cation resins in the cation exchanger. The reason is: when the anion bed approaches invalidity firstly, the silicon leakage has begun in the protective resin already, meanwhile the pH valve of anion bed output water is decreasing. Up to the pH value achieves 7, the conductivity of its output water decreased to the lowest value (shown as a in the fig.); Actually at this time, serious silicon leakage is ongoing and that the process of conductivity reflect in silicic acid to is slow which results in the invalidity of anion bed cannot be judged in time and rapidly. So, the anion resin shall be increased in the anion bed to urge the cation bed out of service firstly and the anion bed invalidity can be judged by conductivity.
Fig. Output Water Quality of Cation Bed
Fig. Output Water Quality of Anion Bed
227
English acidity water quality silicon content conductivity
water flow rate quality of output water
5.1.2.3 Operation Principle of Mixed Ion-exchanger (Mixed Bed) Mixed ion-exchanger is usually set at the end of DM system to increase the purity of product water. The cation/anion bed invalidity and inadequate monitoring will cause water deterioration in short time easily. The setting of mixed ion-exchanger can be a protection to water quality. Mixed ion-exchanger is a kind of water treatment equipments which the ions are exchanged by the way of mixing the cation/anion resins in the same exchanger, it can be considered as a multistage Compound ion-exchanger which consists of crossing cation/anion resins. The cation and anion exchange reaction will take place almost simultaneously due to the cation and anion resins in the mixed ion-exchanger are mixed evenly, in other words, the exchange of cation and anion in the water is taking place staggering and repetitious. The exchanged OH and H+ cannot be accumulated so that they will combined to be water immediately; therefore, mixed bed eliminate the effect from the gegenion basically that the exchange can be reacted thoroughly and obtain water in high purity. If the ion contain is low in the intake water and the mixed bed is operating in good condition, the hyperpure water with the conductivity less than 0.1us/cm can be manufactured. The cation/anion resin will be layered according to their density when the resins in mixed bed are invalidity, then regeneration will be carried out. 5.1.2.4 Operation Principle of Decarburization Device Generally, plentiful carbonate contains in the raw water especially bicarbonate which is the main component need to be controlled in the natural water. After the raw water exchanged ions with H cation resins, the bicarbonate will change to carbonic acid and the pH value of water solution will be 2 4.5. When the pH value of water solution less than 4.3, free carbon dioxide in the water will take more than 99% of the total amount of carbonic acid compound. According to Henry's Law: At a constant temperature, the solubility of a gas in a liquid is directly proportional to the partial pressure of that gas above the surface of the solution in equilibrium. Therefore, the CO2 content in the water will be decreased if only the partial pressure of the CO2 above the water can be decreased. Due to not much CO2 content in the air, its partial pressure takes 0.03% - 0.04% of the amount of atmospheric pressure, here the relevant CO2 solubility in the water under the above-mentioned partial pressure will only be 0.5 1mg/L. However, the free CO2 content which exchanged by H-cation exchanger will achieves 40 180mg/L, so that the CO2 above the water surface can be removed by air flow that the CO2 will break away from the water. Thats the way for decarburization device to remove the CO2 in the water. Decarburization device is filled with hollow polyhedral balls to enlarge the air-water contact surface. Decarburization device is set behind the H ion-exchanger for the reason of that carbonic 228
acid compound in the water will exist as CO2 under the pH value of H ion-exchanger exchanged water, i.e. part of anion in the water can be removed to improve the silica removal of anion exchanger. 5.2 Water Quality Control Standard and Period of Water Treatment System No . Type of Water Sample Analysis Item Residual chlorine Outlet water of activated carbon filter Oxygen consumptio n Control specification s 0 Time of Monitorin g 4h System regular checking Backwash if exceed the standard limit Test rate will be increase when put into operation and approachin g invalidity
Symbol
Unit
Remarks
Cl-
mg/L
CODM n
mg/L
1.5
Turbidity
mg/L
0.2
2h
Sodium ion Outlet water of cation exchang er
Na+
g/L
100
2h
Acidity
SD
mmol/ L
Steady
4h
Outlet water of anion exchang er Outlet water of mixed ions exchang er DM water tank
Electrical conductivity silicon dioxide Electrical conductivity silicon dioxide Electrical conductivity
DD
s/cm
2h Ditto
SiO2
g/L
100
2h
DD
s/cm
0.2
2h Ditto
SiO2
g/L
20
2h
DD
s/cm 229
0.2
2h
Ditto
5.3 Operation of Demineralized Equipments 5.3.1. Regeneration of Primary Demineralization Equipments 1) Partial backwash: Aim to remove the accumulated dirt which formed during operation on the surface layer and middle drainage device away by drainage. Water discharge acid(alkali) filling Chemical Exchanging Partial wash: aim to remove the residual regeneration liquid on the of resin-packed layer resins. Wash: Aim to remove the residual regeneration agent and product on the resins to avoid backward reaction after regeneration. Thorough backwash operation of cation/anion bed: aim to loosen the exchange agent layer to create good condition for regeneration.
2) 3) 4) 5)
6)
7)
5.3.2 Regeneration Secondary Demineralized Equipments (mixed bed exchanger) Drainage, air wash, layers backwash, drainage, acid (alkali) filling, chemical exchange, washing after chemical exchange, resins mixing, wash. 5.4 Common Faults, Judgment and Disposal 5.4.1 Analysis & Disposal Principle for Anomalous Water Quality of Demineralized Water Tank Reason Analysis: Firstly: causal investigation will be carried out rapidly to check if the fault caused by the online DD and silica analyzer failure or by insufficient monitoring. If the instruments are in good condition, to check if there any expired chemicals or chemicals misusage; secondary: sampling test for the water from demineralized water tank, unit condensate water tank shall be carried out; any unqualified water shall be drained and replaced by backup demineralized water. Thirdly: the following situations may cause pollution when equipment operating: 1) Output water from anion bed is deteriorated seriously which results in mixed bed water deterioration; 2) Insufficient mixed bed regeneration before operating or mixed bed invalidity can be observed and stops running. 3) Mixed bed output water returned or backwash valve leakage results in resin layering and water deterioration. 4) Acid/ alkali filling valves or backwash inlet valves leakage results in equipment pollution during regeneration. 230
5) Resins are polluted and aging causes water deterioration. 6) Resin catcher in water outlet of mixed bed is broken causes resin accessing thermodynamic system and be decomposed. The actual fault reasons will be found out by feasibility analyzing and excluding according to the above situations. Disposal principle: firstly, if any pollution is found in demineralized water tank, all the demineralized system operation and regeneration which may cause pollution in demineralized water tank shall be shut down immediately; meanwhile, the operating outlet valve of demineralized water tank shall be shut down; meanwhile, the impurity content of unit water steam system shall be checked, if any impurity of water or boiler water changed, the water filling to the unit shall be stopped and the water in unit cooling cylinder will be drained completely; after that water will be filled into the unit cooling cylinder from backup demineralized water tank until the water qualified and the demineralized water system re-operate again a.s.a.p.; if the pH value of boiler water is low, sodium hydroxide shall be added for neutralization; if the boiler water quality is too bad to exchange, then report shall be made to the director to shut down the boiler and drain the water when the boiler water quality achieves three-stage treatment condition. If the impurity content of filling water and boiler steady, the unit water filling will be stopped to confirm if the water quality of demineralized water tank and cooling cylinder is in good condition (all the unqualified water is drained) then renew the water filling to the unit. Secondary, countermeasures for the above 6 reasons: 1) The polluted anion bed shall be isolated and repaired by regeneration. 2) The polluted mixed bed shall be isolated and repaired by regeneration. 3) The original of mixed bed layering shall be eliminated then resins will be mixed or regenerated again. 4) The leak valves shall be repaired to stop raw water running into the operating equipment. 5) The polluted and aged resins shall be replaced before equipment putting into use. 6) The resin catcher for outlet water of mixed bed shall be examined and repaired to avoid resin leaking into the thermodynamic system. 5.4.2 Cation Bed Output Water with Hardness No. 1 2 Reasons Cation bed is serious invalidity or regeneration insufficiency Overload. Disposal Shut down to carry out examination and repair. Adjust to the normal flow.
5.4.3 Large Electrical Conductivity of Primary Demineralized Water No. 1 Reasons Cation bed invalidity; bad quality of 231 Disposal Shut down the system and startup backup
output water. 2 3 4 Low efficiency of decarburization fan. Anion invalidity. Low period water manufacturing volume of cation/anion bed; input water quality changed. Low period water manufacturing volume of cation/anion bed; water filling device broke results in deviated flow. Low period water manufacturing volume of cation/anion bed; backwash water quantity insufficiency and resin surface unsmooth. Low period water manufacturing volume of cation/anion bed; acid/alkali quantity not enough or concentration too low when regeneration carried out. Low period water manufacturing volume of cation/anion bed; resins decreased. Low period water manufacturing volume of cation/anion bed; resins are polluted.
system. Examine and repair is requested. Shut down for regeneration and start up backup bed. Water quality checking.
Examine and repair is requested.
Backwash shall be enhanced; examine and repair is requested.
The acid/alkali dosing shall be increased to improve concentration.
Resins supplement.
Resin cleaning or regeneration.
5.4.4 Unconspicuous Backwash Layering for Cation/anion Resin of Mixed Bed No. 1 2 3 4 5 5.4.5 No. 1 Reasons Misoperation for backwash layering. Nonstandard proportion for cation and anion resins. Resins validity uncompleted. Resins are polluted. Cation/anion caking or with bubble. Disposal Backwash layering shall be operated according to the procedures. Backwash layering shall be operated according to the procedures. Resins will be washed or soaked by NaOH solution; then layering again. Resin cleaning or regeneration. Backwash flow shall be increased and washed by NaOH.
Activated Carbon Escape during Backwash in Activated Carbon Bed. Reasons Backwash overflow. 232 Disposal To adjust the opening for backwash inlet
valves to control backwash flow strictly. 2 3 Unstable backwash flow. Drainage device is broken. The backwash inlet valves shall be opened slowly. Shut down for examine and repair.
5.4.6 Resin Escape during Mixed Bed Operating No. 1 2 Reasons Unqualified or broken diving helmet for mixed bed output water. The diving helmet not meets the installation requirement. Disposal Diving helmet for output water shall be replaced. Found out the reason by repair personnel and reinstall.
5.4.7 Quartz Sand or Resins Carryover during Cation/anion Bed Washing or Operating No. 1 2 Reasons Layers disorder in the bottom of exchanger. Water proportioning uneven due to unqualified granularity of quartz sand bedding. Disposal Shut down and repair. The quartz sand bedding shall be changed to meet the granularity requirement.
5.4.8 Low Efficiency of Decarburization Device No. 1 2 3 4 5 Fan reversal Inefficient air pressure and air force. Overflow Lack or over filling. Water intake device is broken or water proportioning uneven Reasons Disposal Repair by electrician Repair requested or to replace the fan. Intake water quantity shall be decreased. Filling supplement or decreasing. Repair by repair personnel.
6. Water Steam Supervision System

6.1 General of Chemical Supervision and Water Steam Quality Standard 6.1.1 General of Chemical Supervision Chemical supervision is the key procedure to ensure the safety, economic and stable operation. The main function of chemical supervision is to achieve the following targets by the test methods which suit the power generation development and the scientific management procedures: 1) 2) To enhance the quality supervision for water, steam, oil, hydrogen and fuel; To avoid and lessen the corrosion, encrustation, salification and oil quality deterioration during thermodynamic equipments operating, stop and backup period by effective measures. To observe potential faults of oil filling electric equipments in time. To enhance the fuel supervision to create economic, safety combustion and to improve unit efficiency; 233
3) 4)
5)
To observe and eliminate the chemical hazards in time to avoid accidents.
Chemical supervision shall be carried out as follows: 1) Sampling analysis shall be carried out to feed water, boiler water, condensation water, generator cooling water, closed recirculation cooling water and steam for quality supervision and adjustment; to avoid corrosion, encrustation and salification of the water/steam system and equipments. 2) Any abnormal condition shall be reported in time, corresponding measures shall be taken by specialist to eliminate the hazard and ensure safety and economic operating of units and systems. 3) The reliability of water steam supervision shall be ensured by reliable measuring, corrective judgment and timely disposal. 4) Overall process chemical supervision shall be carried out during the equipment installation, commissioning, operating and backup period actively. 6.1.2 Significance of Chemical Supervision 6.1.2.1 General of Thermodynamic Equipments Corrosion Different types of corrosion will happen on thermodynamic equipments during the operating and in stopped state. The corrosion not only reduces the service life of equipments but also cause economic loss. Besides, the corrosion products come into the boiler water will result in impurity increasing and heating surface encrustation which will speed up the corrosion. Such a vicious circle process will cause boiler accident easily. The mental material for thermodynamic equipments fabrication is mainly carbon steel. Copper alloy usually apply to pipes of heater and steam condenser. Due to there are great differences between various contact medium of thermodynamic equipments, the forms of corrosion will be different. According to the corrosion procedures, corrosion can be divided in to chemical corrosion and electrochemical corrosion; According to the forms, corrosion can be divided into general corrosion and partial corrosion. 6.1.2.2 Corrosion and Corrosion Prevention for Feed Water System Boiler feed water system include the pipeline systems and equipments of condensation water and feed water such as feed water & condensate pipelines, feed water & condensate pumps, low pressure heater, economizer, drainage water tank etc. The key reason for system mental corrosion is that the water flowing through the above system contains dry O2 and CO2. Deoxidization and ammonification disposal will apply to prevent the corrosion of feed water system. 6.1.2.3 Corrosion and Corrosion Prevention for Boiler Water Steam System The water steam system of steam drum boiler is the section from steam drum to superheater. The temperature and pressure of water and steam in the boiler is high when the boiler operating that the boiler wall bear heavy heat transferring work and each part of equipments are under the high stress. Also, the impurity in the feed water will concentrate 234
and separate out; its sediment will accumulate in the boiler. All these factors will cause corrosion, and makes the corrosion complexion. Therefore, the filling water shall be deoxidized. But corrosion will still happen due to the high pH value of the boiler water. The corrosion is mainly including corrosion under sediment, steam corrosion and stress corrosion. 6.1.2.4 Corrosion and Protection of Boiler in Stopped State In boiler stopped state, dissolved oxygen corrosion will seriously taking place on the mental surface of boiler water steam side. This kind of corrosion is called stopped state corrosion. The reason is: abundant outside air will enter into the boiler water steam system. Mental will be corrupted easily due to the O2 in the air dissolved into the water. Meanwhile, although the boiler water will be drained before stopped state, but the residual water is vaporizing that will increases the humidity in the water steam system and forms a water film. The O2 will dissolve into the water film that causes mental corrosion. Boiler protection in stopped state will be carried out by hydrazine, steam pressure holding, feed water pressure holding, alkaline liquor, drying, dryer, nitrogen filling and vapor phase inhibitor (VPI) etc. The protective method shall be selected according to the equipments parameter, time of stopped state and site condition. 6.2 Control Standard for Water Steam Quality 6.2.1 Quality Standard of Condensate Water Control Standard Item Unit Expected Startup Normal Value 0 1.0 0 0.3 0 0.15 Time Interval (H) 24 2 Online instrument record: each 2 hours Manual record: each 24 hours Ditto Ditto
Remarks
Hardness mol/L Anode s/cm Conductivity Dissolved Oxygen
g/L
50
30
30
Na SiO2 Fe Cu
g/L g/L g/L g/L
20 30 50 20
10 20 20 5
5 5 10 3
Periodical inspection
6.2.2 Quality Standard of Feed Water Control Standard Item Total hardness Unit Startup Normal 0 0 Expected Value 0 235 Time Interval (H) 24
Remarks
mol/L
SiO2
g/L
30
20
10
Online instrument record: each 2 hours Manual record: each 24 hours Online instrument record: each 2 hours Manual record: each 24 hours
Dissolved oxygen Oxygen scavenging chemical PH Anode conductivity
g/L
30
g/L
10-50
10-30
2 Primary Ammonification 9.0-9.6
9.0-9.6 9.0-9.6
9.0-9.6
s/cm
0.65
0.3
0.15
2 Every start up and Periodical inspection Every start up and Periodical inspection
Fe
g/L
50
20
10
Cu
g/L
6.2.3 Quality Standard of Boiler Water Control Standard Item Unit Startup Time Expected Interval Normal (H) Value
Remarks Online instrument record: each 2 hours Manual record: each 24 hours Online instrument record: each 2 hours Manual record: each 24 hours Online instrument record: each 2 hours Manual record: each 24 hours
SiO2
g/L
Silicon wash 250 requirement
100
PH25
910
9-10
9.3-9.5
Phosphate radical
mg/L
0.5-3.0
0.5-3.0
0.5-1.5
236
Conductivity
s/cm
60
20
Online instrument record: each 2 hours Manual record: each 24 hours
6.2.4 Quality Standard of Steam Control Standard Item Unit Expected Startup Normal Value 0 0 0 Time Interval (H) 2 Online instrument record: each 2 hours Manual record: each 24 hours Online instrument record: each 2 hours Manual record: each 24 hours
Remarks
Anode s/cm conductivity
Na
g/L
20
10
SiO2
g/L
30
20
10
Fe
g/L
50
20
10
Every start up and Periodical inspection Every start up and Periodical inspection
Cu
g/L
15
6.2.5 Cooling Water Quality Standard for Generator Stator Control Standard Excepted Value Time Interval (H)
Item
Unit
Remarks Online instrument record: each 2 hours Manual record: each 24 hours Online instrument record: each 2 hours Manual record: each 24 hours
PH
6.8
7.0-8.0
Hardness
mol/L
24
Conductivity
s/cm
1.5
1.0
Cu
g/L
40
30
Periodical inspection
6.2.6 Closed Recirculation Cooling Water Item Unit Control Excepted Time Interval Standard Value (H) 237 Remarks
PH
8-9
8-9
Online instrument record: each 2 hours Manual record: each 24 hours Online instrument record: each 2 hours Manual record: each 24 hours
Conductivity
s/cm
30
20
6.3 Operation of Boiler Chemical Dosing System of Boiler 6.3.1 Boiler Water Phosphate Disposal To prevent the production of calcium scale in the drum boiler, besides the guarantee of the feed water quality, usually some coagulant will be put into the boiler water to prevent the calcium ion (the remnant of make-up water or leakage of condenser) from being converted to be scale but to be the sludge which can be discharged when in blowdown. In the power plant, phosphate was extensively used for boiler chemical dosing treatment. The disposal of injected phosphate into the boiler water is called phosphate disposal for short. Under some given conditions, the phosphate disposal not only prevents production of the calcium scale but also act for anti-corruption and anti-interaction of alkalization, which is called coordinate pH value phosphate disposal. The phosphate dosing in the boiler water is available for maintaining dosage of phosphate radicalPO43-.Under boiling alkalization condition (boiler water pH value common range from 9 to 10), calcium ion and phosphate radical will react, see below, 10Ca2+ 6PO43- 2OH- Ca10(OH)2(PO4)6 The production of basic calcium phosphate is a kind of floppy water slag, easy to discharge with the boiler sewage discharge and unable adhesive the boiler wall so as not to turn into the scale. However, boiler load increased, some easy dissolve sodium salts (Na2SO4, NaSiO3, Na3PO4) separate out from the boiler water and turn into the sediment on the boiler tube wall, obviously reduce the Concentration of the boiler water; On the other hand, when the boiler load decreased or boiler stop, the sodium salt sediment on the boiler tube wall is dissolved, increase the concentration of the boiler water again, which is called phenomenon of phosphate disappear temporarily, also phenomenon of salt hide. The harmful of easy dissolve adhesion on boiler tube wall is as same as the scale, see below: a) Lead to react with other boiler tube sediment such as metal corruption production and silicon compound, and then come into being the hard dissolve scale. b) Lead to poor performance of heat transfer, sometimes can directly result in the boiler tube metal overheats to burn out. c) Lead to metal corruption under the sediment, e.g.: when the phenomenon of Na3PO4 Phosphate disappear Temporarily appear, Na2.85H0.15PO4 solid-phase adhesion of easy dissolve salt should be formed on the boiler tube wall with high 238
temperature load; when adhesion separated out from the solution, free NaOH in the boundary layer liquid-phase of boiler tube wall would be produced. When the boiler water partly high concentrated, alkali corruption of boiler tube metal would be produced. So that we use the low phosphate disposal to control the phosphate radical PO43- between 0.53mg/L in the boiler water. 6.3.2 Ammonia Injection Disposal of Feed Water and Condensate Dissolving ammonia NH3in water produce aqua ammonia, alkalescence, whose reaction formula see below: NH3 H2O NH3 H2O NH4
OH
Alkalescence of ammonia can neutralize the acidity of carbonic acid that produced in the reaction of CO2 and water, and the reaction formula is: NH3H2O H2CO3 NH4HCO3 H2O NH4HCO3 NH3H2O (NH4) 2CO3 H2O Therefore, the ammonia injection disposal can increase pH value of feedwater and prevent the acidity corruption of free CO2. At present adjust the feedwater pH value to range from 8.8 to 9.3 in full consideration of copper, iron anticorrosion. The practice proved that, only considering the postpone of the steel corruption, no less than pH value 9 would be better, but in this condition, the copper corruption obviously increase by the pH value , which is the alloy material mostly used in the LP heater, water cooler and condenser in the thermodynamic system.. 6.3.3 Hydrazine Injection Disposal of Feedwater and Closed Cooling Water Hydrazine usually is used as the chemical in the feedwater chemical deoxygenation. It (N2H4) also be called Diamine (jing in China), a colorless liquid under the normal temperature, easily dissolving in water, fuming, poisonous, whose steam would harmful to respiratory system and skin. Hydrazine steam mix with atmosphere in proportion to extend that has the risk to blow up. Hydrazine is kind of reducing agent, especially in the aqueous alkali. It is a so strong reducing that dissolved oxygen can be deoxidized in the water, reaction formulate see below: N2H4 O2 N2 2H2O The reaction produces N2 and H2O, which is harmless to the Thermodynamics Equipment. The effect of hydrazine deoxidize have the closed connection with the water temperature, pH value and the overplus of the hydrazine. Practice proved that under these conditions of the water temperature above 150, water pH value range from 9 to 11 and propriety overplus N2H4, the effect of hydrazine deoxidize is best. Via the ammoniate 239
injection, the feedwater pH value is about 9 to help the hydrazine deoxidize in common power plant 6.4 Reason and Disposal of Water Steam Quality Deterioration 6.4.1 Water Stream Cracking Disposal Principle
6.4.1.1 when discovering the water steam quality deterioration, the analysis should be made . the first, back-check analysis and jugement correctly or not, sampling container is clean or not, find out water steam sampling correct and representative or not; the second, analysis the chemical on use deterioration or not, and check the calculate method correctly or not. 6.4.1.2 When comfirm the correct analysis, report shoud be submitted to the main or shift chief-operator timely about the disposal options of chemical supervision . 6.4.1.3 Shift operator shoud prepare all record about the water steam deterioration degree, reason,disposal process and result.The chemical specialist should organized related personnel to trouble-shooting analysis and disposal in time, renew the water steam starde value as soon as possible. 6.4.2 Three-Stage Disposal Principle The key chemical index such as the boiler feedwater, boiler water and condensate etc, would be disposed by three-stage disposal value. The meaning see below: One-stage disposal value double normal value, possibility of impurity accumulation and corruption, renew the standard value within 72 hours Two-stage disposal value double one-stage disposal value, a certainty of impurity accumulation and corruption, renew the standard value within 24 hours Three-stage disposal value greater than two-stage disposal value and it is proved that the corruption will carry out rapidly and should stop the boiler within 4 hours. In every stage of abnormal disposal, the upper stage should be adopted if not renew within the given time. In the drum boiler, the operation of reduce pressure is one of renew methods The disposal of abnormal steam water quality is implemented according to the below table: Normal Value g/L 10 0.3 8.89.3 9.09.6 240 Disposal Value First Class 1020 0.30.4 <8.8 or >9.3 <9.0 Second Class 2035 0.40.5 8.0 Third Class 35 0.5
Water Sample
Item sodium
Condensate
conductivity s/cm With pH(25 copper ) Without
Feedwater
copper conductivity s/cm Dissolve g/L Boiler water PH oxygen (25) 0.3 7 910
or >9.6 0.30.4 7 9.0 0.40.65 20 8.5 0.65 8.0
Immediately stop boiler when feedwater PH value below 7.0 or condensate sodium upper 400ug/l Remark: When water quality is abnormal, also measurements of CL- Na+ conductivity rate and basicity of boiler water is available to find out reason to take measures. 6.4.2.1 Turbid Feedwater No. 1 Reasons Turbid composed feedwater including condensate water, drain water and make-up water. Disposal Find out, cut off and contaminative water source. disposal the
6.4.2.2 Unqualified Dissolve Oxygen of Feedwater No. 1 2 3 4 Reason Abnormal deaerator running Deaerator internal structure defects Excessive deaerator water make-up for Disposal Adjust the deaerator running Contact overhaul staff disposal the defects Reduce the and balance instantaneous water make-up Contact overhaul staff and disposal timely
Sampling container imprecision
6.4.2.3 Unqualified Silicon and Sodium Content (or Conductivity) of Feedwater No. 1 Reason Unqualified silicon and sodium content (or conductivity) of composed feedwater including Condensate drain, water make-up etc. Steam carry water in deaerator when continuous blowdown flash tank operation Disposal Find out, cut off and disposal contaminative water source the
Adjust operation of continuous blowdown flash tank
6.4.2.4 Unqualified Iron and Copper Content of Feedwater No. 1 Reason Unit start-up initial stag, high iron and copper content of water steam system High iron and copper content of drain Low pH value control Disposal Exchange water, increase the blowdown
2 3
Find out and discharge drain of the high iron and copper content
Increase feedwater value 241
Feed water corruption
Strength the anti-corrosion
aminate
disposal
and
6.4.2.5 Feedwater pH Value Unqualified No. 1 Reason Excessive or ammoniate dosage insufficiency Disposal Check the ammoniate solution concentration, propriety adjust the ammoniate dosage Check and contact overhaul staff, trouble shooting Find out abnormal pH value water source and disposal
2 3
Ammoniate dosing go wrong Abnormal composed feedwater pH value of the condensate and water make-up
6.4.2.6 Condensate Hardness or Conductivity Unqualified No. 1 2 3 Reason Condenser leakage Unqualified water quality condenser water make-up of Disposal Detect and block leakage Replaced with qualified water Cut off the contaminated source and disposal
Unqualified water quality of recover drain
6.4.2.7 Unqualified Dissolve Oxygen of Condensate Water No. 1 2 3 4 Reason Condenser vacuum leakage Too big condenser super-cooling degree Air leak-in of condensate pump running Too much make-up condensate water Adjust the degree Disposal check l and block leakage condenser super-cooling
Startup the standby pump , check defect pump Strength adjust, balance water make-up to avoid water make-up quantity fluctuate
6.4.2.8 Sodium And Silicon Content of Steam Exceed Standard No. 1 2 Reason Sodium and silicon content of boiler water exceed standard Instability Boiler operation condition, high drum water level, big variation of load Steam separator exit defect or low efficiency Too big dosing concentration or too fast speed Unqualified attemperating water 242 Disposal Increase boiler blowdown Report to shift chief-operator, adjust the boiler operation condition Eliminate defect, improve the separator efficiency Strength blowdown, adjust the dosing condition Improve attemperating water quality
3 4 5
quality 6.4.2.9 Turbid Boiler Water State No. 1 Reason Turbid feedwater, too high hardness Disposal Find out, cut off and disposal the contaminative water source and implement blowdown to clarify blowdown Increase blowdown until water quality acceptance
2 3
Boiler long time no blowdown or blowdown inadequate Newly-built or overhaul boiler initial operation stage
6.4.2.10 Silicon And Sodium of Water(or Conductivity) Unqualified No. 1 Reason Feedwater quality unqualified Disposal Find out, cut off and disposal the contaminative water source, adjust the operation of continuous blowdown flash tank Increase blowdown or eliminate the defect of blowdown device
Blowdown abnormal
6.4.2.11 No. 1 2
PO43- Content of Water Exceed Standard Reason Disposal solution Dilute phosphate concentration solution , reduce
Too strong phosphate concentration
Interconnection valve of chemical feed pump outlet is not closed tight, which result in phosphate feed into another boiler Boiler operation condition change suddenly results in high boiler concentrate ratio. Dissolve hide phosphate PO43-
Check interconnection valve swith of pump outlet closed tight or not
Adjust boiler operation condition, strength blowdown Enhance supervise, increase blowdown
6.4.2.12 No. 1 2
Content of Water Below Standard Reason Disposal phosphate Increase solution concentration of phosphate
Low concentration solution
of
No chemical solution of solution tank or no dosing of chemical feed pump Interconnection valve of pump outlet, and not closed tight or wrong open. Condenser leakage seriously and condensate disposal inefficient, 243
Find out reason, eliminate defect
3 4
check interconnection valve of pump outlet colsed tight and open correctly Detect leakage and block leakage of condenser, increase dosage.
result in high hardness feedwater 5 6 Too big blowdown flow When fast change of Boiler operation condition, appearing phenomenon of phosphate disappear Temporarily Reduce blowdown flow Adjust Boiler operation condition, prevent phenomenon of phosphate disappear Temporarily
6.4.2.13 Water pH Below Standard No. 1 2 Reason Phosphate dosage insufficiency Acidity water enter boiler Disposal Increase phosphate dosage Find out reason, cut off the acidity water source, adjust boiler water by feed NaOH adjust blowdown flow Find out reason, prevent organism Increase ammonia content of feedwater within propriety range
3 4 5
Too big blowdown flow Organism inclusion of feedwater Low ammonia content of feedwater
6.4.2.14 Water pH Value Declining Sharply, PO43- Basic Normal No. 1 Reason Acidity water enter boiler Disposal Find out reason, prevent acidity water enter boiler, increase intermitten blowdown and continuous blowdown, adjust boiler water pH recover normal by feed NaOH and Na3PO4 mix solution. Contact relative department to detect leakage of condenser
Condenser leakage
6.4.2.15 Unqualified Generator Cooling Water Conductivity, Copper Content and pH Value No. 1 2 Reason Bad corruption of generator cooling water system No thoroughly washing overhaul of Cooling system After Disposal Take anti-corruption measure Exchange qualified cooling water to feed into small mixed bed
7 Waste Water Station

7.1 Waste Water Station Summarize and Equipment Operation Principle 7.1.1 Waste Water Disposal System Flow Waste Water Waste Water Pool Ph Adjusting Box Coagulation Pool Clarification Pool Clear Water Tank Activated Carbon Filter Neutralization Pool Outlet Water Pool Ash Handling System Sludge Pool Concentrate Pool Ash Slurry Pool 244
Chemical feed devise and compress air system is also included. 7.1.2. Waste Water Disposal Principle pH adjusting box utilize neutralization reaction to adjust waste water pH value until up to the permit discharge rang. Coagulation pool and clarification pool utilize the coagulation & clarification principle to get rid of the suspend substance and colloid (principle same as clarification & water clean) Activated carbon filter has similar function with the equivalent of demineralized water system 7.1.3. Waste Water Disposal System Outlet Water Quality Requirement No. 1 2 3 4 5 6 7.2 Parameter Temperature pH BOD5 COD SS Mineral Oil Unit mg/l mg/l mg/l mg/l Limited value 40 5.5~9 50 100 100 1
Waste Water Station Chemical Feed System Operation
Waste water station chemical feed system include a set of oxidant dosing system, a set of flocculant dosing system, a set of hydrochloric acid dosing system and a set of sodium hydroxide dosing system. 7.2.1 Oxidant dosing: bleaching powder, significant chlorine 10%, adjusts waste liquid pool COD less than 80 mg/L. To locate dosing point at unfrequent waste water pool and waste water pool in order to sterilize. 7.2.2 clarification pool inlet dosage Flocculant dosing: Iron() chloride FeCl3 63mg/l, turbid degree of outlet water less than 20 mg/L. 27
To locate dosing point at inlet water pipe of Clarification Pool in order to coagulation and clarification disposal, and remove the suspend substance and colloid. 7.2.4 7.2.5 Hydrochloric acid dosing: 30% technical hydrochloric acid, dosage 00.20kg/m3, Sodium hydroxide dosing: 30%40% sodium hydroxide, dosage 00.60 kg/m3 pH value control 69.
7.3 Waste Water Station and Waste Water System Common Faults, Judgment and Disposal 245
7.3.1 Waste Water Station Outlet Water pH Unqualified a) b) Reason: online pH meter breakoen. Disposal: contact Heat-control overhaul staff Reason: acid feed pump abnormal of unable feed acid. Disposal: contact overhaul staff Reason: alkali feed pump abnormal of unable feed alkali. Disposal: contact overhaul staff Reason: acid and alkali dosage overabundance or insufficiency,disposal:adjust the acid and alkali dosage
c)
d)
7.3.2 Wast Water Station Outlet Water Turbid Degree and Chroma Unqualified. a) Reason: large quantity waste water and bad water quality produced in desulfurization process. Disposal: dilution and cycle disposal until water quality accept. Reason: mud-scraping rake abnormal in coagulation Clarification pool. Disposal: contact electric overhaul staff Reason: sludge pump cannt discharge mud in coagulation Clarification pool . disposal: washing pipline by industrial water and contact overhaul staff Dosing abnormal of coagulant chemical feed pump. Disposal: adjust flocculant dosage. Dosing abnormal of coagulant aid chemical feed pump. Disposal: adjust flocculant dosage.
b)
c)
d)
e)
8 Hydrogen Generation Plant

8.1 Hydrogen Generation System Summarize and Hydrogen Generation Theory 8.1.1. Hydrogen Generation System Summarize The system provide project accessory of hydrogen generation and hydrogen supply equipment for Quang Ninh Thermal Power Plant (4X300MW) in Vietnam. The system setting including three sets of hydrogen generation equipment 8.4m3/hof HM water electrolyte, three sets of MP and HP compressor system, three sets of MP drying system, a set of closed cooling water equipment, MP cache equipment, HP storage equipment , hydrogen distribution device and accessories of water tank, vacuum device, nitrogen system for purge and control system. 8.1.2 Operation Principle When DC passes the potassium hydroxide solution, water is decomposed into hydrogen and oxygen, the reaction formula see below: Cathod:2H2O +2e H2 + 2OHAnode:2OH-2e H2O + 1/2O2 246
Galvanize: 2H2O = 2H2+ O2 HM system common use KOH as electrolyte, which is 25% KOH solution in weight and corresponding specific gravity 1.236 (20). 8.2 Special Safety Cautions of Hydrogen Generation Station and Hydrogen System 8.2.1 Device and instrument of hydrogen supply station must be regular overhauled and maintained , ensure operation stability and hydrogen purity and humidity up to standard 8.2.2 Within hydrogen suplly station or near other equipements with hydrogen installed, Smoke & fire is strictly prohibited, flammable & explosive deposit is prohibited, and the Smoke & fire is strictly prohibited caution board should be erected. The area (within 10m) in adjacent of hydrogen storage tank should set fence, fire equipment should be install in hydrogen supply station. 8.2.3 Prohibit no work relation personal enter hydrogen supply station. 8.2.4 Prohibit operation with fire burning or possible sparks produced in hydrogen supply station. Work staff forbid put on shoes with spike. If operation of jointing or fire is a must, it should measure the hydrogen content in advance to make sure the hydrogen content of atmosphere less than the 1% in work zone, then approved by production supervisor (Chief Engineer) so as to begin to work. The frozen pipeline valve or other equipments should thaw by steam or hot water, forbidden baking. Instrument or soap water checks the hydrogen leakage of the pipe joints, forbidden using fire. 8.2.5 Before overhaul hydrogen storage equipment (including piping system)and generator hydrogen cooling system, it must separate overhaul part from joint part and add the hard baffle and replace hydrogen by air. 8.2.6 When discharging the pressurized hydrogen gas or emptying the gas storage equipment, the valve shall be opened and discharge the gas slowly. Forbid discharge violently to avoid self-ignite by friction. 8.2.7 Gas cylinders should be erectly fastened on the support bracket, avoid heated and direct sunlight. Storage tank should be printed white color. periodic overhaul hydrogen Storage tank exit to ensure action all right. 8.2.8 When hydrogen supply station is on fire, stop electric equipment operation, cut off power supply, remove the system pressure, and put out the fire with CO2 fire extinguisher. When the hydrogen leakage caused fire, put out with CO2 and airproof the leakage with asbestos to prevent the hydrogen transgress, or cut off the gas supply with another method. 8.2.9 Forbid the tools of possible producing spark, but use copper-made tools when overhauling and operation of hydrogen system. 8.2.10 Use the Anti-explosive Electrical Appliance device in hydrogen station. 247
8.2.11 Mixing hydrogen with oxygen result in the risk of explosive, upper limit 96% hydrogen and 4% oxygen, lower limit 5% hydrogen and 95% oxygen. 8.2.12 Forbid any overhaul when equipment of hydrogen station is runing. if must, stop the equipment in advanced and then repair accoding to related regulations. 8.2.13 Synthetic fibre or wollens work clothes is not suited for worker wear. 8.2.14 The worker should master the operation technology of the hydrogen supply station system and permit work independence after pass the exam. 8.2.15 The door of hydrogen station should be closed. when in-out of hydrogen supply station, the kindling should be handed in and registered.
248
Volume F
Flue Gas Desulfurization and Ash Handling Operation
1 Summary
At present, there have been several dozens kind of practical and skillful flue gas desulfurization (FGD) technology all the world, which can be sorted to wet process, dry process, semi-dry process etc. The wet calcium process (limestone-gypsum) is the most skillful FGD technology, with the most practical achievement and the most stable operation. The shortages of wet process are heavy corrosion, higher equipment investment, higher operation cost, higher space consumption. It is suitable for large-medium power plants or the small power plants with high sulfur content. The advantage of dry process and semi-dry process are lower investment and lower space consumption, but their efficiency are generally lower than wet process, they are suitable for small power plants or the medium power plants with lower sulfur content. 1.1 Basic Conception of Desulfurization Island Limestone-gypsum wet desulfurization system is an integrated process system. It includes: flue gas system, SO2 absorption system, air oxidation system, limestone slurry preparation & supply system, gypsum handling system, process water & cooling water system, bleed system and service air system, etc. The main equipments in the desulfurization are: gas damper, absorber, recirculation pump, oxidation fan, mist eliminator, wet ball mill, etc. With exception of the above system, the auxiliary system are also arranged in the desulfurization island, such as electric system, thermal control equipment and DCS, fire fighting and fire alarm system, etc; Some general system in power plant are also included in the limestone-gypsum wet process desulfurization system, such as lighting system, water supply & drainage system, etc. The definition of power plant desulfurization is: Before the SO2 flue gas from boiler is discharged to the chimney, it is purified by suitable process technology and reliable equipment, to eliminate most of the SO2, then be discharged to atmosphere. The definition of limestone-gypsum wet flue gas desulfurization process (wet process) is: Process the limestone (CaCO3) particle and water in ratio to be mixed slurry as wet reaction absorbent, the slurry react with SO2 in the flue gas, to reduce the SO2 content, to reduce the pollution, and to produce the useful gypsum in the mean time. The material of wet process is limestone. First, mill the limestone to be absorption slurry with wet ball mill, some wet process technology adopt the lime (CaO) as material of absorption slurry. In the absorber, the absorption slurry touch and mix with the flue gas, the SO2 dissolve in the water and react with the calcium carbonate to be calcium sulfite, then react with the delivered air in the absorber, the final reaction product is gypsum. The desulfurized flue gas pass the mist eliminator to filter the liquid mass, then the clean flue 249
gas is discharged to the chimney. The product of wet process is gypsum. The gypsum slurry is delivered to gypsum dehydration system via absorber bleed pump, after being dehydrated to be finished gypsum, in the mean time, the slurry density in absorber is kept on specified level. The main reactions in the limestone-gypsum wet desulfurization process are: a) In the absorber, the SO2 in flue gas is absorbed by water to be sulfurous acid, one portion of the sulfurous acid ionize: SO2 H2O H2SO3 H HSO3 b)

2H SO32
React with the CaCO3 particle in slurry to be CaSO3 1/2H2O particle: CaCO3 2H Ca2+ SO32
Ca2+ H2O CO2 CaSO31/2H2O H
c)
CaSO3 1/2H2O is oxidized by the oxygen in delivered air, to be gypsum at final: HSO3
1/2 O2
H+ SO42CaSO42H2O
Ca2+ SO42- 2H2O
The essential parameters of flue gas desulfurization island: a) The dust content of the inlet flue gas. It will cause the deterioration of system operation if the dust content is high in flue gas, with the result of low absorption efficiency (Increasing the quantity of limestone has very little effect on the efficiency), high GGH differential pressure, etc. Additionally, it is a long period to rectify the deterioration of system. The pH value of absorber slurry. It should be controlled within the specified range. If the pH value is low, the slurry will be ineffective. If the pH value is high, the blockage and scaling will be caused in the system. The pH value is rectified by changing the feeding quantity of limestone on-line, to meet various operation and conditions of boiler. The density of slurry in absorber. It should be controlled within the specified range. The difficulty of crystal forming and belt machine dewatering will be caused if the density is low; and the abrasion will be increased if the density is high. The concentration of Cl- in slurry should be kept under 20000ppm. The reaction activity of limestone. Generally the limestone should be of higher quality of CaO and eligible fineness.
b)
c)
d) e)
f) The SO2 content of outlet flue gas. This parameter should be monitored all the time. If the deviation appears, comprehensive analysis should be undertaken on the boiler load, SO2 content of inlet flue gas, quantity of working recirculation pumps, pH value of slurry, etc. 250
2 Process Flow
Process flow diagram:
251
English FGD (Flue Gas Desulfurization) Boiler Stack ( Chimney) ESP (Dust Catcher)(Electric Static Precipitator)
FGD FGD 2.1 Flue Gas System 2.1.1 System Introduction
IDF Induce Draft Fan Bypass damper FGD Inlet Damper FGD Outlet Damper Seal Air Heater Seal Air Fan BUF (Booster Fan) GGH (Gas-Gas Heater) Oxidization Fan Agitator Absorber Mist Eliminator Recirculation Pump Absorber Bleed Pump Limestone Slurry Tank Recirculation Tank Slurry Hydrocyclone Limestone Wet Mill Belt Feeder Vibration Feeder Limestone Silo Limestone Crusher Remove Iron Ware Belt Feeder Absorber Bleed Pump Emergency Slurry Tank Emergency Slurry Return Pump Process Water Pump ME Washing Pump Process Water Tank From Power Process Water To Power Ash Slurry PH
Limestone-gypsum wet flue gas desulfurization technology is adopted in the flue gas desulfurization system. Spray empty absorbers are arranged, one absorber for each boiler. The original flue gas from 1# boiler and 2# boiler are led to the designed FGD system separately via gas duct, go through the original flue gas damper, after being pressed by BUP, be delivered to the absorber via GGH where the original gas transfer heat to the clean flue gas. In the absorber, the original gas reacts fully with the limestone-gypsum to eliminate the SO2, the temperature of original gas decline to the saturation temperature 252
49. The desulfurized clean gas pass through the mist eliminator, after heat transferring in the GGH, to the clean gas duct, the clean gas damper and chimney, to be discharged to atmosphere. In order to part the FGD system from boiler, 3 sets of zero-leakage gas damper with actuator are mounted for each FGD gas system, one bypass gas damper, one original gas damper, one clean gas damper. When desulfurization system is in operation, the bypass gas damper is on closed position, and the original gas damper and clean gas damper are on open position, original gas is delivered to FGD equipment via original gas damper. Under the requirement to shut off FGD, the bypass gas damper will be automatically opened. And original gas damper and clean gas damper will be automatically closed. To avoid the gas leakage from dampers, the air seal system is set for each gas damper to isolate the gas convection at both sides of the dampers. The duct is plain steel duct. High temperature glass flake is used for the corrosion prevention of original gas duct. Ordinary glass flake resin is used for the corrosion prevention of absorber and clean-gas duct. 2.1.2 Introduction of Main Equipment 2.1.2.1 Flue Gas Damper In order to part the FGD system from the boiler system and isolate the BUP from FGD system, 3sets of zero leakage gas dampers are mounted for each set of gas system.(one original gas damper, one clean gas damper, one bypass gas damper). When the system is in operation, the bypass gas damper is on closed position, and the original gas damper and the clean gas damper are on open position. The original gas is delivered through original gas damper, through the GGH to exchange heat with clean gas, to the FGD equipment for desulfurization. Under the emergency requirement to shut off the FGD system, the bypass gas damper will be automatically opened. The original gas damper and the clean gas damper will be automatically closed. The gas will be discharged via bypass gas duct to chimney directly. The damper seal air is supplied by the damper seal air fan, and the air fan is common for two boilers. Two sets of air fan are arranged, the seal air is supplied to dampers after being heated by electric heater.
253
English
Bolts and screw must be tighten before operating Fixed Ball Bearing Filling Box Floating Ball Bearing Bolts and screw must be removed before operating. Seal Air Valve Pressure Nozzle Hoist Ring Insulation Ball Bearing Filling Box Cylinder Scan Drawing from the Top Closed Position Open Position Linkage Device Direction of Flows Manual Gearbox Discharge Nozzle
Double layers high-strength louver gas dampers are arranged in the desulfurization system in this engineering. The damper frame is made of structural steel with flange. The 254
parts in touch with gas and the blades of bypass damper and original gas damper are made of stainless steel 1.4529. The seal strips are made of C276, and be mounted on both sides of the blade. The special stainless steel seal flakes are mounted around the damper blade. The air is supplied by seal air pipe-valve gate which is mounted on the top of damper. The seal air fan supply air to the damper to ensure the complete compact gas block when the damper is on closed position. The seal air pipe-valve door is driven by connecting-rod which can keep the seal air system on closed position to avoid the damage from gas when the damper is on open position.
English Seal Strip Seal Chamber Blade
Two position limit switches are mounted on the damper, they indicate the open position and closed position of the damper. 2.1.2.2 BUP The BUP is used for increasing gas pressure, to overcome the resistance of FGD system. In this engineering, one BUP will be set for each FGD system of the #1, #2 unit to meet the requirement of desulfurization system when the two units are in full-load operation. The BUP is static blade adjustable axial draft fan from China Chengdu Power Machinery Works. The angle of inlet guide blade on the upstream of wheel could be adjusted to change the inner characteristic of draft fan, to meet the requirement of various load of boiler. It is positive rotation when the gas flow rotation is in the same direction of the draft fan; the characteristic curve is in downtrend. It is negative rotation when the gas flow rotation is in reverse direction of the draft fan; the characteristic curve is in uptrend. The guide blade adjustment is achieved by electric actuator, the adjusting range is -750(closed) +300(open), max +350; mechanical position limit should be applied on the electric actuator according to the adjusting range of guide blade, to protect the guide blade adjusting component, to avoid the damage on adjusting rod. 255
2.1.2.3 GGH The flue gas is washed in the absorber to be saturation, and be cooled to the adiabatic temperature. The flue gas shall be heated before being discharged to chimney, to avoid the condensate water in chimney. Rotary GGH is arranged in this engineering. The technical principle is: The heating components circumvolve slowly through original gas and clean gas. They absorb the heat energy from original gas when it is on the original gas side, and transfer the heat to the clean gas when they rotate to the clean gas side. The clean gas is isolated from original gas by seal plate. The two streams pass through the section bodies on rotor separately. The two gas streams flow in reverse directions. In order to avoid the leakage of original gas to clean gas, anti-leakage control system is arranged. That some clean gas is extracted and charged to the space between clean gas 256
and original gas, because the pressure of seal gas is higher than original gas, the leakage of original gas to clean gas is prevented. Additionally, adjustable seal system is mounted for the rotor. Two soot blowers are arranged in the GGH, one is mounted on the inlet of original gas, one is mounted on the outlet of original gas. When the rotor rotates, these two electric devices pass through the surface of rotor, the travel of spray gun is limited, to ensure it can cover the whole surface of rotor. The common set of spray rod and nozzle is shared by the steam cleaning system and the atmospheric pressure water cleaning system. Another set of cleaning pipe and nozzle is set for high pressure water cleaning system. If the steam cleaning system can not clean the GGH completely, the high pressure water cleaning system should be started up. The spray gun is pushed to storage position when it is not in operation. The drive device is the electric gear box mounted on the rotor driven shaft. It can meet the requirement of main drive and spare drive via transducer. Both the two sets of motor can decelerate to meet the requirement of (low pressure) water cleaning. The seal system is comprised of static seal cladding mounted on the casing; it includes section shape seal plates and axial seal plates. The section seal plates are mounted across both sides of rotor. The longitudinal seal plates are mounted on the end column to form the seal couple together with angle steel of rotor outer flange. Seal strips are mounted on the top of rotor, the bottom of rotor, secondary longitudinal diaphragm and rotor outer flange. The seal strips being correctly mounted can minimize the leakage between original gas and clean gas under the conditions of normal operation. Ring seal strips are mounted between the rotor outer flange and casing at the top and bottom. The bottom ring seal strips are welded on the base plate, to form the seal couple with the angle steel on bottom outer flange. The top seal strips are mounted on the rotor casing by bolts, to form the seal couple with angle steel on top flange. In order to avoid the leakage of gas from the center and ends, double seal device is arranged with an air seal system where the air pressure is higher than the gas pressure in GGH. The lower leakage fan extract the clean gas from the flow to chimney, and deliver it back to GGH with higher pressure to lower the leakage from original gas side to clean gas side. The blow gas is discharged to reheater via sector orifice on the top. It divides the gas flow passing rotor, and isolates the original gas before it leaks to clean gas side. The heat transfer components are made of low-carbon steel, and plated by high quality porcelain enamel which is specially designed for GGH anti-corrosion in FGD system. The heat transfer component is composed of two pieces of heat transfer flake. Among them, one is in shape of wave; the other is groove pressed after being wave pressed. One heat transfer component is composed of one couple flakes. The heat transfer component 257
is mounted in this way that the groove is in the axial direction of rotor, and be mounted in specified distance. The wave lines intersect with the direction of axial and groove in specified angle. The gas flows pass through the wave to form gas whirlpool to transfer heat.
In the FGD system, the inlet pressure of original gas is higher than that of clean gas to form the trend of leakage to the clean gas. Super-low leakage control system is arranged to reduce availably the leakage from original gas to clean gas. The super-low leakage control is composed of one isolation wind and (or) cleaning wind according to the leakage rate. The system is composed of one single fan and related pipe. The low leakage fan extract clean gas from the outlet of GGH, via pipe, to be ejected as isolation wind from the nozzle on the top sector plate; and to be ejected as cleaning wind from the nozzle on the original side of the top sector plate. The principle of isolation wind is: Much higher pressure flow is formed along the longitudinal diaphragm to reduce the leakage from original gas to clean gas as the pressure fortress. The principle of cleaning wind is: Cleaning wind is used to blow the rotor, to eliminate the original gas in the distance of diaphragms and heat transfer component boxes, that the carried gas is clean gas, to eliminate the carried gas leakage. The leakage of original gas is controlled by one positive seal air system which should be operating before the GGH starts operating. a) The wheel hub leakage is also be sealed by inner ring seal strips and hub seal strips. Soot blower leakage, ensure the soot blower to be clean state when it is not working, even the pressure of original gas is higher than the atmospheric pressure, it can also be ensured that no original gas leaked from the joint of soot blower and casing of GGH.
b)
To improve the cleaning effect for GGH, soot blower is arranged in this engineering with the function of steam cleaning, HP water cleaning and LP water cleaning. The steam cleaning and HP water cleaning can be undertaken under normal operation of GGH, and LP water cleaning should be undertaken under low speed when the GGH is shut off. The soot blower device can be divided to tow parts of inner pipe and outer pipe, the working material in inner pipe is HP water, the working material in outer pipe is steam or LP water. 258
2.2 Absorber The gas flows into the bottom of the absorber, to the top, to mix with the suspension of sorbent. The slurry is delivered to the top of the absorber via slurry pipe and spray section by the recirculation pump, the slurry is sprayed out to be specified droplets by atomization nozzle, and dispersed in the circulating reaction pool by the self weight. The droplets absorb the acidity content in the flue gas, such as SO2, SO3, HF and HCl, etc. During the gas pass through absorber and absorb the acidity content, it is vaporized by the water in slurry to saturation condition, and be cooled to the adiabatic saturation temperature. Upon the spray section in the absorber, two-stage mist eliminator is arranged to separate the slurry droplets in the gas. The separate droplets drop to the slurry pool by its self weight. It is easy for the slurry droplets to paste on the flakes of mist eliminator, so it is necessary to wash the flakes of mist eliminator periodically to ensure the smooth transfer of gas in the mist eliminator. In the mean time, the washing water makes up most of the lost water being carried away by gas. Fresh limestone slurry must be fed in the absorber to make up the consumed limestone. At the same time, the outgrowth (most is gypsum) should also be discharged to control the concentration of absorption slurry. The absorber is divided basically to three sections: Absorption Section The absorption section is from the surface of circulation slurry to the bottom of mist eliminator. In this section, some acidity content is absorbed, most is SO2, SO3; SO2 is absorbed to be HSO3-, further to be oxidized SO42-, then react with limestone to be gypsum. 259
Circulation Slurry Tank The circulation slurry tank is section from the absorber bottom to the surface of slurry pool, the depth of slurry pool is 6.0M under normal condition. The function of circulation slurry pool: Oxidize sulfite to be sulfate Dissolve the fresh limestone slurry The sulfate reacts with the dissolved limestone to be gypsum Gypsum crystal formation
The slurry pool is large enough to meet the requirement of the formation of favorable gypsum crystal (CaSO42H2O).The slurry is discharged to gypsum tank by absorber bleed pump. 3 sets of agitators are arranged in the absorber to avoid the sediment of slurry. The agitators undertake not only the function of agitation, but also the function of air dispersion.
Gas Section On the upper part of the absorber, the gas passes through the two-stage roof type mist eliminator to minimize the droplets. The start-up of washing program for mist eliminator is 260
controlled by the slurry level.
Steel is adopted for the absorber structure, glass flake resin is adopted for the inner liner, two-stage mist eliminator is arranged at the gas outlet of absorber. When the clean gas pass through the mist eliminator, most of the droplets are eliminated to ensure the mist content <750mg/Nm3. The washing of mist eliminator is controlled by washing program, the washing type is pulse washing. The interval of pulse washing is longer if the slurry level is higher. The process water is used for the washing. There are two purpose of washing, one is to prevent the dirt formation; one is makeup the water carried away by the gas to maintain the level of slurry.
Each recirculation pump is connected to their spray section separately to transfer the slurry to the nozzle, and spray the fine droplets to the absorption section. The slurry spray system includes the spray components and nozzles. Each spray layer is composed by bus-pipe-type distributing system and nozzles. The spray components and nozzles are designed to cover the whole section area of absorber, and to reach the required covering rate, that the slurry can fully mix with the gas, to realize the designed desulfurization efficiency under the suitable slurry/gas ratio, and no dirt formed on the 261
inner surface of absorber.
3 sets of agitators are horizontally arranged in alignment to keep the slurry in fluidizing condition, and the effective content (CaCO3) is dispersed evenly in the slurry to ensure the SO2 absorption and reaction ability of the slurry. Discharge air gate is set on the top of absorber. It is on closed position during operation. When the FGD is shut off, the bypass gas damper is open, the original gas damper and clean gas damper are closed, the discharge air gate will be open. The purpose of opening of discharge air gate is to eliminate the differential pressure in/out of the absorber from the oxidation fan and shutting off system. The principle of SO2 elimination in absorber is as below: SO2 in gas react with calcium carbonate, to form calcium sulfite: CaCO3+SO2+H2OCaSO3H2O+H2O+CO2 (1)
After the reaction between oxygen and hydrosulfate ion, some calcium sulfite turn into gypsum which is called calcium sulfate dihydrate. CaSO3H2O + SO2 + H2O Ca(HSO3)2 + H2O 262 (2)
Ca(HSO3)
+O2 +2H2O CaSO42 H2O+ SO2 + H2O
(3)
The remained calcium sulfite in slurry is oxidized by the air from oxidization fan to be calcium sulfate. During the reaction, direct oxidization is secondary; whats more important, the hydrosulfite ion react with air to complete the reaction as below: Ca(HSO3)
2
+O2 +2H2O CaSO4 2 H2O + SO2 + H2O
(4)
There are also other reactions in the absorber, such as: sulfur trioxide, hydrogen chloride and hydrofluoric acid react with calcium carbonate to form gypsum, calcium chloride, calcium fluoride: CaCO3 + SO3 + 2 H2O CaCO3 + 2HCl CaCO3 + 2HF CaSO42 H2O+CO2 (5) (6) (7)
CaCl2 + H2O + CO2 CaF2+H2O+CO2
The pH value is controlled by feeding fresh limestone slurry. Sufficient time should be provided to ensure the formation of favorable gypsum crystal (CaSO42H2O)in absorber. The oxidization fan (one working one standby) supply sufficient air to absorber to ensure the formation of gypsum crystal. The oxygen in gas is not sufficient to oxidize the calcium sulfite. So, forced oxidization system should be arranged to supply oxygen to absorber. The air oxidizes the calcium sulfite hemihydrate formed during desulfurization reaction to be calcium sulfate and then to form gypsum. Oxidization air system consists of oxidization air fan and spear-type spray pipe. Two sets of oxidization air fan are arranged for each FGD system, one is working, the other is for standby. The parameters are as below: Flow 7500Nm3/h (in wet condition) Pressure Increase 130kPa Outlet Temperature 121 Motor Power 400kW The fresh air is delivered to absorber via air filter, silencer and pipe. Water is sprayed into the air pipe to cool down the air temperature (more than 100 at the outlet of fan), after the water being vaporized, the air is cooled, damp, to be saturation. The oxidization air is dispersed into the slurry via spray pipe.
263
FRP pipe is arranged in the absorber spray section, carbon steel liner rubber pipe is arranged as slurry recirculation pipe out of absorber, the oxidization air pipe is seamless steel pipe, and the part inside absorber is FRP pipe. The FGD system is designed according to the max chlorine ion concentration 20000ppm of slurry, and all the equipment and components are designed according to this for anti-corrosion which is in touch with slurry. Influence Factors of Desulfurization Efficiency value SO2 Elimination Efficiency. = = Power Consumption = = = =
Recirculation Quantity of Slurry PH Value Activity of Limestone Gas Flow SO2 FGD Concentration at Inlet Cl Content in Gas
Note:: means rise;:means drop;=:means no influence. 2.3 Limestone Slurry Preparation System The limestone is milled to be slurry in the limestone wet mill and flow automatically to slurry recirculation tank, and then be delivered to the slurry hydrocyclone by the mill recirculation pump. The bottom slurry in hydrocyclone flows to the inlet of limestone wet mill; the over; the overflow flows automatically to limestone slurry tank, and be delivered to the system by slurry pump.
264
3 Operation Mode and Control 3.1 Start-up and Shutdown Instruction of FGD system The following steps are completed by the operator via operating the control system of flue gas desulfuriation system. 3.1.1 Start-up after Short Term Shutdown In order to reduce the start-up time, several function group should be started up and operate in standby condition. The desulfurization equipment should be switched on by the sequence as below: 265
a) b) c) d) e)
Recirculation pump Gas duct Oxidization fan Slurry transfer pipe Other common system
The recirculation pumps should be started up one by one to avoid the high load of power supply system. 3.1.2 Start-up of Desulfurization Equipment To avoid much ash leaking to desulfurization system, during the period of boiler start-up or abnormal ESP operation, the flue gas should be delivered to bypass duct, and be discharged to atmosphere directly via chimney. Once the ESP gets in normal operation, and all the conditions have been ready to receive the flue gas, the original gas damper and clean gas damper should be open, the BUF should be started up at the mean time, then the bypass damper should be closed subsequently. It is strictly forbidden to start-up the desulfurization system when the boiler is under the condition of oil combustion or oil supporting combustion. Because organic material is applied in many equipment of desulfurization system, unanticipated damage will occur if oil material is delivered into the desulfurization system. 3.1.3 Short Term Shutdown If short term shutdown is necessary, it is unnecessary to shut off the whole system. Just shut off some equipment which probably will be damaged for continuous operation during the shutdown term and no measurement to avoid the damage, or for which it is unnecessary to waste power. Otherwise, the additional water consumption for cleaning should be also considered. Generally, the following function group should be shut off: a) b) c) Flue gas system Absorber recirculation pump Oxidization air fan
The BUF should be shut when the bypass gas duct is under operation. Process water supply, gypsum dehydration, slurry preparation & distributing and all the agitators could be in operation condition. 3.1.4 Measurement during system shutdown period All the slurry pipes should be washed during the system shutdown period. The agitators should be in operation to avoid the solid deposition. 266
Disturbance and protection of gas desulfurization system The fault influence of desulfurization equipment should be prevented during the automatic operation. The following measurement should be undertaken if the gas duct is in the following faults: a) b) c) d) e) f) g) Disturbance from the BUF GGH does not rotate Recirculation pump is not in operation Original gas damper and/or clean gas damper is not open The temperature of original gas is too high The pressure in gas duct is out the specified range Start up the bypass damper immediately, and shut the BUF, close the original gas damper.
The pressure and temperature should be supervised to protect the desulfurization equipment. Open the bypass gas damper to discharge gas to chimney directly if the temperature of gas before GGH is higher than the max specified temperature (>180). Beside the temperature monitoring system, pressure monitoring system is also arranged which will open the bypass gas damper if the pressure is higher than specified value. Operation Condition of Desulfurization System Condition Description All the auxiliary equipments are operating in normal condition. The FGD devices are controlled automatically by DCS, including slurry flow control circuit, absorber slurry level control circuit, slurry discharge control circuit etc. Shut off the flue gas system, absorber and related auxiliary equipment in sequence. Discharge the slurry to emergency slurry tank, and discharge the excessive slurry to gypsum throw away system from emergency slurry tank. 267 Remark When the desulfurization system is in normal operation, the gypsum slurry should be utilized as possible, or be thrown away.
1 Normal condition
2 Long term shutdown (for periodical examination and repair)
3 Short term shutdown (several days)
Shut off all the auxiliary equipment except the anti-deposition equipment (such as agitators), Slurry is delivered to absorber and slurry tank. Process water system be in operation. Shut off the auxiliary equipment with high capacity of gas & SO2 absorption, Slurry system, process water and agitators should be in operation.
4 Short term shutdown (several hours)
3.2 Monitoring and Adjustment during Desulfurization System Operation 3.2.2 The Essential Control Parameters and Limitation 3.2.2.1 The Control of Gas Concentration at the Inlet of Absorber According to the design, the gas concentration at the inlet of FGD should be controlled under 370mg/Nm3, (dust content of inlet gas). If the dust content is too high, the unexpected problems will occur to influence the quality and utilization value of gypsum, such as the operation condition deterioration, lower absorption efficiency and belt machine dehydrating difficulty. So the dust concentration of inlet gas should be monitored during operation, contact with the site workers in time, shut off the desulfurization system immediately if the dust concentration is too high. 3.2.2.2 Pressure Control at Inlet of BUF To ensure the stable operation of boiler, the pressure can be controlled by adjusting the open degree of BUF guide blade to ensure the stability of inlet gas pressure. To acquire better dynamic characteristic, the signal of boiler load and ID fan condition are adopted as auxiliary signal. During the start-up of FGD system, the bypass damper and the guide blade of BUF should be coordinated to ensure the stability of inlet gas pressure; the pressure control seal ring should be in service when the bypass damper is closed to the specified position, then close the damper completely. During the operation, the pressure at inlet of BUF should be monitored all the time; if the large amplitude oscillation of pressure appears, manual control should be taken to adjust the open degree of guide blade to ensure the stability of BUF inlet pressure. 3.2.2.3 pH value of absorber slurry The pH value should be controlled within the specified range, if the pH value is too low, the slurry will lost the absorption ability to influence the desulfurization efficiency and quality of gypsum; at the mean time, if the pH value is too high, the blockage and scaling will be caused in the system. The stability of pH value is controlled by adjusting the slurry supply via open degree of limestone slurry supply control gate, to realize the dynamic regulation. The optimum value of pH is controlled within 4.5-5.8 in single circulation absorber. 268
3.2.2.4 Control of Slurry Level The slurry level is changing under the influence of slurry supply quantity, slurry discharge quantity and gas flow, etc. According to the slurry level, the adjusting valve on filter water pipe and the interval of washing mist eliminator will be adjusted to ensure the stability of slurry level. The slurry level should be controlled on 13.50.5m, it is strictly forbidden to operate above 14.00m to avoid the pollution from slurry flowing to GGH via gas duct. 3.2.2.5 Density Control of Slurry in Absorber The slurry density should be controlled within the specified range. If the density is too low, the problem will occur as gypsum formation difficulty and belt machine dehydration difficulty. If the density is too high, the problem will occur as higher equipment abrasion, high power consumption of slurry recirculation pump, high risk of equipment scaling. The density should be controlled within 1050-1150Kg/m3. The density adjustment is realized by adjusting the quantity of slurry discharged to ash/slag system. Ensure the slurry reception condition of ash/slag system when the slurry density in absorber reaches 1100Kg/m3. The slurry density in absorber should be controlled within 1050-1150Kg/m3 by adjusting the slurry discharge quantity via adjusting of absorber slurry density control ring and the open degree of manual slurry discharge gate. 3.2.2.6 Cl- Content Control of Gypsum Slurry in Absorber To prevent or reduce the corrosion of equipment and system, desulfurization waste water system should be under normal operation condition to ensure the suitable quantity of water discharge. The Cl- Content should be controlled under 10000ppm. When the ClContent is too high, increase the slurry discharge quantity to ash/slag system, and increase the make up quantity of process water to maintain the slurry level in absorber. 3.2.2.7 To ensure the activity of slurry, the limestone should be in higher quality of CaO, with eligible fineness. 3.2.2.8 The SO2 content of outlet gas should be monitored at all time. If deviation appears, analysis should be undertaken on the boiler load, SO2 content of inlet gas, operation of recirculation pump, pH value of slurry, etc, and relevant measurement should be taken. 3.3 Inspection during System Operation Equipment Inspection Items and Requirement Check the current, vibration, sound of all the rotational parts to be normal; check the temperature of mechanism and motors to be normal; check the temperature and flow of cooling water to be normal; check lubrication (hydraulic pressure) oil pressure temperature, quality, level to be normal; ensure the joints of guide actuator and damper blades are tight, no distortion, blend, rip; no 269
BUF and auxiliaries
the
seepage or leakage, check CRT display normally or not. Check the current, vibration, sound of all the rotational parts to be normal; check the temperature of mechanism and motors to be normal; check outlet pressure to be normal; check inlet filter clean or not; Check the current, vibration, sound of all the rotational parts to be normal; check the temperature of mechanism and motors to be normal; check the temperature and flow of cooling water to be normal; check lubrication (hydraulic pressure) oil pressure temperature, quality, level to be normal; drive belt elasticity suitable or not, no distortion, abrasion within normal range; check the temperature of outlet and inlet to be normal; no free vibration and resonance vibration with check valve and pipe; the inlet filter is clean, the joint is tight, no distortion, no blend, valves in correct position; no seepage, no leakage. Check the current, vibration, sound of all the rotational parts to be normal; check the temperature of mechanism and motors to be normal; lubrication level to be normal, oil quality eligible or not, joint screw tight or not, no seepage, no leakage. No block; normal valve open degree; normal inlet flow, no seepage, leakage. Check the current, vibration, sound of all the rotational parts to be normal; check the temperature of mechanism and motors to be normal; gypsum conveyance and gypsum thickness to be normal; valve open degree and react times of electromagnetic valve, roller and driver works normally, no block, rip or holes with filter, no block with cleaning water nozzles, water washing filter is clean; suitable vacuum state; gypsum splash normally; local instrument indication normal; no seepage, leakage. Check the current, vibration, sound of all the rotational parts to be normal; check the temperature of mechanism and motors to be normal; the pressure of washing water to be normal; lubrication oil level and quality to be normal; the pressure of seal air to be normal; no seepage, leakage. Dampers are in suitable open degree, cylinder drive to be normal; the pressure and flow of seal air are normal; no leakage with seal component. Check slurry level in absorber to be normal; the current, vibration, sound of pumps, agitators to be normal; check the temperature of mechanism and motors to be normal; check open degree of valves and auto valves to be normal; no block in PH gauge pipe; no abnormal vibration and sound in system area; local instrument indication to be normal; no seepage or leakage. Check liquid level of each tank to be on normal position; 270
Seal air fan
Oxidization fan and all pumps
Agitators
Slurry hydrocyclone
Gypsum separator and belt dehydration machine
Regenerative gas-gas heater (GGH)
Dampers and seal equipment
Absorber
Water tanks and
slurry tank
check the open degree of valves and instrument valves to be correct; no abnormal vibration and sound with pipes; no leakage on the equipment and auxiliaries of system. Level gauge of limestone silo and limestone powder silo indicate normally; the indication value is within normal range; no abnormal status with valves open degree and pipe vibration; fluidization system works normally; no seepage or leakage. All the indications are within designed value range; interlock and protection are in normal service status; no alarm signal, the operator on duty registers the gauge on schedule.
Silo
CRT
3.4 Maintenance of FGD System 3.4.1 GGH Cleaning To avoid the scaling in GGH, On-line cleaning must be taken on the GGH if the speed increasing of differential pressure or the differential pressure is higher than designed value. During the normal operation of GGH (speed of rotating body n1.5), steam cleaning should be taken at intervals of 8 hours. The duration of whole program is ~ 2.3 hours (each time). It should be manually started up by the operator. When the differential pressure (P) of GGH reaches ~1.5P, alarm is given for starting up HP water cleaning. The HP water cleaning should be taken at intervals of one week during normal operation, or be taken during the GGH shutting down. The duration of whole program is ~9 hours. This program can be only manually started up by request of operator. The water cleaning program should be automatically completed by GGH local ash blow control cabinet (including the return of fault signal etc) according to the remote signal of startup or shutdown from operator. GGH steam cleaning Check and ensure the conditions for steam cleaning can be satisfied (no interlock) GGH is under operation and rotor speed n1.5 (min 1) Upper soot blower and lower soot blower on outside position Air supply valve is closed HP nozzle cleaning valve is open Start up the GGH steam cleaning function group
GGH HP water cleaning Check and ensure the conditions for HP water cleaning can be satisfied (no interlock) GGH is under operation HP pump is not running 271
General valve is closed Start up the GGH HP water cleaning group
HP water cleaning instruction During HP water cleaning, GGH speed should be lower to 0.75n. Start up the HP water cleaning program which is controlled by PLC soot blow control cabinet. The signal of startup or shutdown is from DCS. HP water cleaning monitoring: The following signal can break off HP water cleaning program.
The temperature of HP water P>100bar (3HUQ10 CP310) max 1 3.4.2 PH gauge cleaning and rectification Two PH gauges are mounted on the absorber; they should be cleaned in sequence. If the measurement value is abnormal, or alarm of large deviation is given, cleaning device should be manually started up. The PH gauge under cleaning should be shut off. Manual test should be taken at least once one week, and the result should be compared with the online test result, if there is deviation, the PH gauges should be rectified in time. 3.5 Fault and Emergency Handling of Desulfurization System 3.5.1General Principle of Fault and Emergency Handling of Desulfurization System 3.5.1.1 If the fault or emergency appears, all the personnel should handle it according to regulation under the leading of monitor, the monitor instruction should be strictly executed unless it is harmful to personnel or equipment. 3.5.1.2 If the fault or emergency appears, the operator should inform monitor and related leaders immediately, and take effective and feasible measurement to prevent more damage, limit the range of fault or emergency, eliminate the causes, resume the system as soon as possible. The operators should handle the emergency immediately under urgent circumstance, then inform leaders as soon as possible. 3.5.1.3 The equipment out of operation conditions or bringing damage to personnel or equipment in operation should be shut off and disposed immediately. 3.5.1.4 If fault is identified with the gas system, check the bypass damper to be open or not, if not, quickly press the quick button of bypass damper, inform monitor, contact boiler operators to ensure the safe operation of boiler. 3.5.1.5 About the emergency handling of desulfurization, what should be considered is not only the equipment within system, but also the influence on other auxiliaries, and the prevention of secondary pollution. 3.5.2 Emergency Shutdown of Desulfurization System The FGD system should be shut off by interlock under anyone of the following cases. If 272
the system is not shut off by interlock, manually open the bypass damper and shut off the FGD system immediately. BUF trips due to fault. The gas temperature at BUF inlet exceeds 180. Original gas damper and clean gas damper are closed due to fault. Boiler MFT. EPS trips or the number of electric fields in service is less than 2 due to fault. The drive of GGH trips and the standby drive can not be started up on interlock successfully in result of GGH shutdown.
3.5.3 Non Emergency Shutdown of Desulfurization System The FGD system should be shut off by interlock under anyone of the following cases after acquiring the confirmation from department leaders. 2 sets of agitator are out of service Dust concentration at inlet of system is higher than 300mg/Nm3, the operator should shut off the system. Limestone slurry preparation and supply system can not supply slurry normally, the pH value of absorber slurry is lower than 4.0 and decline continuously. Density of slurry in absorber exceeds 1200Kg/m3, and can not declined to normal value within short time.
Unexpected emergency occurs to be harmful to personnel and equipment. The control system of desulfurization system can not monitor normally due to fault. The differential pressure is high and increase continuously after being adjusted by operators.
273
Training Materials for SD Negative Pressure Fly Ash System

1 System Overview
Each unit (#1 and #2) consists of two negative pressure transportation subsystems. Four separate subsystems (1A, 1B, 2A and 2B) can run automatically (or manually) and the ash in respective electrostatic precipitator (ESP) ash bucket, economizer ash bucket and air preheater dust bucket through the negative pressure fan will be sent out. Three sets of negative pressure fans (per unit) generate vacuum necessary for the system running (that is, transport air), of which two operate and one is standby. Two ash warehouses can simultaneous receive ash from the four transportation subsystems (each unit has two). Four subsystems each include an independent and specialized pipeline connecting to their respective ash warehouses, and each unit contains two pipelines. ESP ash bucket is equipped with a gasification system, which will transport the continuous, stable and compressed air provided by the gasification fan of ash bucket and heated to the electrostatic precipitator ash bucket, so that the ash in the ash bucket can maintain dry and flow, and the ash in the ash bucket can smoothly flow to the pipeline when the fly ash system runs. Dust collection equipment is installed in the top of the ash warehouse and includes two sets of cloth bag filter dust collectors (per unit), each of which is equipped with two air lock valves. Cloth bag filter dust collector includes an automatic injection type cloth bag filter with the relevant instruments and can filter fly ash to prevent fly ash from entering the negative pressure fan. The ash collected by the cloth bag dust collector under its own gravity through four air lock valves (each dust collector is equipped with two air lock valves) enters the ash warehouse. The purpose of the air lock valve is to ensure that fly ash can decline into the ahs warehouse smoothly but the system in operation is not interrupted. The ash warehouse stores temporarily fly ash, until fly ash is unloaded through an unloading device for the final disposal. The top of each fly ash warehouse is installed with a ventilation filter, which can filter air generated from the system in operation and replaced when the ash warehouse dumps ash, and then can discharge it to the atmosphere. The bottom of each fly ash warehouse is equipped with an air chute, which can distribute the gasification air evenly in the warehouse and promote the ash to flow toward the unloading mouth. The gasification air is from three sets of gasification fans in the ash warehouse, and is heated through the air gasification cycle heater installed on the gasification pipeline and thus the gasification air can remain dry. The gasification devices in the ash warehouse are designed for the continuous operation mode.
2 Control Overview
274
Fly ash system is designed for automatic or manual operation mode. When the system is under the automatic control, ash in all the ash buckets can be emptied by the pipeline vacuum value based on the program orders. When the system is under the manual control, operators can choose any ash bucket and change the time for emptying the ash bucket. Under two operation modes, only one-way branch pipe is allowed to run and only one ash bucket transportation valve (H-type valve) is opened during any time. The system can be operated in the fly ash handling system CRT workstation or power plant DCS. The workstation includes a computer, keyboard, mouse and printer and other equipment. CRT workstation includes the development and operation software provided by the program-controlled manufacturer, the layout of the fly ash system is graphical, and the system can be operated through the control of a soft keyboard and its operations can be monitored. The program-controlled manufacturer provides logic control of the system. The controller and all input/output modules are connected with PLC Logic cabinets of the fly ash system installed in the region of the electrostatic precipitator. Logic cabinet can control the switch of the power supply, temperature controller, circuit breaker, ash bucket gasification heater, ash bucket of electrostatic precipitator, ash transportation valve and branch isolation valves and other equipment terminal interface modules. Remote I/O cabinets of the ash warehouse contain all the equipment and I/O frames in operation and control, as well as negative pressure fans, gasification heaters and cloth bag filter/separators of the ash warehouse, ventilation filters, switching valves of pipelines in the ash warehouse and other equipments interfaces. Redundant network cables are used for communication among DCS and CRT workstations of the power plant, PLC logic cabinet and remote I/O cabinets of the fly ash warehouse. Multi-core cables connect the motor control centre (MCC) of the fly ash warehouse, situ maintenance button stations (Tag906, 907) of fly ash negative pressure fans A and B, and situ button stations (Tag904, 905) of dry dischargers of the fly ash warehouses A and B and others to the remote I/O cabinets of the fly ash warehouse. Multi-core cables connect with all MCC and PLC logic cabinets. The situ maintenance button station of the fly ash negative pressure fan includes situ permission instructions and motor fretting (start-up) button for maintenance of the fan, for instance after the drive belts of the fan are replaced. In addition, each situ button station includes an emergency stop button, which is directly connected to the corresponding motor control center (MCC). The button with built-in reset function is a push -pull mushroom type button.
3 Operating Procedure of Fly Ash Transportation System

The following is the overview of the operating procedure of a typical ash removal system, assuming that all ash buckets of the ash transportation subsystem A are collecting ash (relatively to "Bypass"), choosing the vacuum fan A as the working fan. The ash transportation subsystem A operates (the operation mode of subsystem B is exactly the same as that of the subsystem A), and at the same time, assuming that the flow fans 275
in the ash warehouse are operating (designed for continuous operation), the pulse timer of the ventilation filters in the ahs warehouse works when powered on (as long as the flow in the ash warehouse goes, the ventilation filters will work). A. Operators complete the following initial selections on the CRT display or DCS of the operation and control station of the ash removal system: a) Selecting COLLECT. ( or Collection) for each ash bucket. (Selecting the button Through BYPASS - COLLECT) Selecting AUTO for the ash removal subsystem A of Unit # 1 (relatively to MANUAL). Selecting the working fan for the vacuum fan A. Selecting START for operator after all the initial selections are implemented.
b)
c) d) B.
The filtering dust collector on the ash warehouse A begins circulating, and the pulse control timer is excited (powered on) so that the cloth bag filter begins to work. The upper and lower two valves of the corresponding air lock valve cooperating with the balance valve begin circulating, open and close, and at the same time the flow electromagnetic valve of the filtering dust collector is excited (powered on), open. When the lower valve of the air lock valve is opened, the flow electromagnetic valve is excited and open, and when the lower valve is closed, the flow electromagnetic valve is de-excited (powered off) and closed. a) The isolation valves in the following system when being opened / closed may form a separate ash transportation channel and vacuum channel connecting to the filtering dust collector A: The isolation valve of the vacuum fan is adjusted to the correct channel (Vacuum fan A): -- Fan isolation valve is opened -- Fan isolation valve is closed c) The branch isolation valve in the first electric field of the ESP dust bucket is opened. Inspecting and confirming that the ash warehouse is not at a high level of materials by procedure logic, and a separate smooth transportation channel has been established (through the limit switch of the valve). The vacuum destroying excitation valve is (powered on) closed. Vacuum Fan A starts.
b)
d)
e) f)
C. When all the discharging valves (H-type valves) of the ash buckets are closed, the vacuum degree of the system will be increased after the fan starts. When the vacuum degree reaches the set point PSML, the PLC will send a signal to enable the ash bucket discharging valve at the most remote end of the first column of the 276
electrostatic precipitator bucket valve (H-type valve) to be open. (The ash bucket has been selected as "Collect", and it in accordance with the procedure works first in the sequence of ash transportation (or "Collect") ash bucket) a) If the set point PSML is not reached in the scheduled time, the PLC will send an alarm signal "Vacuum Low" (FLY ASH SYSTEM VACUUM LOW). This phenomenon is likely resulted from the vacuum leakage of the pipeline system or an H-type valve not closed. b) When the H-type valve receives the signal and starts, a timer starts at once to work. In the set time, the vacuum degree of the system must decline below the set point PSL, and otherwise, it will trigger the "Vacuum High" and alarm (FLY ASH SYSTEM VACUUM HIGH). (Usually, the time set by the timer is based on the time required for emptying the whole ash bucket). Before the end of delay of the timer, the timer returns to zero (reset) if the vacuum degree of the system declines below PSL. D. When ash in the ash bucket is discharged into the fly ahs pipeline, the vacuum degree of the system will rise to the set point PSH, when the current E-type valve in the open state receives the signal and is closed to prevent the pipeline from overloading. When H-type valve is closed, as no more ash is discharged into the pipeline, the vacuum degree of the system will gradually decline to PSMH, and when the H-type valve receives the signal again and is re-opened. Such "open close" cycle of the H-type valve is a typical feature of the system in operation. E. As ash in the ash bucket is gradually emptied, the vacuum degree of the system will gradually decrease. When the vacuum degree of the system declines to the set point PSL, the ash bucket is basically emptied, so that the H-type valve of the ash bucket receives the signal and is closed. The H-type valve closed leads to the vacuum degree of the system re-rising, and when the vacuum degree reaches the set point PSML, the PLC sends a signal to open the H-type valve of the next ash bucket selected in the sequence of opening ash collection. For each of ash bucket in the column, repeating the operating sequence from C to E in the above steps.
F.
G. When the vacuum degree of the system declines to PSL in the operation process of the final ash bucket selected from the column, that is the fourth ash bucket, its H-type valve is closed. H. The branch isolation valves in the second row of ash buckets receive a signal and are opened, and at the same time the branch isolation valves of the row of ash buckets whose ash has been discharged receive the signal and are closed. I. The sequence of discharging ash and operation process of the second row of ash buckets are identical to the row of the ash buckets whose ash has been discharged. The beginning system normally stops: 277
J.
a)
The pulse injection timer of the filtering dust collector still remains the working state, and the upper and lower valves of the corresponding air lock valve continue to cycle for a predetermined period of time, to ensure that the filter bag is clean and the filtering dust collector is completely emptied. After a delay to clean up the pipeline, the running vacuum fan receives a signal and stops. Before the fan stops (for about 2 seconds), the corresponding vacuum destroying valve is powered off and opened. The branch isolation valves of the ash bucket and fan isolation valves are closed.
b)
c)
K.
The operating process of ash removal is concluded.
4 Chain and Licensing Conditions

4.1 The chain and licensing conditions and requirements of the fly ash transportation system are listed below: 4.1.1 The system must form a separate and smooth negative pressure air flow channel before the system vacuum destroying valve is closed. 4.1.2 When the system operates, only a materials transportation valve of ash bucket (H-type valve) is allowed to be opened. 4.1.3 All H-type valves must be closed before the procedure for ash removal of the system ash pipeline starts. 4.1.4 The negative pressure fan prior to the commencement by permission must have a single and smooth transportation channel to form. 4.1.5 Before the H-type valve is permitted to be during the operation in automatic ash transportation mode, the negative pressure value of the system must reach the minimum allowable transportation value of PSML. 4.1.6 The lower valve of the air lock valve must be fully closed before the upper value of the air lock valve is permitted to be opened. 4.1.7 The upper valve of the air lock valve must be fully closed before the lower value of the air lock valve is permitted to be opened. 4.1.8 If the alarming condition of "Ash warehouse has high level of materials" takes place in the ash warehouse, the system related to the ash warehouse could not be activated. However, when the system is already beginning running and then the alarm of "Ash warehouse has high level of materials" takes place in the ash warehouse, the system continues to run (only alarming).
5 Alarm
When the alarm signal occurs, pressing (ACK) Acknowledgement button first and pressing (RESET) to reset and remove the alarming display after the alarm is eliminated. 278
(For the critical alarm signal of the system, the system must be reset first and then be allowed to restart.) A. Fly Ash System Vacuum Low a) Reason: a "Vacuum Low" alarm signal lasts more than 30 seconds. The possible reason is that the materials transportation valve of ash bucket could not be closed or the pipeline is damaged. System response: the system stops running at the current ash bucket, for the vacuum degree of the system fails to rise up to PSML, it is unable to turn to the nest ash bucket.
b)
B. Fly Ash System Vacuum High a) Reason: the vacuum value remains continuously above the set point PSMH for more than 15 minutes. The possible reason is that the ash bucket is blocked or the materials transportation valve of the ash bucket can not be opened. System response: the system stops at the current ash bucket, for the vacuum degree of the system can not decline to PSL, the current E-type valve remains the open state.
b)
C. High Temperature at the Export of Negative Pressure Fan A (B) a) Reason: for the high temperature at the export of the negative pressure fan, the possible reasons include poor lubrication or mechanical failure of the fan. System response: the transportation system is shut down.
b)
D. High Pressure Difference of Filtering Dust Collector A (B or C) a) Reason: the differential pressure switch senses high pressure difference inside and outside the cloth bag, and this situation takes place within 10 minutes continuously for three times. The possible reason is that the cloth bag is blocked or the clean equipment of the cloth bag fails. System response: when the cloth bag dust collector alarms for the first time due to high pressure difference of the cloth bag, the current H-type valve should be closed and the system vacuum destroying valve is powered off and opened. The "on-demand" ash cleaning control procedure of the filtering dust collector continues to operate and the air lock valve at the lower end of the dust collector continues to operate circularly to a predetermined period of time (about 2 minutes). The vacuum destroying valve is powered on and closed and the current H-type valve is re-opened and the system resumes operating. If the dust collector cloth bag within 10 minutes has the high pressure difference for three times, an alarm signal takes places and the system starts to stop normally. (After cleaning the pipeline and before the system stops, the pulse injection control procedure and air lock valve cycle procedure of the filtering dust collector system continue to run for 5 to 10 minutes). 279
b)
E. High Level of Materials of Filtering Dust Collector A (B) a) Reason: for high level of materials of the fly ash filter/dust collector, the possible reason is that the air lock valve has mechanical failure or there is a problem about the setting of the cycle time for the air lock valve. System response: as noted above, the response is the same as the system response of "High pressure difference of filter/dust collector".
b)
F. Low Level of Materials in Ash Warehouse a) b) Reason: the low level of materials is detected in the ash warehouse. System response: alarming alone. Operators can contact and stop discharge ash by the ash warehouse.
G. High Level of Materials in Ash Warehouse a) b) Reason: the high level of materials is detected in the ash warehouse. System response: the transportation system associated with the ash warehouse is not allowed to start and the system alarms alone. If the transportation system alarms in the process of operation due to in the high level of materials in the ash warehouse, the ash in the ash warehouse should be immediately discharged.
H. Ultra High Level of Materials in Ash Warehouse a) Reason: the high level of materials is detected in the ash warehouse and there is the danger of overflowing ash out of the ash warehouse. System response: the system alarms and the corresponding fly ash transportation system shall be closed to prevent the ash pipeline from being blocked and the cloth bag of the filtering dust collector from being damaged. The ash in the ash warehouse must be immediately discharged. Before the fly ash transportation system is permitted to restart, the ash warehouse must not alarm due to the high level of materials, and the level of materials in the ash warehouse is detected to be lower than the set value of the high level of materials.
b)
I. Cloth Bag of Filtering Dust Collector A (B) Damaged a) Reason: the identified significant change in the flow of ash particles is detected by the ash detector installed in the gas female pipe at the entrance to the negative pressure fan and this situation lasts a predetermined period of time. The reason is usually the cloth bag of the filtering dust collector damaged or the cloth bag fallen. System response: alarming alone. Operators should timely close the system by step sequence to prevent possible damage to the system equipment.
b)
J. Negative Pressure Fan A (B or C) Trips or Fails to Start a) Reason: "Start-up" signal has been received, but the PLC can not receive the operation signal of the fan motor. 280
b)
System response: the system is closed or fails to start
K. Flow Wind Heater of Ash Warehouse A (B or C) is Overheating a) Reason: the high temperature of the heating elements is detected by the flow wind heater, and the possible reason is that the flow rate of the flow wind passing by the heater is low. System response: the heater is closed, but the flow wind continues. The heater is permitted to restart after pressing RESET button.
b)
L. Flow Wind Heater of Ash Bucket is Overheating a) Reason: the high temperature of the heating elements is detected by the flow wind ash bucket, and the possible reason is that the flow rate of the flow wind passing by the heater is low. System response: the heater is closed, but the flow wind continues. The heater is permitted to restart after pressing RESET button.
b)
M. Fly Ash System Valve Fails a) Reasons: the fly ash system valve (with limit switches) is detected not to be fully opened or closed in the scheduled time. The usual reasons include pipeline obstruction, fault of cylinder actuator, air inadequate in the compression instrument or failure of limit switches. System response: according to the serious situation of the valve failure, the system can be stopped or closed.
b)
N. Air Bock Valve Fails a) Reasons: the air lock valve can not be completely closed in a short scheduled time. The possible reasons are the failure of limit switches or actuators of related cylinder, or loss of gas source of instruments, or mechanical problems of the air lock valve. System response: the air lock valve stops cycling. If the problem is not promptly treated, the transportation system will be resulted in failure.
b)
O. Electrical Failure of Fly Ash Negative Pressure Fan A (B) a) Reasons: the reasons for failure alarming may be the power-off of MCC, the overload of the motor current or other electrical fault of MCC. System response: the drive motors of the devices affected are closed or fail in starting.
b)
281
Training Materials for ESP

1 Test and Inspection before Putting into Operation
The electrostatic precipitators newly installed or overhauled before being put into operation should be tested and accepted according to the relevant standards and regulations. The main inspection contents are: a) All work sheets shall be completed, all safety measures listed for the overhaul shall be removed and the common parapets, signs and others shall return to the normal state. All equipment and components are complete, with clear and correct signs. The combination surfaces shall be tight with integral heat insulation and adequate lighting. All motors have been wired, grounding wires are firmly connected, and security enclosures are installed and will not collide or contact with the rotating parts. For the anode and cathode shaking devices, ash unloading valves, spiral ash dischargers and other rotating equipment and their decelerators, their oil is qualified and their oil level is normal and transportation chains and others are added with good fuel and rotate flexibly. All instruments, power switches, protection devices, adjusting devices, temperature measuring devices, alarm signal and indicator lights and others are integral, complete and normal. The heating devices of the high-voltage insulation casing rooms and the ash buckets are intact. There is no debris inside the compartment of high-voltage rectifiers, insulation porcelain pieces are clean, rectifier transformers and reactors have no leakage oil with qualified oil and normal oil level. Lead wires of all parts of the rectifier devices contact well, damping resistors are intact, control cabinets of rectifiers and automatic adjusting devices are intact, and adjusting buttons or handles are complete with the correct indication. High-voltage isolation disconnecting links should contact well, operation mechanisms are flexibly and reliably grounded and all disconnecting links should be at the grounding position. h) High-voltage cables of electrostatic precipitator body indoors are clean and have no debris, and lead wires contact well and damping resistors are intact. All switches and disconnecting links in low voltage distribution cabinets should be intact and all power fuses and operating fuses are intact. After it is confirmed that automatic control cabinets of thyristors, heating and shaking devices and other switches are all at the disconnecting positions, the 282
b)
c)
d)
e)
f)
g)
i)
j)
equipment above is powered on. For minor repairs or stoppage due to fault, the relevant tests and inspections in general are only conducted for the rotation parts or the troubleshooting parts, and they can be put into operation after they are confirmed to be normal.
2 Start of ESP
Prior to the start of the electrostatic precipitator, it should be confirmed that there is no one inside the electrostatic precipitator, all manhole doors have been closed, no one is in the high-voltage regions, and high-voltage isolation disconnecting links have been put into the operating shift. Starting the heating devices for 4 to 8 hours in advance and heating the porcelain casings, pillar insulators and electric ceramic shafts in the insulation room, to prevent condensation, creepage and dielectric puncture. Enabling the heating equipment of the ash bucket to put into operation and removing the moisture in the inside wall of the ash bucket. Opening the shaking devices of the dust collection electrode and discharge electrode of the electrostatic precipitator and removing the dust attached to the electrodes. Opening the master fan and preheating and drying the electrode system in the electric field. Opening the grounding devices and inputting the high-voltage power supply. See Figure 1 for the operating sequence for start of the electrostatic precipitator.
Start
Turn on power supply of the distribution cabinet
Turn on heating power supply of insulator
Close doors of entry and manhole
Start dust discharge and treatment devices
Start discharge electrode shaking devices
283
Start dust collection electrode shaking devices
Pull the grounding devices
Start the fan
Determine whether flue gas being treated is in the normal state
Turn on the power supply of ESP operation cabinet
Automatic
Manualcommissioning Automatic or manual
Connect DC HV to ESP to operate automatically
Connect DC HV to ESP and set voltage manually
End
Figure 1 Operating Sequence for Start of Electrostatic Precipitator
3 Operation and Inspection of Electrostatic Precipitator (ESP)

ESP operates under the adverse conditions with high temperature and corrosive gases. Sometimes the flow, pressure and concentration of flue gas fluctuate intensely and the flue gas contains bonding tar-like substances, and thus under such conditions, the equipment functioning must be regularly checked and defects exposed must promptly be removed in order to prevent dust removal efficiency from declining.
284
After the electrostatic precipitators newly installed or overhauled are put into operation normally, conducting the characteristic tests with load, recording point by point with boost the first and secondary voltage, current and conduction angle, until flashover occurs, making a volt-ampere characteristic curve, determining the optimal parameters accordingly and adjusting to the best operating conditions. In the operation of ESP, it should be monitored whether all the meters and indicator lights of the high-voltage rectifier control cabinet and console tables are abnormal. Recording the first and secondary voltage, current and conduction angle once every two hours in the operation, and conducting regular patrol inspection and making records twice by each team: a) The equipment in the low-voltage distribution room is inspected and there should not be overheating, discoloration, burnt flavour, abnormal sound or oil leakage The oil color and level of the rectifier transformer are normal, the oil temperature on the surface of the transformer is normal with the maximum of not more than 85 , and the color of silica does not change. The damping resistors are intact, with no discharge phenomenon. There is no significant discharge phenomenon on the top of high-voltage rectifier transformers, high-voltage isolation switches, DC high-voltage lead wires, contact lines and dust collectors. The temperature in the high-voltage rectifier control cabinet does not exceed the prescribed allowable temperature and. SCR fan should start if it exceeds. Any inspection in the process of operation is prohibited under the charged case in the high-voltage compartments or by opening the manhole cover of the high-voltage insulator room. ESP body, pipelines, each manhole door and others should be close without air leakage. The ash buckets and ash bucket heating devices should operate normally, without blocking ash or ash leakage phenomenon, the braking devices and other rotating equipment operate normally without abnormal sound and with normal vibration and temperature, and the oil level of the reduce is normal with no leakage phenomenon. The heating devices and thermometer in the high-voltage insulation casing room are normal. The protective covers and console lighting of all movement components must be maintained in a good condition. Rotating equipment should be refueled based on the specific time and the oil level is maintained to be normal.
b)
c)
d)
e)
f)
g)
h)
i)
j)
See Table 1 for the parts and frequency of inspection of ESP in operation. 285
Table 1 Parts and Frequency of Inspection of ESP in Operation.

Item Chimney Shaking device Shell Parts Smoke evacuation Transmission All parts of shell and Frequency 2 times per day 3 times per day 1 time per day shaking system Normal shaking Manhole door has poor Normal No increase in concentration Abnormal processing Inspection parts Inspection parts Adding an asbestos rope for sealing Repair of all of all
sealing and can not leak air; Insulating layer does not drop off; Flange mouth does not leak air; The top plate does not rust
Repair Repair Inspecting power parts supply the All
Power supply
Secondary current
3 times per day
Corona current and working voltage
Voltage Meter
1 time per day
Meeting the required value Electric heater has no disconnected wire
Replacement
Insulator Room
1 time per day
Hot air system is normal
Inspecting the fan pipeline
Making records if deficiencies are found in the process of operation and notifying timely the maintenance staff. Reporting the major deficiencies to the persons responsible immediately and at the same time making records.
4 Shutdown of ESP
When the mainframe equipment shuts down, the ESP can be temporarily shut down, and the high-voltage isolation disconnecting link of the electric field is placed to the grounding position. After the electric field is powered off, the heating devices and shaking mechanisms continue to operate until the electrode fouling is cleaned and the shaking devices may stop working. Fouling in the ash bucket is discharged but not completely. When the ESP needs overhaul, repair and long-term shutdown, it can be temporarily shut down, and the shaking devices work continuously for at least 4h and then the heating system stops working. All fouling in the ash buckets is fully emptily. Grounding rods are additionally grounded in the electric field and the site should be maintained clean and shutdown records are made well. See Figure 2 for Operating Sequence for Shutdown. 286
Stop operating
Fan stops
Close flue flashboard
Rectifier stops
Grounding devices are grounded
Stop shaking at discharge electrode
Stop shaking at dust collection electrode
Dust removal devices stop
Cut off the heating power supply of insulator
Close heating equipment of the materials buckets
End
Figure 2 Operating Sequence for Shutdown
5 Fault of ESP
287
The type of fault of ESP is related to its structure and the methods of its use. According to the investigation from the industry concerned, the most common operating fault of ESP is the broken discharge wires, accounting for 68% of the targets investigated, and the fault is largely resulted from mechanical fatigue, frequent partial spark discharge or corrosion. Another common fault is the failed shaking, accounting for 40% of the targets investigated. In addition, insulation fault and electrode fault respectively account for 28%, the fault of the ash bucket accounts for 24% and the fault of the transformer rectifier accounts for 20%. The fault of the shaking system is mainly caused by the error resulted from the deformed components due to heating when the system is installed and the system impacts in operation.
6 Analysis of Typical Faults and Reasons

6.1 Fault of Discharge Electrode 6.1.1 The discharge wire breaks. There are many reasons for the broken discharge wire, such as inadequate intensity of discharge electrode caused by corrosion and ageing, electric corrosion, shortcomings in the process of installation, and construction and excessive force in shaking and anti-corona arisen from dust with high resistivity. Because of smoke and dust, the support components of discharge electrode are corroded or worn, thus shortening the life. Repeatedly shaking, when the discharge electrode shakes, the weight drop and the discharge electrode play to enable their contact part to cause electric corrosion. The broken wire from electric shock is resulted from the burr on the dust collection electrode and vibration and swing of the discharge electrode, so that the distance between electrodes is shortened and the partial electric field intensity is increased, generating spark discharge with concentrated stress, thus breaking the discharge wire. The electric corrosion in general forms when the dust collector has operated for many years. 6.1.2 Enlargement of discharge electrode. The reasons for the enlargement of exterior dust on the discharge wire are related to dust properties, concentration, shaking force and shaking body. In the electric field, film forms because the discharge wire adsorbs dust with positive electricity. Due to ineffective shaking of cleaning ash, the accumulated dust enables the discharge wire to enlarge. When dust with high resistivity is collected, this situation will only lead to reducing corona and current, weakening corona discharge and increasing spark discharge. Aimed at the situations above, it is necessary to adjust the shaking force and also re-adjust the shaking time and cycle. For the enlargement of electrode when flue gas is below dew point temperature or caused by frequent opening and shutdown, it is necessary to strengthen the insulation measures and improve the modes of power supply. Before the temperature of the flue gas drops to the dew point, a need is to shake and clean continuously the electrode, which is also continuously shaken within a few hours after ESP shuts down. 288
6.2 Faults of Dust Collection Pole Major faults of dust collection pole: a) Accumulated dust on the dust collection pole. Like the enlargement of dust on the discharge electrode, the partially accumulated dust on the dust collection pole will lead to reducing the discharge characteristics, thus making the reducing efficiency of dust collection. The partially accumulated dust is related to the nature and concentration of dust and shaking conditions and other factors, and is mainly resulted from inadequate shaking force or uneven distribution of shaking force, and sometimes from the loose collecting bolt connected with the dust collection polar plate, causing bad transfer of shaking force, when it is necessary to identify the reasons by entering the electric field. Deformed polar plate. The deformed polar plate makes the spacing between electrodes change. The reason is that the temperature of flue gas is too high and elongation of the polar plate is restricted, or that the accumulated high temperature dust causes regenerative effect on the polar plate, or the temperature of flue gas exceeds the regulated temperature value, or the breakthrough arcing inside the dust layer causes deformation of the polar plate. If the reasons belong to the space margin due to not reserved elongation or the installation of the polar plate, when the polar plate deforms by inputting flue gas, the phenomenon is that the voltage of cold power transmission can be up to the rated value, and when inputting soot, the voltage along with the increasing temperature drops drastically. When stopping inputting flue gas, the voltage rises again gradually. Most of such a fault takes place in the new electrostatic precipitators. If the partial deformation is caused by accumulation of heat and arc, the causes are necessarily identified, the deformed polar plate is replaced and the spacing between poles will be adjusted or the performance of the shaking system will be improved.
b)
6.3 Faults of Shaking Device ESP is shaken with a torsion arm hammer, and the shaking hammer is situated in the electric field outside the precipitator at the transmission part and the faults from the shaking part can be determined based on the changes in secondary voltage or current and the reducing efficiency of dust removal. For the shaking of the discharge electrode, if the insulation part fails, the entire electric field is unable to work, this situation will soon be found in general, but individual hammers are damaged or defective and can be found only when overhaul. Shaking and transmission devices have the following several major faults. a) Shaft block. The main reasons for shaft block include: 1) the supporting bearing of the shaking shaft is seriously worn; 2) the shaking bearing housings are not on the same level, exceeding the compensation capacity of the flexible coupling and impacting the axiality of the shaking shaft.
289
b)
The hammer and shaking anvil in operation are not centralized. In addition to the reasons of installation, it is mostly caused by thermal expansion of the shaking shaft and the ensuing displacement of the shaking hammer. The shaking and transmission ceramic shaft of the discharge electrode is fractured. It first is the quality problem of the ceramic shaft, which must be strictly inspected before being installed, and those that have no product certificate or whose surface has cracks or defects can not be used. And a timely review should also be conducted when commissioning. The second reason is the excessive torque of the shaking shaft; in addition, the fracture is also caused by fouling or condensation, excessive leakage current or uneven heating of the ceramic shaft and other factors.
c)
6.4 High-voltage Insulator High-voltage insulator is prone to mechanical damage. In addition, when the high-voltage insulator adheres to conductive dust, its insulation performance will be lost, resulting in the reduced efficiency of the electrostatic precipitator. If the insulator is attached to dust comprehensively and uniformly, the leakage current will increase and the corona current required for dedusting will reduce; if the attached dust distributes unevenly, the insulator will become heated because of increase in partial current, so that the insulator own performance would drop significantly and flashover discharge status would show inside the insulator casing. This is the main reason for the damage accident. Another accident is creepage and condensation, which is resulted from the much water content in the flue gas, low temperature, bad heating or no heating facilities, or condensed water on the insulator. Third, the insulator is not installed levelly, and thus the load of the entire discharge system supported is uneven, resulting in the broken insulator easily. 6.5 Power Supply Based on the classification of the equipment, the major faults of the power supply include the following. a) Rectifier transformer: 1) the original equipment has a small oil pillow and injects oil at 60 ; 2) The oil temperature of the rectifier transformer laid outdoors layout rises and alarms frequently due to insolation in summer or poor ventilation in ceiling; 3) Oil leaks from the transformer; 4) coils, silicon stacks, piezoresistive capacitive components and others in the rectifier transformer generate overcurrent and overvoltage and are damaged due to the open circuit, short-circuit, arcing and other faults of the electric field. High-voltage power supply: 1) burned SCR, such is common in general in summer, 2) small axial fans in the high-voltage control cabinet fail frequently, mostly resulted from the problems of the bearing; 3) network damping resistors are burned and are replaced by ceramic damping resistor in some factories; 4) AC contactors in the high-voltage control cabinet are worn by spark and dust, iron core surface is uneven, with a lack of absorption and high vibration noise. 290
b)
c)
Low-voltage power supply: a programmable controller is used for shaking program control, which fault is caused by the high temperature working environment.
6.6 Electrical Fault There are several electrical faults below. 6.6.1 SCR of boost rectifier can not conduct or fuse of SCR is burned out Phenomena: a) b) Alarm sounds, tripping indicator light is on and the rectifier trips: Starting again, there is no voltage twice and the "manual" or "automatic" boosting is void.
Reasons: a) b) c) The adjusting circuit malfunctions and control electrode has no voltage; Fuse of SCR contacts badly; The capacity of the fuse of SCR is small or the primary side circuit of the boost rectifier transformer has fault.
Treatment Methods: a) b) Reverting alarm for inspection or replacement of the fuse; If the fuse has no fault, the maintenance team shall be informed to treat it.
6.6.2 Protection components of SCR of the boost rectifier or SCR is broken through Phenomena: a) The boost rectifier transformer has abnormal sound and generates suddenly great noise in the start-up and operation, but shocks by sense; The alarm sounds, tripping indicator light is on and the contactor trips; After starting again, the primary and secondary voltage and current rise rapidly and are more than the normal values and at the same time flashover and tripping occur.
b) c)
Reasons: a) b) RC-absorption components are damaged or SCR has poor quality; Over voltage is generated in the primary circuit.
Treatment Methods: Reverting alarm and then informing the maintenance team to treat it. 6.6.3 One of SCRs of the boost rectifier transformer is on and the other is off. Phenomena: 291
a)
After the rectifier transformer starts, the primary and secondary voltage and current can all indicate the abnormal and needles are swinging; The boost rectifier transformer has an abnormal sound and generates "Uttering a word" as the current direction swings to the increase direction.
b)
Reasons: a) b) The adjusting circuit malfunctions; A wiring of SCR control electrode is open.
Treatment Methods: a) b) Stopping the rectifier transformer immediately to operation; Informing the maintenance team to dealing with it.
6.6.4 HVDC circuit is open Phenomena: a) After the rectifier transformer starts, the primary and secondary voltage rises rapidly, but primary and secondary current has no indication; In the operation of the rectifier transformer, the primary and secondary voltage is normal, but the primary and secondary current suddenly has no indication and the rectifier transformer trips.
b)
Reasons: a) b) HV isolation switch is not closed in place; The resistor connected in the HV circuit in series is burned out.
Treatment Methods: a) Stopping the rectifier transformer immediately to operate, closing the isolation switch and then starting according to the provisions; Taking timely repair.
b)
6.6.5 The rectifier silicon stack components inside the boost rectifier transformer are broken through Phenomena: a) After the rectifier starts, the primary voltage is low, the primary current is large and close to the rated value, and the secondary voltage is only adjusted to around 30 kV and the secondary current is low; The above phenomena take place in the operation of the rectifier, the thermometer of the rectifier transformer has a higher indication than the original and the oil level rises or the oil overflows out from the refueling hole. 292
b)
Reasons: One or two silicon stack components in the rectifier bridge in starting and operation is broken through so that a high-voltage coil is short circuit. Treatment Methods: As the undervoltage protection circuit can not move, if failing to detect the abnormal oil temperature and the failed oil temperature protection, or it is not long after being input, the rectifier transformer may be burned out, or even catch fire, and starting or operation must stop immediately, checking the transformer and informing the maintenance team to treat it. 6.6.6 The boost rectifier transformer in operation trips Phenomena: a) b) The alarm sounds and the tripping indicator light is on; When re-starting, the voltage can not rise, or can rise to a certain value and then trip again.
Reasons: a) HVDC circuit (including plate and lines in the electric field) is provided with permanent breakthrough points or short-circuit points; The components of the rectifier device fail; The ash bucket is full of ash to make the cathode and anode short circuit.
b) c)
Treatment Method: a) b) Reverting the alarm and inspecting the equipment; If the reasons belong to the above (1) (2), the maintenance team is informed to treat, and if the reasons are included in (3), the ash discharging system may be treated to remove fouling.
6.7 Faults of Equipment From the point of view that the faults of the equipment cause decrease in efficiency of dust removal, the greatest impact is on the short circuit to earth. If a short circuit is generated, the electric field can not be powered on and the dust removal function immediately suspends. The forms of the short circuit to earth include complete or incomplete short circuit. Although the extent in the incomplete short circuit does not meet that in the complete short circuit, voltage and current drop sharply and a little increase in voltage will result in flashover. Phenomena when the electric field is short circuit: flashover, over-current and arcing at the same time exit and the low-voltage tripping alarms. If the power supply fails, the 293
overcurrent protection part works in general and high-voltage tripping alarms; SCR, resistors, capacitors, transistors, transformers and silicon stacks are damaged, and rapid fuses are burned out and so on, as belong to the faults of the power supply, and thus the silicon rectifier transformer is checked and power supply in open circuit is prohibited. 6.8 Analysis of Faults based on Indications of Meters and Instruments The reasons for the faults of ESP contain those of ESP own and also those of dealing with the nature of the flue gas. Because of the complex nature of the flue gas, the faults of ESP are diversified. The apparent same faults essentially may have significant distinction, and the faults with the same type due to degree of faults and different working conditions may bring about the phenomena that vary widely. In recent years China's ESP technology managers through long-term observation and practice have summed up methods for analysis of faults of ESP based on the indications from meters and instruments. 6.8.1 The primary and secondary voltmeters and ammeters have no indications 1) The contactor in the main circuit can not be closed. The major reasons are: the contacts of the safety interlock disk and high-voltage isolation switch locking device are not closed to enable the start operation circuit to be disconnected, the control fuse core in the start operation circuit is burned out or contacts badly, the automatic voltage regulator has internal tripping, and the relay contacts are not released. Although the contactor in the main circuit is closed, when HK3 is input "automatically" or "manually", there is no voltage but the current rises.
2)
The major reasons are: a) The automatic voltage regulator is powered off. At this time, the primary and secondary current is zero, but there is about 50V of the primary voltage and about 8 kV of the secondary voltage (both known as start leakage voltage) and the conduction angle of SCR indicates to zero. The most common reason for the power-off of the regulator of A type power supply device is that the commonly open auxiliary contact that belongs to a device preventing power supply in the master contactor and that is impacted at the moment when the control power supply is connected contacts badly, the contact itself is designed to connect the general low-voltage control circuit and has a working power supply voltage of only 23 V for the automatic voltage regulator that is actually on or off, and it contacts very easily badly as the voltage is low. Contacts in D-type power supply device are connected in series in the 220 V control power supply circuit, so that the fault rate of power-off of the automatic voltage regulator is greatly reduced. A simple method for determining whether the automatic voltage regulator is powered off is to press the flashover indication button once, and the flashover indication light should be on if the regulator is powered on. 294
b)
The power fuse or fast fuse in the main circuit is burned out. In such circumstance, the primary and secondary current is zero, and there is no start leakage voltage and the conduction angle of SCR indicates 100%. The indication of the conduction angle of SCR is from the number of trigger sequence pulse output by the automatic voltage regulator; as the main circuit is disconnected, no secondary current is fed back to the automatic voltage regulator, and in accordance with the automatic tracking principle of sparks, the number of the output pulse from the regulator will increase to a maximum, corresponding to the indication of 100% conduction angle, and thus such situation understood will facilitate to determine the fault quickly.
6.8.2 The secondary voltage is zero and the secondary current shows. 6.8.2.1 In most cases, short circuit in the electric field occurs. The main characteristics for such a situation are: a) When the electric field is put into operation, the secondary current with the secondary voltage increases rapidly, with the turning point of the corona voltage; When starting just, there is no primary or secondary start leakage voltage; The electric field has no flashover and the needles of all voltmeters and ammeters do not swing from up to down; In the circumstance with the same secondary current, the primary current declines after short circuit; the primary current also rises as the secondary current rises and is restricted at the current limit after the short circuit for the electric field in the flashover state; For the electric fields whose original secondary voltage and current are small, thanks to the increase in the secondary current and the high-impedance characteristics of the rectifier transformer, the primary voltage rises, and for those electric fields whose original secondary voltage and current are big or current limit in the automatic voltage regulator is small smaller, the primary voltage drops; The value of insulation of the electric field measured with 2500 VM meter is below 10M or zero. The common reasons for full short circuit in the electric field are: filled ash bucket, metal short circuit in the electric field and the completely broken insulation component. 6.8.2.2 The electric field is incompletely short circuit. When the voltage of the electric field begins to rise for such fault, the secondary voltage gradually increases to a certain value and then suddenly drops to zero by breakthrough, and the current subsequently rapidly increases and is restricted within the current limit. At this time, the parameters of the electric field are completely the same as the short circuit of the electric field. For stopping operating, after "Manual drop" is set and the primary voltage drops to a certain value, the secondary voltage restores to a certain value. 295
b) c)
d)
e)
f)
The electric field is provided with a start leakage voltage, and the insulation of the electric field is measured with 2500VM meter and the size of data is resulted in the reasons for the breakthrough but can not be up to zero. The usual reasons for the incomplete short circuit of the electric field are: debris between the cathode and anode, the becoming close distance between the cathode and anode caused by bent polar plate due to thermal expansion, and seriously polluted insulator, etc. 6.8.2.3 Faults of the secondary voltage measuring circuit or needles own. The parameters and characteristics are different from the short-circuit electric field, but can refer to the parameters when short circuit; in light of the electric field in the same status, analyzing whether the electric field is really short circuit or the incorrect short circuit is indicated on the needle. If the fault belongs to the secondary voltage measuring circuit, D-type power supply devices will be provided with low-voltage delay tripping. 6.8.3 Low secondary voltage Due to the reduced load and the changes in the characteristic curve of the electric field, the secondary current has reached the current limit at the low voltage value. When the first and second electric fields are normally put into operation, the dust concentration in the third electric field is low and the secondary voltage likewise is restricted by the current limit. In these cases low voltage is a normal phenomenon. The reasons for low-voltage faults are: 6.8.3.1 Bad shaking. Bad shaking between the anode and cathode will cause the secondary voltage to drop, the secondary current to reduce and the flashover of the electric field increase. Common reasons are: a) Blocked shaking mechanism is normally caused by the blocked hammer, and one of the reasons is that the hammer is not restored after maintenance of the electric field in addition to improper installation causing the hammer blocked. Fractured fuse; When shaking, fault of the control circuit or improper choice of a cycle; Shaking device is installed at an incorrect place and is not welded firmly, and the acceleration of shaking the electrodes reduces.
b) c) d)
6.8.3.2 Change in the distance between different electrodes in the electric field. The reasons for the change are: a) b) c) Metal objects within the electric field; Deformed components in the electric field; Deformed polar plate and lowered secondary voltage due to thermal expansion, and the following characteristics are provided to the latter phenomenon: 296
The secondary current is large in the same voltage, and the more number of the bent polar plate, the bigger current. Voltage rises normally at the cold state and drops at the hot state. As the load increases, the voltage is gradually declining. When opening the manhole of the corresponding electric field, the voltage can partly or completely rise. After the finance is shut down, it can be found that the wind stop plate of the ash bucket is bent. d) e) Insulation parts are humid and polluted; Power supply devices have serious partial excitation. Partial excitation taking place in the power supply devices is because the waveforms of voltage input into the primary side of the rectifier transformer are asymmetric up and down after AC is controlled by SCR, in addition to the slight increase in the primary current for the mild partial excitation, and the other parameters do not change significantly and the most serious case of partial excitation is provided with only positive waves or negative waves, this voltage is equivalent to DC ripple voltage, when the secondary voltage and current are very small but the primary current is very big and is often beyond the rated value. The primary voltage in the continued flow of the circuit inductance is about 200V and the conduction angle of SCR indicates 100%. Because of the abnormal magnetic field, the rectifier transformer has internal abnormal vibration and sound, and the increase in iron and copper consumption enables the temperature of the rectifier transformer to rise. The reason for the gently partial excitation is generally that the parameters of the two groups of circuits that generate sequence trigger pulse are asymmetric, but the reason for the serious partial excitation may be the fault of a group of pulse output circuit or a SCR. 6.8.4 The secondary voltage is higher than the normal value The size of the secondary voltage is related to the installation quality of the electric field, the size of the electrostatic precipitator, the nature of flue gas and concentration of dust, characteristics of power supply devices and operating conditions of equipment and other factors. Under the similar circumstances, the voltages of the front and rear electric fields are different, and the following situations will enable the secondary voltage to increase after these normal differences are removed. 6.8.4.1 High-voltage circuit contacts badly and is opened or closed from time to time. At this time, the features of the parameters of the electric field are: flashover of the electric field is frequent, the voltage at the end point of flashover is high or normal sometimes, the current is small or even disappears when it is high, and it is possible to transit to a full open circuit if such circumstance is not promptly removed,. 297
Parts with bad contact: the spring piece at the clamp mouth is concave after the high-voltage isolation switch is repeatedly operated, so that connections are loose or the switch is not in place due to the corroded operational mechanism; the working grounding wires are loose or interrupted; the damping resistor has been burned out and can also be shocked by high-voltage but the distance between the disconnected parts is short, and the connection point between the damping resistor and the cathode wall-through casing may also be loose or burned out. 6.8.4.2 High-voltage circuit is completely opened and the relevant characteristics are: a) When closing the main contactor, there is a very high primary and secondary start leakage voltage; After boosting, the primary and secondary voltage rises rapidly, the secondary voltage can reach 85 to l00kV, the primary voltage can reach 380V, the secondary current is zero, and the primary current is less than 10 A.
b)
6.8.5 The secondary voltage and current are normal and the primary current is very large The main reason is that the primary current measurement and indication circuit fails or the rectifier transformer has an internal problem. Capacitor or silicon stack at the high-voltage DC side is broken through, as is the common fault inside the rectifier transformer. The most common approach to determine whether the rectifier transformer fails is to make the power supply devices put into operation when the transformer is open, and at this time the secondary current is zero and the primary current will increase rapidly with the increasing primary voltage.
298
Volume G
1. Overview of fuel system
Fuel Operation
The anthracite for power plant comes from Hon Gai coal mine of Cam Pha district in Quang Ninh province, and it is conveyed into power plant with belt conveyer. Double-line belts are used in coal transmission system, and there will be four dry coal sheds, two open coal yards and three stacker/reclaimers in its first and second stages. 1.1 Coal discharging system The annual coal consumption of two sets of belt conveyer for first stage is about 1,650,000 ton, and total coal consumption for first and second stages is about 3,300,000 ton per year. The system receives coal from coal mine with the owners double-line belt via No.6 coal transfer station. The coal conveying quantity from No.6 coal transfer station to coal yards or boiler's raw coal storehouse is 1000t/h normally, and No.6 coal transfer station has one coal sampling device, one roller screen, one reversible blending belt conveyer and one metal detector and one workshop are set respectively cross belt No.3A and No.3B. The workshop with air conditioner and office facilities is designed for four workers and coal unloading. There is suitable structure/ pulley block and coal unloader in No.6 coal transfer station could smoothly achieve its function of conveying coal from outer mine into power plant. 1.2 Coal storage system There are two stack yards in dry coal shed with coal storage capacity of 68,000 tons. The open coal yard has the coal storage capacity of 30000 tons. Total amount of coal storage capacity of all coal yards is 98000 ton, which could meet the coal dosage of 16 days for 2*300MW generators. 68000 tons of reserve in dry coal sheds could meet the coal dosage of 11 days for 2300MW generators. In dry coal shed, there are one stacker with the capacity of 1000t / h and one portal-type scraper reclaimer with the capacity of 1000t/h. There are one bucket wheel stacker with the capacity of 1000t/h, one crawler type coal bulldozer and one wheel loader in open coal yard. 1.3 Coal loading system Coal for the power plant (the owners belt conveying) is conveyed to No.6 coal transfer station and then conveyed from transfer station to coal yards or boiler's coal storehouse. The specification of the belt used from No.6 coal transfer station to coal yards or boiler coal storehouse is its width of 1200mm, its running speed of 2.5m/s, its capacity of 1000t/h. An unloader is installed for loading coal to boiler raw coal storehouse on belt 1A/B section. One coal sampling device and moisture detection device are installed on belt 2a/2b section. There are belt weighing systems installed on belt 2a, 2b, 3a, 3b, 8 and 9 sections. There are metal detectors and metal remover installed respectively on belt 3A, 3B, 7 and 10 sections. There is one roller screen, one reversible coal feeder with belt weighing function, on-site coal sampling system installed in No.6 coal transfer station.
2 Interlock and protection of coal conveying system

299
2.1 Interlock and protection of coal belt conveyor: 2.1.1 Audio signal interlock means that audio signals are not sent or there is no enough time to start the mechanical equipment. 2.1.2 Interlock for preventing wrong order of start of mechanical equipment means that the equipments will be started in adverse direction of coal flow, and the equipments will be stopped in in the same direction of coal flow. 2.1.3 Accident interlock means that all equipments will be interlocked in adverse direction of coal flow if one mechanical equipment is failed and stopped because of fault or accident(except that own fault of wood separator, it cannot be interlocked ). 2.1.4 One emergency button is set in program control room. Press this emergency button and all equipments in the system will stop immediately. 2.1.5 Two-level deviation switch(one for alarm,the other for poweroff), coal flow detector, belt speed meter, two-way rope pull switch, protection device against longitudinal tearing of conveyer belt, coal jamming detection device, and motor overload protection device etc. a) Deviation switch: deviation switch of conveyer belt is installed 50-100 mm away from the belt edge. First-level deviation value is set to warn as belt conveyer knocks the deviation switch and moves about 20mm; second-level deviation switch is set to stop as belt conveyer knocks the deviation switch and moves about 100mm. b) Coal flow detector:Detect the change of coal flow. c) Belt speed detector: It will begin slip alarm when the actrual moving speed reaches 0.8-0.3 times of rated speed for continuous 15 seconds. It will stop when actual running speed reaches 0.3 times of rated speed for continuous 4 seconds. d) Protection device against longitudinal tearing: When coal volume of over 400g falls on Protection device against longitudinal tearing and output resistance value of less than 2k, it will start protective device. e) Coal jamming detection device:it will stop while coal jamming is detected for 3 seconds time delay. f) Motor overload protection:the setting value is normally 1.1-1.3 times of rated current.
2.2 Stocker/reclaimer interlocks 2.2.1 Operation interlock principle: According to the requirement of process flow, electric interlock loop is set between upper level equipment and lower level equipment, and the lower level can start only after the upper level starting. Contrarily, when the trip of upper level equipment occurs, the lower level equipment will also be interlocked. In order to facilitate the inspection of fault point on the equipment, all interlocking 300
mechanisms have characterized with symbol of functional mode, and the changeover switch on cab control platform can temporarily release the interlock circuit, and all sequence and interlocking is carried out by PC except emergency protection function. 2.2.2 Description for overall interlock mechanism: Big trolley can not move when the rail clamp device is unfastened; big trolley still can not move when wind storm is released; it will automatically stop when cantilever rotates or changes, and knocks the limit of preserve. 2.2.3 Interlock between stacker/reclaimer and program-control of coal conveying. The stacker supply system of conveyer belt interlocks the control points While stacking; the reclaimer supply system of conveyer belt interlocks the control points while reclaiming; the stacker/reclaimer must be operated according to the requirement of control room, the stacker/reclaimer must be operated in accordance with its operating condition of system while receiving order of stacking and/or reclaiming. There is one interlock changeover switch at left operating platform which controls the interlock of stacker/reclaimer and coal conveying control room. 2.3 Stacker/reclaimer protective device: This conveyer has null protection, overload protection, short-circuit protection, limit protection, cantilever anti-crash protection, conveyer belt deviation protection, strong wind speed and fire alarm protection etc. 2.3.1 Travel mechanism protecting device: a) b) Big trolley and rail clamp device, anchorage device interlock A limit switch is set on both end of travel rail.
2.3.2 Rotating mechanism protecting device: a) b) c) Rotating angle limit retainer Rotating torque retainer Rotating angle position display.
2.3.3 Pitching mechanism protecting device: a) b) c) Pitching angle limit retainer Angle position display When the arm spans over ground conveyer belt, normal interlock will be active between rotating mechanism and pitching mechanism. It will be released in normal operation.
3 Inspection of coal conveying equipment, operation caution, failure estimate and resolution
3.1 Belt conveyer 301
3.1.1 Inspection of belt conveyer before operation 3.1.1.1 Ensure that the maintenance work is completed and the maintenance sheet is returned back when receiving notice sheet of equipment operation. 3.1.1.2 Ensure that sundries in site are cleaned and all maintenance staff leaves from the site. 3.1.1.3 There are no warning signs on site control box, the selecting switches are complete and intact in right position, and each indicator are in good condition. 3.1.1.4 The anchor bolts and coupling bolts of motor, reduction gearbox and its drive components are not loose or lost. 3.1.1.5 The grounding wire of motor shall be complete and intact, its power circuit insulation is good. 3.1.1.6 Reduction gearbox, liquid coupling and cut-off device shall be complete and intact with no oil leakage. Oil level of reduction gearbox shall be normal. 3.1.1.7 Every rotating part is connected completely, and every security protection hood is firm, various idler has no damage or broken with no deformation of its bracket. 3.1.1.8 There shall be no sundries on belt surface with no torn or damaged edge of belt and no adhesive failure. 3.1.1.9 Each component of tension device shall be in good condition with no jam of trolley and chute, and there is enough space for up-and- down movement. 3.1.1.10 The coal chute shall be clear with no serious jam and oil leakage. 3.1.1.11 The block rubber of coal chute shall be sealed completely with no serious abrasion. 3.1.1.12 T-joint baffle plate and its power device shall be in good condition, and move flexible with right changing position. 3.1.1.13 Every sweeper shall be complete and intact with good contact to belt surface. 3.1.1.14 The deviation switch of belt conveyer, tension switch, coal jam switch, speed switch, anti-avulsion safety protection system etc shall be complete and intact. 3.1.1.15 Inspect if there shall be no accumulated coal and coal jam and no big sundries blocking on the frame of belt weighing system and keep certain space around belt conveyor. 3.1.1.16 Inspect if there is no jam on the frame of electronic belt weighing system and use electronic belt weighing system the electronic belt scale. 3.1.1.17 Ensure that the coal level gauge is complete with right indication. 3.1.2 Operation supervision of belt conveyer 3.1.2.1 The operator should monitor closely the operation of all power equipment and 302
transmission equipment during operation of the belt conveyor. The motor should operate with no abnormal noises and smell. The current value shall reach its normal value in 5 seconds after the system starts. 3.1.2.2 The temperature of motor bearing and reducer shell shall not exceed 75 and its vibration shall not exceed 0.1 mm during operation. 3.1.2.3 Monitor the coal caking during operation, and stop the belt conveyer immediately and remove promptly if serious coal caking and jam occur. 3.1.2.4 Check if there are any sharp materials and big extraneous matter in coal flow, avoid the accident of torn rubber belt and jam of coal chute, and stop immediately and handle promptly if sharp materials and big extraneous matter are found out. 3.1.2.5 Metal remover, electronic belt weighing system, wood separator and sampling system shall be operated in normal operation conditions. 3.1.2.6 The cleanser, brake, buffer air lock and camera base shall work in good conditions. 3.1.2.7 The deviation of belt conveyor shall not exceed 100 mm (the centerline as a standard of reference), the operator can only adjust with deviation idler, stop the belt conveyer immediately if such adjustments is null and void, seriously affect its operations. 3.1.2.8 Inspect if there is fire risk in this system. 3.1.2.9 Inspect if the wedge of pressed plate on the blocking rubber of coal chute is fixed firmly. 3.1.3 Notes on operation and maintenance of belt conveyor. 3.1.3.1 Do not step over the moving coal conveying belt and alterative coal conveying belt. 3.1.3.2 Do not clean and maintain during operation of conveying belt 3.1.3.3 Load evenly on the belt conveyor, and keep no deviant of loading position and no oil leakage from coal belt. 3.1.3.4 Keep the instantaneous flow readings of electronic belt weighing system on belt conveyor not exceed its rated value. 3.1.3.5 Inspect periodically the frame of electronic belt weighing system and keep it no coal plot and no coal jam; inspect periodically if every components of derrick are coated with engine oil, and the groove roller on the top of frame of electronic belt weighing system is in good condition and flexible rotation. 3.1.3.6 Keep the current reading not exceed its rated value during operation of belt conveyor. 3.1.3.7 Inspect the coal storage level of coal warehouse and avoid coal shortage from 303
coal jam. 3.1.3.8 Check if there are any abnormal vibration and oil leakage of motor, gear box, hydraulic coupling and coupling. 3.1.3.9 Keep the surface temperature of motor, gear box and bearings normal 3.1.3.10 Analyze, report timely and handle correctly the belt deviation and slip during operation. 3.1.3.11 Investigate immediately, report and handle timely the fault if the trip occurs during the operation of the belt conveyor; do not restart until complete fault removal and the order of restart from major man on duty. 3.1.3.12 Emergency stop: Stop the belt conveyor at once if the following accidents occur: a) b) c) d) e) f) g) The damage and injury accidents of conveyer or power transmission line occur; Severe vibration of rotating equipment with abnormal noises occur; The Rubber belt is fractured, pierced or seriously damaged; Serious deviation and slip of rubber belt can not be handled; The bearing temperature increases rapidly, and exceeds 60C; Serious jam of coal chute can not be handled; Dangerous safety threats of larger iron pieces, the detonator etc on belt conveyor is found during operation. Instantaneous increase and no timely return of ammeter reading occur. The balance weight device touches the ground; The slow-down of motor and current increase (or zero) with roaring noise occur; A fire accident of Coal transmission System occurs; Smoke or fire from site Operation control box with obvious short-circuit or burnt evidence appear.
h) i) j) k) l)
3.1.4 Estimate and handle of regular faults of coal conveying belt. a) Causes: 1) 2) 3) 4) 5) b) Caking coal on roller or idler. Deviate of belt joint. Deviate of coal unloading point. Centre deviate of belt conveyor or idler deformation. Improper belt adjustment.
Resolutions: 304
1) 2) 3) 4) 5)
Remove the caking coal. Ask the maintenance staff to bond the belt again. Ask the maintenance staff to clean coal chute. Ask the maintenance staff to inspect and handle. Ask the maintenance staff to inspect and handle.
3.1.4.2 Belt slip a) Causes: 1) 2) 3) 4) b) Water or oil on the back of belt or roller. Overload of belt conveyer. No adequate belt tension or non function of belt tensioning device. Serious abrasion of wrapped rubber on main drive roller.
Resolution and prevention: 1) 2) Clean the oil and dust, drip the rosin or fine coal powder. Stop immediately the belt slip conveyer and backwards belt device, clean the jammed coal and then restart. Ask the maintenance staff to handle. Ask the maintenance staff to handle.
3) 4)
3.1.4.3 Belt breakage or tearing a) Causes: 1) Collision between belt and steel plate or angle steel on coal chute. 2) Belt cut by iron pieces or objects with sharp edges lost from coal chute during operation. Too much belt deviate. Belt torn because roller and idler fall off and cause the belt hanged on the frame. Lost sharp materials between roller and belt. Belt cut by angle steel of cleanser and coal wiper. Torn or broken glued joint Poor quality of glue on the belt. Overload due to large belt tension.
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10) Poor quality of the belt. 305
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Resolution: Stop the conveyer immediately, investigate the cause and contact with the maintenance staff. Do not restart the belt conveyer before the cause is found out.
3.1.4.4 Coal jam a) Causes: 11) Too wet coal. 12) Large pieces of coal or abnormal material. 13) Failure by too much coal and belt slip. 14) Non function of interlock or non-stop of the conveyer. b) Resolutions: 1) Clean the coal chute when the conveyer stops. If the coal is too, its conveying load shall be less. Prevent coal jam by interval feeding vibrator. Clean the coal chute when the conveyer stops. Ask the maintenance staff to handle. Stop the conveyer immediately. Inspect carefully and ensure every belt protection is available.
2) 3) 4)
3.2 Stacker-reclaimer 3.2.1 Inspection of stacker-reclaimer before operation 3.2.1.1 Inspection of traveling system of stacker/reclaimer 1) There shall be no cracks, no obvious sinkage or no distortion on the rail surface. The bolts on orbit shall be complete without loose or shedding faults. There shall be no obstacle around the rail. Rail grounding wire shall be complete and intact and reliable. The blockers on both sides of rail shall be complete and intact and firm. There shall be trim of cable drum without deformation, its chute shall have no deformation and its pulleys move flexible. The cable coiling and uncoiling drive device shall be complete and intact without loose anchor bolts and coupling bolts. The grounding wire of drive motor is intact. Every limit switch, on-site operation switch and over torque limit switch are intact for normal operation. The traveling anchor device is intact, and it can be released. The rail clamping device and cleanser shall be complete and intact with good 306
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tangency. 8) The wiring of motor shall be complete and intact without loose or lost anchor bolts and coupling bolts. Every gearbox shall be complete and intact without loose or lost bolts.
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10) The oil level of every gearbox shall be normal without oil leakage. 11) Every braking device shall be complete and intact with no jam of the moving components. There shall be no serious brake abrasion with good lubrication of every bearing. 12) The oil level of every braking device shall be normal without oil leakage. 13) Every safety protection shroud shall be complete and intact and firm. 14) Every filler tube shall be complete and intact, and its inlet shall be complete and not damaged with good lubrication of every bearing. 15) There shall be no serious abrasion and jam of every driving gear with good occlusion. 16) There shall be no serious abrasion of every wheel with good touch. 17) There shall be no damage of electric cable and communication cable, there shall no winding and distortion of them with good order on the ground. 3.2.1.2 Inspection of cantilever belt conveyer 1) The wiring of motor shall be complete and intact without loose anchor bolts and coupling bolts. Hydraulic coupler shall be complete and intact with good wiring of connecting components and no oil leakage. Every gearbox is intact with no loose anchor bolts and coupling bolts as well as no oil leakage. The lubricant tube of every bearing shall be complete and intact with good Lubrication of every bearing, and there shall no damage or lost nozzle. Every safety protection shroud shall be complete and intact and firm. The belt shall have no degumming, torn hole, flash, rupture, tilted joint. There shall be no debris around belt conveyer and no coal jamming in coal hopper. All idlers of belt conveyor shall be complete and intact, there shall be no jam with free space for up-down movement of tensioning device, and there shall no coal jam in roller and idler. Every blocking rubber and wiper in coal chute of belt conveyer shall be complete 307
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and intact with no serious abrasion and no shedding. 10) There shall be no coal jam on each part of cantilever shelving and no other materials around the corridor and ladder. 11) The protection switches such as cantilever anti-collision switch, limit switch, cord switch of belt conveyer, Off-center switch shall be complete and intact. 3.2.1.3 Inspection of swing mechanism 1) There shall be no coal jam or other obstacle affecting swing on the swing platform, swing rail. There shall be no serious abrasion, no partial deformation, no crack of rail without loose or lost bolts. There shall be no serious abrasion of swing wheel with good contact with the rail surface. The horizontal side centering wheel shall keep good contact and normal clearance with the rail side surface. The wiring of swing motor shall be complete and intact with no loose or lost anchor bolts and coupling bolts. The gearbox shall be complete and intact with no loose or lost bolts. The oil level of gearbox shall be normal with no oil leakage. The braking device shall be complete and intact with no jam of the moving components. There shall be no serious brake abrasion with good lubrication of every bearing. The oil level of braking device shall be normal with no oil leakage.
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10) The safety protection shroud shall be complete and intact and firm. 11) The lubrication of bearing shall be good. 12) Big swing gear shall be occluded tightly with big gear rim with good lubrication and no serious jam. 13) The limit switch and on-site operation switch shall be complete and intact. 3.2.1.4 Inspection of luffing mechanism 1) Every components of hydraulic oil tank shall be connected completely and the oil level of oil tank shall be normal with no oil leakage. The oil level gauge and oil pressure gauge of hydraulic oil tank shall be complete and intact, its hands shall be normal for operation with correct reading. Hydraulic oil pump and its driving device shall be complete and intact without loose anchor bolts and coupling bolts. The wiring of motor shall be normal. 308
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The duct and fittings of hydraulic system shall be completely connected with no serious aging, crack and oil leakage. Every component of hydraulic oil tank shall be completely connected with no oil leakage. Every valve of hydraulic system shall be complete and intact with no loose or lost anchor bolts and coupling bolts which are available in current usage. Every limit switch and on-site operation switch shall be complete and intact.
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3.2.2 Operation of the stacker/reclaimer 3.2.2.1 Power supply and preparation before operation: As for power supply of 6kv high voltage, do not open the door of transformer room when operating high voltage switch. For power supply of 400v low voltage, switch on the knife switch, switch on the air switch on each subcircuit, switch on the breaker of main power supply, and then switch-in indicator lights. Measure three-phase voltage and inspect if it is balanced, then switch on the switch of control power (Push the manual control lever of operation switch on null position), and then the control power gets the current and the indicator of control power lights, and the power supply is accomplished. Release the anchorage device before operation. Four operation modes of adjusting, manual operation, automation and inching are available on the program-controlled switch. Its adjusting operation mode is used for debugging and maintenance. It combines the breaker trip, limit switch, belt deviation switch, cantilever anti-collision switch with centralized control interlock indicator and the interlock of belt and bucket wheel. Manual and automation operation modes are used for operation. The manual operation mode is used for stacking coal and the automation operation mode is used for reclaiming coal. The inching operation mode is used for maintenance and repair. 3.2.2.2 Manual operation:Push the program-controlled switch to the mode of manual operation mode. a) Rotating operation:Operate the rotating switch when the stacker-reclaimer works in manual operation mode, the rotating mechanism will rotate and its speed is in its rated value. When the stacker-reclaimer works in auto-operation mode, the rotating speed is V=V0/cos. Big trolley operation:Operate the switch of rail clamp device and release the rail clamp device, put the travel switch to forward position or backward position, and then big trolley will move. Put the switch to null position and big trolley will stop. When the stacker-reclaimer is in adjusting mode, make the cantilever parallel with rail, big trolley will move rapidly. When the stacker-reclaimer is in operation, big trolley should move slowly and evenly. Travel transducer control big trolleys speed. The sound and light warning device is available when big trolley is moving. Luffing operation: Operate the luffing switch, the hydraulic system will work and the cantilever mechanism will move up or down. 309
b)
c)
d)
Stacking operation:inspect and ensure that the operating switch on interlock platform is on null position; inspect and ensure that the main voltage-380V of three phase power on right interlock platform (or No.1 switch cabinetNo.4 switch cabinet)is normal. 1) 2) 3) Release the left and right anchor. Switch on the breaker of control power supply (13QF; QF14). Switch on main breaker (QF), press ON button 2SB (or 3SB), main power supply will be switched electrically on and the switch-on indicator (2HL, 3HL, 7HL) lights. Switch on the bypass breakers (1QF to 7QF2) step by step. Switch on the key switch (13SA) of control power supply, the indicator(1HL)of control power supply lights. Push the control selecting switch (12SA) to manual position. Push the switch of rail clamp (9SA) to idle position, right and left rail clamp will be released in delayed time, and the indicator of rail clamping device for idle position lights on touch screen, and the warning sound comes out. Push the hopper reversing switch (10SA) to stacking position, the hopper reversing plate will move, it stops till stacking limit of reversing plate. The indicator of hopper reversing plate for stacking position lights on touch screen, and the warning sound comes out. Push the hopper reversing switch (10SA) to null position. Push the hopper reversing switch (11SA) to stacking position, the hopper reversing plate will move, it stops till stacking limit of reversing plate. The indicator of hopper reversing plate for stacking position lights on touch screen, and the warning sound comes out. Push the hopper reversing switch (10SA) to null position.
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10) Push the switch of big trolley (4SA) to the Slow ahead (Slow astern) position, the big trolley moves to the designated place. Push the switch of big trolley (4SA) to null position, big trolley will stop. 11) Push the rotating switch (8SA) to the Left turn (or Right turn) position, adjust the cantilever belt conveyer to the designated place for stacking. When the rotating operation reaches its place, push the rotating switch (8SA) to null position, the cantilever rotating will stop. 12) Push the luffing switch (7SA) to the Up (or Down) position, make the inlet height of cantilever belt conveyer 3 to 4 meters away from the stack in the yard, then push the luffing switch (7SA) to null position, the cantilever luffing will stop. So the preparation is completed, wait for the signal of stacking permission 310
from the centralized control center of the yard. Pushing the switch of cantilever belt conveyer (5SA) to the stacking position after receiving the signal of stacking permission, the cantilever belt conveyer starts and the bucket wheel send the signal of stacking to the centralized control center of the yard. When the centralized control center of the yard receives the signal, start the belt conveyer, and operate it for stacking. When the stacking level reaches the designated height, push the rotating switch to the Left turn (or Right turn) position. According to the requirement of 1.3, the rotating stacking of cantilever belt conveyer reaches from H point to G point, it will stop rotating; push the switch of big trolley to the slow astern position, make the bucket wheel big trolley slow astern for T time, push the switch of big trolley to null position, big trolley stops. Push the rotating switch (8SA) to the Left turn (or Right turn) position, rotate the cantilever belt conveyer to rotating stacking in the opposite direction, stop rotating; push the switch of big trolley to the slow astern position, make the bucket wheel big trolley slow astern for T time, push the switch of big trolley (4SA) to null position, big trolley stops. Repeat above operation till the completion of stacking. After completion of stacking, the belt conveyer stops its operation. Push the switch of cantilever belt conveyer (5SA) to null position, and then the cantilever belt conveyer stops; drive big trolley to its anchored place; Push the switch of rail clamp (9SA) to the Clamping position, clamp with right and left rail clamp, The indicator of rail clamping position lights on touch screen, and the warning sound comes out; Release the left and right anchor of big trolley; Push the control selecting switch (12SA) to null position; Push the control selecting switch (13SA) to null position, the indicator of control power supply (1HL) goes out; Switch off the main breaker, press the Switch off button (4SB) or (5SB),the main power supply is off, and the indicators of switch-off (4HL, 5HL, 6HL) lights. And then the stacking operation is completion. e) Operation of reclaiming: Inspect and ensure that the operation switch of interlock platform is in null position; inspect and ensure that the main three-phase 380V voltage of right interlock platform (No.1 switch and No.4 switch cabinet) is normal. 1) 2) Release the right and left anchors of big trolley. Switch on the main breaker (QF), press the Switch on button2SB (or 3SB), the main power supply is switched on, the indicators of the switch-on (2HL,3 HL, 7 HL) lights. Switch on the key switch of control power supply (13SA), then the indicator of control power supply (1HL) lights. Push the control selecting switch (12SA) to manual position. Push the switch of rail clamp (9SA) to idle position, then the right and left rail clamp are released in delayed time, the . The indicator of rail clamp for 311
3)
4) 5)
reclaiming position lights on touch screen, and the warning sound comes out. 6) Push the hopper reversing switch (10SA) to the reclaiming position, the hopper reversing plate will move, it stops till reclaiming limit of reversing plate, The indicator of hopper reversing plate for reclaiming position lights on touch screen, and the warning sound comes out. Push the hopper reversing switch (10SA) to null position. Push the hopper reversing switch (11SA) to the reclaiming position, the hopper reversing plate will move, it stops till reclaiming limit of reversing plate, The indicator of hopper reversing plate for reclaiming position lights on touch screen, and the warning sound comes out. Push the hopper reversing switch (11SA) to null position. Push the switch of big trolley (4SA) to the Slow ahead (Slow astern) position, the big trolley moves to the designated place. Push the switch of big trolley (4SA) to null position, big trolley will stop. Push the rotating switch (8SA) to the Left turn(or Right turn) position, adjust the cantilever belt conveyer to the designated place for reclaiming. When the rotating operation reaches its place, push the rotating switch (8SA) to null position, the cantilever rotating will stop.
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10) Push the luffing switch (7SA) to the Up (or Down) position, make the height of the reclaiming bucket wheel cantilever belt conveyer 0.2 to 0.4 meter away from the stack in the yard, then push the luffing switch (7SA) to null position, the cantilever luffing will stop.(Note: do not insert the bucket wheel into the stack to move or rotate before operation of the bucket wheel.) So the preparation is completed, wait for the signal of reclaiming permission from the centralized control center of the yard. Pushing the switch of cantilever belt conveyer (5SA) to the Reclaiming position after receiving the signal of stacking permission, the cantilever belt conveyer starts and the bucket wheel send the signal of reclaiming to the centralized control center of the yard. When the centralized control center of the yard receives the signal, start the belt conveyer, and operate it for reclaiming. When the stacking level reaches the designated height, push the switch (6SA) of bucket wheel to the Start) position, the bucket wheel start. According to the requirement of 1.3, the rotating reclaiming of cantilever bucket wheel reaches from A point to B point, it will stop rotating; push the switch of big trolley (4SA) to the slow ahead position, make the bucket wheel big trolley slow ahead for T time (reclaiming depth of bucket wheel: 1/5 to 2/5 of its diameter), push the switch of big trolley (4SA) to null position, big trolley stops. Push the rotating switch (8SA) to the Left turn (or Right turn) position, rotate the bucket wheel for reclaiming from C point to D point, stop rotating; push the switch of big trolley (4SA) to the slow ahead position, 312
make the bucket wheel big trolley slow head for T time, push the switch of big trolley (4SA) to null position, big trolley stops. Repeat above operation till the completion of reclaiming. After completion of reclaiming, Stop the cantilever rotating; Make the cantilever luffing lift, stop the lift of the cantilever luffing when the bucket wheel is away from the stack; Push the switch of bucket wheel (6SA) to the Stop position, stop the operation of bucket wheel; Push the switch of cantilever belt conveyer (5SA) to null position, and the cantilever belt conveyer stops; inform the centralized control center of the yard, and stop the belt conveyer; Drive big trolley to its anchored place; Push the switch of rail clamp(9SA) to the Clamping position, clamp with right and left rail clamp, The indicator of rail clamping position lights on touch screen, and the warning sound comes out; Release the left and right anchor of big trolley; Push the control selecting switch (12SA) to null position; Push the control selecting switch (13SA) to null position, the indicator of control power supply(1HL) goes out; Switch off the main breaker(QF), press the Switch off button (4SB) or (5SB),the main power supply is off, and the indicators of switch-off(4HL, 5HL, 8HL) lights. And then the reclaiming operation is completion. 3.2.2.3 Operation of inching: Push the program-controlled selecting switch to the Inching position. Push the switch on operation button box to the inching position, press the Forwards and Backwards button, the belt conveyer will move with inching. Push the switch button on bucket wheel button box to the inching position, press the button, the bucket wheel will move with inching. 3.2.2.4 Automation operation: a) Stacking:Turn the program control selecting switch to manual position. While opening the switches of the distributing plate, inverting plate and coal chute of bucket wheel, the electric liquid pushing pole moves and then distributing plate, inverting plate and coal chute of bucket wheel move to the coal stack. While opening the switches of the travel mechanism, rotating mechanism and luffing mechanism, the stacker/reclaimer will move to the coal stack position. Push the program-controlled selecting switch to automation operation position, press the program-controlled operation button, and then the cantilever belt move. The conveyer starts to stack coal to the stack yard. When the material probe sends signal of full stack, the cantilever luffing will lift for a distance of height automatically. When the cantilever luffing will lift automatically for several times and the material probe sends signal of full stack again, it will move backwards for a distance. Press the program-controlled stop button, and then the automation stacking will stop. When the moving reaches the backward limit and the material probe sends signal of full stack again, the automation stacking will stop immediately. 313
b)
Reclaiming: Turn the program control selecting switch to manual position. When opening the switches of the distributing plate and the coal chute of bucket wheel, the electric liquid pushing pole moves and then distributing plate and coal chute of bucket wheel move to the stack. While operating the switches of the travel mechanism, rotating mechanism and luffing mechanism, the stacker/reclaimer will move to the coal stack position. Set the travel distance data on the touch-screen. Set the method of the angle of horizontal reclaiming: Pushing the rotating switch to the left turn (or right turn) position, the cantilever rotate left (or right) to reach the required angle; Pressing the right(or left) angle setting button, the data of first required angle sends to PLC. The rotating mechanism continue to rotate right (or left), and reach to the required angle; Pressing the right (or left) angle setting button, the data of second required angle sends to PLC. The set angle shall be more than 10. Push the rotating switch to the stop position, the cantilever will stop rotating. Rotate the cantilever between two angles, push the travel switch and luffing switch, move the bucket wheel to the reclaiming position. Push the program-controlled selecting switch to automation operation position, press the program-controlled operation button, then the cantilever belt moves, the bucket wheel rotate after cantilever belt moves for 5 seconds; it stops when the moving reaches to the setting distance. The cantilever starts rotating to left (or right) and the bucket wheel reclaims. When the cantilever rotates to the second angle (first angle), it stops rotating. The cantilever stops when the moving reaches to the setting distance, then the cantilever start to rotate to right (left) in opposite direction. During automation reclaiming, the data of travel distance can be modified on the touch screen. Press the left (or right) angle setting button during the cantilever rotating to left(or right), the cantilever continue to rotate. Release the left (or right) angle setting button, the cantilever stops rotating. Then the data of new required angle sends to PLC. Modify the rotating angle and modify the reclaiming scale. Press the program-controlled stop button, then the automation reclaiming stops.
3.2.2.5 Stop of the stacker/reclaimer When every shift is over, the operator shall stop in sequence: put all instruction switches to null position at first, turn off the power, finally close the control key switch and leave. 3.2.3 Notes on operation and maintenance of the stacker/reclaimer 3.2.3.1 Do not carry out any maintenance and removal during operation. 3.2.3.2 Monitor carefully the current changes of all operating equipments during operation, and keep the current not exceed its rated value. 3.2.3.3 Monitor carefully the operating equipments during operation; keep the oil level of gearbox normal. The temperature of equipments shall be no more than 75,the vibration shall be no more than 0.01mm,and the bearing temperature shall be no more than 85.Report to major man on duty timely and take active prevention 314
measurement when these value approach and reach their limit values. 3.2.3.4 Keep cantilever belt conveyer no serious deviation, slip and torn. Keep each idler and roller flexible moving with no jam and abnormal noises. 3.2.3.5 Keep the travel mechanism of big trolley stable without any jammed rail and slowdown. 3.2.3.6 Keep the cable drum and tray complete and intact with normal synchronous retractable cable and no loose cable. 3.2.3.7 Keep the oil level, oil temperature and hydraulic system of hydraulic oil tank vary in its normal range. 3.2.3.8 Stop the stacker/reclaimer immediately and remove them if any big pieces of metal material, steel rope and other extraneous matter are found during reclaiming. 3.2.3.9 The luffing, travel, and rotating limit switch can be used only for limit switch stop, emergency switch can be used only for emergency stop. The switch on operation platform can be used for normal stop. 3.2.3.10 Keep the operation of bucket-wheel and rotating mechanism stable without any abnormal noises during reclaiming, stop the stacker/reclaimer immediately and find out the fault if any abnormities occur. 3.2.3.11 when the bucket wheel is buried by landslides materials, stop the bucket wheel and rotating mechanism of the stacker/reclaimer immediately; do not operate luffing mechanism and withdraw the stacker/reclaimer from material stack and then start the bucket wheel for normal operation of reclaiming. 3.2.3.12 Do not overload, and keep the reclaiming height of 400mm to 600mm (equivalent to half height of the bucket wheel) and the reclaiming depth of less than 3m (no more than the radius of bucket wheel). 3.2.3.13 Stop the operation immediately, drive the stacker/reclaimer to the anchoring position, clamp with rail clamp and lay the bucket wheel on the ground when the wind speed reach to 14m/s. 3.2.3.14 Turn over the radial gate of main hopper twice to prevent material caking. 3.2.4 Common fault of stacker/reclaimer, estimate and handle of these faults 3.2.4.1 Failure of cantilever rotating mechanism a) Causes 1) 2) 3) 4) Fault of electric system or motor. No release of brake device. Jammed and of rotating wheel, fault of conveying components. Too much dust in bearing, poor lubrication, severe abrasion or damage of the 315
rollers and the rail. b) Resolution: Ask the maintenance staff to resolve. 3.2.4.2 Failure of big trolley a) Causes: 1) The wheel jammed by large coal pieces or limit switch pinned by large coal pieces. Fault of electric system or motor. No release of rail clamp. No release of brake device.
2) 3) 4) b)
Resolution: 1) Inspect if there are any extraneous matters on the wheel and remove them. Inspect rail or limit switch before restart. Ask the maintenance staff to resolve.
2)
3.2.4.3 Pump emptying a) Causes: 1) 2) 3) 4) 5) 6) 7) b) Insufficient oil of oil pump. Jammed vent of oil tank. Overhigh oil viscosity. Jammed oil filter. Low oil level of oil tank. Jam or no release of oil pump. Overhigh speed of oil pump.
Resolution: Ask the maintenance staff to resolve.
3.2.4.4 Hypotony or no oil pressure of oil pump a) Causes 1) 2) 3) Wrong turn. Serious abrasion or damage of oil pump. Too low oil viscosity. 316
4) 5) 6) b)
Failure of overflow valve. Deficient oil of oil pump. Wrong rotating speed of oil pump.
Resolution: Ask the maintenance staff to handle.
3.2.4.5 Too small flow or no flow of hydraulic oil a) Causes: 1) 2) 3) 4) 5) 6) b) Oil pump emptying. Air in oil system. Big leakage of oil pump. Jammed oil screen of pump inlet. Big overflow of pump outlet or low pressure. Wrong rotating of pump or too low rotating speed of pump.
3.2.4.6 No movement of cantilever lifting a) Causes: 1) 2) 3) 4) b) No adequate pressure in the luffing pump. Failure of magnetic valve. Failure of overflow valve. Misoperation of limit switch.
3.3 Roller picker (wood separator) 3.3.1 Inspection of roller picker (wood separator) before operation: 3.3.1.1 The changeover switch position of roller picker (wood separator) shall be correct and the Ammeter shall be intact with normal indication. 3.3.1.2 Inspect on-site work permission sheets are ready. 3.3.1.3 The wiring and ground wiring of motor shall be complete and intact with no damage of the coupling. 317
3.3.1.4 The oil level of every retarder shall be normal with no leakage and infiltration of oil, and the oil quality shall be good. 3.3.1.5 The fixed bolts of every operating mechanism shall not be loose and lost. 3.3.1.6 There shall be no loose welding in picking box, and the liner shall not be loose with no deformation. The cloverleaf type sieve shall be complete and intact with no jam and block. 3.3.1.7 Inspect the gate shall be tight with no leakage of coal powder, no caking coal and no jammed coal. 3.3.2 Start and stop operation of roller picker (wood separator) 3.3.2.1 Site start and stop operation of roller picker (wood separator): 1) When the start condition is ready after the equipment inspection, inform the major men on duty or main program control operator to start the wood separator on site. Put the selector switch of program control switch room to release position and the on-site selector switch to on-site position. Push the start button. Ensure that the operation shall be normal with no block, jam, noise and vibration after 2-4 seconds of start. Ensure that there is no coal in the system after the completion of work, and stop. Push on-site and program-controlled selector switches to program-controlled position.
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3.3.2.2 Program-controlled operation of roller picker 1) 2) Inspect roller picker on site and ensure the roller picker is ready for start. Start operation of roller picker: Click the icon of roller picker for operation mode on CRT screen, select the manual operation mode till the operation interface pops out, and then click the start button. Stop operation of roller picker: Click the icon of roller picker (wood separator) for operation modes on CRT screen, select the manual operation mode till the operation interface pops out, and then click the stop button.
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3.3.3 Common faults of roller picker (wood separator), estimate and handle these faults 3.3.3.1 Coal jam a) Causes: 1) The screen shaft jammed by big pieces of sundries, slow rotating speed or no rotating. Sundries on sieve surface affecting coal flow. 318
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Overload or heavy moisture of raw coal.
Resolutions: 1) 2) 3) Clean and remove the sundries after stop. Clean the sundries on sieve surface. Control the conveying coal volume.
3.3.3.2 Low efficiency a) Causes: 1) 2) b) Damage or broken of Screen Shaft, Loose or lost of sieve.
3.3.3.3 Vibration, abnormal sound and high temperature. a) Causes: 1) 2) 3) 4) b) Unbalance of coupling or loose of anchor bolts. Damage of bearings or loose of bolts. Internal fault of reducer. Motor fault.
3.3.3.4 Failure of screen shaft a) Causes: 1) 2) 3) 4) 5) b) Jammed sundries. Reducer fault. Damage of bearings. Broken nylon pin of coupling. Fault of electric parts.
Resolution: 1) 2) Stop the roller picker immediately, and remove the sundries. Ask the maintenance staff to handle.
3.4 Metal separator 319
3.4.1 Inspection of metal separator before operation 3.4.1.1 The suspension mechanism shall be complete and intact with no loose connecting parts. 3.4.1.2 The wiring of motor and metal detector shall be good with no damaged electromagnet core and no broken cable. 3.4.1.3 The tension of metal removing belt shall be proper. The metal removing belt shall be no damage with complete magnet force. 3.4.1.4 The indicators and buttons in electrical cabinet shall be complete and intact and the origin indication of ammeter shall be null. 3.4.1.5 There shall be no sundries between metal removing belt and electromagnet core. Remove if any. 3.4.1.6 Inspect if the lubrication of all parts is adequate and good. 3.4.2 Operation of metal separator 3.4.2.1 On-site operation of metal separator 1) Start and stop of plate metal separator: Push on-site centralized control switch on the Control panel to the On-site position, push the belt selecting switch from A point to B point, press the moving forward button of No.1 (or NO.2) metal separator, No.1 metal separator moves to the position above A (B)point, No.1 metal separator stops moving, and the metal separator begins to excite electromagnet, the indicator of iron absorption lights. Press the return button to stop the iron absorption, and then the metal separator returns to the discard, the metal separator stops automatically and stops electromagnetic excitation and discard, the indicator of iron absorption is off. Start and stop of plate metal separator: Push on-site centralized control switch on the Control panel to the On-site position, press belt start button on the panel of control cabinet, then the discard belt begins to run, the indicator of belt operation lights at the same time; press the start button of electromagnetic excitation on the panel of control cabinet, then main AC contactor KM1 in control cabinet begins to switch on, and the metal separator absorbs iron, the indicator of iron absorption lights. Watch the voltage and current of electromagnetic excitation from the AC voltmeter and ammeter on the panel of control cabinet. Stop the electromagnetic excitation, press the stop button of electromagnetic excitation on the panel of control cabinet; the metal separator stops iron excitation, and the indicator of iron absorption on the panel of control cabinet is off, the hands of AC voltmeter and ammeter return to null, or press the belt stop button, the discard belt and electromagnetic excitation stop at the same time, the indicators of iron absorption and belt operation is off at the same time. 3.4.2.2 Program-controlled operation of metal separator 320
2)
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Program-controlled manual operation of plate metal separator a) Push the on-site centralized control switch on control panel to the centralized control position, the centralized control room will receive the signal of centralized control preparation, the metal separator shall be in its initial position (discard iron position). When the centralized control room sends the signal for selecting A belt operation, No.1 metal separator will move forward immediately and stops above A belt, and begin to excite electromagnet to absorb iron. When the centralized control room sends the signal of selecting B belt, No.2 metal separator moves immediately to reach above B belt, and then electromagnetic excitation and iron absorption starts, the electric control device begins to time. After the timing setting (this can be achieved by adjust 0 to 7 on the dial device from 15 to 120 minutes, the value of No. 0 potentiometer is in max; when the value of potentiometer is in min, if the value of dial device is 0, the time is 2 minutes), No.1 metal begins to move, and it stops when it reaches above B belt, and then it begins to excite electromagnet and absorbs iron. 10 seconds later, No. 2 metal separator returns to the discard position and discard iron. After the timing setting (same as above ), No.2 metal separetor moves above the belt, and absorb iron. So the operation period repeats. When the centralization signal disappears, the metal separator returns automatically to the discard position and stop exciting electromagnet. When the metal separators alternate to move above A belt, the centralization control room sends the signal of centralization control to B belt. When No.1 metal separator moves above A belt, No.2 metal separator moves directly above B belt, excite electromagnet and absorbs iron; when No.2 metal separator moves above A belt, No. 2 metal separator returns to the discard position and stop exciting electromagnet and absorbing iron. After discarding iron 20 seconds later, it moves above B belt, excites electromagnet and begins to absorb iron. No.1 metal separator moves directly above A belt, excite electromagnet and absorbs iron at the same time. When the metal separators alternate to move above b belt, the centralization control room sends the signal of centralization control to A belt. When No.2 metal separator moves above B belt, No.1 metal separator moves directly above A belt, excite electromagnet and absorbs iron; when No.1 metal separator moves above B belt, No. 1 metal separator return to the discard position and stop exciting electromagnet and absorbing iron. After discarding iron 20 seconds later, it moves above A belt, excites electromagnet and begins to absorb iron. No.2 metal separator moves directly above B belt, excite electromagnet and absorbs iron at the same time. When the metal separators alternate above the belt, excite electromagnet and absorb iron in the setting time, the metal separators automatically discard iron for 20 seconds and return above to the corresponding belt, excite electromagnet and absorb iron. When one signal is 321
b)
c)
removed, one metal separator returns to the discard position, stops exciting electromagnet and absorbing iron; the other one continue to remain above the belt and operation in alteration mode. 2) Program-controlled manual operation of plate type metal separator: Push the on-site centralization control shift switch SA1 to the centralization control position. When the centralization control room receives the centralization control preparation signal, it sends the centralization control start signal or centralization control retain signal, and then the metal separator begins to excite electromagnet and absorb iron. The discard belt becomes to move, the centralization control room receives the feedback signals of electromagnet excitation and belt operation; when the centralization control room sends the centralization control stop signal or centralization control cancel signal, the motor separators begin to stop exciting electromagnet, and the discard belt stop moving, the electromagnet excitation and belt operation received by the centralization control room will disappear.
3.4.3 Common faults of metal separator, estimate and handle 3.4.3.1 Common faults of belt type metal separator, estimate and handle a) Breaker trip during operation Causes: 1) 2) Main AC contactor KM1 caking; Short-circuit due to breakdown of rectifier component.
Resolution: 1) 2) b) Replace the contact point or component; Replace the rectifier component.
Failure of electromagnetic excitation of metal separator Causes: 1) 2) Excitation circuit disconnection; Breaker trip of Excitation circuit.
Resolution: 1) 2) c) Inspect the circuit of electromagnetic excitation system; Inspect the circuit, switch on the breaker if no faults.
No indication of instruments and indicators Causes: 1) 2) Damage of instruments and indicators; Disconnection of wiring. 322
Resolution: 1) 2) d) Replace instruments and indicators; Inspect the wire.
Start failure of electromagnetic excitation of metal separator Causes: 1) 2) 3) 4) Trip of thermal overload relay; Damage of thermal overload relay; Motor fault of metal separator; Damage of AC contactor.
Resolution: 1) 2) 3) 4) Reset thermal overload relay; Replace thermal overload relay; Inspect motor of belt and resolve; Replace AC contactor.
3.4.3.2 Common faults of plate type metal separator, estimate and handle a) Breaker trip during operation Causes: 1) 2) Main AC contactor KM5 and KM6 caking; Short-circuit due to breakdown of rectifier component.
Resolution: 1) 2) b) Replace the contact point or component; Replace the rectifier component.
Failure of electromagnetic excitation of metal separator Causes: 1) 2) 3) Trip of breaker; Excitation circuit disconnection; Damage of AC contactor.
Resolution: 1) 2) Find the cause and switch on the breaker; Inspect the circuit of electromagnetic excitation system; 323
3) c)
Replace AC contactor.
No indication of instruments and indicators Causes: 1) 2) 3) Damage of instruments and indicators; Disconnection of wires; Trip of breaker.
Resolution: 1) 2) 3) d) Replace instruments and indicators; Inspect the wire; Find the cause and switch on the breaker.
No motor movement of metal separator Causes: 1) 2) 3) 4) Trip of thermal overload relay; Damage of thermal overload relay; Motor fault of metal separator; Damage of AC contactor.
Resolution: 1) 2) 3) 4) Reset thermal overload relay; Replace thermal overload relay; Inspect motor of belt and resolve; Replace AC contactor.
3.5 Sampling device of coal as fired and coal as received 3.5.1 Test item of sampling device before operation 3.5.1.1 Inspect all bolts of motor and reducer, ensure that they are not loosing or lost, and the protection of motor and reducer shall be firm and intact. 3.5.1.2 There shall be no oil leakage of reducer and hydraulic coupling with normal oil level and good oil quality. 3.5.1.3 The lubrication of bearings shall be good. 3.5.1.4 There shall be no coal jamming in coal pulverizer, belt conveyer, splitter and coal chute. 3.5.1.5 Every indicator, switch and button shall be complete and intact. 324
3.5.1.6 The shift switch shall be in concentration position, and the interlock switch shall be in the interlock position. 3.5.2 Operation of sampling device of coal as fired and coal as received 3.5.2.1 Push the shift switch to the on-site position and the interlock switch to the interlock position. 3.5.2.2 Press the start button after the belt conveyer starts and move normally, and them the belt conveyer, splitter, coal pulverizer and coal inlet sampling device gradually are switched on automatically for operation. 3.5.2.3 Press manually the stop button after operation, and then the bucket elevator, splitter, coal pulverize, belt conveyer and inlet sampling device will stop simultaneously. 3.5.2.4 When the interlock switch is in off position, start them separately according to the sequence of bucket elevator, splitter, coal pulverize, belt conveyer and inlet sampling device. So the start operation of sampling device is accomplished. 3.5.2.5 Press the stop button according to the sequence of inlet sampling device, belt conveyer, coal pulverizer, splitter and bucket elevator for stop operation, and push the shift switch to the concentration position. 3.5.3 Common faults of sampling device of coal as fired and coal as received, estimate and handle same as belt conveyer. 3.6 Unloading trolley 3.6.1Operation of the unloading trolley 3.6.1.1 On-site operation method 1) Push the program-controlled/on-site switch on the control cabinet of unloading trolley to the on-site position. Switch on the main power supply switch on to on the control cabinet of unloading trolley to the I position. Press the power on button on the on-site control cabinet of unloading trolley. Inspect and ensure that there is no fault warning on the fault information display interface on the control cabinet of unloading trolley, or press the reset button if there are any faults, and reset. Shift the three-way flapper of the unloading trolley to the feeding or bypass position according to the requirement of different stacking positions. The program control operator inspects and ensures that every signal indicators shall be correct on the operation interface. The on-site operator begins the on-site operation after receiving confirmation from the program control operator, and presses the trolley forward or trolley 325
2)
3) 4)
5)
6)
7)
backward button, and then the unloading trolley accomplishes automatically the following movements: a) b) c) Start the hydraulic pump starts and the hydraulic pump start indicator lights. Release the rail clamp and the rail clamp release indicator lights. Release the brake device of big trolley, and the unloading trolley moves forward or backward as required.
3.6.1.2 When the unloading trolley moves above the bunker required for feeding, the on-site operator presses the stop button, and then, the unloading trolley accomplishes automatically the following movements: a) b) c) Stop the unloading trolley moving and close the brake device. Clamp the rail clamp, and then the rail clamp close indicator lights. Stop hydraulic pump moving.
3.6.1.3 Program-controlled automation operation method of the unloading trolley 1) Turn on the power supply of the unloading trolley on site; shift the program-controlled and on-site selecting switch on the control cabinet of the unloading trolley to the program-controlled position, and then the power on, program-controlled, feeding (or feeding the last bunker) indicators light on the unloading trolley operation interface. Inspect and ensure that there is no fault warning on the fault information display interface on the control cabinet of the unloading trolley. Contact with the on-site control staff, and confirm to operate the unloading trolley. Choose the bunker required for feeding and click that icon of unloading trolley feeding in the interface, and then the unloading trolley accomplishes automatically the following movements: a) b) c) d) Start hydraulic pump, and then the signal of hydraulic pump start returns. Release the rail clamp, and then the signal of rail clamp release returns. Release the motor brake, and then the signal of motor brake release returns When the signal of operation returns, the unloading trolley moves forward or backward as required.
2)
3) 4)
5)
When the unloading trolley moves to the pre-assigned bunker, it will stop. The unloading trolley accomplishes automatically the following movements: a) b) c) Stop the unloading trolley. Clamp the rail clamp. Close the motor brake. 326
6)
Select the last bunker interface when the unloading trolley feeds the last bunker, and click the icon of the unloading trolley feeding the bunker, and then three-way flapper will turn automatically to the bypass position, and then the indicator of feeding last bunker lights.
3.6.1.4 Program-controlled operation method of the unloading trolley in case of encoder fault 1) Turn on the power supply of the unloading trolley on site; push the program-control/on-site switch on the control cabinet of the to the program-control position, the indicators of power, program-control, feeding (or feeding the last bunker) light on the operation interface of the unloading lights. Inspect and ensure that there is no warning information in the window of fault display on operation interface of the unloading trolley. Click the characters the encoder is valid, and then they will change to the encoder is void, and the trolley stop button pops out. Contact with on-site control staff, and ensure that the unloading trolley can run. Move the unloading trolley selecting to any bunker in main process interface, click the icon of unloading trolley feeding, and then the unloading trolley will accomplish automatically the following movements: a) b) c) Hydraulic pump starts, and then the indicator of hydraulic pump start lights. Release the rail clamp, and then the indicator of rail clamp release lights. Release the braking device of big trolley, and then the unloading trolley move forward or backward.
2)
3)
4) 5)
6)
Press the trolley stop button when the unloading trolley moves to the bunker for feeding. The unloading trolley will accomplish automatically the following movements: a) b) c) The unloading trolley stops moving, and the braking device closes. Clamp rail clamp, and then the indicator rail clamp close lights. Stop hydraulic pump operation.
3.6.2 Notes on operation and maintenance 3.6.2.1 Do not permit the staff to operate this device except the unloading operators, and non-unloading staff shall not stay in this device. 3.6.2.2 The program-control operator shall send the operation confirmation to the on-site operator before every feeding of the bunker, and then the bunker position is correct. 3.6.2.3 Do not maintain, clean, and replace during operation. 327
3.6.2.4 Monitor closely the control instruments of the operation mechanisms. Their value shall not exceed their rated limit. 3.6.2.5 Keep big trolley run smoothly and evenly with no gnawing rail, no abnormal vibration of drive device, no temperature increase and noises. 3.6.2.6 The cable drum and tray shall be complete and intact with normal synchronous retractable cable and no loosing or jam. 3.6.2.7 The indication of oil temperature and oil pressure in hydraulic station shall be normal with no abnormal noises and oil leakage. 3.6.2.8 The indication of dust remove device shall be normal and the dust remove fan shall be no abnormal vibration and noises. 3.6.2.9 Press the emergency stop button immediately if any abnormities of the unloading trolley occur, find the causes and resolve before next operation. 3.6.2.10 Do not carry out the reverse operation and release the rail clamp when the big trolley does not stop completely. 3.6.2.11 Ensure that three-way flapper is on the bypass position or there is no coal on the belt to when big trolley run in the bunker, avoid the coal overflow of coal chute. 3.6.2.12 When the raw coal bunker becomes the maintenance bunker, the three-way flapper shall not be pushed to the bypass position, and the unloading trolley can move only after all coal on it is empty. 3.6.2.13 Report to main man on duty immediately if any trip or no power supply for the unloading trolley occur during operation, operate it after the maintenance staff resolves these faults. 3.6.3 Fault investigation and resolution 3.6.3.1 No release of braking control device Causes: a) b) c) Wrong voltage of braking control device; Fault of braking control device; Big clearance of brake liner due to abrasion.
Resolution: Ask the maintenance staff to handle. 3.6.3.2 Big AC noise from the motor Causes: a) b) No release of rail clamp; Fault of motor winding; 328
c)
Abrasion of motor rotor.
Resolutions: a) b) Release rail clamp; Ask the maintenance staff to handle.
3.6.3.3 Noise from the reducer of big trolley Causes: a) b) c) Sundries in gear oil; Damage of bearing; Abnormal gear device.
Resolutions: a) b) Inspect the oil quality; Ask the maintenance staff to handle.
3.6.3.4 No movement of big trolley Causes: a) b) c) d) e) f) Wrong position of the on-site/program-control selecting switch; Cable disconnection; No release of forward and backward limit switch; No complete release of limit switch of rail clamp; Broken fuse; Breaker trip.
Resolutions: a) b) c) d) e) f) Push the selecting switch to correct position; Inspect and repair the cable; Reset limit switch; Complete release the rail clamp; Replace fuse; Inspect designated value of the breaker.
4. Fuel system
4.1 Inspection before start-up 4.1.1 Inspection of fuel discharge 329
4.1.1.1 Check fuel level of 2 fuel depots, fuel quantity and record in detail. 4.1.1.2 Blow and clean whole fuel discharge system: 1) Open the oleophobic valve of main fuel discharge pipe; open the front oleophobic valve of fuel discharge pipe in fuel discharge pump; open interconnection valve of main fuel discharge pipe and main steam pipe; blow and clean main fuel discharge pipe. Close gasoline interconnection valve and close two fuel discharge valves after blowing. Open the pump outlet valve and close the pump inlet valve. Open the inlet valve of No.1 (or No.2) fuel tank and the steam blowing valve of fuel discharge pump, and then blow fuel discharge system. Close steam blowing valve while the steam appears from the top of oil depot.
2)
3)
4)
4.1.1.3 Inspection of valve position of this system: 1) When discharging fuel with the steam driven pump, open the inlet and outlet valves, close every blowing valve, and lubricate every part and discharge all water in cylinder. When discharging fuel with electric pump, open inlet and outlet valve, close every blowing valve, open cooling water and adjust it normal, and keep manual shaft turning device normal.
2)
4.1.1.4 Inspect and ensure that the joint of rubber hose is firm with no oil leakage; provide a small fuel bucket for collecting leakage oil. 4.1.2 Inspection before start-up of heavy fuel oil system: 4.1.2.1 The overhaul and maintenance of fuel depot and equipment shall be accomplished, and all operation permission sheets shall be available. 4.1.2.2 Inspect and ensure that the gear pump moves flexibly(slightly turn by hand). 4.1.2.3 Inspect and ensure that power supply is normal and the rotation direction of motor is correct. 4.1.2.4 Inspect if the inlet and outlet diameter of fuel pipe meets the requirement and the height of sucking fuel and lift exceed the requirement. 4.1.2.5 Ensure that every fixed parts shall be firm(Including joints of in-and-out pipe). 4.1.2.6 Insert the inlet fuel pipe into fuel tank not too high and avoid the air entering; do not insert the fuel pipe into the bottom of fuel tank, avoid no sucking due to the pipe inlet close 4.1.2.7 All system valves shall be complete and intact, the marks shall be correct and they are in close position. 330
4.1.2.8 All equipments shall be complete and intact; the operation power supply of fuel feed pump shall be on and all measuring instruments shall be complete and intact; the power supply and indication shall be correct; all operation handle, light signal shall be complete and intact. 4.1.2.9 Contact with main men on duty, and start the boiler, open main valve of fuel depot till all are opened completely. 4.1.2.10 Open steam heating valve and drain valve of fuel tank gradually till the remaining water in steam system flows out completely, and then open steam heating valve and drain valve, and heat up the big fuel tank. 4.1.3 Inspection of dirty oil system before operation 4.1.3.1 Inspect and ensure the pipe connection of this system is correct, the instruments are complete and intact and the power supply in power control cabinet is normal. 4.1.3.2 Close class first and second drainage outlet on this device. 4.1.3.3 For first usage, open the water injecting valves and air exhaust valves on fuel collector box of oil and water vacuum splitter and dirty fuel absorber, fill the industrial water into oil and water vacuum splitter and dirty fuel absorber till they are full of water, and then close all water inlet valves, drain valves, air exhaust valves. 4.1.3.4 Inspect oil content of oil and water in drain pool. If the thickness of floating oil reaches to 5mm, start the oil absorber for absorb. Otherwise, use vacuum splitter. 4.2 Start and stop of fuel system 4.2.1 The operation sequence of oil supply system When the oil temperature reaches to 75C, the fuel system will start. 4.2.1.1 Blowing and preheating of equipments and system: 1) Contact with main man on duty, cooperate with main centralized control operator, and take charge of overall command and communication together with main man on duty. Operation of blowing and preheating of oil return system: Open main oil return valve of fuel tank, open main oil return valve at stokehole, and close main fuel supply valve at stokehole. b Open main steam valve of steam heat tracing of heavy fuel system, open hot steam valve of ignition boiler, connect to the steamer, put in hot oil tracing source of heavy oil tracing. Open the boiler drain valve slightly, and then close after remaining water flows completely out. Inform the fuel depot, open stokehole steam valve oil interconnection, and open steam blowing valve of main oil return pipe and blowing preheating for oil return 331
2) a)
b)
c)
system. d) When the air from No.1 (No. 2) depot appear, report to the main man on duty, close all valves of above a and b provision except return oil valve of No.1 and No.2 oil depots Blowing and preheating operation for oil supply system: Open oil return valve of No.1 (2) depot, open connecting valve between main oil supply pipe and oil return pipe, open inlet valve of No.1 (2) main fuel supply pipe and report this to the main man on duty. Close stokehole oil return valve; and open oil inlet valve of stokehole; open the boiler steam valve of steam and oil combined valve; open steam blowing valve of main oil supply pipe and inform the operator of oil depot; start blowing and preheating for oil supply system. When the air from No.1 (No.2) appear, report to the main man on duty. Close connecting valve between main oil supply and main oil return pipe and the valves of provision open the oleophobic valve of No.1 (No.2) heater. Blowing and preheating operation from big fuel tank to pump inlet blowing system Open oleophobic valve of main pump inlet pipe, open the blowing valve of main oil outlet pipe and preheat for blowing. Close all valve opened as above provision a when oleophobic valve of main pump inlet pipe is hot. Blowing preheat operation for each pump, filter; oil return system Open the inlet valves of No.1, No.2 and No.3 oil supply pumps, and open the inlet valve of No.1, No.2 and No.3 filter, and open the steam blowing valve of No.1, No.2 and No.3 oil supply pump and then preheat the pumps and filters for blowing. When oleophobic valves of filters are hot by touch, open the small circulation valve of No.1, No.2 and No.3 oil supply pump and open oil pump valve; close the inlet valve for No.1, No.2 and No.3 oil supply pump at the same time, and close the outlet valve and oleophobic valve of No.1, No.2 and No.3 filter, and preheat the oil return system for blowing. When oleophobic valves of pumps are hot by touch, close each opened valve. Preheating for all systems and devices for blowing before operation is accomplished till then. Report this to the main chief on-duty.
3) a)
b)
c)
4) a)
b)
5) a)
b)
c)
4.2.1.2 Start-operation: 1) Open the oil supply valves of No.1 (or No.2) oil depot, the inlet valve of No.1 (or No2, or No.3) oil supply pump; and inlet valve of No.1, No2 and No.3 filters, the oil return valves of No.1 and No2 depots and oil return valve of the boiler. 332
2) 3)
Inspect strictly No.1, No.2 and No.3 oil supply pump before start. Switch-on the start switch of No.1, No.2 and No.3 oil supply pump, and start the oil supply pumps. When the outlet pressure of No.1 (or No2, or No.3) oil supply pump reaches 3.5MPA, Open smaller circulation valve slowly till all valves are completely opened, ensure the outlet pressure shall be stable at that time. When the small circulation operation lasts normally 30 minutes, report to the main chief on duty. Open the following valves at the same time: inlet valve of No.1 (or No.2) heater; steam valve and drain valve of No.1 (or No.2) heater, main oil inlet valve of No.1 (or No.2) boiler. Close the oleophobic valve of No.1 (or No.2) heater. Open slightly the bypass outlet valve of oil supply pump, close the valve of small circulation and add pressure to oil supply pipe. When heavy oil pressure of No.1 and No.2 stokehole reach to 3.0 to 3.3MPA, Contact the attendant of oil depot, inspect the current change, and slightly open the oil return valve of No.1 and No.2 stokehole, close small circulation valve of the pumps, completely open the outlet valve of oil supply pumps. Close the bypass outlet valve, oil return valve and interconnection valve between main oil supply pipe and main oil return pipe, keep the current of pump lower than rated one. And then keep the stable operation for 30 minutes. Adjust the steam heating valve of No.1(or No.2) heater in No.1(or No.2) depot, keep the temperature of the outlet oil in fuel depot within 80C to 90C, Keep the temperature of the supply oil within 100C to 120C. Open each inlet valve of oil supply pump in accordance with current of oil supply pump, and slightly open each bypass outlet valve of alternative pump, make the alternative pump warm.
4)
5)
6)
7)
8)
9)
10) Adjust the switch to the interlock position; one pump is used for operation and the other for alternative one. Report this to main chief on duty. Till then, the start of depot is accomplished. 4.2.2 Operation procedure of full stop of oil supply system: 4.2.2.1 After the boiler lights off, begin to operate immediately when receiving the stop command from main chief on duty. 4.2.2.2 Release the alternative interlock; stop operation of oil supply pump, report to main chief on duty. 4.2.2.3 Operate the oil return system for blowing: a) Stops operation of oil supply pump, operate immediately when receiving the permission from the fuel depot. Close main fuel inlet valve at the stokehole of No.1 and No.2 boilers, open steam 333
b)
&oil interconnection valve and oil return valve at stokehole of No.1 and No.2 boilers. Open main blowing valve of oil return pipe and inform the staff of fuel depot. c) The steam appears on top of No.1 and No.2 depots 5 minutes later, report to main chief on duty. When main chief on duty receives the notice from fuel depot, closes each valve of above item b.
d)
4.2.2.4 Blowing operation of the system and equipment before oil supply pump: a) After oil supply pump stops running, begin to operate immediately after reporting to main chief on duty. Close the following valve: Fuel supply valve of No.1 (or No.2) depot, the outlet and bypass valve of No.1,No.2 and No.3 pumps, small circulation valve of No.1,No.2 and No.3 pumps Open the following valve: the oleophobic valve of main inlet pipe of the pumps, inlet valve and oleophobic valve of No.1,No.2 and No.3 pumps, the oleophobic valve of No.1,No.2 and No.3 filters, steam blowing valve of main outlet pipe of No.1 and No.2 depot, steam blowing valve of No.1,No.2 and No.3pumps , and then begin blowing. Blow for 10 minutes till it burns the hand, close all valves of above item C.
b)
c)
d)
4.2.2.5 Blowing operation of oil supply system, pump outlet and oil return system : a) b) Begin this operation immediately after operation of item 3. Open the following valves: main fuel supply valve at the stokehole of No.1 and No.2 boilers, steam and oil interlock valve at the stokehole of No.1 and No.2 boilers, steam blowing valve of main oil supply pipe. Inform the staff in fuel depot, open interconnection valve between main oil supply pipe and main oil return pipe; begin blowing. When the steam appears on top of No.1 (or No.2) depot, open the following valves: The outlet and bypass valve of No.1, No.2 and No.3 oil supply pump, small circulation and steam blowing valve of No.1, No.2 and No.3 oil supply pumps, main vale of oil return pipe, oleophobic valve of the heater; Begin blowing for 15 minutes; Main valve of oil return and oleophobic valve of the heater. Report to main chief on duty when it's hot by touch; close valves opened of above item b and c. 4.2.2.6 Open the valve of No.1 (or No.2) depot and heating valve of No.1 (or No.2) heater, open drain valve fully, and close all system valves, and close main valve of steam inlet of fuel depot. Report to main chief on duty. 334
c)
4.2.2.7 Record the operation in detail; report to main chief on duty in time about equipment defects during operation; write down the defect. 4.2.2.8 Inspect fully all system, equipment and valve positions, avoid the missed operation. 4.2.3 Operation procedure of fuel discharging 4.2.3.1 Inspect if the heating temperature of tank can is normal, and the detailed requirements are as follows: Oil type Heavy fuel No.100 Heavy fuel No.200 Heating temperature 60 C to 70 C 70 C to 80 C
4.2.3.2 Open steam valve of fuel discharge pump, make pump move slowly. 4.2.3.3 Open the discharging valves on upper and lower part of oil tanker; fasten the joint with copper spanner if oil leak from the joint of fuel discharging pipe. If there is still a little oil leakage, put a small fuel bucket to collect. If there is a heavy oil leakage, close the valves both on upper and lower part of oil tank, and contact the maintenance staff to replace the rubber mat of the discharging joint. Discharge fuel again after the replace. 4.2.3.4 Open the fuel oil discharging valve between leather hose of fuel discharging pipe and main pipe, the discharging begins. 4.2.3.5 When the steam pump work normally, open slowly the air intake valve wider to increase the discharging speed. Use steam pump to discharge oil at the beginning. When steam pump works normally, start electric discharging pump to speed up the fuel discharging. When oil discharging is over, stop the electric discharging pump and use the steam pump to discharge the oil from the bank bottom. 4.2.3.6 After the removal of the tank bottom, stop steam discharging pump, close the heating valve of the tank and dismount the heating joint. 4.2.3.7 Close each inlet valve on the f pump; open each pump front oleophobic valve and the oleophobic valve of fuel oil discharging pipe; open the interlock valve between main steam & fuel pipe and discharging pipe , and then blow; open the steam blowing valve of the pump and oleophobic valve and blow. 4.2.3.8 After the fuel oil discharging leather hose is blowed cleanly, close the fuel oil discharge valves on both upper and lower part of tank, the valve between fuel discharging leather hose and main fuel discharge pipe, and then ask the maintenance staff to demount the fuel discharging joint. 4.2.3.9 When the steam appears on top of fuel oil depot, and the main discharging pipe is blowed cleanly, close the steam & oil interlock valve, each blowing valve and oleophobic valve, and then close the fuel oil discharging valve of fuel depot after 335
the blowing is accomplished. 4.2.4 Operation of dirty oil system 4.2.4.1 turn on the power supply of control box, shift the switch to the on-site /automatic position, press the start buttonand press the start switch of vacuum oil and water splitter or oil & water absorption device (as the level of oil slick and then the system begins to work in automatic mode. 4.2.4.2 When the liquid level of the pool reaches the high level (the start position), the vacuum oil & water splitter or oil slick absorption device will start automatically, and the split oil returns to the oil collection tankthe purified water from the vacuum splitter flows out to the trench, the separated water from oil slick absorption device returns back to oil drainage pool. 4.2.4.3 When the oil level in oil collector tank reaches the high level, the oil supply pump will start automatically; send the collected oil to oil tank of the system; when the oil level reaches the stop potion, the oil supply pump will stop. 4.2.4.4 There is an online test monitor connected parallelly with drain pipe (refer to the specification of detailed operation method and maintenance) which can online test. The setting value for oil consistence of the drain is 5ppm/L. When oil consistence of the drain is over and above the setting value, the alarm will make, electro valve of the drain will close at the same time. Do not blow the drain to the trench. Open the return valve, the water returns to the oil drainage tank for next handle. 4.2.4.5 The Oil drainage separate automatically during the automatic operation of this system. If liquid in oil drainage pool reaches the low level, this system stops. 4.2.4.6 When the remote control or manual control is requiredpush the shift switch to the relevant position, and then the system could automatically enter into the remote control or manual control mode. 4.2.4.7 If the differential controller or safety valve is activethe system will alarm. Please stops and remove or replace the macromolecule filter element. 4.2.4.8 Inspect if the pump turning is correct, and inspect each measuring instrument and equipment are in good condition. 4.2.4.9 Close first level drainage outlet and second level drainage outlet on the device. 4.2.4.10 Open water discharging valve and air exhaust valve on top of macromolecule oil absorption chamber. 4.2.4.11 Fill the vacuum fuel collector box and inlet tube with water. 4.2.4.12 Push the oil drainage switch to the auto position. 4.2.4.13 Press the start button on electric cabinet of this system, and then the motor screw pump begins to pump water. 4.3 Notice on the operation and maintenance of fuel oil supply system 336
4.3.1 Maintenance and safety of the system 4.3.1.1 Install the earthing device and prevent the injury due to power leakage. 4.3.1.2 Inspect regularly the fasteners and ensure the fasteners have no loosening and the sound of gear pump is normal. 4.3.1.3 There shall be one coarse strainer at oil inlet to prevent scrap iron and bigger sundries from absorbing into pump which may cause the abrasion of gear and jam the gear pump. 4.3.1.4 The oil seal is the easily damaged part. Replace the oil seal if there is oil leakage from the drive shaft. 4.3.1.5 The ball bearing is used on the oil pump. The gear pump will make noise and the power output of the gear pump will decrease down if the ball bearing abrades seriously. Replace the ball bearing. 4.3.1.6 After maintenance of gear, control strictly the axial clearance and concentricity without any over-deviation while reassembling, otherwise it will not work normally. 4.3.1.7 Do not operate the gear pump in the environment of high temperature or in the open area. 4.3.2 Maintenance of oil supply pump during operation 4.3.2.1 The bearing temperature, vibration, tandem of oil supply pump and motor shall not exceed its rated vale during operation. 4.3.2.2 Keep the lubrication oil the bearing adequate with good quality, and the oil type shall meet the requirement; the bearing of oil cup shall screw 2 circles and refuel for each shift. 4.3.2.3 Keep the cooling water of each bearing moving smoothly with no jamming and adequate water. 4.3.2.4 Keep the current and pressure of pump stable, the temperature of fuel oil supply normal during operation. 4.3.2.5 Keep every meter complete and intact with correct indication. 4.3.2.6 Keep every valve in the system complete and intact with correct signs; ensure that the switch position is correct with no oil and steam leakage. 4.3.2.7 Keep the temperature of heating tank in alternative pump normal, and ensure that the position of each interlock is correct. 4.3.2.8 Inspect the equipment isolation system and ensure that it is correct and safe. 4.3.2.9 Keep the oil tanks and their alternative tanks normal and the oil temperature of fuel depot shall meet the requirement. 4.3.2.10 Keep the operation of cooling return water moving smoothly; keep the 337
equipments and ground tidy 4.3.2.11 During oil discharging, balance the movement of steam pump with no abnormal noises and water beating in its tank, keep its steam operation normal and the connection intact and complete, exhaust regularly the water in the tank. 4.3.2.12 Keep the operation of all filters normal with no jamming. 4.3.2.13 Keep the operation of the heater normal with no leakage of oil and steam. 4.3.2.14 Keep the drainage oil level low and normal without abnormal change. 4.3.3 Notice on operation and maintenance of oil supply system 4.3.3.1 Inspect all equipment thoroughly before operation and know fairly well about it. 4.3.3.2 Review the operation permission sheet carefully, operate the system step by step, and open the valve which has to be opened and close the valve which has to be closed, avoid oil & steam cross and leakage of heavy oil due to misoperation. 4.3.3.3 Inspect all oil system and steam system thoroughly and evenly after operation, avoid oil & steam cross and leakage of heavy oil due to missed item, misoperation and equipment fault. 4.3.3.4 This task shall be lead by station main staff on duty or the operator, be controlled by the operation chief on duty. The operators shall obey the operation procedure, contact regularly and report the state of operation. 4.3.4.5 Review the operation thoroughly before operation, and study the operation procedure, process and the position of all valves, avoid time delay due to uncertainty. 4.3.3.6 Repeat to review after one step of operation, and avoid oil & steam cross and leakage of heavy oil due to misoperation. 4.3.3.7 Contact with the operators of front and back procedure, execute strictly the order and obey the direction, report the operation to the main chief on duty. 4.3.4 Operation of dirty oil system and maintenance notes 4.3.4.1 Inspect the operation of every instrument, the meter and the indicator. The indication shall be same as its actual liquid level. The indicator state shall comply with the actual operation. Stop and inspect if any abnormity occurs. 4.3.4.2 Inspect and ensure that fuel collector box of oil and water vacuum splitter and dirty fuel absorber shall be normal. Stop and resolve the oil leakage of system absorption if it decreases. 4.3.4.3 If the water pump and oil drainage pump exchange frequently, it means that the electrode of fuel collector box is void. And then stop the operation, separate the pump for cleaning and reset. 4.3.4.4 Keep no sundries in the oil drainage pool, stop the operation and remove if any. 338
Keep the oil level of oil and water vacuum splitter less than 500 to 100mg/l. otherwise, it will increase the oil absorption saturation of macromolecular filter element, reduce the service life of filter element, and even cause the overflow 4.3.4.5 Stop the operation and inspect when the online consistence detector sends the signal of overhigh oil consistence. Stop the operation and clean the detector components if the digital indication is not stable. 4.3.4.6 Stop cleaning or replacing macromolecular filter element during operation of pressure controller, or pressure valve, or safety valve. Open the right cover board of macromolecular absorption. Release the screw of fixing filter element, grasp the filter element and turn it two circles to one direction and pull out the filter element, and remove the filter element, break 2 to 3 layers, and take out the outer layer and clean it in the fresh water, mount it into the macromolecular absorption box, install it according to its opposite sequence of removing. Replace the filter element if it can operate after maintenance. 4.3.4.7 Flow out the water in case of no operation for a long time, turn off the power supply, and lubricate all rotating components. 4.4 Common faults of fuel oil system equipment, estimate and handle 4.4.1 High oil content in drainage a) Causes: 1) 2) 3) b) Invalid absorption of splitter; No full tank; Serious oil pollution.
Resolutions: 1) 2) 3) Replace the absorption materials; Exhaust the air and fill the tank full; Clean repeatedly or remove, and flow out.
4.4.2 Noises and vibration a) Causes: 1) 2) 3) 4) 5) b) Misalignment between pump shaft and motor shaft; Air in conveying liquid; Unbalance of rotor. Serious abrasion of seal ring. Loosing of connecting bolts.
Resolutions: 339
1) 2) 3) 4) 5)
Adjust the alignment; Decrease the temperature and remove the air; Replace the spare parts; Replace the seal ring; Fix the bolts.
4.4.3 Deficient flow a) Causes: 1) 2) 3) 4) 5) b) Serious abrasion and collision of impeller; Serious erosion and abrasion of seal ring; Deficient speed of rotation; Big clearance between the unshrouded impeller and pump cap; Jamming of absorption parts or outlet.
b) Resolutions; 1) 2) 3) 4) 5) Replace the impeller; Replace the seal ring; Increase the speed of rotation; Replace the impeller; Remove the jamming.
4.4.4 No oil supply of pump a) Causes: 1) 2) 3) b) Wrong direction of motor rotation; Jamming of the shrouded impeller or suction and exhausting pipeline; No oil immersion of the centerline of the fuel impeller.
Resolutions: 1) 2) 3) Replace rotation; Remove the jamming; Adjust the oil immersion.
4.4.5 Vaporization of oil supply pump a) Causes: 1) Too low oil level of oil tank; 340
2) 3) 4) b)
No closing of cleaning door; Jamming of filter; High temperature of inlet.
Resolutions: 1) 2) Change the oil tank for operation immediately; Stop the fault pump and use the alternative pump; inspect every valve and ask the maintenance staff to repair.
4.4.6 Low pressure of oil supply a) Causes: 1) 2) 3) 4) 5) 6) 7) 8) b) Over-turn of return valve; Increase of oil consumption in the boiler; Oil leakage of oil supply pipeline; Air in absorption inlet; Low speed of pump rotation; Jamming of absorption pipeline; Jamming of the impeller; Damage of the impeller or abrasion of seal ring.
Resolutions: 1) 2) 3) Adjust return oil valve; Interlock immediately the alternative pump; Ask the maintenance staff to handle.
4.4.7 Oil pressure increase of oil supply a) Causes: 1) 2) 3) b) Smaller turn of oil return valve or loose valve; No operation of interlock valve; Sudden reduction of oil.
Resolutions: 1) 2) Inspect the return oil valve, ask the maintenance staff to handle; Contact with the chief on duty and find out the reason.
5 Fire protection and prevention of fuel oil system and coal conveying
341
system
5.1 Fuel oil system 5.1.1 Access regulation of oil depot 5.1.1.1 The operator on duty shall close and lock the door after the operator on duty and outsiders entry. 5.1.1.2 Do not allow the non-staff to enter the oil depot. The visitor and maintenance staff can enter the oil depot only when they get the permission from the main man on duty. 5.1.1.3 Hand over actively the lighter, match and other inflammable and explosive materials to the operator on duty for keeping, and enter after check-in on the record book for access at the oil depot. 5.1.1.4 The persons for access of oil depot shall obey the management of the operator on duty, and accept the check-in. Anyone who can not obey the regulation will not be permitted to enter into the oil depot. 5.1.1.5 Do not wear the shoes with iron sole, chemical fiber clothes, and the cotton clothes are recommended; do not move optionally the equipment. 5.1.1.6 Do not use the mobile communication devices in the oil depot; do not use mobile phone in oil depot. 5.1.1.7 The maintenance staff who wants to enter the oil depot must get the permission sheet first. If the welding and fire shall be needed during the maintenance, class 1 permission must be got. Do not begin the maintenance before any prevention measures. 5.1.1.8 All tools in oil depot must be made with copper; do not use metal tools to operate or hammer. 5.1.2 Fire regulation and operation notes 5.1.2.1 Do not keep any sundries and any inflammable and explosive materials; do not construct any temporary building. 5.1.2.2 Remove the weed around the oil depot and the protecting embankment. 5.1.2.3 Do not smoke in oil depot, do not operate while the line on live; do not heat the equipment and oil pipe with open flame and do not hammer with iron tools. Try to use tools with copper spanner and wood hammer or copper hammer, plastic torch. 5.1.2.4 Stop the operation immediately and close the inlet and outlet of oil tank if the fire due to lightning, or other fire overspread may threat the safety of oil depot. 5.2 Coal conveying system 5.2.1 Technical prevention measure of fire accident for coal belt conveyer 342
5.2.1.1 Extinguish promptly when the coal stack burns spontaneously; do not stack the burning coal on the belt. 5.2.1.2 Remove and clean periodically the dust on the overground cable in the transfer station 5.2.1.3 Keep adequate extinguishing devices on the coal conveying equipment, inspect periodically the fire extinguishers and ensure they are in their service life. The water pressure for extinguishing fire in coal belt conveyer shall no less than that which can inject the water above the height 10m. 5.2.1.4 Unload all coal on the belt conveyer after conveying, remove and clean the jammed coal and dust if any. 5.2.1.5 Do not smoke in operation site. 5.2.1.6 Inspect the equipment at any time; ensure that there is no possibility of insulation aging or short circuit which may cause the fire accident. 5.2.1.7 Do not stack the sundries and any inflammable and explosive materials on the coal conveying corridors and stairs.
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Volume H
Appendix -- Operation and Management System of Thermal Power Plant
1 Scope The standard provides suiting up, taking over shift, discipline on duty, operation and handling of maintenance work sheet, periodic tests of equipment, rotation, patrol inspection, logs, accounting records, data management, telephone contact and other working contents and requirements, working procedures, responsibilities and authorities, inspection and examination and other matters of operators on duty during the attended period in Power Company Limited The standard applies to all operating positions of Power Company Limited. 2 Management Contents and Requirements 2.1 Regulations on Suiting up 2.1.1 Clothing is the labor insurance working clothes of the company. Spring and fall clothing, summer clothing and winter clothing shall be followed under the requirements in different seasons and the uniform clothing is required. 2.1.2 Working clothes shall be worn neatly and shall not have some parts likely to be grounded by the rotating machinery, and it is prohibited to wear long clothes (referring to overcoat and windbreaker) and scarves as well as sleeveless shirts, shorts, skirts, windbreaker, overcoats, synthetic type and other bizarre dresses. 2.1.3 Shoes are the corresponding professional labor insurance working shoes. It is prohibited to wear slippers, sandals and high-heel shoes. It is prohibited to wear spiked shoes and shoes with iron base when entering oil and hydrogen zones. 2.1.4 Safety helmets must be worn when entering the production site. Hair shall not be long enough up to the shoulders at most, or else her/his hair must be included in the helmets. 2.1.5 Those who entering various dangerous areas to engage in the specific tasks shall wear the corresponding protective articles and use the special tools and equipment (such as protective glasses, insulating shoes, insulating gloves and gas masks.). When it is likely to contact the surface of high-temperature objects prior to work, operators must wear special gloves and special working clothes, and shall wear protective glasses when observing the furnace flame and installing or taking fuses, etc. 2.2 Regulations on Shift Exchange and Taking over Shift 2.2.1 Procedures for shift exchange and taking over shift: inspecting by patrol the related equipment of the post referring to the position records asking the relevant situations of the previous shift on the position participating in the meeting of the 344
set (or unit) before on duty signing for shift exchange punctually meeting after on duty 2.2.2 Operators before taking over shift must understand clearly the following situations: a) b) Operating mode, maintenance items and security measures. Operating status and parameters of major equipment, automatic devices and protection input situations. Equipment with shortcomings and hidden trouble and the operation status. Common tools, appliances, meters and instruments, keys and data and others with or without the lack available or being damaged. Operating status, maintenance work and unusual changes and others of equipment during the period from the previous shift exchange to the current taking over shift. Whether the site sanitation and civilized production situations meet the requirements. The leaders or main personnel on duty must understand the mental state and ideological state of subordinate staff.
c) d)
e)
f)
g)
2.2.3 Requirements for the meeting before on duty: a) b) Taking over shift punctually before five minutes. Arranging teams neatly so seriously in accordance with the regulations at the place specified. Making concise reports in turn from the main to the auxiliary positions. The host shall focus on the focal point, sum up the working situations concisely and arrange the tasks, attentions and anticipated accidents for the present team. Taking over shift correspondingly when the uniform signal is sent, and signing first to agree to take over shift for personnel taking over shift, and then signing to leave the position for personnel with shift exchange.
c) d)
e)
2.2.4 Those that have any of the followings are prohibited to take over shift (or "Five Stops"): a) b) c) d) No period of stopping operation or test; Accidents being handled; Unclear records, unknown clarification or uncertainty in heart; Untidy site, the appliances, meters and instruments, keys, or drawings and data in shortage or being damaged, without explanation or records; Other situations hindering safe operation. 345
e)
2.2.5 When taking over shift, if an accident is being handled and major operations are running by the previous team, the operators who will take over shift shall have the obligation to assist in the operations but shall not conduct any operation without authorization under the requirements and command of the leaders or main personnel on duty. 2.2.6 The main personnel on duty shall report the situations concerned to the leaders on duty within 15 minutes after taking over shift; the assistant leaders on duty and the main personnel on all auxiliary positions shall report the situations concerned to the leaders on duty within 20 minutes. 2.3 Discipline in Operation on Shift 2.3.1 Discipline in operation on duty is required to follow 10 prohibitions: a) Prohibiting reading newspapers, magazines and non-professional books, but allowing reading professional books without affecting the normal work; Prohibiting loud noise or name-calling, fighting, whistling, singing or heckling; Prohibiting spitting anywhere, pouring tea at will, or throwing meals, wastepaper and debris and others disorderly; Prohibiting going to other positions, slipping away from own positions, dozing, being late or leaving early; under exceptional circumstances and when necessary to leave own positions, those in accordance with the regulations shall transact the leave procedures and shall not leave until the consent of their superiors responsible. There may not be any positions; Prohibiting damaging or misappropriating public and private goods, removing or moving arbitrarily security facilities, and dialing position clock indiscriminately (the position clock may be adjusted at 9:00 am Sunday and is based on the time checked by the leader on duty, and the unusual adjustment is subject to the approval of the leader on duty; Prohibiting doing private tasks or talking about stocks and speculating in the stock market; No smoking; Prohibiting carrying children, relatives and friends to go to work; Prohibiting baking items in the equipment, or heating and boiling water with electric furnace; Prohibiting cooking food or snacking within the period on duty.
b) c)
d)
e)
f)
g) h) i)
j)
2.3.2 The following shall be carried out when on duty: a) Those that do not pass the examination shall not separately supervise and operate; 346
b)
Supervisors shall sit correctly, and shall not remove their shoes and raise feet and place their feet on the panel board or tables or chairs in any premises; Position certificate shall be worn when entering the production areas; Those when supervising the disk shall not do the other things unrelated, and shall not chat with others, read or do other little tricks; Those that supervise the disk shall closely monitor meters, pay attention to changes in trends, skim over all frames and meters, monitor importantly the major meters and frames and take calm analysis when finding abnormal situations, and then adjust and process timely and report the superior personnel on duty; The personnel who supervise the disk shall be changed in a stable working condition, and the person handing over the disk must clearly explain the operation mode, status and attentions and the person who will take the disk must be aware of all; Maintaining the clean and beautiful places on duty regularly, placing the appliances, meters and instruments, keys, records and dish and tea utensils neatly, and returning the drawing and data to the original places after being used; Dining regularly at the fixed places, tidying up the remnant immediately after the meal and putting it in the designated locations, for maintaining environmental sanitation. Prohibiting dining in the centralized control room; Promoting civilization and politeness on duty, and speaking and acting politely, welcoming leaders concerned and foreign visitors hospitably, standing up when replying to the question; the personnel who supervise the disk shall politely decline any questions; Non-duty personnel shall not enter the control room without the permission of the leaders on duty, and the personnel unrelated to operation are not allowed to go within the cordon;
c) d)
e)
f)
g)
h)
i)
j)
2.4 Regulations on Operation 2.4.1 Large-scale operations and the handling of the work sheet shall generally not be carried out within 30 minutes before and after shift exchange and taking over shift. 2.4.2 In strict accordance with the rules and regulations, all operations and protection, the input and retreat of automatic devices and others must be conducted. 2.4.3 In accordance with the "Electrical Safety Regulations" and relevant technical standards as well as the on-site system and regulations, the operations required for an operating sheet (card) must be done with an operating sheet (card). 2.4.4 Under non-emergency situations the normal operation and command procedures shall be followed, and operational orders shall be issued gradually. The command 347
procedures for the operations involved in multi-profession are: leader on duty the main personnel on duty of the set operators; the day-to-day operations not involved in the system or not affecting other sets shall be conducted by the main personnel on duty of the set in accordance with the procedures. 2.4.5 Under emergency situations, unless endangering personal or equipment safety, the unified command of the leader on duty shall be followed and the leader on duty under emergency situations can issue operational orders beyond command. 2.4.6 Personnel at all levels must issue operational orders accurately and clearly and issue only one complex (multiple) operational command once, followed one by one. The personnel who issue orders must speak loudly and use the unified scheduling terms. For example: "0", "1", "2" and "7" are read aloud to "Dong", "Yao", "Liang" and "Guai" Close (open): disconnecting link, switches Install (remove): grounding wire, masking columns, railings and safety net Hang up (take down): marking plates, etc. Increase (decrease): voltage, cyclic wave, pressure, temperature, vacuum, speed, force, and flow and others. Increase (decrease): active power, passive power and so on Maintenance: voltage, cyclic wave, pressure, temperature, vacuum, speed, force, and flow and others Activate (stop): pumps, fans, etc. Open (stop): machines, furnaces, etc. Input (retreat): automatic devices, protective equipment, nozzles, oil guns, bypass, and electric field and so on. Open (close): shutters, valves, throttle, etc. Load (unload): fuses, control insurance and so on Separate (parallel): generators, busbar, system, etc. 2.4.7 Operational orders shall specify clearly operating objectives, contents, time, requirements, and attentions and other matters. 2.4.8 Dual names shall be used for equipment, following the site names. 2.4.9 The acceptable operational orders shall be repeated and checked by the acceptors. 2.4.10 The issuers when issuing the operational orders shall enable the acceptors to repeat and check, and answer: "Yes! Implement" if no error, for the official enforcement of the orders.
348
2.4.11 All operations must be under custody according to the provisions of "Safety Rules". Guardians in the process of monitoring shall not leave the operators and operation site. 2.4.12 Electrical operations shall follow the following steps. a) Operating sheets must be used if necessary according to the provisions of the "Safety Rules". Operating sheets shall be filled out by the operators, (for the complex operations and the operations required by the leaders on duty within one hour after taking over shift, the operating sheets shall be completed by the previous team, and shall be inspected carefully by the operators responsible on duty, who shall sign for use if qualified and shall assume the responsibilities of the person filling out the sheets), and shall be reviewed by the guardians, the main personnel and leaders on duty at all levels and be signed if no error after confirmation. Before the formal implementation of operations, the equipment name, number and location shall be checked on DCS (NCS) and operation exercises will be simulated and the formal operations will be conducted if no error.
b)
c)
2.4.13 Each specific operation shall follow the procedures of calling out the names voted checking repeating - operating inspecting eliminating, namely: a) b) c) Guardian reads operation items and contents. Operators check the equipment and number without error. Operators with hands (or tools) touch the operating mechanisms of the equipment. Operators repeat operation items and contents. Guardian observes that the equipment and the number touched by the operators shall be consistent with the items on the surface of the operating sheet. Guardian issues operation order: "Yes! Implement!" Operators conduct operations and pay attention to the changes in equipment status. Operators together with the guardian check the equipment status if it runs normally, and then the guardian shall mark "" or give clear indication of opening and closing volume in the marking column of the items being implemented.
d) e)
f) g)
h)
2.4.14 All operation items shall be reported to the issuer after being completely implemented.
349
2.4.15 The guardian and operators shall stands on the appropriate locations in operation to facilitate the requirements of easy operation, clear surveillance and avoiding danger. 2.4.16 The items being operated by a single person shall comply with "Safety Rules", and follow the principle above and a confirmation system shall be carried out. 2.4.17 The insurance taken down and switches pulled out after the operation shall be placed neatly at the positions regulated and the cabinet doors shall be well closed. 2.4.18 The masking columns installed and the marking plates hung shall be normalized and eye-catching. 2.4.19 The tools and equipment must be worn when operation in accordance with the regulations, and their integrity situations shall be checked prior to use and their technical parameters shall be consistent with the relevant requirements. 2.4.20 If there is doubt or abnormality in operation, operation shall immediately be stopped and will not continue until the identification of the reasons. 2.4.21 In the whole process of operation, operators shall be serious and concentrate on their attention and are prohibited to chat or joke or do other actions scattering their energy. 2.5 Regulations on Transacting Work Sheet of Equipment Maintenance 2.5.1 When all the equipment within the scope of operation jurisdiction is under maintenance, the procedures to permit construction for maintenance work sheet shall be transacted according to the provisions of "Safety Rules". 2.5.2 The issuer of work sheet, person responsible for the work, working licensor and acceptor of completion of the work must pass the factory examination and assessment and the list of the qualified personnel shall be published, and the work sheets transacted by other personnel will be invalid. 2.5.3 The work sheets of complex safety measures, planned maintenance and electrical type shall be issued ahead of one day and be sent to the site, and all licensor of work sheets after receiving the maintenance work sheet shall review the pass rate of the sheets as well as the necessity and possibility of the work immediately; all work sheet that will be qualified by supplement shall be received, and all ones that will not qualified after supplement shall be refused and shall be returned immediately for re-signature, and the relevant records shall at the same time be made. 2.5.4 Work sheet shall be in duplicate and be filled out uniformly with ball pen or pen, with clear and neat handwriting, accurate terms and complete and appropriate measures. 2.5.5 The review of work sheet shall include the following: a) Maintenance work surely necessary. 350
b) c) d)
Possibility of the measures required for completion of maintenance. Clear work tasks and locations. Time for maintenance work estimated to be within the time approved by scheduling or controlled by the company. Safety measures already reasonable and complete. The sheets are qualified, clean and integral, and the defacement is clear, the issuer shall sign or seal on the defacement, and the number of defacement in each work sheet shall not be more than two and the total number may not be more than five. If safety measures are inadequate, the licensor shall supplement and complete in the column of additional safety measures of operators and shall sign
e) f)
g)
2.5.6 Procedures to start the permit of work sheet a) The licensor or the person designated by him/her shall do all safety measures in accordance with the requirements of sheets. The licensor jointly with the person responsible for the work will go to the site to check whether all safety measures have been done well, and shall explain the attentions concerned to the person responsible for the work. The leaders on duty, the licensor of work and the person responsible for the work in order shall sign on the required part of the work sheet to permit the start, and shall make records and registration. The one of the work sheet in black is prepared for maintenance and the one of it in red is for operation, and both of them shall be kept properly. For the maintenance work with the need of unlocking for entering the premises and of unlocking or removing the locking by misuse, operators must open the lock or unlock, and the maintenance personnel when leaving the maintenance site shall promptly notify the operator to restore the lock to the original condition.
b)
c)
d)
e)
2.5.7 When any of the following situations happens, the operators on duty shall promptly point out or correct until the maintenance personnel stop their work and then they will immediately be ordered to leave the site. a) Expanding the scope of maintenance work or replacing the person responsible for the work without authorization. Moving, removing or changing the safety measures without authorization. Endangering the personal and equipment safety. The procedure for extension of the work sheets due is not done.
b) c) d)
2.5.8 Acceptance procedure of completion of maintenance work. 351
a) b)
Inquiring maintenance situations of equipment. The licensor or the person responsible for the position designated by the licensor will go to the site to inspect that the maintenance of the equipment has indeed completed, the equipment marks are integral and heat insulation has restored, shelves have been removed and the site sanitation has been cleared, with commissioning conditions. If conditions permit or the equipment must not be accepted until joining the operation, the one of work sheet held for maintenance shall be recovered and then the equipment will be put into operation for inspection. It is required for the person responsible for maintenance to complete item by item or cancel or change the maintenance and commissioning records. The person responsible for the work and the licensor of work in order shall sign on the required part of the work sheet for write-off, and make records, registration and reporting.
c)
d)
e)
2.5.9 If one of the following conditions appears, the acceptance of and cancellation procedures for the handling of work sheet shall be refused. a) The equipment after maintenance fails through the inspection, commissioning and testing, and there are no views and signature of the technical person responsible. The equipment and site are not clean and garage after maintenance is not removed. Records and data are incomplete and explanation is unclear, without recognition of the leaders concerned. The defect is not yet removed and secure and reliable technology measures are not yet taken.
b)
c)
d)
2.5.10 The qualified equipment after the acceptance through maintenance shall be promptly put into operation or included in the reserve. 2.5.11 Hot work sheet shall be transacted in accordance with the related provisions of the management of the companys hot work sheet. 2.5.12 Thermal work sheet shall be transacted and implemented according to the relevant provisions of the company. 2.5.13 Under special circumstances, when it is necessary to suspend the maintenance work and restore the equipment operation, the consent of the person responsible for the work must be obtained, the retention work sheets will be recovered, and the staff will be arranged and the site will be cleaned and operations will not resume until the conditions are prepared.
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2.5.14 The maintenance work sheet, hot work sheet and thermal work sheet and others shall be properly kept by classification in accordance with the regulations. 2.5.15 For the maintenance work unable to be completed within the time expected due to some reasons, the person responsible for the work under the requirement of the extension of the work sheet shall apply for extension in advance to the work licensor and the leader on duty. And the licensor and the leader on duty based on the actual situations shall reply in writing with the procedures for extension or do not agree with the extension. Work sheet is often only permitted to be extended once. 2.6 Regulations on Periodic Test of Equipment and Job Rotation 2.6.1 The equipment shall be periodically tested, and job rotation shall be conducted on the uniform organization and regular basis according to the time, contents and requirements regulated by the relevant profession. 2.6.2 Periodic tests and job rotation shall be under the situations of good organization, specific tasks, uniformity and harmonization, conforming operations and detailed records, and it shall be done before operation that a comprehensive understanding of the operation situation of the equipment meeting the regular work requirements will be conducted, and the accidents shall be envisaged. 2.6.3 In the process of a regular test and job rotation, it shall immediately stop if there are unusual circumstances, and will continue after the reasons are identified and dealt with normally. 2.6.4 Regular work can not be carried out on schedule as a result of special circumstances, the special engineer of operation shall be reported, the situations will be recorded in the operating record and dedicated record book, and the regular work will not be completed until being processed as quickly as possible normally. If before the regulated time for the regular test and job rotation, the equipment has been maintained just or was tested due to other reasons or has worked, the test or rotation can not be conducted after the content of the special engineer of operation 2.6.5 For the work that can be conducted with the need for guardianship or the use of operating sheet (card), the system of filling out the sheet and review and guardianship shall be implemented. 2.6.6 The situations and results of regular work shall be promptly recorded in the specialized record book. 2.6.7 The special engineer of operation shall periodically inspect the implementation of the regular test and job rotation, and arrange immediately the deficiencies in the equipment found in the regular test and job rotation for maintenance to ensure that the equipment can always be maintained in a good operating and standby state. 2.7 Regulations on Patrol Inspection of Equipment
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2.7.1 The operates on duty during on duty shall take patrol inspection of the equipment in accordance with the cycle, routes and requirements regulated in "Management standard for patrol inspection" of the company, and shall properly use the point-inspection instrument in accordance with the provisions of the point-inspection instrument and complete the entry of the relevant information. 2.7.2 If one of the following special circumstances is encountered, the time interval between the two inspections shall be shortened and the inspection frequency shall be increased. a) Equipment and system are in an unusual operation mode or have weak contact with the main network. Equipment operates at full load or overload or can not operate with the normal output. Equipment has a significant deficiency or hidden danger. The new equipment has been put into operation in the early period or the equipment is put into operation again through maintenance and elimination for long-term standby after the accident takes place. Bad climate and environment (such as acute storms, strong lightning, freezing and high temperature).
b)
c) d)
e)
2.7.3 Patrol inspection must comply with the relevant provisions of "Safety Regulations" and must be carried out by two persons for the equipment and regions where potential dangers and accidents exist. 2.7.4 Patrol inspection of equipment must be careful and shall follow "Two Six-aspect and Three Comparisons", namely: The locations where operators may be close shall not be omitted The checkpoints that shall be touched will be touched by hand The situations that shall be seen will be made sure The locations where a sound shall be listened to will be clear with ear The regions where odor shall be smelled will be smelled with nose The situations that shall be analyzed will be analyzed with the brain Comparing the actual instructions of meters with the standards Comparing the same type of devices mutually Comparing the current inspection with the previous one 2.7.5 When taking a patrol inspection of equipment, the related tools (such as a flashlight, listening needle, vibration measurement device and thermometer and the relevant records and table paper) shall be carried, checking while making records, not with 354
gloves, ear plugs, discoloration glasses and others, and protective glasses shall be worn when inspecting the coking and combustion conditions of the combustion chamber,. 2.7.6 In the process of patrol inspection, for unusual circumstances found, those that can be immediately dealt with shall be immediately done, but those that can not be dealt with immediately and that need not be immediately done shall be timely reported to the superior person responsible on duty, and meanwhile the relevant records shall be made. 2.7.7 The patrol inspection of the high-voltage electrical equipment is allowed only to be done by the personnel who are approved by the company and have the right to individually take patrol inspection of high-voltage equipment. 2.8 Management Regulations on Operation Logs, Accounts, Operating Records and Data 2.8.1 Various records, accounts and data shall be classified, positioned and stored properly, with good taking over shift according to the regulation. 2.8.2 Loving all kinds of technical data, which can not be torn up, scrapped at will or be used as cushion and for wiping tables and chairs and packing things and others. 2.9.3 Parameters shall be punctually accurately and seriously copied or data shall be punctually printed as required, and problems found shall be promptly reported and it is forbidden to "do a list" or deliberately disable an automatic recording device and meter. 2.8.4 All records at the site shall be made uniformly with black pen or ball pen, with clear and neat handwriting, the words disconnecting with body or not out of grid, and trying to achieve Fangsong fonts as required. 2.8.5 All records shall be accurately detailed with accurate time and shall not be allowed to be altered or scrapped at will. 2.8.6 All records at the site must be signed by the recorders or operators but not be signed instead. 2.8.7 Various recording accounts and data shall be sorted and stored after use, and the relevant technical statistics and summary shall be made well. 2.8.8 The site data and printing equipment are prohibited to be moved for private use. 2.8.9 All the records, accounts and data that will be entered into EAM system as required shall be timely and accurately entered and saved. 2.9 Regulations on Contact by Telephone 2.9.1 Operators shall care for communication equipment, handle light with care and touch light, and will be prohibited to press and crash in chaos.
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2.9.2 It is prohibited to chat, listen to music, joke and so on by telephone, and operators shall take the initiative to allow the production call if non-production call. 2.9.3 Operators must speak clearly and use the unified scheduling terms, and shall repeat when receiving orders and check their accurateness. 2.9.4 Keeping polite and civilized: it is prohibited to use vulgar language and vent discontent by telephone. 2.9.5 Except the leader and the main personnel on duty, all the other staff will not be allowed to use the scheduling telephone, and accept the scheduling orders and convey the scheduling operation orders. 2.9.6 For the important duty positions or scheduling units, it shall be guaranteed at any time that two-way and more communication lines are open. 2.9.7 Before communication, the two sides shall take the initiative to call the factory names, position titles and names, accept scheduling orders, report the situations to the scheduler, and issue operation orders by telephone and require that a recording telephone shall be used for recording. 2.10 Regulations on Shift Exchange 2.10.1 The places of equipment established shall be comprehensively inspected once and the fields and equipment concerned shall be cleaned thoroughly prior to shift exchange. 2.10.2 Taking the initiative to introduce the operating situations and mode of equipment, changes in equipment, main operations of the team and the present problems, attentions and preventive measures to the personnel taking over shift. 2.10.3 If there is one of the following conditions, the personnel taking over shift shall be accompanied to observe on the site: a) b) Existence of significant deficiencies of equipment; Important safety measures of the maintenance items and new equipment of the team; The equipment in intermittent operation with the need for starting the handover team; Sanitation of the site equipment needed to be handed over at the site; The unfinished work left by the team; Tools, equipment, instruments and accessories damaged and lacked by the team
c)
d) e) f)
2.10.4 Reporting the situations concerned on duty to the superiors before 30 minutes at punctual shift.
356
2.10.5 Reviewing the records and signatures of the subordinate positions before 30 minutes at punctual shift. 2.10.6 Re-inspecting once the position records before 15 minutes at punctual shift, whether the followings are accurate and complete, or else some else shall be added: a) b) c) d) e) f) Operating time and contents; Changes in equipment; Time and situations of fault and the process of treatment; Equipment defects and technical measures; Tasks and instructions issued by the superiors; Operating modes of equipment and system.
2.10.7 Operators on duty shall be from beginning to end and take over shift fully and completely, achieving "Five handovers and five non-handovers": a) b) c) d) e) f) Handover at the site; Written handover; Oral handover; Thorough handover; Initiative handover; Not handover if part of operation, test or handling of the accident does not end; Not handover when the preparations for the personnel taking over shift are not done well or the personnel think the records unclear and unknown; Not handover if the site is unclean and when the tools and equipment, instruments and meters and data are in disorder or lost to inhibit the normal work of the personnel taking over shift: Not handover if the notice on orders from the superior is not clear and there are other some to hinder safe operation but without safety measures; Not handover when the personnel taking over shift are found to be mental disorder or drink.
g)
h)
i)
j)
2.10.8 After the personnel taking over shift sign on the record book to agree to take over shift, the formal taking over shift will not be implemented until the leader on duty gives orders or issues the uniform shift signal. 2.10.9 Lining up in the place regulated, counting the persons, and holding a summary meeting after on duty; the leader of the set will briefly summarize the production 357
situations of the team, and publicize labor discipline, rules and regulations, examination results, main operations and evaluation on accident treatment, criticize and correct bad phenomena and behaviors, appraise good staff and deeds and arrange the tasks after duty. 2.11 Management Regulations between Duties 2.11.1 All personnel on duty shall prepare strict, scientific and pragmatic management rules and assessment methods based on the relevant provisions; 2.11.2 All personnel on duty shall take meticulous and clear tasks, and security and training and other personnel shall perform their duties and fulfill their duties; 2.11.3 Various records, operation analysis, safety analysis, monthly and quarterly and annual work plans and the summing-up and others of each person on duty shall be qualitatively and quantitatively completed and sent to the departments concerned for review; 2.11.4 The leaders on duty shall be aware of the ideological status of their members and take ideological work in a timely manner to ensure the smooth progress of all works; 2.11.5 The problems in the operation shall be timely analyzed and discussed and some preventive measures shall be prepared: 2.11.6 Anti-accident exercises and technical competitions shall be regularly conducted. 2.11.7 Competitions between duties shall be launched, competed, analyzed and counted. 3 Inspection and Examination 3.1 Standardizing duty is mainly based on inspection and examination, and at the same time inspection and examination combined with relevant departments of the company will be carried out from time to time.
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300MW PROJECT

Contract No. 32003/QNTPJSC-SEC DateOct. 31, 2005

Vietnam Quang Ninh 2300MW Thermal Power Plant Project

Training Material for Operators

March 11, 2008 Compiled By Shanghai Electric (Group) Corporation

Vietnam Quang Ninh Phase I 2300MW Project

QUANG NING THERMAL POWER JOINT STOCK COMPANY

QUANG NING THERMAL POWER JOINT STOCK COMPANY 2300MW PROJECT

Training Material for Operators

Approval: Review: Compilation:

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Volume A Brief Introduction to the Unit

Vietnam Quang Ninh Phase I 2300MW Project

2 Main Electrical Wring and in-plant Electrical System

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

3 Main Equipment, System Condition

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

There is no condensate polishing system for the project.

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project

Sodium hypochlorite: 10% NaCIO

Vietnam Quang Ninh Phase I 2300MW Project

Vietnam Quang Ninh Phase I 2300MW Project