Bop Operation Manual Qn1 Sec G 04 TP 005 (195) Dang

SEC
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 300 MW Anthracite Coal Fired Power Station
BOP Operation Manual
Date 2008-09-16
No. : QN1-SEC-G-04-TP-005
Rev.: A
SEC
Index
1 Scope ................................................................................................................................................................... 4 2 Specific quoting documents ............................................................................................................................... 4 3 Fuel Oil Unloading and Storage & Supply System Operation Manual ......................................................... 4 3.1 Equipments and general description of fuel oil system and fire fighting system .......................................... 4 3.2 Basic properties and technical specification of fuel oil system..................................................................... 4 3.3 Interlock and protection of system ................................................................................................................ 6 3.4 Startup and shutdown of system ................................................................................................................... 6 3.5 Inspections and notices before startup of fuel oil system.............................................................................. 9 3.6 Operation regulating of fuel oil system (oil supply and unloading)............................................................ 10 3.7 Operation regulating of effluent oil system..................................................................................................11 3.8 Operation Check and maintenance of fuel oil system ................................................................................. 13 3.9 Safety operation cautions of fuel oil system ............................................................................................... 13 3.10 Common fault, judgment and disposal of fuel oil system and equipments ............................................... 15 4 Water Treatment Plant Operation Manual.................................................................................................... 21 4.1 General Description .................................................................................................................................... 21 4.2 Technical Specification ............................................................................................................................... 21 4.3 Operation .................................................................................................................................................... 22 4.4 Common faults, judgment and treatment at the water purification station ................................................. 27 5 Demineralization system Operation Manual ................................................................................................. 28 5.1 General description ..................................................................................................................................... 28 5.2 Technical specification of equipment.......................................................................................................... 29 5.3 Control standard and period of water quality of feed-water treatment system ........................................... 30 5.4 Operation of demineralized equipments ..................................................................................................... 31 5.5 Common faults, judgment and disposal ...................................................................................................... 43 6 Water Steam Supervision System Operation Manual................................................................................... 46 6.1 Technical specification................................................................................................................................ 46 6.2 Chemical supervision during unit operation ............................................................................................... 51 6.3 Chemical protection of standby unit ........................................................................................................... 55 6.4 Operation of the boiler chemical dosing system of the boiler..................................................................... 57 6.5 Reason and treatment of water steam quality deterioration ........................................................................ 59 7 Waste Water Treatment Plant Operation Manual ........................................................................................ 64 7.1 General description of waste water station and system............................................................................... 64 7.2 Technical specification................................................................................................................................ 64 7.3 Operation of waste water treatment equipments ......................................................................................... 66 7.4 Common faults, judgment and Treatment of wastewater station and wastewater system........................... 69
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8 Hydrogen Generation Plant Operation Manual............................................................................................ 70 8.1 General descriptions of hydrogen plant and hydrogen system.................................................................... 70 8.2 Technical norms of equipments .................................................................................................................. 70 8.3 Equipments operation ................................................................................................................................. 72 8.4 Common faults, judgment and Treatment of hydrogen station and hydrogen generation system............... 76 8.5 Special safety cautions of hydrogen generation station and hydrogen generation system .......................... 79 9. Circulating Water System & Auxiary Cooling Water System Operation Manual .................................... 80 9.1 Equipment Technical Specification............................................................................................................. 80 9.2 Circulating Water System ........................................................................................................................... 81 9.3 Auxilary Cooling Water System.................................................................................................................. 87 10 ESP System & Deslagging and Ash Handing System Operation Manual ................................................. 90 10.1 10.2 10.3 10.4 10.5 10.6 Scope .................................................................................................................................................... 90 Specific quoting documents ................................................................................................................. 91 Principal specification of system.......................................................................................................... 91 Startup, operation and maintenance and stop of ESP system ............................................................... 94 Startup, operation, maintenance and stop of negative-pressure ash removal system ......................... 100 Startup, operation, maintenance and stop of the hydraulic deslagging system................................... 105
11 FGD and Limestone Supply System Operation Manual............................................................................110 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 SCOPE ................................................................................................................................................110 NORMALIZED DOCUMENT QUOTATION ...................................................................................111 FGD SYSTEM QUIPMENT SPECIFICATION .................................................................................111 START-UP OF DESULFURIZATION SYSTEM .............................................................................. 129 MONITORING AND REGULATION IN FGD SYSTEM OPERATION ......................................... 145 SHUT DOWN OF THE FGD SYSTEM ............................................................................................ 160 FGD SYSTEM FAULT AND ACCIDENT HANDLING .................................................................. 164 OPERATION OF LIMESTONE SUPPLY SYSTEM ........................................................................ 171 11.9 LIMESTONE HANDLING SYSTEM DESCRIPTION ............................................................ 174
12 Air Compressor System Operation Manual............................................................................................... 176 12.1 12.2 12.3 12.4 12.5 Direction for use of control panel....................................................................................................... 176 Instrument-use air compressor operation ........................................................................................... 176 Air compressor operation maintain .................................................................................................... 176 Air compressor shutdown protection.................................................................................................. 177 Air compressor dryer operation maintain ........................................................................................... 177
13 Fire-fighting System Operation Manual .................................................................................................... 177 13.1 Overview................................................................................................................................................. 177 13.2 Startup mode of fire-fighting pump ........................................................................................................ 177 13.3 Operation mode of fire-fighting pump .................................................................................................... 178 13.4 Chain conditions of fire-fighting pump................................................................................................... 178
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13.5 Diesel fire-fighting pump system............................................................................................................ 178 13.6 Descriptions of fault and alarm of diesel engine fire-fighting pump ...................................................... 180 13.7 Descriptions of function buttons ............................................................................................................. 180 13.8 Inspection items in the operation of diesel pump group ......................................................................... 181 13.9 Regular maintenance of diesel pump group ............................................................................................ 181 14 Appendix ....................................................................................................................................................... 182 14.1 Twenty-five Key Requirements to Prevent Serious Accident and Failure in Electric Power Operation (Chemical Part) Issued by China Grid ............................................................................................................ 182 14.1.1 Prevention from large area corrosion............................................................................................ 182 14.1.2 Prevention from tube explosion of pressure vessel .................................................................... 182 13.1.3 Prevention from motor damage ..................................................................................................... 182 14.2 General Principle of Electrical Part and Pump........................................................................................ 182 14.2.1 Inspection items before power on the motor are as follows: ..................................................... 182 14.2.2 Inspection items during operation of the motor are as follows: ................................................. 182 14.2.3 Inspection items during operation of cables are as follows: ...................................................... 183 13.2.4 General operation requirements of the motor .............................................................................. 184 14.2.5 Measurement Manual of insulation resistance of the motor are as follows: ........................... 184 13.2.6 Operation principle of power failure and supply of the motor: ................................................... 184 14.2.7 Permissible startup times of the motor with squirrel cage type rotor shall be in accordance with following Manual strictly. ............................................................................................................................. 185 13.2.8 Definition of the motor status: ........................................................................................................ 185 14.2.9 Common faults, judgment and treatment of electrical equipments .......................................... 185 14.2.10 Operation of the water pump........................................................................................................ 187 14.3 General Principle of Chemical Technology Supervision ........................................................................ 189 14.3.1 Guidelines of chemical technology supervision ........................................................................... 189 14.3.2 Chemical supervision during startup phase of unit ..................................................................... 190 14.3.3 Normal operation management of the unit ................................................................................... 190 14.3.4 Abnormal quality management of water vapor ............................................................................ 192 14.3.5 Supervision during repair phase of the unit.................................................................................. 193
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1 Scope 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, FGD 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. Staff of Quang Ninh Thermoelectric Co., Ltd. at all levels engaging in chemical operation, power generation operation, equipment maintenance and production technology management must be familiar with all the standard and the relevant parts and strictly implement them. 2 Specific quoting documents DL/T 543-1994 Quality Inspection Standard for Water Treatment Equipment Used in Power Plant DL/T 561-1995 DL/T 794-2001 DL/T 5068-1996 SD 223-1987 DL434-1991 GB12145-1989 Guide for Chemical Supervision of Water and Steam in Thermal Power Plant Guide for Chemical Cleaning of the 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 Manual 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 Fuel Oil Unloading and Storage & Supply System Operation Manual 3.1 Equipments and general description of fuel oil system and fire fighting system The project is equipped with 2 5000 t oil tank, 2 oil unload pumps, 8 oil supply pumps, and 3 scavenge oil pumps, 1 deoiler, 4 fuel oil heaters, 1 drain flash tank, and 1 fuel oil cooler. Fuel oil system is furnished with oil supply piping and oil return pipe to boiler burner, according to single header circulating system for oil supply and return to boiler. The fire fighting systems is equipped with foam tank, various mobile fire fighting apparatuses and fire water system. 3.2 Basic properties and technical specification of fuel oil system Arrange ment mode Lift Indoor, horizontal type
Model Screw type oil unload pump
HSNH1300-54
Quantity
Medium
Heavy oil, oil temperature 50 70%
Flow rate
95 m3/h limit value is 6 m, guaranteed value is 5.5 m
80 mH2O
Efficienc y
NPSHr
Speed
1450 r/min
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Model
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL YB225M-4(
Motor
) Speed 1450 r/min
Shaft power Voltage
32.2 KW
Rated power
45 KW
400 V AC Arrange ment mode Lift Outdoor submersibl e pump
Model Submers ible pump for wastewa ter with oil
32QW12-15
Quantity
Motor model Efficienc y Rated power
YB90S-4(expl osion-proof motor ) 40 0.9 KW
Flow rate
10m3/h
10 mH2O
NPSHr Shaft power
5m 1.1 KW
Speed Voltage
1450 r/min 400 V AC
Front screen of heavy oil unload pump
Type
30 mesh
Model
LY-100
Quantity
1LY-100
Heavy oil Screen paramet ers
Oil temperature 25~50
Flow rate
95 m3/h ()
Piping design pressure Inlet/outl et alarm pressure differenc e Arrange ment mode Outlet oil temperat ure Design oil pressure
0.6 MPa
Inlet/outl et pipe diameter
DN150
Inlet/outlet operating pressure difference
0.1MPa
0.5MPa
Fuel oil heater
Type
Horizontal type U-tube
Model
ZJRQ-28
Horizontal type
Quantity
Inlet oil temperatur e Operating oil pressure
25
50
Fuel oil flow
95 m3/h(each)
0.8 MPa
1.5 MPa
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Heated steam operatin g temperat ure Heated steam design pressure Oil supply pump Model
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Heated steam design temperatur e Max. heater pressure drop Heated steam Operatin g pressure
250
300
0.6 MPa
1.5 MPa
< 5 MLC (On shell side) Flow rate Lift
Heater area
28 m2
SMH660R40E6-7W23 YB180M-4
26.5 m/h 100m
Motor model
3.3 Interlock and protection of system Interlock control is carried out by 8 oil supply pumps for fuel oil system together with boiler combustion system. 3.4 Startup and shutdown of system 3.4.1 Startup operation sequence of heavy oil system Oil store system can be started if oil temperature of large oil tanks is heated to 75 . 3.4.1.1 Purging and preheating for equipment, and system (1) Contact foreman, shift supervisor to cooperate, and the foreman is responsible for total command and contact work. (2) Purge and preheat operation for oil return system a) Open primary, secondary oil return valve on #1(#2) oil, close main oil feed valve before the boiler. b) Open main heat supply valve in heavy oil system, and open heated steam valve of boiler. Connect turbine, and turn on tracing steam supply for boiler heavy oil. Slightly open boiler drain valve, wait until remaining water has been drained up before closing. c) Inform oil store to open front steam, oil interconnection valve, and open steam purge valve on oil return header, so as to carry out purge and preheat for oil return system. d) If the gas is emitted at the top of #1 (#2) oil tank, report it to the foreman. Except oil return valve on #1, #2 oil tank is open, close all valves in items a, c. (3) Purge and preheat operation for oil feed system a) Open oil return valve of pump for #1 (#2) oil tank. Open interconnection valve form oil supply mains to oil return mains of the pump. Open inlet and outlet valves for corresponding heaters. Report this to foreman. b) Close front oil return valve, and open oil feed valve of boiler, then open steam, oil interconnection valve of boiler, finally open steam purge valve on oil feed mains. Then inform oil store to start purging and preheating for oil feed system. c) If the gas is emitted at the top of #1 (#2) oil tank, report it to the foreman. Close interconnection valve form oil supply mains to oil return mains of the pump and all valves
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open in item b. Open oil drain valve of heater. (4) Purge and preheat operation for large oil tank to pump inlet system a) Open oil drain valve in pump inlet mains, and open purge valve in outlet mains of oil tank, in order to carry out purging and preheating. b) Wait until oil drain valve in pump inlet mains is hot, close all valves open in item a. (5) Purge and preheat operation for all pump body, filter, and pump oil return system a) Open inlet valve of first, second-stage oil supply pump, and open oil drain valve at corresponding filter inlet, then open steam purge valve for first, second-stage oil supply pump, in order to carry out purging and preheating for all pumps and filters. b) Wait until oil drain valves for all filters is very hot, open partial circulating valves for first, second-stage oil supply pump, and open oil return valves for first, second-stage oil supply pump, and close inlet valves for first, second-stage oil supply pump, then close outlet valves and oil drain valves for corresponding filters, in order to carry out purging and preheating for oil return system. c) Wait until oil return valve is very hot, close all opened valves. By now, purge and preheat operations before startup of all system, equipment are completed, and report it to the foreman. 3.4.1.2 Startup operation (1) open the following valves: oil supply valve on #1 (#2) oil tank, inlet valves on first, second-stage oil supply pump to be started and outlet, inlet valves for corresponding filters; oil return valve on #1 (#2) oil tank. (2) Make an overall, carefully pre-startup inspection for first, second-stage oil supply pumps to be started. (3) Close start switches for second, first-stage oil supply pumps to be started respectively, and start second, first-stage oil supply pumps respectively. (4) When outlet pressure for first, second-stage oil supply pumps reaches 3.5MPA, slowly open partial circulating valve up to fully open. At this time, ensurethat outlet pressure is stable, and maintain partial circulation for 30 minutes under normal condition. (5) If partial circulating operation is normal and stable within 30 minutes, report it to the foreman and open the following valves: outlet, inlet valves for corresponding heaters, steam valves and drain valves for corresponding heaters, and main oil feed valve of boiler. Close oil drain valve of #1 (#2) heater. (6) Slightly open outlet bypass valve for first, second-stage oil supply pumps, and close partial circulating valve a little bit, to pressurize the oil feed pipeline. (7) When front heavy oil pressure reaches 3.0-3.3 MPA, contact attendant in the oil store to observe the current change, and slightly open front oil return valve successively. At this time, ensure that pump current does not exceed the specified value by closing partial circulating valve of the pump, fully opening outlet valve of oil supply pump, and closing outlet bypass valve, high speed oil return valve of boiler and interconnection valve from oil supply mains to oil return mains of the pump etc., then maintain stable operation for 30 minutes. (8) Adjust heated steam valve on #1 (#2) oil tank. Control the oil outlet temperature in the oil store
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between 80 and 90 degree, and control the oil supply temperature between 100 and 120 degree. (9) According to the current of oil supply pump, open inlet valves of all standby pumps, and slightly open outlet bypass valves of all standby pumps successively, in order to prepare for warm-up of cylinder. (10) Adjust positions of interlock switches for all pumps. Two primary, secondary pumps operate, and two primary, secondary pumps serve as standby. Report it to foreman. By now, startup operations for oil store are completed. 3.4.2 Operation sequence for full shutdown of heavy oil system 3.4.2.1 After boiler shutdown, immediately start to operate as soon as receiving a stop command form the foreman. 3.4.2.2 Parallel off interlocking of standby pump, and stop operation of oil supply pump, and then report it to foreman. 3.4.2.3 Purge operation for oil return system a) Stop oil supply pump and start to operate as soon as receiving a notice form the oil store. b) Close main oil feed valve before the boiler, and open front steam, oil interconnection valve and oil return valve, then open purge valve in oil return header. Inform the oil store. c) If the gas is emitted at the top of #1 (#2) oil tank for 5 minutes, report it to foreman. d) After receiving a notice form the attendant, the foreman shall close all valves opened in item b. 3.4.2.4 Purge operation for system & equipment before oil supply pump a) Shut down oil supply pump and report it to the foreman, then start to operate. b) Close the following valves: oil supply valve on #1 (#2) oil tank, outlet valves for first, second-stage oil supply pumps and bypass valve, as well as partial circulating valves for first, second-stage oil supply pumps. c) Open the following valves: oil drain valve in inlet mains for first, second-stage oil supply pumps, inlet valves and oil drain valves for first, second-stage oil supply pumps, oil drain valve of filter for first, second-stage oil supply pump, and steam purge valve in first, second-stage oil supply and outlet mains, as well as steam purge valve for first, second-stage oil supply pump. Start to purge. d) If oil drain valves is very hot after purging for 10 minutes, close all valves opened in item c. 3.4.2.5 Purge operation for oil feed system, pump outlet and pumps oil return system & equipment a) Start to operate as soon as operation of item 3 is finished. b) Open the following valves: main oil feed valve before the boiler, front steam, oil interconnection valve, steam purge valve in oil feed mains. Inform the oil store to open the interconnection valve from oil supply mains to oil return mains of the pump, and then start to purge. c) If the gas is emitted at the top of #1 (#2) oil tank, open the following valves Outlet valves and bypass valves for first, second-stage oil supply pumps, partial circulating valve for first, second-stage oil supply pump and steam purge valve, and main oil return valve of the pump, as well as oil drain valve of heater. Start to purge. If main oil return valve of the pump
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and oil drain valve of heater is very hot after 15 minutes, report it to the foreman, and close valves opened in items b, and c. 3. 4.2.6 Release parallel operation of #1 (#2) oil tank and heated steam valve for corresponding heater, and fully open drain valve, and close valves of all system, then close main steam feed valve for oil store steam. Report it to the foreman. 3.4.2.7 Make a detailed record for operation, and timely report equipment defects occurred during operation to the foreman, and register the defects. 3.4.2.8 Totally check positions of all system, equipment and valves, in order to prevent items missing. 3.5 Inspections and notices before startup of fuel oil system 3.5.1 Inspection before oil unloading 3.5.1.1 Check oil levels in two oil tanks and remaining oil amount, and make a detailed record. 3.5.1.2 Purging the whole oil unloading system 1) Open oil drain valve in oil unloading mains, and open oil drain valve in the oil unloading pipe in front of oil unload pump, then open interconnection valve between oil unloading mains and steam mains, in order to purge for oil unloading mains. 2) Upon completion of purging, close steam, oil interconnection valve, and close two oil drain valve opened. 3) Open outlet valve of the pump, and close inlet valve of the pump, and open oil valve on #1 (or #2) oil tank, then open steam purge valve for oil unload pump, so as to purge oil unloading system. 4) Wait until steam is emitted at the tank top, close steam purge valve. 3.5.1.3 Check valve positions in the system: 1) If the oil is discharged by a steam operated pump, open outlet, inlet valves, and close all purge valves, and feed oil to all lubrication parts, then drain remaining water in the cylinder. 2) If the oil is discharged by an electrically driven pump, open outlet, inlet valves, and close all purge valves, and open cooling water and adjust properly, then check that manually-operated turning is normal. 3.5.1.4 Check oil unloading rubber pipe connection for fastness and oil leakage, and prepare a small oil bucket for leaked oil. 3.5.2 Prestartup inspection of heavy oil system: 3.5.2.1 Major and minor repairs for all oil store system and equipment are completed, and the work sheets are handled and finished. 3.5.2.2 Check to see if the gear pump rotates flexibly before operation(gently turn by hand). 3.5.2.3 Check to see if the power pack is normal and rotational direction of the motor is correct. 3.5.2.4 Whether the pipe sizes at oil inlet and outlet meet the requirements, and whether oil suction height and the lift exceed specified requirements or not. 3.5.2.5 Check to see if all fasteners are secure (including inlet and outlet pipe connections). 3.5.2.6 When inserting the oil tank before startup, the oil inlet pipe cannot be too high, in order to prevent air from interfusing; the oil pipe cannot be inserted to tank bottom, in order to prevent oil from being suck up due to closed nozzle.
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3.5.2.7 All valves in the system are complete, and their marks are correct and located in close positions. 3.5.2.8 All equipments are complete, and entire, and operating power source for oil supply pump is switched on; all instruments are complete, and entire, and their power source is switched on, and indicated correctly. All operating handles, and light signals are complete, entire and convenient. 3.5.2.9 Contact the foreman to start the boiler, and slowly open main steam supply valve in oil store up to fully open. 3.5.2.10 Slightly open steam heating valve and drain valve on oil tank. Wait until remaining water in the steam system has been drained up, fully open steam heating valve and drain valve, to heat the large oil tank. 3.5.3 Maintenance and safety of the machine 3.5.3.1 Grounding device shall be provided to prevent getting wound due to creepage. 3.5.3.2 Frequently check fasteners for looseness, and if sound of gear pump is normal. 3.5.3.3 Oil inlet shall be equipped with a strainer, in order to prevent scrap iron and laree impurities from sucking into the pump, abrading gears or seizing the gear pump. 3.5.3.4 Oil seals are wearing parts. If oil leakage occurs in the drive shaft, the oil seal shall be replaced. 3.5.3.5 Ball bearing is used by the oil pump. If it is worn, noise of the gear pump is serious, and its output will be reduced, so the bearing shall be replaced. 3.5.3.6 After maintenance of the gears, the axial clearance, concentricity of the pump shall be controlled strictly during reassembly. The tolerance cannot be exceeded, otherwise it cannot operate normally. 3.5.3.7 It is strictly prohibited to operate the gear pump at a place where ambient temperature is extremely high (over allowable motor temperature)or at the open air. 3.6 Operation regulating of fuel oil system (oil supply and unloading) 3.6.1 Operation sequence of oil unloading system 3.6.1.1 Check heating temperature of oil tank truck for propriety, specific requirements are as follows: Oil type heating temperature #100 heavy oil 60-70 degree #200 heavy oil 70-80 degree 3.6.1.2 Open steam inlet valve on steam operated oil unload pump, to allow the steam operated pump to run slowly. 3.6.1.3 Open oil unloading valves at upper and lower parts of oil tanker. If oil leakage is found in oil unloading joint, then the joint shall be tightened by a copper spanner. If a little of leaked oil persists, a small oil bucket can be used to hold it. If oil leaked amount is larger, then close oil unloading valves at upper and lower parts of the oil tanker. Contact maintenance personnel to replace rubber gasket on oil unloading joint. Restart to unload oil after replacing. 3.6.1.4 Open the oil unloading valve from oil unloading rubber pipe to the main piping, and then start to unload oil. 3.6.1.5 If oil pumping of steam operated pump is normal, slowly open the steam inlet valve wider,
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to accelerate unloading speed. Based on the feature of dry absorption capability of steam operated pump, begin with steam operated pump to unload oil, and wait until steam operated pump is operated normally, then start motorized oil unload pump to unload oil quickly. After oil unloading is completed, stop motorized oil unload pump, pump out residual oil at bottom of oil tank truck by the steam operated pump. 3.6.1.6 Wait until residual oil at bottom of the oil tank truck has been removed, then stop steam operated oil unload pump, and close heated steam valve in the oil tank truck, then remove the heating coupling. 3.6.1.7 Close inlet valves of all pumps, and open oil drain valves in front of all pumps and oil drain valve in oil unloading pipeline, and then open interconnection valve form the steam mains to oil unloading mains, in order to carry out purging. Open steam purge valve and oil drain valve at outlets of all pumps, to carry out purging. 3.6.1.8 After oil unloading rubber pipe has been purged, close upper and lower unloading valve on the oil tank truck, and close oil unloading valve from oil unloading rubber pipe to the mains. Contact maintenance personnel to remove the oil unloading coupling. 3.6.1.9 after the steam is emitted at the top of the oil store and oil unloading mains has been purged, close steam and oil interconnection valve, and close all purge valves and oil drain valves, then the purging is completed, finally close oil unloading valve in the oil store. 3.7 Operation regulating of effluent oil system 3.7.1 Specification 3.7.2 Pre-operation inspection of effluent oil system 1) Check to see if connecting pipelines in the system are correct, and if all instruments are intact, and if power source of electric control box is normal. 2) Close primary drain outlet, and secondary drain outlet on the device. 3) During initial use, open water injection valve above oil collecting chamber of oily sewage vacuum separator and water injection valve above oil collecting chamber of effluent oil absorber, and all vent valves. Inject industry water to the vacuum separator and effluent oil absorber respectively, until they are full. Then close all water injection valves, drain valves, vent valves. 4) Check oil content of oily sewage in oily sewage pool. If floating oil thickness reaches 5 mm, start floating oil absorber, otherwise start the vacuum separator. 3.7.3 Operation of effluent oil system 3.7.3.1 Switch on power source of control box, place changeover switch in Local, Automatic positions. Press Start button, and press start switch on the vacuum separator or floating oil absorber (according to floating oil thickness), then the system enters into automatic operating state. 3.7.3.2 When the level of water pool reaches a high position< start position>, the vacuum separator or floating oil absorber will automatically start. As soon as the separated oil returns to oil collecting tank, the purified water from the vacuum separator is discharged to an underground drain, and the separated water from the floating oil absorber returns to the oily sewage pool. 3.7.3.3 If oil level in oil collecting tank reaches a high position, the oil transfer pump will automatic
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start, and the recovered oil is transferred to an oil tank of the system. If the level reaches stop position, the oil transfer pump stops. 3.7.34 The drain pipes is connected with a online monitor in parallel(for its operation mode and maintenance, see the Instruction). The set value of oil concentration in drained water for online detection is 5 ppm/l. If effluent oil concentration is higher than the value, an automatic alarm is given, and motorized drainage valve is closed. Drainage to underground drain is forbidden. Water return valve is open, the effluent is returned to the oily sewage pool for another treatment. 3.7.3.5 The whole system operates automatically, and oily sewage is automatically separated. If the level in oily sewage pool reaches to a low position<stop position>, the system shut down. 3.7.3.6 If remote control or local manual control is required, place the changeover switch to the corresponding position, and then remote automatic control or local manual control can be affected by the system. 3.7.3.7 If differential pressure controller or safety valve operates, the system will raise an alarm. Shut down and clean up or replace macromolecule filter element. 3.7.3.8 Check if rotational direction of the pump is correct, and check all meters and instruments for intactness. 3.7.3.9 Close primary drain outlet, and secondary drain outlet on the device. 3.7.3.10 Open the valve at drainage outlet and vent valve at the top of macromolecular adsorption chamber. 3.7.3.11 Vacuum chamber, oil collecting chamber and inlet pipeline in the machine are filled with clean tap water. 3.7.3.12 Turn oil drain switch to Automatic position. 3.7.3.13 Press start butt on the electric control box of the machine, motorized screw pump starts to pump water. 3.7.3.14 If the ambient temperature is low or oil viscosity is large, open the heater. 3.7.3.15 After the oil-water separator is operated normally, observe operating conditions of all motors at any moment. In case of abnormality, shut down and check. 3.7.3.16 inlet piping in the machine shall be free from air leakage; otherwise suction ability for the machine would be affected, and even resulting in maloperation of the machine. If a motor-driven plunger pump has always been kept operating state, while the screw pump does not work, then shut down and repair the parts leaked, and fill the device with clean water, then restart the machine. 3.7.3.17 If the gauge glass in oil collecting chamber of the machine is filled with oil, while the plunger pump for oil drain does not operate automatically, but it can be started when oil drain pump is turned to Manual position; it is likely to be the unction of oil level electrode. Shut own and remove the level electrode. Clean up the surface before restarting the machine. 3.7.3.18 If spring loaded safety valve is open(i.e. value of pressure gauge 0.25 MPa), shut down and replace filter element in macromolecular adsorption chamber. 3.7.3.19 If the device is out of service for a long time, the water in the device shall be drained and cut off the power source of the equipment, and motional parts of the pump shall be filled with some lubrication oil.
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3.8 Operation Check and maintenance of fuel oil system 3.8.1 Maintenance and check during normal operation of oil supply pump 3.8.1.1 Temperature of oil supply pump for operating and all bearing of the motor, vibration, axial hunting does not exceed specified value. 3.8.1.2 Lubrication oil for all bearings is sufficient, and oil quality is good. Oil type shall meet the requirements. For bearings with an oil cup, tighten two turns and fill oil in each shift. 3.8.1.3 Cooling water for all bearings is expedite, unblocked, and water flow rate is adequate. 3.8.1.4 Current, pressure for the operating pumps are stable, and oil supply temperature is normal. 3.8.1.5 All gauges are complete, their indications are correct. 3.8.1.6 Valves for all systems are complete and entire. Marks are correct. Switch positions are correct. There are no signs of oil leakage, steam leakage. 3.8.1.7 Warm-up temperature of standby pump is normal, and positions of all linkage switches are correct. 3.8.1.8 Isolation for equipments and systems to be repaired is correct, and safety measures are complete. 3.8.1.9 Operation and standby for all oil tanks are normal. Temperature in oil store meets the requirements. 3.8.1.10 cooling water return for all operating, standby pumps is unblocked. All equipments and the ground shall be clean. 3.8.1.11 If steam operated pump runs stably during oil unloading, there are no signs of abnormal sound and water hammer in the cylinder; steam connections operate normally, all connection parts are secure and complete, and periodically discharge the accumulated water in the cylinder. 3.8.1.12 All filters are put into operation, and operated normally, without plugging phenomena. 3.8.1.13 The heater is operated normally, free from oil leakage, steam leakage phenomena. 3.8.1.14 Oil level in effluent oil basin keeps at a low position, free from abnormal change. 3.8.1.15 Lightings in the site, in particular, the lightings for all oil tanks are OK. 3.8.1.16 Various fire fighting apparatuses in the oil store shall keep intact, and be placed at designated place in order. 3.8.1.17 The used waste cotton yarn and garbage shall be placed in a designated box, and periodic cleaning shall be made for them. It is forbidden to stack waste cotton yarn garbage in the garbage yard at discretion. 3.8.1.18 No fire is allowed in the oil store. If electric arc welding job is to be carried out, special work sheet must be prepared, and take corresponding safety measures. 3.8.1.19 Weeds, and garbages in the oil store shall be removed periodically. 3.8.1.20Usually, the oil store shall be tidy, clean, and sanitary. 3.9 Safety operation cautions of fuel oil system 3.9.1 Notices when operating of oil supply pump 3.9.1.1 Before operation, contact the foreman, and shift supervisor to come to an agreement. 3.9.1.2 Once switching is completed, timely report operating conditions to the foreman. 3.9.1.3 If stopping of the operating pump is defective, timely report it to the foreman, and contact maintenance personnel to remove it or note down the defects.
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3.9.1.4 Shift record shall be made, and current operation and standby mode shall be clearly told. 3.9.2 Notices when startup of heavy oil system 3.9.2.1 Before operation, an overall, earnest, careful inspection operation shall be performed to all equipments, so as to know everything fairly well. 3.9.2.2 Earnestly review operation ticket. Earnestly operate step by step. Valves not yet opened must be opened, and valves not yet closed must be closed, in order to prevent back flow of oil and steam, and running, emitting of heavy oil due to maloperation. 3.9.2.3 After operation is completed, an overall, earnest inspection shall be performed to all oil, steam systems, equipments, in order to prevent running, emitting of oil, steam due to missing, maloperation, hidden trouble of the equipment. 3.9.2.4 This job is leaded by operation director or operation technician in the workshop, and operation foreman is responsible for uniform command. All operating personnel shall strictly execute the command and perform necessary contact and report works. 3.9.3 Notices when full shutdown of heavy oil system 3.9.3.1 This operation is leaded by an operation director or operation technician, and operation foreman is responsible for uniform command and contact works. The whole operation is required to be completed within 60 70 minutes. 3.9.3.2 Make sure to earnestly review the operation tickets before operation, and acquaint with operation sequences, steps and actual positions of all valves, in order to avoid delaying time due to sheer ignorance. 3.9.3.3 After every operation is carried out, review shall be made to prevent back flow, running, and emitting of oil and steam due to maloperation. 3.9.3.4 It is required to coordinate the contact between senior staff and junior staff, and strictly, earnestly execute the command, and obey uniform command. All operating personnel must contact each other and make necessary report works. 3.9.4 Operation, maintenance and notices for effluent oil system 3.9.4.1 Conditions of all instruments, meters, and indicator lights shall be observed carefully during operation. Whether level height indicated is identical with the actual height, and whether the indicator lights are matched with actual operating equipments. In case of any abnormality, shut down and check. 3.9.4.2 Carefully observe if the levels of oil collecting chamber in oily sewage vacuum separator and oil collecting chamber in floating oil absorber are stable. If the level drops, it means that leakage is occurred in suction pipeline in the system, shut down and clean. 3.9.4.3 If water pump and oil drain pump are switched frequently, it means that the electrode bar in the oil collecting chamber is failed. Shut down, and remove the electrode bar and clean up its surface, then put it into service. 3.9.4.4 There must be no foreign matter, impurities in the oily sewage poor. If so, shut down and clean them up. Meanwhile, oil amount at inlet of vacuum separation purifier for oily sewage shall be less than 500100 mg/l. Otherwise, oil absorption saturation of macromolecular filter element would be accelerated, and service lifetime of the filter element would be shorted, and even resulting in overstandard of drainage.
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3.9.4.5 When online concentration monitor gives a signal which means that oil concentration is too high, shut down and check. If digital indication is unstable, shut down and clean the detection elements. 3.9.4.6 If differential pressure controller or pressure or safety valve operates, shut down and clean up or replace macromolecular filter element. Open right cover plate on the macromolecular adsorption chamber. Screw off the screws to fasten the filter element. Grasp the filter element with hand, and draw it out by rotating two turns toward one direction. After the filter element is removed, cut off 2 3 layers with a knife blade, and strip off the outer layer of filter element being cut off. After washing in the clean water and drying, reinstall the filter element to macromolecular adsorption chamber. After reinstalling in reverse order of disassembly, it can be put into service. If the filter element removed cannot be used after cleaning, replacing a new filter element is necessary. 3.9.4.7 If the device is out of service for a long time, it is required to drain the water in the device, and cut off power source of the equipment. Motional parts of the pump shall be filled with some lubrication oil. 3.10 Common fault, judgment and disposal of fuel oil system and equipments 3.10.1 Liquid cannot be drained out or displacement is low a) Possible cause 1) Pump body is not filled with oil. 2) Oil suction height exceeds vacuum height. 3) Air leaked in oil suction pipeline. 4) Rotational direction is wrong. 5) Oil pipe blocked or other faults. 6) Rotational speed of oil pump is low. 7) Safety valve is open. 8) Cone tightness of safety valve is poor. b) Remedy: 1) Fill the place where the vacuum pressure gauge is connected with oil. 2) Raise oil suction surface. 3) Check all connections. 4) Reconnect the motor. 5) Check and eliminate the fault. 6) Check and rectify with a tachometer. 7) Adjust the spring pressure of safety valve. 8) Regrind with fine paste. 3.10.2 Liquid leaked in oil pump a) a) Possible cause 1) Packing gland not compacted. 2) Sealing ring has been used for a long time and worn. 3) Misalignment of sealing ring and not corrected. 4) Oil leaked in some washers .
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b) Remedy: 5) Tighten nuts. 6) Replace. 7) Remove and smoothly tighten nuts. 8) Replace. 3.10.3 Power required by the motor is too big a) Possible cause 1) Viscosity of sucked liquid is too big. 2) Discharge pressure is too high. 3) Resistance of discharge pipeline is too big. 4) Running of rotary parts is obstructed, resulting in intense heat due to friction. b) Remedy: 1) Preheat or reduce discharge pressure. 2) Reduce discharge pressure. 3) Check and eliminate the fault. 4) Remove, check and rectify. 3.10.4 Oil supply pump tripped a) Possible cause 1) Power supply system failed. 2) Mechanical part of pump body damaged. 3) Pump shaft locked. 4) Overload. b) Remedy: If linkage pump does not put into service, immediately start standby pump to guarantee the oil pressure. Inform local patrol operator to check the circumstance, and contact maintenance personnel to repair. 3.10.5 Vaporization of oil supply pump a) Possible cause 1) Oil level in oil tank is too low. 2) Flush valve not closed. 3) Fine filter plugged. 4) Inlet temperature is high. b) b) Remedy 1) Immediately transit operation. 2) Stop failed pump, put into standby pump, check all valves; contact maintenance personnel to repair if necessary. 3.10.6 Oil pump evacuated a) Possible cause 1) Oil level in oil tank is too low. 2) Air entered into the pump. b) Remedy
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1) Immediately transit operation. 2) Contact maintenance personnel to repair air leakage point. 3.10.7 Oil supply pressure raised a) Possible cause 1) Oil return valve is closed a little bit or valve head fallen off. 2) Front linkage valve operated. 3) Oil consumption decreased suddenly. b) Remedy 1) Check oil return valve, contact maintenance personnel to repair if necessary. 2) Contact shift supervisor to find out the cause. 3.10.8 Low oil supply pressure a) Possible cause 1) Opening of oil return valve is too big. 2) Oil consumption of boiler increased. 3) Oil supply pipeline leaked. 4) Air admitted to suction inlet. 5) Pump speed is low. 6) Suction pipeline plugged. 7) Impeller channel plugged. 8) Impeller damaged or seal ring worn. b) Remedy 1) Adjust oil return valve. 2) Immediately link to start standby pump. 3) Contact maintenance personnel to repair. 3.10.9 Bearing leaked a) Possible cause 1) Gasket of shaft sleeve damaged. 2) Gasket not flat or too hard. b) Remedy: contact maintenance personnel to repair. 3.10.10 Oil tank caught fire a) Possible cause 1) Outside open fire. 2) Improper hot work measures. 3) Spark caused due to static electricity. b) Remedy: immediately dial fire telephone; start foam tank, and extinguish the fire with fire fighting apparatus; release parallel operation of an oil tank if it catches fire. 3.10.11 Pump cannot pump oil a) Possible cause 1) Rotational direction of the motor is wrong. 2) Enclosed impeller channel or suction pipeline blocked. 3) Centerline of the impeller not immersed by fuel oil.
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b) Remedy 1) Change rotational direction. 2) Remove blocked part. 3) Adjust immersed height. 3.10.12 Flow rate not enough a) Possible cause 1) Impeller corroded and worn seriously. 2) Seal ring worn, corrode seriously. 3) Rotational speed not enough. 4) Clearance between open impeller and casing cover is too big. 5) Suction inlet or discharge outlet plugged. b) Remedy 1) Replace impeller. 2) Replace seal ring. 3) Increase rotational speed. 4) Replace impeller. 5) Eliminate blocked part. 3.10.13 Lift not enough a) Possible cause 1) Oil delivered containing air. 2) Impeller corroded, worn seriously. 3) Clearance between open impeller and casing cover is too big. b) Remedy 1) Decrease liquid temperature, eliminate gas. 2) Replace impeller. 3) Readjust clearance. 3.10.14 Excessive power a) Possible cause 1) Process exceeds service range. 2) Specific gravity of the medium is too big. 3) Mechanical friction occurred. b) Remedy 1) Operate the pump within service range. 2) Replace large power motor. 3) Find out the cause, and replace worn parts. 3.10.15 Bearing damage and overheat a) Possible cause 1) Bearing damaged. 2) Bearing clearance too big. 3) Lubrication oil quality unqualified or short of oil. 4) Misalignment between pump and motor.
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b) Remedy 1) Switch oil supply pump, and inform maintenance personnel to repair. 3.10.16 Noise and vibration a) Possible cause 1) Misalignment between pump shaft and motor shaft. 2) Liquid delivered containing gas. 3) Rotor unbalanced. 4) Seal ring worn excessively. 5) Coupling bolt loosened. b) Remedy 1) Adjust concentricity. 2) Decrease liquid temperature, and eliminate gas. 3) Replace parts. 4) Replace seal ring. 5) Tighten various bolts. 3.10.17 Large start load of oil pump a) Possible cause 1) Due to large thrust clearance of oil pump, thrust function of thrust disk and balance disc is lost, leading to friction between movable and stationary parts, and excessive start load, and even that oil pump cannot be started. b) Remedy 1) Stop pump and repair 3.10.18 Faults of mechanical part a) Possible cause 1) Oil level in oil tank is too low. 2) Air entered into oil inlet pipeline. 3) Packing worn seriously. 4) Oil filter plugged. b) Remedy 1) After linkage pump is put into service automatically, close operation switch to transit operation, then stop oil filter and corresponding pump, and start standby pump. 3.10.19 Motor overload a) Possible cause 1) Misalignment. 2) Specific gravity became larger. 3) Friction occurred in rotating parts. 4) Device resistance become lower, operation point leans to large flow rate. b) Remedy 1) Align opposite wheels. 2) Change operating process. 3) Repair frictionized portion.
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4) Check pressures in suction and discharge pipelines and original changes. 3.10.20 Auxiliary power interrupted a) Possible cause 1) Power supply system for auxiliary power failed. b) Remedy 1) Contact shift supervisor to restore power source, and pull the oil pump switch to stop position, then release interlocking switch. 3.10.21 Faults of electrical part a) Possible cause 1) Motor is smoking or catches fire. 2) There is abnormal sound or burnt smell in the motor. 3) Spark occurred in a switch. 4) Motor current exceeds rating. 5) Intensive vibration occurred in a motor. 6) Motor tripped. b) Remedy 1) Rapidly cut off power source for the motor, and start standby motor. 3.10.22 Fuel oil screen plugged a) Possible cause 1) There is impurity in the oil. b) Remedy 2) Switch oil filter, and clean. 3.10.23 Abnormal sound in delivery pump a) Possible cause 1) Idle running of pump. 2) Screws worn seriously. 3) Pump bearing damaged. 4) There is mechanical impurity in the pump. b) Remedy 1) Shut down and check inlet pipeline of pump for blocking, and air leakage. 2) Shut down and inform maintenance personnel to repair. 3) Shut down and inform maintenance personnel to repair. 4) Shut down and inform maintenance personnel to repair. 3.10.24 V-belt slipped a) Possible cause 1) Belt tensions not enough. 2) Pump load is too big. 3) There is oil stain on the pulleys. b) Remedy 1) Shut own and inform maintenance personnel to repair. 2) Check outlet pipeline for unblocking.
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3) Shut down and remove. 3.10.25 High oil content of blowdown water a) Possible cause 1) Failure of separators adsorption material. 2) The shell not full-flow. 3) Serious oil pollution in each stage. b) Remedy 1) Regenerate or replace adsorption material. 2) Exhaust gas up to full-flow of the shell. 3) Back wash or clean and perform blowdown. 4 Water Treatment Plant Operation Manual 4.1 General Description 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. 4.2 Technical Specification Equipment name Major technical parameter Raw water booster pump General pump service Q=200m3/h, H=15m N=15kW, V=400V Q=180m3/h, H=65m N=75kW, V=400V Q=200m3/h, inlet silt content 5kg/m3 Effluent turbidity20PPM lift Q=200m3/h, H=35m N=37kW, V=400V Q=200m3/h, inlet turbidity 20PPM Outlet turbidity3PPM Q=190m3/h, H=35m N=37kW, V=400V Q=600m3/h, H=110m N=315kW, V=6.60kV Unit Set Set 2 Set 2 Set 2 Set 2 Set 2 Set Qty 2 Remark One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for
Mechanical acceleration clarification tank Clear pump water
Filter chamber
Lift pump of filtered water Electric fire-fighting pump
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Fire-fighting pump driven by diesel fuel Fire-fighting pressure stabilizer Industrial pump water
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL standby Q=600m3/h, H=110m N=315kW
3
Set 1 Set
One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for standby Two are in operation and one is for standby, each pump has H=70m, Q=80m3/h, N=30kW and V=400V.
Q=21m /h, H=110m Q=110m3/h, H=60m N=55kW, V=400V Q=130m3/h, H=45m N=37kW, V=400V Set
2 Set 2 Set
Living water pump
Living frequency Total feed water conversion feed 3 Q=0~160m /h, H=70m water device Q=300m3/h, H=30m N=45kW, V=400V Q=0-85l/h, H=70m N=0.25kW, V=400V Q=0-400l/h, H=50m N=0.37kW, V=400V
volume
Active carbon filter backwashing pump Coagulant metering pump Coagulant aid metering pump Agitation tank Living chlorination equipment water
Set 2 Set 2 Set 2 Set 2 1 Set 1 Set 2
One is in operation and the other is for standby One is in operation and the other is for standby One is in operation and the other is for standby
Effective chlorination amount 9.5g/h Effective chlorination amount 700g/h Q=350m3/h, H=35m N=55kW, V=400V
Set
Cleaning station chlorination equipment Filter chamber backwashing pump
One is in operation and the other is for standby
4.3 Operation 4.3.1 Control of Operation Parameters Water sample Item Unit Control standard Time interval Remark
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Raw water Water out of classification tank
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Alkalinity Turbidity Electroconductivity Settling ratio Turbidity mmol/l mg/l s/cm 5min% mg/l mg/l mg/l MPa 10-20% 10 5 0.1 0.05 8h 8h 8h 4h 4h 4h 4 4
Turbidity Water out of Residual chlorine gravity filter Pressure chamber difference
4.3.2 Startup and shutdown of mechanical agitating clarifier 4.3.2.1 Preparatory work for mechanical agitation clarification tank prior to startup 1) The dosage in the coagulant and coagulant aid solution tank is adequate and the liquid level is 1/2 high above the solution pool. 2) There should be no debris inside the clarification tank and the manholes are closed. 3) Sampling tubes and washing pipes should be smooth. 4) The agitator should be filled with lubricant, and its oil level is normal and is in good standby. 5) The bottom discharge valve, middle discharge valve, water exit valve, sampling valve and rinsing water valve of the clarification tank should be closed. 4.3.2.2 Startup of Mechanical agitation clarification tank 1) Start the raw water booster pump, open the exit valve after the pressure is stable, operate the coagulant and coagulant aid chemical dosing system, and regulate the effluent flow and dosage according to the needs, the preliminary water discharge is 100-200T/H, and the quantity of the coagulant and coagulant aid is 1 to 1.5 times the normal amount. 2) Start the mud scraper of the clarification tank, which is operating when lubricant can not be interrupted. 3) When the impeller of the agitator is immersed into water, start the agitator of the clarification tank, adjust the rotation speed to 4.8-14.5 r/min and the hoist speed to 120-1200 r/min, and check whether the agitator is in normal operation; when a circulation is created, fine mud can be input if sludge is loose with small particles in the first reaction room. 4) When the clarification tank begins to output water, the effluent water should be drained into trench if it is unqualified; when the effluent water from the clarification tank is qualified (Turbidity is less than 10mg/L), water can only flow into the clarification tank, and meanwhile water flow rate slowly increases, there is in general 30 tons of flow in every 10 minutes and the coagulant is appropriately adjusted to the normal (200-250T/H). 5) When the effluent water quality of the clarification tank is poor, the reasons should be determined rapidly and the timely treatment should be completed. 6) The sewage on the bottom of the clarification tank prior to startup should be disposed once, and then the tank is started according to the steps above. 4.3.2.3 Stoppage of mechanical agitation clarification tank
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1)
Close the water exit valve of the raw water booster pump, disable the raw water booster pump, stop inputting water into the clarification tank, stop the coagulant and coagulant aid chemical dosing system and stop the agitator and mud scraper finally. 2) When the clarification tank stops for a short term (less than 72H), the agitator can continue running to drain mud appropriately, and the sludge formation maintains not to sediment to prevent blades from being damaged. 3) When the clarification tank stops for a long term (more than 72H) or is overhauled, the sludge in the clarification tank should be dumped before the agitator stops running. 4.3.3 Startup and stoppage of Gravity filter chamber 4.3.3.1 Inspection r prior to startup of the gravity filter chambe 1) The inside of the chemical pool should be clean and have no debris. 2) There should be no debris or manhole leakage inside the filter chamber. 3) Water purification blower should be in the standby. 4.3.3.2 Startup of Gravity filter chamber 1) When the effluent turbidity of the clarification tank is less than 10 mg/L, water is allowed to enter the gravity filter chamber. 2) Open the water inlet valve of the gravity filter chamber and the positive discharge valve of the gravity filter chamber, and wash the valve positively and open the positive discharge valve until the effluent turbidity of the gravity filter chamber is less than 5 mg/L, and input water into the chemical pool through opening the water inlet valve of the chemical pool. 3) Monitor the effluent turbidity of the gravity filter chamber is not more than 5 mg/L and the residual chlorine in the chemical water is not more than 0.1 mg/L. 4.3.3.4 Stoppage of the gravity filter chamber 1) Stop inputting water into the gravity filter chamber from the clarification tank and close the water inlet valve of the gravity filter chamber. 2) If the gravity filter chamber stops for overhaul, open the pollution discharge valve at the bottom of the gravity filter chamber and drain the internal water. 4.3.3.5 Air scrub of Gravity filter chamber 1) Air scrub and backwashing of gravity filter chamber: close the water inlet valve and exhaust valve of the gravity filter chamber, open the reverse discharge valve and connecting butterfly valve of the gravity filter chamber and backwash the filter material. 2) Air scrub and waterdrainage of gravity filter chamber: close the reverse discharge valve and connecting butterfly valve, open the drainage valve, and drain to 100mm above the filter layer by gravity. 3) Air scrub and air inflow of gravity filter chamber: close the drainage valve, open the front drainage valve of air inflow and air exit valve and emptying valve of water purification blower in order to enable smooth exhaust in the air scrub, and air scrub the filter layer. 4) Air scrub, air inflow and backwashing of gravity filter chamber: open the connecting butterfly valve and close the reverse discharge valve, water from the clean water area at the upper part of the bulkhead flows into the water separation chamber and filter area via a connecting pipe,
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and is drained into the gutter from the backwashing pipe via a backwashing drainage valve (that is, drainage backwashing + Air scrub). 5) Air scrub and backwashing of gravity filter chamber: close the compressed air valve and blower exit valve and conduct backwashing. 6) Drainage before air scrub and operation of the gravity filter chamber: drain some water that are unqualified in the preliminary filteration. Close the backwashing drainage valve and the connecting butterfly valve, open the water inlet valve and drainage valve prior to operation, drain the preliminarily filtered water, and then close the drainage valve prior to operation. Open the connecting butterfly valve, and the filter chamber goes into the normal operation. 4.3.4 Operation of chemical dosing system 4.3.4.1 Overview of chemical dosing system The distance between the chemical dosing room at the cleaning station and the chemical dosing point is about 30 meters and the water pressure on the chemical dosing point is about 0.15 MPa. A set of coagulant chemical dosing system, a set of coagulant aid chemical dosing system, a set of sodium hypochlorite chemical dosing system of clarification tank and a set of living water sodium hypochlorite chemical dosing system are set up. 1) Coagulant dosing: the dosage of PAC is 10 to 20 mg/l and the preparation concentration is 5% to 10%; 2) Coagulant aid dosing: the dosage of solid polyacrylamide (PAM) is 1 to 2 mg/l and the preparation concentration is 1%, and the dosage concentration is 0.1 to 0.2%; 3) Germicide dosing: sodium hypochlorite (generated from 4% saturated saline solution by electrolysis). The inlet dosage of the clarification tank si 1.0 to 2.0 mg/L; the dosage of living water is no more than 1.0 mg/L, and the largest dosage is about 5 g/l and the water pressure on the dosage point is 0.10MPa. 4.3.4.2 Startup and shutdown of chemical dosing system 4.3.4.2.1 Startup of chemical dosing system 1) The liquid level of coagulant and coagulant aid solution is higher than the 1m. 2) The liquid level of sodium hypochlorite system metering tank is higher than 40 cm, dosage in the granulated salt storage room is adequate and living water is normal. 3) Check that the metering pump and its motor meet the inspection standard in the General Clauses. 4) Open the first and second manual dosage oulet valve of coagulant and coagulant aid solution tank and the living water inlet valve of sodium hypochlorite metering system. 5) Open the inlet and exit valve of the metering pump, start the coagulant and coagulant aid metering pump and sodium hypochlorite chemical dosing system, and check whether the inlet pressure is normal. 4.3.4.2.2 Shutdown of chemical dosing system 1) Press Stop button at CRT or local metering pump, and close the inlet and exit valve of the metering pump and the first and second exit valve of the solution pool. 2) Press the raw water pump at CRT or Stop button of the domestic water pump and stop the raw water pump or domestic water pump and then close the water inlet and exit valve.
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4.3.5 Inspection and adjustment during operation 4.3.5.1 Operation, maintenance and attentions of Chemical clarification tank 1) Under the supervision projects and time interval provided, the effluent quality of the clarification tank should be measured and the results are recorded in the operation statements. 2) According to the effluent quality the dosage supervision and adjustment should be done. 3) The sludge settling ratio of the second reaction chamber is controlled at 10 to 20% (5 min). 4) Under the sludge settling ratio of the second reaction chamber, the sewage disposal time interval (one-time sewage disposal every 8H for two minutes) is determined, sludge running and missing phenomena are not allowed, sewage disposal at the bottom is done once every day shift and the discharge capacity is determined according to the effluent quality of the clarification tank and the height of sludge. 5) Stabilize the operating conditions of the clarification tank, and the change scope of the flow is generally not more than 10% of the original flow each 10 minutes. 6) The oil level of the agitator is strictly controlled and the oil dosage should not exceed the maximum oil level line and should not be less than the minimum oil level line when it is in operation. 7) The following matters should be paid attention to in the operation of the agitator: a) Current should have no unusual fluctuations. b) The agitator should operate in balance, without abnormal vibration and noise. c) The oil temperature of the reducer should generally not exceed 30. d) There should not be obvious leakage at each seal part. 8) When adjusting the startup height of the agitator impeller, it is strictly controlled in the scope of the upper and lower stop line of the scale and nuts must be locked in the process of adjustment. 4.3.5.2 Operation, maintenance and attentions of gravity filter chamber 1) Air scrub is carried out when the filter chamber runs for 20 hours. 2) Air scrub is carried out when the effluent quality of the filter chamber deteriorates markedly. 3) Air scrub is carried out when the effluent flow of the filter chamber changes little. 4) Air scrub is carried out when the effluent quality of the filter chamber exceeds the standard. 4.3.5.3 Operation, maintenance and attentions of chemical dosing system 1) The liquid level of the coagulant and coagulant aid solution pool is more than 20cm, and a prescription if filled if it is less than 20 cm. 2) Check whether the dosage in the granulated salt storage room of sodium hypochlorite chemical dosing system is adequate, and the liquid level of the measuring tank is above 20cm. 3) Check whether the sodium hypochlorite generator is working normally. 4) The outlet pressure of the metering pump is more than the water pressure of the dosing point, the pressure gauge pointer swings, and there is no leakage phenomenon at the connection between the pipeline and flange. 5) Check the metering pump and motor body according to the General Clauses.
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6)
If the metering pump fails, the system is switched and another metering pump is put into operation.
4.4 Common faults, judgment and treatment at the water purification station 4.4.1 Reasons for deteriorated effluent quality of the clarification tank and treatment S/N 1 Reason Inadequate or excessive dosage. Treatment Stop the filter chamber, drain the effluent of the clarification tank to the trench, and adjust the dosage immediately Stop the filter chamber, drain the effluent of the clarification tank to the trench and dispose sewage immediately. Stop the filter chamber, drain the effluent of the clarification tank to the trench and reduce the flow. Stop the filter chamber, drain the effluent of the clarification tank to the trench and adjust the system to stabilize temperature and flow. Drain and wash the clarification tank
Slagblanket rises as the sludge is not timely discharged The flow of the clarification tank is too big; the lifting load speed of the clarification tank is over 50 t/h. The original water temperature increases too fast, by 1 to 2 hourly. There is mud on the bottom of the clarification tank due to its long-term operation. Inlet water contains air. Not clean the clarification tank regularly
6 7
Clean the pump mesh timely, to prevent pump flange from leaking. Clean the clarification tank regularly
4.4.2 All pretreatment rotation equipment trips Possible reasons: the power supply of MCC cabinet fails and the chemical water fails. Treatment methods: 1) Report to the leader on duty and professionals and make records. 2) Take inspection and treatment by contacting the centralized control through the leader on duty. 3) Close the operation switch of the outrage equipment. 4) Put the original operating system into operation again after the power supply is restored. 4.4.3 Sludge in the clarification tank circulates badly and drifts, and sludge formation is in chaos S/N 1 Reason Treatment The rotation speed of the agitator is Temporarily reduce the rotation speed and wait improper, resulting in abnormal for 1 to 2 hours, and recover the rotation speed circulation. after the water is clarified; the rotation speed may be too high if the clarified water deteriorates again, but often because of low rotation speed, the stirring effect changes bad. Due to high turbidity of the raw water, the impeller runs at low-speed and the Adjust the rotation speed and eliminate accumulated silt (sewage) at the lower part of
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL the enrichment room and outside cover.
sludge accumulates at the recycling part
4.4.4 Water yield of the clarification tank in operation declines seriously and the water level can not be maintained S/N 1 2 Reason The sewage valve is not closed or seriously leaks after it is opened. Raw water abnormally booster pump runs Treatment Close the sewage valve or make maintenance Check whether the current of the raw water booster pump is normal.
4.4.5 Water quality of the clarification tank blanches S/N 1 2 S/N 1 2 3 4 5 6 7 S/N 1 2 3 4 5 Reason Excessive dosage Excessive spoil disposal capacity Reason Too big initial flow Sudden increase in load in operation Excessive dosage Too fast rotation speed of the agitator Suddenly declining temperature Inadequate spoil disposal Spoil disposal washing valve not closed Reason Big turbidity of inlet water Too big load Too long operation time Backwash by halves Bias of filter material and water hat damaged Treatment Adjust the dosage. Control the spoil disposal capacity Treatment Reduce the flow Adjust the load balance Control the dosage Adjust the rotation speed of the agitator Reduce the output Control the normal spoil disposal Close the spoil disposal washing valve Treatment Adjust and treat water quality of the clarification tank Reduce the load Backwash and strengthen the air scrub Backwash thoroughly Maintenance
4.4.6 Alum floats on the clarification tank
4.4.7 Unqualified effluent turbidity of the filter chamber
5 Demineralization system Operation Manual 5.1 General description The normal output of the feed-water treatment system equipment of the boiler is 240 t/h and the largest output is 290 t/h. The feed-water treatment system of the boiler is set to two columns of unit first-class desalination (2 sets of 60 t/h activated carbon filter 1 set of 120 t/h reverse flow cation exchanger 1 set of 120 t/h for decarbonizer 10 m3 middle water tank reverse flow anion exchanger) 2 sets of 120 t/h mixed bed.
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5.2 Technical specification of equipment Equipment output Equipment Nominal S/N Qty name diameter Normal Max. Activated carbon filter Strong acid cation exchanger Decarbonizer and blower Middle tank water
Filling Grain diameter mm 0.8~1.6
Model
Height
DN2800
60
73
2.0m
DN2500
120
145
001X7 Multi-plane ball
1.6m
0.315-1.25
3 4
2 2
DN1600 V=10 m3
120
H=1600mm
strong acid anion exchanger
DN2500
120
145
D202II
2.5m Cation =500mm Anion =1000mm
0.315-1.25
Mixed bed
DN2000
120
150
MB001X7 MB201X7
0.7-1.25 0.7-1.25
Hydrochloric acid storage tank Alkali tank storage
V=25 m3
V=25 m3
Hydrochloric acid metering boxcation Hydrochloric acid metering boxMixed Alkali metering boxanion Alkali metering boxMixed
V=1.6m3
10
V=1.0m3
11 12
1 1
V=1.6m3 V=1.0m3
13 14
Acid mist absorber with 2 filling Hydrochloric 1
DN500 Cation 2.6t/h(0.4mpa)
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Equipment name
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Equipment output Normal Max. Filling Grain diameter mm
S/N
Qty
Nominal diameter
Model
Height
acid metering boxcation 15 Hydrochloric acid metering boxMixed 1
bed
Mixed bed Anion bed Mixed Mixed
1.0t/h(0.4mpa)
16 17 18 19 20
Alkali metering pumpcation 1 Alkali metering pumpmixed 1 Resin trapper Safety shower Compressed air tank Name water sample of 2 2 2
2.0t/h(0.4mpa) 1.0t/h(0.4mpa)
V=8.0m3
5.3 Control standard and period of water quality of feed-water treatment system S/N Analysis item Residual chlorine Oxygen consumption Symbol ClCODMn Unit mg/L mg/L Control standard 0 1.5 Supervision time 4h System assessment Backwash when exceeding the standard Increase the number of tests when putting into operation and being close to failure Ditto Remark
Outlet water of active carbon filter
Turbidity
mg/L
0.2
2h
sodion Outlet water of cation exchanger
Na+
g/L
100
2h
Acidity
SD
mmol/L
Stable
4h
Outlet
Electroconductivity
DD
s/cm
2h
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water of anion exchanger 4 Outlet water of mixed ion exchanger Deionization water tank
silicon dioxide Electroconductivity silicon dioxide Electroconductivity
SiO2 DD SiO2 DD
g/L s/cm g/L s/cm
100 0.2 20 0.2
2h 2h 2h 2h Ditto
Ditto
5.4 Operation of demineralized equipments 5.4.1 Startup and shutdown 5.4.1.1 Startup of desalination system 5.4.1.1.1 Preparation before operation of demineralized equipments 1) The water level of the clean pool is one second above and the raw water pump is in good standby status. 2) The manual inlet valve and outlet valve of the activated carbon filter, cation bed, anion bed and mixed bed are opened, the emptying valve at the bottom of the resin trapper is closed, the exit valve is opened, and all the pneumatic valves are closed and display the same as the CRT; The one-time valves of flow gauge, sodium gauge and conductance meter are closed, with intact appearance and zero indication; the on-site control cabinet power supply and gas source are connected, the green valve indicator light is on and the air pressure is 0.4 to 0.8 MPa. 3) The manual inlet valve of the decarbonization valve is opened, the power supply of the decarbonization fan is connected and is in good standby status, the liaison valve of the middle water tank is opened, the emptying valve at the bottom is closed, the entrance valve of the middle water pump is opened, and the outlet valve is closed, meeting the general inspection standards. 4) The manual inlet valve and outlet valve of the desalination tank are opened and the emptying valve at the bottom is closed. 5) The desalination pump meets the general inspection standards, and the manual inlet and outlet valve are opened. 5.4.1.1.2 Commissioning operations of desalination equipments 1) Start the raw water pump, open its outlet valve and supply water to the activated carbon filter. 2) Commissioning of the activated carbon filter: open the water inlet valve and exhaust valve of the activated carbon filter, fill water into the activated carbon filter, and open the conventional well-flushing effluent valve and close the exhaust valve after water flows out of the exhaust pipe; when turbidity is less than 0.2 mg/L, the conventional well-flushing is qualified, open the effluent valve and close the conventional well-flushing effluent valve. 3) Commissioning of the cation bed: open the water inlet valve and air valve of the same series cation bed, fill water into the cation bed, and open the conventional well-flushing effluent valve and close the air valve for conventional well-flushing after water flows out of the air valve of the cation bed; when the Na+ is less than 100 ug / L, the conventional well-flushing is qualified,
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start the decarbonization fan, open the effluent valve, close the positive discharge valve and fill water into the middle water tank; when the liquid level in the middle water tank reaches two thirds above, start the middle water pump, open its outlet valve and send water to the cation bed. 4) Commissioning of the anion bed: open the water inlet valve and air valve of the same series anion bed, open the positive discharge valve and close the air valve after water flows out of the air valve; when DD is less than 5us/cm and SiO2 is less than 100ug/L, the conventional well-flushing is qualified, open the effluent valve and close the positive discharge valve and fill water into the mixed bed. 5) Commissioning of the mixed bed: open the water inlet valve and the air valve of the mixed bed and fill water into the mixed bed; after water flows out of the air valve, open the positive discharge valve and close the air valve for conventional well-flushing; when DD is less than 0.2us/cm and SiO2 is less than 20ug/L, the conventional well-flushing is qualified; open the effluent valve and close the positive discharge valve, and send water into the desalination water tank. 5.4.1.2 Stoppage of the desalination system 1) Stop the raw water pump and close its inlet and outlet valve. 2) Close the pneumatic water inlet valve and the effluent pneumatic valve of the activated carbon filter. 3) Close the pneumatic water inlet valve and the effluent pneumatic valve of the cation bed, and stop the decarbonization fan. 4) Stop the middle water pump and close its inlet and outlet valve. 5) Close the pneumatic water inlet valve and the effluent pneumatic valve of the anion bed. 6) Close the pneumatic water inlet valve and the effluent pneumatic valve of the mixed bed as well as the water inlet valve of the desalination tank. 7) Open the exhaust valves of all equipments, and close all exhaust valves after pressure relief. 8) According to the water level of the chemical pool, decide whether to close the water inlet valve of the clean water pool. 5.4.2 Inspection and adjustment of the desalination system in operation 1) There is water leakage at the connection between the pipeline and flange, the position of the valve switch is correct, the effluent residual chlorine and turbidity of the activated carbon filter is qualified, and the outlet Na+ of the cation bed is less than 100 ug/L, the outlet DD of the anion bed is less than 5us/cm, the outlet DD of the mixed bed is less than 0.2us/cm and SiO2 is less than 20ug/L. 2) The decarbonization fan has no abnormal sound, with normal vibration and temperature; the desalination water pump and the middle pump meet the inspection standards of general rules. 3) When the equipment is close to failure, increase the number of tests, prevent the unqualified water from being sent out. 4) Check whether there is resin inside the resin trapper, stop the mixed bed in time if resin is found, and record the defects and contact the relevant personnel for maintenance treatment.
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5)
Stop the failed equipment timely and regenerate; if two sets of equipments are put into operation at the same time, adjust the operating conditions of the equipments reasonably, avoiding two sets of equipments from failing at the same time. 6) When the cation bed Na is more than 100 ug/L, the cation bed fails; when the effluent electroconductivity of the anion bed is more than 5us/cm or SiO2 is more than 100ug/L, the anion bed fails and regeneration should be conducted. Check that the pressure difference of the switch in operation is less than 0.15Mpa, or else decommissioning, regeneration. 7) Analyze the alkalinity of raw water every 2h, the effluent turbidity of the activated carbon filter and the effluent acidity of the cation bed; when sea water back flows, strengthen the analysis, measure once every 1h and analyze chlorine every 4h once. 8) Check that the water level of each water tank is above one second height of liquid level. 9) Check that all on-line meters display normally and one-time meter has no discontinuous flow or leakage. a) When the mixed bed is put into operation, input the electroconductivity meter: open the water sample inlet valve of the electroconductivity meter to maintain flow 200 ml/min around; observe that the water flow should be continuous, stable and have no disconnected flow and air from the liquid discharge pipe, and input the power supply of the corresponding electroconductivity meter. b) When stopping the mixed bed of anion bed, stop the electroconductivity meter: stop the power supply of the corresponding electroconductivity meter and close the water sample inlet valve of the electroconductivity meter. c) When putting the anion bed into operation, put the sodium meter into operation: open the manual entrance valve of the sodium meter, pull out the black adjustment knob to regulate the flow rate to be 40 ml/min, and then reset the adjustment knob. Open the power switch at the bottom of the sodium meter. d) When putting the cation bed into operation, put the sodium meter into operation: disconnect the power switch at the bottom of the sodium meter, push in the switch valve of the flow tank so that the flow tank is full of water and generates siphon phenomenon. Close the manual sampling entrance valve of the sodium meter. 5.4.3 Backwashing activated carbon filter of activated carbon filter 5.4.3.1 Preparations for backwashing the active carbon filter 1) The clean water tank maintains a high water level, the activated carbon backwashing pump is provided with startup conditions and the entrance valve is opened. 2) Check whether the backwashing entrance valve of the operating or standby active carbon bed is closed tightly. 3) Roots blower is in good standby status. 5.4.3.2 Backwashing operation must be carried out if the active carbon filter in operation meets the following conditions 1) It is put into operaton for the first time or starts after long-term suspension. 2) The inlet and outlet pressure difference is up to 0.1MPa. 3) The effluent quality exceeds the standard.
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4)
The activated carbon filter operates continuously for 80 hours. If stopping for over 24 hours, backwashing should be carried out before stopping. 5.4.3.3 Backwashing steps of active carbon filter 1) Stopping: close the water outlet and inlet valve of the filter, open the exhaust valve and close it after pressure relief for 30s. 2) Drainage: open the exhaust valve and positive discharge valve of the filter, and close the positive discharge valve when the water level drops to the sight glass center. 3) Air scrub: open the air inlet valve of the filter, start the Roots blower, adjust the air flow to 10 to15 m3/min and scrub for 5 to 10 min. 4) Backwashing: stop the Roots blower, close the air inlet valve and exhaust valve of the filter, start the backwashing pump, open the exit valve of the pump, open the backwashing influent valve and backwashing drainage valve of the filter slowly; when the filter is filled with water, increase flow gradually and control water intensity at 13 to 16l/m2s, until the drained water is clarified and transparent, stop the backwashing pump and close the backwashing drainage valve and water inlet valve. 5) Positive washing: open the water inlet valve and the exhaust valve of the filter; after water flows out of the air valve (about 60s), open the positive washing drainage valve, and the flow rate is 5 m/h (flow is 40 m3/h), take the positive washing until the water is clarified and transparent, and then close the water inlet valve and positive discharge valve of the filter and turn into operation or standby.
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW TURBINE & AUXILIARIES OPERATION MANUAL Table for Operation steps of the activated carbon filter Positiv e washi ng draina ge valve 13-16 10-15 5-8 5-1 0 5 5-1 0 <10 Control parameter Air inle t valv e Root s blow er Flo w m 3/ h Rever se water streng th l/m2.s Air scrub streng th l/m2.s Flo w rate m.h
-1
Operation methods
Influe nt valve
Efflue nt valve
Backwas hing influent valve
Backwas hing drainage valve
Exha ust valve
backwash ing pump
Tim e min
Commissio ning
Pre-commissi oning Operation Drainage
5 <10
Air scrub
Scrubbing Back washing Positive washing
Back washing
Note means that the valve starts or the pump operates
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW TURBINE & AUXILIARIES OPERATION MANUAL 5.4.4 Regeneration of demineralized equipments 5.4.4.1 Regeneration of one stage desalination equipment 5.4.4.1.1 Preparations for regeneration 1) There is sufficient desalination water in the desalination water tank, and check that all the water pumps are in good standby status. 2) Adjust the flow and pressure of the operating desalination equipment to ensure making water, and check that all the related valves of desalination equipment in operation and acid-base system are closed. 3) The compressed air storage tank is intact and the pressure is around 0.6MPa. 4) Acid and alkali metering box for the anion and cation mixed bed is provided with acid-base fluid for regenerating a bed body, the high level acid and alkaline storage tank have enough acid and alkali, and the acid and alkali metering pump and regeneration system are in good standby status. 5) The acid and alkali concentration are in good standby status. 6) The waste liquid tank is in a low liquid level. 7) Check that all valves of the regeneration system are flexibly used. 8) Close the inlet and outlet valve of the on-line chemical monitoring instruments of the regeneration equipment, cut off the power supply, and the rest meters are in good operation. 5.4.4.1.2 Regeneration operation of one stage demineralization equipment 1) Small backwashing Start the self-use desalination water pump, open the small anion (cation) backwashing influent valve and backwashing drainage valve, backwash for about 10 minutes and control the backwashing flow, so that resin expands at most and it is suitable that the backwashing height of resin is up to the peephole middle. After the effluent is clarified, stop small backwashing. 2) Waterdrainage Stop the self-use desalination water pump, close the small backwashing influent valve and the backwashing drainage valve, settle the pressure resin layer of resin for five minutes, and then open the air valve and middle discharge valve to drain water until there is no water in the pressure resin layer. Close the air valve, and check whether resin falls off when draining. 3) Fill acid (base) Open the manual regenerated liquid inlet valve and pneumatic valve of the cation (anion) bed, start the self-use desalination water pump and acid (base) metering pump, open the jet influent valve of the cation (anion) bed to pre-spray, adjust the cation (anion) bed flow and control it at 15m3/h around; after the flow is stable, open the acid (base) outlet valve of the metering tank, adjust the acid concentration to be 2% to 2.5% and the alkali concentration to be 1.5% to 2%, fill 2.0m3 acid into the cation bed and fill 2.4 m3 base into the anion bed. 4) Replace After filling acid (base), stop the acid (base) metering pump, close the exit valve of the acid (base) metering tank, remain the original flow to replace for about one hour until the acidity of the middle waste discharge from the cation bed is less than 10 mmol/l and DD of the middle waste discharge from the anion bed is less than 100 to150us/cm, stop the regeneration water pump and
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stop replacing, stop the self-use desalination water pump, and close the manual valve at the mixer outlet and the acid (base) inlet valve of the bed body 5) Small positive washing Open the manual influent valve, influent pneumatic valve and air valve of the cation bed and put the activated carbon filter into operation; after water flows out of the air valve of the bed body, open the middle discharge valve, close the air valve, wash the cation (anion) bed positively slightly, and control the flow at 100/h for eight minutes. 6) Positive washing Open the positive discharge valve of the cation (anion) bed, close the effluent pneumatic valve of the cation (anion) bed, wash the cation (anion) resin positively, control the flow at 120 t/h, open the one-time sampling valve of instrument, and take positive washing until Na+ in the cation bed effluent is no less than 100 ug/L; the anion bed effluent DD 5 us / cm and SiO2 100 ug/L, and the qualified positive washing water is put into opeaiton or for standby. 7) Large backwashing the cation (anion) bed a) Start the self-use desalination water pump, open its exit valve, open the backwashing influent valve and backwashing drainage valve of the cation (anion) bed, and adjust the backwashing flow from small to large as large as possible when no resin falls off. b) After the drained water is clarified, reduce the flow gradually so that resin can naturally settle. c) After backwashing, stop the self-use water pump, close all the valves above, and open the emptying valve and middle discharge valve of the cation (anion) bed. d) Drain the cation (anion) bed to the middle discharge and conduct regeneration according to the regeneration operation steps of the cation (anion) bed. Note: large backwashing the cation (anion) bed after it is newly put into operation, maintenance or long-cycle operation, and then the amount of the regenerated anti-acid (base) is 2 times the normal amount.
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW TURBINE & AUXILIARIES OPERATION MANUAL Table for regeneration operation sequence of the cation (anion) ion switch: Cation bed valve Large backwashing influent valve Small backwashing influent valve Pump fan Flow t/h
Influent valve g
Backwashing valve
Postitive discharge valve
Middle discharge valve
Effluent valve
Mixer outlet valve
Acid inlet Metering valve of tank regenerated outlet liquid valve
Exhaust valve
Raw water pump
Self-use desalination water pump
Acid metering pump
age
tive
Note means that the valve starts or the pump operates
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW TURBINE & AUXILIARIES OPERATION MANUAL 5.4.4.2 Regeneration operation of two-stage desalination equipment (mixed bed) 5.4.4.2.1. Preparations for regeneration 1) The operation desk and on-site electromagnetic valve box have been supplied with power and gas, and the atmospheric pressure is 0.4 MPa above. 2) The acid-base system is in good standby status, and the acid-alkali metering box is provided with enough acid-base solution. 3) The self-use desalination pump, alkali metering pump and middle water pump are in the good standby status. 4) All the acid-base entrance valves of the mixed bed system should be closed, and the inlet and outlet manual and pneumatic valves of the renewable mixed bed are closed. 5) The flow of the equipment in operation is properly adjusted to ensure the water level of the renewable water and desalination water tank. 6) Various meters are provided with commissioning and operation conditions. 7) The sampling primary valve of the mixed bed outlet electroconductivity and silicon meter should be closed. 5.4.4.2.2. Regeneration operation 1) Waterdrainage Close the manual influent valve and influent pneumatic valve, and stop the mixed bed. Open the positive washing drainage valve and exhaust valve, drain until the second peephole of resin layer can be seen, close the positive washing drainage valve, and prevent siphon when draining. 2) Air scrub Open the backwashing effluent valve and air inlet valve, adjust the air pressure at 0.10Mpa to 0.15Mpa, scrub for five minutes and then close the air inlet valve. 3) Backwashing delamination Open the backwashing influent valve and backwashing drainage valve of the mixed bed, start the self-use desalination pump, open its outlet valve, backwash the mixed bed, and control the flow at 50t/h for 15 min. When the anion and cation resin are obviously separated, close the backwashing influent valve and backwashing drainage valve. Note: resin should settle stably after delamination. If the water backwashing delamination is poor, soak it into the alkali, and delaminate again. 4) Waterdrainage Open the positive washing drainage valve and exhaust valve for drainage, and close them after draining to around 200 mm above resin. 5) Fill the acid and alkali Open the regenerated acid liquid manual inlet valve and pneumatic valve of the mixed bed, the regenerated alkali liquid manual inlet valve, pneumatic valve, middle drainage valve, the influent pneumatic valve and effluent manual valve of the acid (base) mixer, start the self-use desalination water pump, open the exit valve of the pump slowly and adjust the flow of regenerated acid liquid to be 8m3/h and the flow of regenerated alkali liquid to be 9m3/h (the temperature about 40 ); Open the exit valve of the acid (base) metering box, start the acid (base) metering pump, open the exit valve of the acid (base) metering pump, and adjust the acid
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concentration to be 3%; open the manual outlet valve and pneumatic valve of the alkali metering box, adjust the alkali concentration to be 3%, and fill 0.8m3 acid and 0.8 m3 alkali into the mixed bed respectively. 6) Replacement After filling the regulated acid (alkali), close the acid outlet valve of the acid metering tank of the mixed bed, stop the acid metering pump and the alkali outlet valve of the alkali metering box, stop the alkali metering pump and maintain the flow to replace for 60 min; when replacing to the drainage neutral, the middle drainage DD is less than 20s/cm and the replacement ends. 7) Positive washing after replacement After replacement, stop the self-use demineralization water pump, close the middle drainage valve of the mixed bed, the manual regenerated acid liquid inlet valve and pneumatic valve of the mixed bed, the manual regenerated alkali liquid inlet valve and pneumatic valve of the mixed bed, the influent pneumatic valve and the manual effluent valve of the acid (base) mixer; put the one-stage desalination equipment into operation, open the influent valve and positive discharge valve of the mixed bed, and wash the resin of the mixed bed positively. When the electroconductivity of the positive washing drainage is less than 10s/cm, the positive washing ends. 8) Waterdrainage After replacement, the positive washing is qualified; close the influent valve of the mixed bed, open the exhaust valve and the positive washing drainage valve of the mixed bed, and drain water up to 200mm the resin surface, close the positive washing drainage valve, and prevent siphon when draining. 9) Mix resin Open the backwashing effluent valve and exhaust valve, manual air inlet valve and pneumatic air inlet valve of the mixed bed to mix resin for about five minutes, and after the air pressure is 0.1 MPa and it is mixed evenly, close the manual inlet valve and pneumatic valve, wash the drainage valve fully positively quickly, open the influent valve to drop resin rapidly, and prevent the layered resin in settlement, for about 30s. 10) Positive washing After resin drops, adjust the positive washing drainage valve to wash the mixed bed slowly, and after the exhaust valve drains, close the exhaust valve and wash the mixed bed positively until the mixed bed effluent DD is less than 0.2us/cm and SiO2 is less than 20ug/L; if the water quality of the drainage water does not meet the requirements, re-wash the mixed resin positively.
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW TURBINE & AUXILIARIES OPERATION MANUAL 5.4.4.2.3. Table for operating procedures of desalination mixed bed equipment Alkali Back drainage valve Positive drainage valve Influent valve of alkali mixer Alkali inlet valve outlet valve of the alkali metering box Influent valve of acid mixer Acid inlet valve Acid outlet valve of the acid metering tank
Backwashing influent valve
Effluent valve
Air inlet valve
Exhaust valve
Middle discharge valve
Acid metering pump
Alkali metering pump
Self-use demineralization water pump
Ti m
Note means that the valve starts or the pump operates 5
15
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW TURBINE & AUXILIARIES OPERATION MANUAL 5.4.5 Operations of water supply acid-base system 5.4.5.1. Preparations for dumping acid and alkali 1) Make clear delivery receipts and ask the relevant information clearly after tankers come, to prevent mixed dumping acid-base. 2) Inform the lab technicians of the laboratory class to take samples for testing. 3) Wear acid-proof suits, rubber boots, protective masks, gloves and gas masks. 4) Record liquid level of high pH level tanker. 5) Prepare water and anti-acid-base burn liquid at the dumping acid-base site, and safety shower pedal is not blocked and there is sufficient water pressure on the pipe. 6) The acid-base pipeline is not leaked, valve switch is flexible, liquid level indicator is precise, and the acid mist absorber is normal. 5.4.5.2 Operations of dumping acid (base) 1) When an acid (base) tanker comes to the site, the acid (base) transport hose on the tanker is butt jointed with the dumping acid (base) pump entrance. 2) The dumping acid (base) delivery pump is powered on and the local indicator light is on. 3) Open slowly the acid outlet valve of the acid (base) tanker. 4) Start the dumping acid (base) delivery pump, and input acid into the high level acid (base) tank. 5) After dumping acid (base), stop the dumping acid (base) delivery pump, close the pump exit valve, the acid outlet valve of the acid (base) tanker and the acid inlet valve of the high level acid (base) tanker, and meanwhile remove the hose connected and clean the ground. 6) Record the acid (base) concentration, quantity, liquid level of high level acid tank and acid tanker number in the handover sheet. 5.4.5.3 Attentions to dumping acid (base) 1) When connecting the hose, the fixed bolts connected with the flange must be tightened to prevent leakage when dumping acid (base). 2) When removing the hose, take careful and confirm that no residual pressure exists in the hose, to prevent residual acid (base) liquid from splashing. 3) When dumping acid (base), wear ant-acid (base) suits, rubber boots, protective masks, gloves and other protective equipment surely and open the air inlet valve of low level storage tank slowly. 4) When being splashed by acid (base) liquid, wash with plenty of water or in safety water shower immediately, and conduct treatment in accordance with the medical protective provisions of the Rules of work of electric job security". 5.4.5.4 Operations of filling acid (base) into the metering tank 1) The high level acid (base) tank has enough acid (base) solution. 2) The acid (base) metering tank exit valve and emptying valve have been closed. 3) Acid mist absorber is normal. 4) Pay attention to observing the liquid level of the metering tank at the exit valve of high level acid (base) tank and acid (base) metering tank inlet acid (base) valve, to prevent overflow.
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5)
Stop filling acid (base) into the acid (base) metering tank, close the exit valve of the high level acid (base) tank and the inlet acid (base) of the acid (base) metering tank, and pay attention to closing to prevent overflow. Note: when filling acid (base) into the metering tank, the site must be supervised. 5.4.6 Discharge waste liquid from the water treatment waste liquid tank 5.4.6.1 Preparations 1) Waste liquid pump and Roots blower are in good standby status. 2) Self-control air source pressure is 0.4 to 0.8 Mpa. 3) Valves and pipelines are not leaked. 5.4.6.2 Discharge waste liquid from the water treatment waste liquid tank 1) When the wastewater tank is at a high level, start the Roots blower, open the air inlet valve of the waste liquid tank, stir the air in the waste liquid tank, stop the Roots blower after 5 minutes, and close the air inlet valve of the wastewater tank. 2) Start the waste liquid pump, open its exit valve and transmit wastewater to the wastewater treatment station. 3) When the waste liquid tank is at a low level, stop the wastewater pump and close its exit valve. 5.5 Common faults, judgment and disposal 5.5.1 Analysis of abnormal reasons and treatment principle of water quality of the desalination water tank Analysis of abnormal reasons: first: check rapidly whether the online DD or silicon meter fail or it is caused by the not timely monitoring of the operator, confirm that the meter is accurate, and then check whether the medicine for test is overdue or fails or a wrong medicine is used, after all are confirmed to be accurate; 2: sample and test the water quality of the desalination water tank and the condensation water tank of the unit, drain the unqualified water, and put the standby desalination water equipment into operation; third: analyze whether the operating equipment has the following circumstances when being contaminated: 1. the effluent of the anion bed is seriously deteriorated, impacting the effluent of the mixed bed, thus the water quality is deteriorated; 2. the mixed bed not regenerated well is put into operation for fails, as is timely not monitored to stop it; 3. the effluent of the mixed bed flows back or the backwashing valve is not sealed or the air valve is not sealed, resulting in resin delamination so that the effluent of the mixed bed is deteriorated; 4. the acid inlet valve or the alkali inlet valve or the backwashing water inlet valve of the operating equipment is not sealed, the equipment is regenerated to cause the operating equipment being contaminated; 5. resin contaminated and aged causes the effluent being deteriorated; 6. the effluent resin trapper of the mixed bed is damaged, causing resin to enter into the thermal system to be decomposited. Against these possible causes, analyze and eliminate them and find reasons for treatment. Treatment principle: first, if the desalination water tank is contaminated, stop filling water into the condensation water tank of the unit immediately, thus causing the contaminated desalination system of the desalination water tank to operate and regenerate possibly, and meanwhile close the effluent valve of a group of desalination water tanks in operation; at the same time, view
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immediately whether there is a change in the indicator of the water vapor system of the unit, and stop filling water into the unit immediately if the water supply and boiler water indicators change, drain all water out of the condensation water tank of the unit, and then fill water into the condensation water tank of the unit with the standby desalination water tank, fill a lot of water in the unit until the indicator is normal, and meanwhile resume the operation of the standby water desalination equipment as soon as possible; if PH of the boiler water is low, add sodium hydroxide and neutralize it; if the quality of the boiler water is poor and the water changed can not be qualified, when it is up to Class 3 processing value, report to the leadership about application for stopping the boiler and draining the boiler water. If the water supply and boiler water indicator has not changed, suspend to fill water into the unit, confirm the water quality of the desalination water tank and condensation water tank of the unit, drain the unqualified water, and restore fill water into the unit after the water quality is ok. Second, take corresponding measures for six possible reasons: 1. isolate the contaminated anion bed and regenerate it so that it can be normal; 2. isolate the contaminated mixed bed and regenerate it so that it can be normal; 3. eliminate the reasons for the mixed bed delamination, re-mix resin and positively wash or re-regenerate; 4. check the leakage valve, and stop the renewable water into the operating equipment, 5. replace the contaminated and aged resin, and do not put the equipment into operation before replacement; 6. maintain the effluent resin trapper of the mixed bed, and do not leak resin into thermal system. 5.5.2 Effluent water from the cation bed has hardness S/N Reason Treatment 1 2 S/N 1 2 3 4 The depth of the cation bed fails or regeneration is bad Load is over allowable value Reason The cation bed fails and effluent water quality is poor The efficiency of the decarbonation fan is low. The anion bed fails Stop and maintain Recover the normal flow Treatment Stop the series and put standby series into operation Contact the maintenance personnel Stop regenerationand put backup bed into operation
5.5.3 Electroconductivity of one stage demineralization water is big
The periodic output amount of fabricated Check water quality water from the cation and anion bed is too low and the influent water quality changes. The periodic output amount of fabricated Contact the maintenance personnel water from the cation and anion bed is too low and the influent device is damaged, and current bias occurs The periodic output amount of fabricated water from the cation and anion bed is Strengthen backwashing, maintenance and treat and conduct
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too low and the backwashing water volume is insufficient and resin surface is not level 7 The periodic output amount of fabricated Increase the amount of acid base and improve water from the cation and anion bed is concentration during regeneration. too low and the amount of acid base is insufficient or concentration is too low during regeneration. The periodic output amount of fabricated water from the cation and anion bed is too low and resin is reduced The periodic output amount of fabricated water from the cation and anion bed is too low and the resin is polluted Reason Backwashing misoperated delamination is Supplement resin
Clean resin and recover
5.5.4 The cation and anion resin backwashing delamination of the mixed bed is not obvious S/N 1 2 3 4 5 Treatment Conduct backwashing delamination operation according to the provision of Manual Conduct backwashing delamination operation according to the provision of Manual Leach with NaOH solution or immerse resin, and then re-delaminate. Clean resin or recover Increase backwashing flow and leach with NaOH Treatment Adjust the opening of the backwashing water entrance valve, and control backwashing flow strictly Open the backwashing entrance valve slowly Stop and maintain Treatment Replace the effluent water hat Contact the maintenance personnel, investigate the cause and re-install
Proportion of cation and anion resin does not meet the provision Resin is not fully ineffective Resin is polluted Cation and anion resin cluster or have bubble Reason Too big backwashing flow
5.5.5 Active carbon falls off when the active carbon bed is backwashed S/N 1
2 3 S/N 1 2
Control the backwashing water flow unstably The drainage valve damaged Reason The effluent water hat of the mixed bed is unqualified or damaged The water hat installed does not meet the requirements
5.5.6 Resin in the mixed bed in operation falls off
5.5.7 Quartz sand or resin in the cation or anion bed in conventional well-flushing or operation is taken out
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S/N 1 2 Reason
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Treatment Stop and maintain Change quartz sand cushion with qualified granularity
Confused layers at the bottom of switch Unqualified granularity of quartz sand cushion causes uneven water distribution Reason Fan turns reversely Inadequate wind pressure and force Too much flow Inadquate or too much filling Water inlet device is damaged or is provided with uneven water
5.5.8 Decarburizator has low efficiency S/N 1 2 3 4 5 Treatment Contact the maintenance electrical personnel for
Contact the maintenance personnel or change the fan Reduce inlet flow Supplement or reduce filling Contact the maintenance personnel to treat
6 Water Steam Supervision System Operation Manual 6.1 Technical specification 6.1.1 Water-vapor sampling system equipment Name of point Condensate outlet Parameter sampling sampling point Pressure MPa pump 2.8 of Instrument disposition SC pH O2 SiO2 N2 M H4
Temper ature CC 42 170 170 291 291 360 360 360 360 541 50
Deaerator outlet pipe 0.8 Deaerator inlet pipe Economizer inlet Economizer outlet Boiler waterleft 0.8 20 20 20
Boiler waterright 20 Saturated left Saturated right steam steam 20 20 17.5 04
Superheated steam Closed clod water
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Name of point
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL of Instrument disposition SC pH O2 SiO2 N2 M H4
Parameter sampling sampling point Pressure MPa 5
Temper ature CC 541 153 133.5 181.8 50
Reheater steam
Boiler sewage 0.423 disposal tank Low-pressure heater 0.423 drainage High-pressure heater 1.755 drainage Boiler feedwater Condenser hotwell 1 Condenser 21 hotwell 0.2
Note is the sampling points and instruments set, and is manual sampling points set is to set a block of meter and all sampling points operate alternately. Water-vaport on-line instrument: S/N Name 1 2 3 4 5 6 Conductance meter Specification and model DDG-5188 Unit Set Set Set Set Set Qty 72 52 62 32 12 12 Manufacturer Shanghai Lihe Shanghai Lihe Shanghai Lihe POLYMETRON COMPANY POLYMETRON COMPANY POLYMETRON COMPANY
Hydrogen conductance DDG-5188 meter Acidity meter Oxygen meter Silicon (four-channel) Hydrazine meter meter PHG-5288 9182 9210 9186
Set
6.1.2 Chemical dosing system equipment S/N 1 Name Ammonia tank solution Model and specification V=1.0m31000 Unit Set Qty 2 Remark Material:1Cr18Ni9Ti with motor agitating
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Feed-water ammonification metering pump
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL device N=1.1kW Set Q=58l/h Set Q=22l/h Set V=1.0m31000 Set Q=58l/h Set Q=22l/h Set V=1.0m 1000
3
Frequency conversion, hydraulic pressure diaphragm Frequency hydraulic diaphragm conversion, pressure
Condensated water ammonification metering pump Hydrazine tank solution
Material:1Cr18Ni9Ti with motor agitating device N=1.1kW Frequency hydraulic diaphragm Hydraulic diaphragm conversion, pressure
Feed-water hydrazination metering pump Closed cooling water hydrazination metering pump Phosphate tank solution
pressure
Material:1Cr18Ni9Ti with motor agitating device N=1.1kW
6.1.3 Vapor-quality control standard 1) Condensated water quality standard Control standard Item Hardness Positive KWH Dissolved oxygen Sodium silicon dioxide Iron Copper 2) Unit mol/L s/cm g/L g/L g/L g/L g/L Startup 0 1.0 50 20 30 50 20 Expected Normal value 0 0.3 30 10 20 20 5 0 0.15 30 5 5 10 3 Time interval (H) 24 2 2 Read the online meter once per 2h and manual meter once per 24h Ditto Remark
Assessment Ditto
Feed-water quality standard Control standard Item Unit mol/L Startup 0 Expected Normal value 0 0 Time interval (H) 24 Remark
Total hardness
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silicon dioxide g/L
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Read the online meter once per 2h and manual meter once per 24h Read the online meter once per 2h and manual meter once per 24h
30
20
10
dissolved oxygen Chemical deoxidant PH Positive KWH Iron Copper 3)
g/L
30
g/L
9.0-9.6
10-50 9.0-9.6 0.3 20 5
10-30 9.0-9.6 0.15 10 3
2 2 2 Startup or assessment Startup or assessment Time interval (H) First-class ammonification 9.0-9.6
s/cm g/L g/L
0.65 50 -
Boiler water quality standard Control standard Item Unit Startup Normal Expected value Remark
silicon dioxide
g/L
Silicon cleaning 250 requireme nt 910 9-10
100
Read the online meter once per 2h and manua meter once per 24h Read the online meter once per 2h and manual meter once per 24h Read the online meter once per 2h and manual meter once per 24h Read the online meter once per 2h and manual meter once per 24h Time interval (H)
PH25
9.3-9.5
phosphateradica mg/L l
0.5-3.0
0.5-3.0
0.5-1.5
Conductivity 4)
s/cm
60
20
Steam quality standard Control standard Item Unit Startup 0 Normal 0 Expected value 0 2 Remark
Cation conductance
s/cm
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Sodium g/L
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Read the online meter once per 2h and manual meter once per 24h Read the online meter once per 2h and manual meter once per 24h
20
10
silicon dioxide
g/L
30
20
10
Iron
g/L
50
20
10
Startup and assessme nt Startup and assessme nt Time interval (H)
Copper
g/L
15
5)
Cooling water quality standard of generator stator Item Unit Control standard Expected value Remark Read the online meter once per 2h and manual meter once per 24h Read the online meter once per 2h and manual meter once per 24h
PH
6.8
7.0-8.0
Hardness
mol/L
0 1.5
0 1.0
24
Electroconductivity s/cm
Copper 6)
g/L
40 Control standard
30 Expected value
Assessment Time interval (H)
Closed circulating cooling water Item Unit Remark Read the online meter once per 2h and manual meter once per 24h Read the online meter once per 2h and manual meter once per 24h
PH
8-9
8-9
Electroconductivity s/cm
30
20
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6.2 Chemical supervision during unit operation 6.2.1 Chemical supervision at initial startup stage 6.2.1.1 Preparations for startup 1) Prepare analytical instruments and chemical medicines before the start of the units, clean the instruments and prepare sufficient medicines. 2) Prepare adequate and qualified demineralized water. 3) Check that the steam-water sampling device, dosing equipment and chemical instrument should be intact and in good standby status, and the closed cooling water system is in normal use. 4) The dosing pump should be provided with above two thirds lubricant and all dosing pumps are in good standby status. 5) Check whether the sampling cooling water should be sufficient, and open all the cooling water inlet valves of samplers and observe whether the cooling water pressure is normal; defects found will be timely processed. 6) Check that the liquid level of the phosphate metering tank, ammonia metering tank and hydrazine metering tank should be higher than two thirds, or else it should be dosed. 7) Open the exit valve of the liquid medicine metering tank and the entrance valve of the phosphate pump, ammonia metering pump and ammonia metering pump. 8) Contact the centralized control operator to open the primary continuous sewage disposal, sampling and dosing valve. 9) Contact the maintenance thermal-control personnel to prepare for putting the chemical instruments into operation prior to startup. 6.2.1.2 Chemical monitoring when starting 1) When the unit start, the leader on duty shall timely notify the chemical principal, who arranges the opening of the cooling water entrance valve of the water-steam sampler of the unit and observes that the cooling water pressure is normal, and contacts promptly to maintain and treat the defects found. 2) When the unit begins to start, contact the centralized control operator to open the primary sampling, dosing and continuous sewage disposal valve; after it has been verified that all the primary valves are opened, adjust the cooling water volume of each sampler, adjust the sampling water flow to wash the samplers; after the samplers are clean, adjust the manual sampling water flow at 500 ml/min, and maintain stable flow and adjust the sampling water temperature at 25 to 30. 3) Wash the condenser with water: when water flows into the condenser, after starting the condensate pump, the leader on duty notices the chemical principal to begin washing the condenser. The chemical principal starts the condensated water ammonification pump to ammonify condensated water, and adjusts the condensated water pH at 8.8 to 9.3. Wash it until the condensated water hardness is close to 0 mol/L, iron content is no more than 50 g/L and SiO2 content is no more than 30 g/L, and thus the condenser washed is qualified, as is reported to the leader on duty. The leader on duty can not conduct the next step until receiving the chemical water quality report.
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4)
5)
6)
7)
Wash the deaerator with water: when starting to fill water into the deaerator, the leader on duty notices the chemical principal to begin washing the deaerator, and coordinates at the same time to put the deaerator heater into operation in order to ensure the deoxidization effect. Chemical operator starts the feedwater ammonification pump and hydrazine pump to add ammonification and pump into the feedwater, maintaining feedwater pH of 8.8 to 9.3 and deaerator content of 10 to 50 g/L. Monitor water samples of the rear sampling point of the deaerator, and if the hardness is close to 0 mol/L, iron content is no more than 50 g/L, SiO2 content is no more than 30 g/L and dissolved oxygen is no more than 30 g/L, the deaerator washed is qualified, as is reported to the leader on duty. The leader on duty can not conduct the next step until receiving the chemical water quality report. Wash the boiler with water in cold status: when the boiler is filled with water, the leader on duty notices the chemical principal to fill water into the boiler, and the chemical principal starts the phosphate dosing pump to dose into the steam drum and opens the continuous and intermittent blowdown of the boiler. The chemical principal blows down samples of the water-steam sampling devices and inputs the manual sampling system, and analyzes the boiler water pH, phosphate content, iron content and SiO2 content. Control the boiler water pH at 9.0 to10.0 and phosphate radical at 0.5 to 3.0mg/L; when the iron content is no more than 50 g/L and SiO2 content is no more than 30 g/kg, the leader on duty is reported about the qualified boiler washed in cold status. The leader on duty can not conduct the next step until receiving the chemical water quality report. Wash the boiler with water in hot status: after the boiler is ignited, the leader on duty notices the chemical principal that the boiler has been ignited, and the continuous and intermittent blowdown of the boiler maintain fully open, so that the boiler water is clarified as soon as possible. Test chemically the boiler water pH, phosphate radical, iron content and SiO2 content, and control the boiler water pH at 9.0 to 10.0, phosphate radical at 0.5 to 3.0mg/L, iron no more than 300 g/L and SiO2 content no more than 300 g/kg; test the iron content, SiO2 content, copper content and sodium content in steam; when SiO2 content in steam is more than 30g/kg, iron content is more than 50 g/L, copper content is more than 15 g/L and sodium content is more than 20 g/L, the leader on duty is reported about the qualified steam and rolling can be done. The leader on duty can not conduct the next step until receiving the chemical water quality report. Recycling requirements of condensated water after the steam turbine is rolled: the leader on duty notices the chemical principal that the steam turbine has been rolled, and requests at this time that the condensated water in the steam turbine can not be recovered and must be discharged from the condenser; after the condensated water of the steam turbine is clear and transparent visually outside, test the condensated water hardness, iron content and copper content by sampling; when the condensated water hardness of the steam turbine is close to 0mol/L, iron content is no more than 50 g/L, copper content is no more than 15g/L and SiO2 content is no more than 20g/L, the leader on duty is reported that the condensated water can be recycled .
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8)
Wash silicon in the boiler by heating and lifting pressure: begin washing silicon when the main steam pressure of the boiler rises to 7.5MPa. While washing silicon, monitor the boiler water pH, phosphate content, iron content and SiO2 content at the same time, and control the boiler water pH at 9.0 to 10.0, phosphate radical at 0.5-3.0mg/L, iron no more than 300 g/L and SiO2 following the requirements of washing silicon; when the SiO2 content in the boiler water is up to the next pressure level allowable SiO2 content, pressure can continue to rise, and silicon is washed according to the circular manner of lifting pressure - lifting load decreasing pressure (to the point higher than the starting value of the previous lifting pressure) lowering the boiler water concentration (increasing the boiler blowdown and improving water purity) - lifting pressure until reaching the rated pressure. SiO2 content of the boiler water and SiO2 content and pressure of steam are correspondingly shown in the table as follows: Steam drum pressure MPa SiO2 content of the boiler water (g/L SiO2 content of steam (g/L 7.510.0 3000 30 10.012.5 1500 30 12.515.0 500 30 15.016.0 400 30 16.017.0 300 30 17.018.4 250 30-20
In the process of lifting pressure of the boiler, the SiO2 content of the boiler water and steam is continuously analyzed. After SiO2 content of the boiler water and steam is qualified, the leader on duty is timely reported, in order to adjust the operating conditions of the boiler to conduct the next parameter pressure. 9) After the end of washing silicon, analyze chemically comprehensively the steam, boiler water, feedwater and condensated water quality, and adjust dosage or sewage disposal in accordance with water quality; the water quality indexes of the water-vapor system are up to the normal value standards within eight hours when the units are parallel in; contact the leader on duty to make timely adjustment if failing in meeting the standards. 10) Contact the thermal-control personnel to put related chemical instruments into operation (but the pH scale must be input after the constant temperature system works) and do a good job in detailed records when starting them. 6.2.2 Chemical supervision during normal operation stage of generating units 1) Patrol inspect and read the online instrument once every two hours, conduct a manual laboratory test every day, investigate the reasons timely if the water vapor quality is unqualified, check and confirm the experiment, increase in the number of analysis if the experiment is correct, and strengthen water supply, correct the boiler water, contact the centralized control personnel, adjust the operating conditions, and report to the chief and leader on duty. Treat the problems related and make records in accordance with the vapor quality deterioration third-class treatment principle and methods. 2) According to water-vapor quality, notice the centralized control personnel to adjust the continuous blowdown of the boiler and ward the blowdown work regularly. 3) According to analysis conditions of water quality, adjust timely the amount of ammonia, deoxidant and phosphate, guarantee that their content is qualified and at the same time
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maintain the minimum level of chemical dosage. Chemical dosage should be uniform and continuous as far as possible. 4) When the dissolved oxygen in the deaerator water and condensed water exceeds the standard, strengthen supervision and make operating records, control the deaerator content, and at the same time contact the centralized control personnel to adjust and treat. 5) Check the dosing equipment in operation every two hours once, treat the problems found timely, or contact the maintenance personnel to eliminate them. 6) Adjust the temperature and flwo of samples in the allowed range and contact promptly the maintenance personnel to treat the flaws. 7) Wash the sampling water of the high-temperature water-vapor sampling bracket to dispose sewage at 10:00 every Monday once. 8) During the operation of the units, monitor the leakage of the condenser closely. When the hardness or conductivity of the condensated water exceeds the standards, increase the number of analysis, control the boiler water pH and phosphate radical within the qualified scope, strengthen the sewage disposal, report to the chief and leader on duty and make records. 9) The continuous blowdown of the boiler should be adjusted based on the control standard of the boiler water and blowdown rate, avoiding too big blowdown rate from affecting economy and too small blowdown rate from affecting the steam quality. The regular blowdown of the boiler under normal circumstances is conducted once every morning shift daily; when the boiler water concentration is over 50% of the normal value, the boiler water is turbid and the quality of feedwater is bad, the number of blowdown should be increased. 10) Check the quantity of testing medicines and prepare the dosage for weekend on day shift every Friday. 6.2.3 Chemical monitoring of the boiler during stoppage stage 1) After the generating unit stops, the chemical person on duty should stop the corresponding water-vapor chemical monitoring instruments, close the corresponding water-vapor sampling valve and sampling cooler, cooling water inlet and outlet valve. Pay attention to purging the remaining water in various sampling pipes, to prevent the sampling system from being corroded and blocked. When the thermal equipments stop or are backupped, maintain them according to the relevant provisions of stoppage (backup) maintenance. 2) After the generating unit operates normally in a short term, protect the boiler from corrosion by maintaining feedwater pressure, and purge the remaining vapor inside the pipeline connected the steam turbine body for anti-corrosion of the steam turbine after stopping so that the cylinder keeps dry. 3) When the generating unit is partly repaired or stops for not more than 30 days, protect it by using the method that hot boiler discharges water and waste heat is used for drying. 4) When the generating unit is overhauled or stops for more than 30 days, protect it by stopping using octadecyl amine.
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6.3 Chemical protection of standby unit In order to prevent the thermal equipment from being corroded during stoppage (standby) period and ensure the secure and economic operation of the unit, according to Manual for chemical supervision and Rules of anti-corrosion for thermal stoppage (standby) equipment in thermal power plants, it is necessary to take effectiveanti-corrosion protection measures for the thermal equipment during the stoppage to prevent the boiler, heater, steam turbine and other equipment from being corroded and damaged, and the protection measures are specially prepared as follows combined with the actual situation of the company: 6.3.1 Anti-corrosion protection methods 6.3.1.1 Ammonia deoxidant comined passivation + water discharged from hot boiler and waste heat for drying 1) Scope of use The method applies to the circumstance under which the unit stops for less than a week. 2) Technical points Using feedwater and condensated water chemical dosing system to inject ammonia and deoxidant to the system two hours before the boiler stops, improve PH value and deoxidant concentration and form protective membrane under the high temperature, and then the boiler discharges hot water and is dried by waste heat. 3) Operating methods Using feedwater and condensated water chemical dosing system to inject ammonia and deoxidant (acetone oxime in the first and second stage and hydrazine in the third) to the system two hours before the boiler stops; PH is up to 9.5 to 10.0 at the entrance to the economizer, the deoxidant concentration is 30 to 50 mg/L and the deaerator concentration of the boiler water is 200 to 400 mg/L. In the process of stopping the boiler, maintain two hours when the steam drum pressure declines to 4.0 MPa and then continue to release pressure; when the steam drum pressure declines to 0.5 to 0.7 MPa (135MW generating unit) and 0.6 to 0 .9 MPa (300MW generating unit), discharge the boiler water rapidly. In the course of discharging water, open fully the air valve, exhaust valve and water drain valve, and ventilate and discharge moisture in the boiler naturally. After the end of discharging water, close the air valve, exhaust valve and water drain valve and seal up the boiler. 4) Attentions While the boiler release pressure and drains water, control strictly that the temperature of the upper and lower wall of the steam drum does not exceed the allowable value. 6.3.1.2. Adding octadecylamine and water discharged from hot boiler and waste heat for drying 1) Scope of use The method applies to the circumstance under which the unit stops for more than a week. 2) Technical points When the unit stops, add octadecylamine into the thermal system, and it is volatile at a high temperature to form steam after it enters into the boiler, thus full of the boiler, steam turbine and the whole thermal system. A layer of hydrophobic octadecylamine protective film forms on the metal surface of all parts of the thermal system, to separate the metal from the air, thereby
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preventing the metal from being corroded by water, oxygen and carbon dioxide in the atmosphere during the stoppage of the equipment, protecting the equipment. 3) Operating methods a) Using special rapid dosing device of octadecylamine emulsion and connect its outlet hose to the outlet pipe of the hydrazine pump. b) Dosing: 10% pure octadecylamine emulsion 200 kg/time, (135MW generating unit), 400kg/time (300 MW generating unit). c) When the main steam temperature drops to 500 below and it is estimated that it is about 1.5 to 2 hours before the main steam valve is closed after the unit stops (usually, it is estimated under the power level in the coal powder warehouse), and the leader on duty notices the chemical principal to begin to dose (at this time feedwater flow is suppressed as much as possible. Superheated steam temperature can be adjusted at 400 to 500 and can not be higher than 500 , and the water level of the steam drum is controlled at low water level). d) Chemical dosing is under control completed generally for about 30 minutes. After dosing, wash the dosing box and pump with water, open the dosing pump for 10 minutes, and wash the dosing pipeline. e) Report to the leader on duty after dosing, and the generating unit should systematically circulate for 1 to 1.5 hours before downtime after completion of dosing. f) Stop the boiler and hot boiler discharges water: when the steam drum pressure drops to 0.5 to 0.7MPa (135MW generating unit) and 0.6 to 0 .9 MPa (300MW generating unit) in the process of stopping the boiler, discharge the boiler water quickly. In the course of discharging water, open fully the air valve, exhaust valve and water drain valve, ventilate and discharge the moisture from the boiler naturally. After discharging water, close the air valve, exhaust valve and water drain valve and seal up the boiler. 4) Attentions a) While the boiler releases pressure and drains water, control strictly that the temperature of the upper and lower wall of the steam drum does not exceed the allowable value. b) Since dosing, begin to record PH and conductivity meter of feedwater, boiler water, superheated steam and condensated water, and make a record every five minutes (usually, the conductivity increases slightly but PH does not change)l if conductivity and PH are significantly abnormal, conduct manual re-testing immediately by sampling. c) Record the boiler operation parameters (load, feedwater flow, main steam temperature and water level of steam drum) during dosing every five minutes. d) After beginning to dose, pay attention to water samples at the sampling points. When there is white turbidity in water samples, dosing is normal, or else the dosing liquid has not completely entered into the system and the chemical dosing system (including the feedwater system) should be timely inspected. e) There is no foreign body in the liquid when dosing, and massive octadecylamine should be stirred up and scattered to prevent the pump from being blocked.
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6.4 Operation of the boiler chemical dosing system of the boiler 6.4.1 Phosphatizing the boiler water 6.4.1.1 Preparations for phosphatizing 1) Check that the relevant valves of all equipments of the phosphatizing system are switched off. 2) Check that the system is in good standby status. 6.4.1.2. Preparation of phosphate solution 1) Around 1% Na3PO4 12 H2O and Na2HPO4 12 H2O or NaOH are respectively prepared in the phosphate solution tank, and a mixed solution is generally not prepared. 2) Weigh appropriate solid Linsuansanna, Na2HPO4 or sodium hydroxide once, pour into the phosphate solution tank and co-ordination phosphate solution tank, open the inlet valve of the deionization water, and close the inlet valve after the water level is up to a certain height, start and stir the motor so that liquid in the solution tank is fully dissolved and mixed evenly before stopping the stirring motor. 3) If phosphate is easily not dissolved, open the heating device so that the solution temperature is up to 50 to 60, and then open the stirring motor to stir until the solution is dissolved completely. 6.4.1.3. Phosphate dosing steps 1) Contact the centralized control personnel to open the primary boiler water dosing valve. 2) Open the exit valve of the metering tank. 3) Open the inlet and outlet valve of the metering pump. 6.4.1.4. Manually start and stop the dosing pump 1) Switch the design metering pump to the on-site shift, start the dosing pump, and adjust the dosage of the dosing pump according to needs. 2) Check that the motor, gearbox and all rotating parts have no abnormal noise and pressure gauge is slightly higher than the steam drum pressure, and the dosing pump can not leave after the pressure is normal. 3) Stoppage of the dosing pump: stop the dosing pump and close the exit valve of the dosing pump. 6.4.1.5. Automatic dosing operation 1) Switch the phosphate dosing pump and coordination phosphate dosing pump control knobs to Programmed-control shift and switch the frequency converter to Input. 2) In Soft hand state of the CRT, start the dosing pump and adjust the pump frequency manually on the CRT. 3) In the Automatic" state of the CRT, phosphate dosing pump and coordination phosphate dosing pump enter into the automatic dosing state according to the phosphate radical concentration of the boiler water and automatically start and stop, and coordinate dosing. 4) Stoppage of the pump: in the Soft hand" state of the CRT, press the dosing stop switch to end the stopping the pump. 6.4.1.6. Automatic phosphate dosing exists When the automatic dosing fails, it can be switched to the manual dosing; switch the pump in the system to the Soft hand" state of the CRT, and switch the control knob on the start and stop
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button of the CRT or the on-site switch box to on-site to start and stop the dosing pump on the site. 6.4.2 Feedwater and condensated water ammonification treatment 6.4.2.1. Preparations for ammonification 1) Check that the relevant valves of all ammonification system equipments are switched off. 2) Check that the system is in good standby status. 6.4.2.2. Preparation of ammonia solution 1) Open the water inlet valve of ammonia solution metering tank, and close the water inlet valve when the water level reaches a certain level. 2) Open the ammonia inlet valve of the ammonia metering tank, ammonia filling inlet valve and ammonia bottle outlet valve to fill ammonia, pay attention to the pressure display (for example, the ammonia bottle outlet valve should be immediately closed to change the ammonia bottle filled with ammonia liquid if no pressure), close the ammonia bottle outlet valve, ammonia filling inlet valve and ammonia inlet valve of the ammonia metering tank after filing sufficient amount of ammonia. 6.4.2.3. Manually start and stop the dosing pump 1) Contact the centralized control personnel to open the primary ammonification valve. 2) Open the exit valve of the ammonia metering tank and the entrance and exit valve of the ammonia pump, switch the dosing metering pump to the on-site shift, start the dosing pump, and adjust the dosing pump stroke in accordance with needs to adjust dosage. 3) Check that the motor, gearbox and all rotating parts have no abnormal sound, and the dosing pump can leave after the pressure is normal. 4) Stoppage of the dosing pump: stop the dosing pump and close the exit valve of it. 6.4.2.4. Automatic dosing operation 1) Switch the ammonia pump control knob to the Programmed-control" shift and switch the frequency converter to Input. 2) In Soft hand state of the CRT, start the dosing pump and adjust the pump frequency manually on the CRT. 3) In the Automatic" state of the CRT, phosphate dosing pump enters into the automatic dosing state according to the feedwater pump, closed cooling water and condensed water pH value. 4) Stoppage of the pump: in the Soft hand" state of the CRT, press the dosing stop switch to end the stopping the pump. 6.4.2.5. Automatic phosphate dosing exists When the automatic dosing fails, it can be switched to the manual dosing; switch the pump in the system to the Soft hand" state of the CRT, and switch the control knob on the start and stop button of the CRT or the on-site switch box to on-site to start and stop the dosing pump on the site. 6.4.3 Water and closed cold water hydrazination 6.4.3.1. Preparations for hydrazination 1) Check that the relevant valves of all ammonification system equipments are switched off. 2) Check that the system is in good standby status.
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6.4.3.2. Preparation of the ammonia solution 1) Check whether the connecting pipe is connected with the hydrazine metering pump liquid pump well, and insert the pump inlet pipe into the hydrazine storage barrel. 2) Open the entrance valve of the hydrazine metering tank, start the hydrazine self-suction pump, and inject appropriate hydrazine to the hydrazine metering tank. 3) Stop the hydrazine metering pump liquid pump, and close the entrance valve of the hydrazine metering tank. 4) Open the water inlet valve of the hydrazine solution metering tank, and close the water inlet valve when the water level reaches two thirds liquid level. 5) Start the agitator to stir until the solution is evenly mixed before stopping preparation. 6.4.3.3. Manually start and stop the dosing pump 1) Contact the centralized control personnel to open the primary hydrazination valve. 2) Open the exit valve of the hydrazine metering tank and the entrance and exit valve of the hydrazine pump, switch the dosing metering pump to the on-site shift, start the dosing pump, and adjust the dosing pump stroke in accordance with needs to adjust dosage. 3) Check that the motor, gearbox and all rotating parts have no abnormal sound, and the dosing pump can leave after the pressure is normal. 4) Stoppage of the dosing pump: stop the dosing pump and close the exit valve of it. 6.4.3.4. Automatic dosing operation 1) Switch the hydrazine dosing pump control knob to the Programmed-control" shift and switch the frequency converter to Input. 2) In Soft hand state of the CRT, start the dosing pump and adjust the pump frequency manually on the CRT. 3) In the Automatic" state of the CRT, hydrazine dosing pump enters into the automatic dosing state according to the feedwater flow to change frequence automatically. 4) Stoppage of the pump: in the Soft hand" state of the CRT, press the dosing stop switch to end the stopping the pump. 6.4.3.5. Automatic hydrazine dosing exits When the automatic dosing fails, it can be switched to the manual dosing; switch the pump in the system to the Soft hand" state of the CRT, and switch the control knob on the start and stop button of the CRT or the on-site switch box to on-site to start and stop the dosing pump on the site. 6.5 Reason and treatment of water steam quality deterioration 6.5.1 Water-vapor cracking treatment principle 1) When the water-vapor quality is deteriorated, strengthen the analysis, first of all check whether our own analysis and determination are right and the sampling containers are clean, identify whether the water-vapor samples are correct and representative, and then analyze whether the drugs used go bad and whether calculation methods are accurate and correct. 2) After determining that the analysis is accurate, report to the chief and the leader on duty timely to propose the chemical supervision and treatment advices.
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3)
For the deterioration in the water-vapor quality, the persons on duty make records on the extent, reasons, and treatment processes and results of water-vapor deterioration. If there are accidents resulted from chemical reasons, chemical professional staff should be organized to conduct accident analysis and timely treatment, to restore water-vapor standard value as soon as possible. 6.5.2 Tertiary treatment principle The key chemical indexes of the boiler feedwater, boiler water and condensated water are processed according to the tertiary treatment values, and the meaning of tertiary treatment values are as follows: First treatment value - 2 times the normal value, with the possibility of accumulated impurities and corrosion, it should be restored to the normal value within 72 hours. Secondary treatment value - 2 times first treatment value, the accumulated impurities and corrosion will surely occur and it should be restored to the normal value within 24 hours. Tertiary treatment value - more than the secondary treatment value, experience has shown that corrosion will be rapidly carried out and the boiler should stop in four hours. In every level of the non-normal treatment methods, if it can yet not return to the normal within the required time, a higher level of treatment method should be taken. In the steam drum boiler, one of the methods for restoration of the normal value is relieve pressure in operation. When the water-vapor quality is abnormal, the contents in the table below shall be implemented: Water sample Condensated water Item Sodium g/L Normal value 10 Treatment value First class 1020 0.30.4 <8.8 or >9.3 <9.0 or >9.6 0.30.4 7 9.0 Second class Third class 2035 0.40.5 8.0 35 0.5
Electroconductivity 0.3 s/cm pH(25) Copper 8.89.3 No 9.09.6 copper
Feedwater
Electroconductivity 0.3 s/cm Dissolved oxygen 7 g/L
0.40.65 20 8.5
0.65 8.0
Boiler water
PH
(25)
910
If feedwater PH is less than 7.0 or condensated water sodium is more than 400 ug/l, the machine should be immediately shut down Note: when there is abnormal water quality, CL-, Na+, conductivity and alkalinity in the boiler water should also be determined in order to identify the reasons and take corresponding measures. 6.5.3 Feedwater turbidity S/N Reason Treatment
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1
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Identify the polluted water source, cut off the pollution source and treat the water source. Treatment Adjust the operation of the deaerator Contact the maintenance personnel to treat the failure. Reduce the instantaneous replenished water and balance replenishment
The condensated water, drainage and supply water of feed water are turbid Reason The deaerator operates abnormally The internal device of the deaerator fails Too much replenished water in the deaerator The sampler is not sealed
6.5.4 Unqualified dissolved oxygen in feedwater S/N 1 2 3 4
Contact the maintenance personnel to treat timely 6.5.5 Unqualified silicon content and sodium contentor conductivityin feedwater Reason Treatment The silicon content and sodium content Identify the unqualified water source, cut off in the condensated water, drainage and the pollution source and treat the water source. supply water of feed water are unqualified When the continuous blowdown Adjust the operation of expansion tank is put into operation, blowdown expansion tank steam with water of the deaerator goes into it. Reason In the early stage when the generating unit starts, the water-vapor system has high copper and iron content. The iron and copper content in drainage are high. pH controlled too lowly Feedwater system is corrided Treatment Change water and increase the sewage disposal capacity Identify the drainage with high iron and copper content and remove them. Improve the feedwater pH. Strengthen ammoniation treatment and do a good job in antisepticise. Treatment Detect the ammonia solution concentration and make appropriate adjustment of ammonification volume. Check and contact the maintenance personnel to eliminate the failure. the continuous
S/N 1
6.5.6 Unqualified iron and copper content in feedwater S/N 1
2 3 4
6.5.7 Unqualified feedwater pH S/N 1 Reason Too high or low ammonification volume
2 3
The ammonification system fails
The pH of condensated water and Identify the water source with abnormal pH, feedwater comprising supply water is and treat the water source.
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normal
6.5.8 Unqualified condensated water hardness or conductivity S/N 1 2 3 Reason The condenser leaks The replenished water in the condenser is unqualified Unqualified reclaimed drainage water Treatment Check and block leakage Change qualified water Cut off pollution source and treat the water source Treatment Investigate and block leakage the Adjust the under cooling degree of the condenser Activate the standby pump and maintain the defective pump. Strengthen the readjustment and balance water replenishing to prevent water replenishing capacity from fluctuating. Treatment Increase the discharge capacity of the boiler Report to the leader on duty and adjust the operating conditions of the boiler. Eliminate defects and improve the separative efficiency Strengthen sewage disposal and adjust the chemical dosing situation. Improve the desuperheater water quality Treatment Identify polluted water source, cut off it and treat water source, to carry the boiler sewage disposal until clarification Implement the boiler sewage disposal of
6.5.9 Unqualified dissolved oxygen in condensated water S/N 1 2 3 4 Reason Vacuum part of the condenser leaks. The undercooling degree condenser is too bid.
Air goes into the condensated water pump in operation. Excessive condensated replenishing capacity water
6.5.10 Silicon and sodium content of steam exceed the standard S/N 1 2 Reason Silicon and sodium content of the boiler water exceed the standard The operating conditions of the boiler are instable, steam drum water level is high and the load changes greatly. The steam-water separator has flaws or low efficiency. Too big dosing concentration or too fast dosing. Desuperheater water quality is bad. Reason Turbid feedwater or too big hardness
3 4 5 S/N 1
6.5.11 Boiler water is turbid visually outside
The sewage of the boiler is not disposed for long time or the discharge capacity is not enough. The new period or the initial stage of the maintenance boiler put into operation.
Increase the discharge capacity of the boiler until water quality is qualified.
6.5.12 Silicon content and sodium content (or conductivity) of the heater water are unqualified
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S/N 1 Reason
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Treatment Identify polluted water source, cut off it and treat water source, and adjust the operation of the continuous sewage disposal expansion tank of the boiler. Increase the discharge capacity of the boiler or eliminate the defects of the sewage disposal device. Treatment phosphate solution Dilute phosphate concentration Check whether outlet liaison valve of the pump is opened or closed correctly. Adjust the operating conditions of the boiler and strengthen the sewage. Strengthen sewage. Treatment Increase phosphate concentration Investigate the cause, and eliminate defects Check whether the outlet liaison valve of the pump is closed tightly or is opened correctly. Investigate and block the leakage of the condenser and increase the dosage. Reduce discharge capacity Adjust the operating conditions of the boiler to prevent phosphate from disappearing temporarily. Treatment Increase phosphate dosage Investigate the cause, and eliminate the source of acid water and add NaOH into acid water to adjust pH. supervision and increase the
Feedwater quality is poor
Boiler sewage is not normal.
6.5.13 The boiler water PO43- is higher than the standard S/N 1 2 Reason Too big concentration
The outlet liaison valve of the dosing pump is not closed tightly so that phosphate is added into another boiler. The operating conditions of the boiler change drastically and the concentration rate of the heater water is high. Hidden phosphate is dissolved.
6.5.14 The boiler water PO43- is lower than the standard S/N 1 2 3 4 Reason Low phosphate solution concentration Solution tank has no liquid medicine or the dosage pump does not work The outlet liaison valve of the pump is loose or opened wrongly. The condenser seriously leaks, the condensated water is badly treated, causing large feedwater hardness. Too much discharge capacity The operating conditions of the boiler change drastically and phosphate temporarily disappears. Reason Inadequate phosphate dosage Acid water enters into the boiler
5 6
6.5.15 The boiler water pH is lower than the standard S/N 1 2
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3 4 5
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Adjust the discharge capacity Investigate the cause and eliminate organic matter Add ammonia content of feedwater to the applicable scope Treatment Identify the source of acidic water quickly, eliminate acid water to enter into the boiler, and strengthen the regular discharge and open the continuous blowdown volume. Add NaOH and Na3PO4 mixture to the boiler so that the boiler water pH returns to the normal as soon as possible.
Sewage volume is too much. Organic matter mixed in feedwater Lower ammonia content of feedwater
6.5.16 The boiler water pH declines sharply and PO43- is basically normal S/N 1 Reason Acid water enters into the boiler
The condenser leaks
Contact relevant departments to investigate the leakage of the condenser. Treatment Taking antisepsis measures. Exchange the qualified cooling water and input small mixed bed.
6.5.17 Unqualified conductivity, copper and pH in cooling water of generator S/N 1 2 Reason The generator cooling water system is corrided seriously. The cooling system cleaned incompletely maintained is
7 Waste Water Treatment Plant Operation Manual 7.1 General description of waste water station and system 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 Chemical feed devise and compress air system is also included. 7.1.2 Requirement of effluent quality of wastewater treatment system No. 1 2 3 4 5 6 S/N Parameter Temperature pH BOD5 COD SS Mineral Oil Name Parameter Unit mg/l mg/l mg/l mg/l Unit Limited value 40 5.5~9 50 100 100 1 Qty Remark
7.2 Technical specification
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1 Generating tank
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL unit drain of drain V=200m3 Q=150t/hP=0.4MPa Q=8.68 m3/minP=0.06MPa Q=30m /minP=0.06MPa wastewater V=1500m325184 Q=100t/hP=0.2MPa V=1500m325184 Q=100t/hP=0.3MPa V=50m 534 V=50m 534 Q=100t/h diameter 9800mm
3 3 3
Set Set
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Drain pump generating unit tank Roots blower Roots blower Irregular tank
2 Set Set Set Set Set Set Set Set Set Set Set Set Set Set Set Set Set Set Set PCS Set Set PCS Set PCS Set PCS Set PCS 2 2 1 2 1 2 1 1 1 1 2 1 2 2 1 1 2 2 1 1 2 1 1 2 1 2 1 1 2 N=4kW N=4kW N=55kW N=22kW N=4kW N=22kW N=22kW N=15kW
Irregular wastewater tank discharge pump Wastewater tank Wastewater pump pH adjustment pump Flocculation tank Clarification tank Sludge sump Sludge discharge pump Clarification pool Clarification delivery pump water
V=20m3434 Q=10t/hP=0.3MPa V=150m 684 Q=100t/hP=0.3MPa 2000mm filling and 3200mm diameter V=100m3554 V=200m 5104 Q=200t/hP=0.3MPa Q=100t/hP=0.3MPa Q=10t/hP=0.2MPa V=10m3 Q=100L/hP=0.5MPa Q=100t/hP=0.3MPa V=10m V=3m
3 3 3 3
Activated carbon filter Neutralizing tank Outlet pool Bckwashing pump Output pump Unloading alkali pump Sodium storage tank hydroxide
Alkali metering pump Unloading acid pump Acid storage tank Acid metering pump Oxidant metering tank Oxidant metering pump FeCL3 dissolution tank FeCL3 delivery pump FeCL3 metering tank
Q=20L/hP=0.5MPa Q=300L/hP=0.5MPa V=20m V=1m

3 3
Q=10t/hP=0.2MPa
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32 33 Wastewater pump
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Q=20L/hP=0.5MPa Q=100t/hP=0.2MPa Set Set 2 2 N=15kW
FeCL3 metering pump delivery
7.3 Operation of waste water treatment equipments 7.3.1 Operation of chemical dosing system 7.3.1.1 General Waste water station chemical feed system include a set of oxidant dosing system, a set of coagulant aid dosing system, a set of hydrochloric acid dosing system and a set of sodium hydroxide dosing system. 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. 2) Coagulant aid dosing: Iron( ) chlorideFeCl3clarification pool inlet dosage 27 to 63mg/l, turbid degree of outlet water less than 20 mg/L. 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. 3) Hydrochloric acid dosing: 30% technical hydrochloric acid, dosage 0 to 0.20kg/m3, 4) Sodium hydroxide dosing: 30% to 40% sodium hydroxide, dosage 0 to 0.60 kg/m3pH value control 69. 7.3.1.2 Source of wastewater 1) Pickling waste liquid of the boiler 2) Drainage from backwashing the filter and regenerated wastewater of ion exchanger 3) Wastewater from washing the air preheater 4) Industrial wastewater 7.3.2 Wastewater treatment method and procedure 7.3.2.1. Operation of the water pump 1) Inspection before startup a) Clean the water pump body and its surrounding, where there is no sundries to obstruct operation of the water pump. b) Guarantee sufficient liquid level in the pool. c) Open the inlet valve of the pressure gauge of the water pump and check if the indicator of the pressure gauge is normal or not. d) Check if there is full of liquid in the water pump or not or it is required to open exhaust valve of the water pump and inject liquid into the water pump. 2) Startup of the water pump a) Close the outlet valve of the water pump. b) Power on the water pump for startup. c) Check if operation of pump is normal or not and open outlet valve of the water pump to check if flow of the water pump and indicator of the pressure gauge are within regulated scope.
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d) Variation of pressure and flow of the water pump shall meet manual when flow changes. 3) Shutdown of the water pump a) Close outlet valve of the water pump and stop the water pump. b) Close the water inlet and outlet valve and isolate the power supply and then hang an alarm board according to the manual when stopping the pump for repair. 7.3.2.2 Startup and shutdown of Roots blower 1) Inspection before startup a) Check if there are sundries which may obstruct operation of the water pump around the blower. b) Check if the pressure gauge and amperemeter are normal or not. c) Check if the pipeline valves of Roots blower are opened or not. 2) Startup of Roots blower a) Open the air outlet and exhaust valves of Roots blower. b) Power on the blower for startup and operate for about 0.5 minute. Open air inlet valve of wastewater storage pool which needs air inlet and close exhaust valve of blower. c) Check if operation of blower is normal or not after operation. d) Check if indicators of the pressure gauge and amperemeter are within regulated scope or not. e) It is only required to start up another blower after opening air inlet valve of wastewater storage pool which needs air inlet if one blower is already in operation. 3) Shutdown of Roots blower a) Open exhaust valve of blower and close corresponding air inlet valve of wastewater storage pool. b) Stop Roots blower and close air outlet and exhaust valves of blower. 7.3.2.3 Startup and shutdown of the dosing metering pump (acid, alkali, flocculating agent and oxidation pump) 1) Inspection before startup a) Clean the water pump and surrounding environment to remove sundries which may obstruct operation of the water pump. b) Guarantee sufficient liquid level in the metering tank. c) Open inlet valve of the pressure gauge of the water pump to check if indicator of the pressure gauge is normal or not. 2) Startup of the dosing pump a) Open inlet and outlet valves of the water pump. b) Power on the water pump for startup. c) Check if operation of the water pump is normal and indicator of the pressure gauge of the water pump is within regulated scope or not. 3) Shutdown of the dosing pump a) Power off the dosing pump. b) Close water inlet and outlet valves and isolate the power supply and then hang an alarm board according to the manual when stopping the water pump for repair.
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7.3.2.4 Operation of the wastewater treatment system 1) Inspection before startup a) Check if the wastewater treatment system is powered on or not. b) Check if pumps and blowers are in good standby status or not. c) Guarantee sufficient liquid medicine, acid and alkali in every dosing box. d) Check if the irregular wastewater Treatment basin, wastewater Treatment basin, PH adjustment box, flocculation tank, clarification tank, concentrated tank, neutralizing tank and water outlet pool are in good standby status or not. e) Check if ampere meter, pressure gauge, flow meter and every chemical measurement instrument are in good standby status or not. f) Check if the activated carbon filter is in good standby status or not. 2) Irregular wastewater treatment operation of the drainage tank of the unit a) Open air inlet valve of irregular wastewater Treatment basin and start up drainage pump of drainage tank of the unit. b) Open the water inlet valve of the wastewater Treatment basin and close the irregular wastewater Treatment basin when irregular wastewater Treatment basin has a high liquid level. c) Start up one Roots blower for aeration for about 20 hours and open the dosing valve then start up the dosing pump of the deoxidizer to adjust the dosage so that COD of wastewater can be less than 80ppm when one of irregular wastewater Treatment basins has a high liquid level. d) Open the water outlet valve of the wastewater Treatment basin and start up the wastewater pump so that wastewater can pass through PH adjustment tank, flocculation tank, activated carbon filter, neutralizing tank and water outlet pool and so on in sequence. PH adjustment tank and final neutralizing tank shall monitor values according to on-line PH meter and acid and alkaline system can charge and adjust automatically. e) Start up water outlet pump to store the water in water storage box of the ash removal system after the water quality meets the drainage standard. f) Sludge in the clarification pool is drained to the concentrated tank, and start up drainage pump of the concentrated tank to drain sludge to the sludge pool of the ash removal system at the same time. 3) Constant wastewater treatment operation of drainage tank of the unit and water supply treatment system of the boiler a) Open the water inlet valve of the wastewater Treatment basin when there is wastewater in the drainage tank of the unit and water supply treatment system of the boiler. b) Open water outlet valve of wastewater Treatment pool and start up wastewater pump when liquid level of the waste liquid tank is high. Wastewater will pass through PH adjustment tank, flocculation tank, clarification tank, activated carbon filter, neutralizing tank and water outlet pool and so on in sequence. The acid and alkaline system can be automatically adjusted by dosing in the PH adjustment tank and final neutralizing tank according to the monitoring values of on-line PH meter
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c)
4)
Start up the water outlet pump to drain to the ash system water storage tank after the water quality meets the drainage standard. d) Sludge in the clarification tank is drained into the concentrated tank, and start up drainage pump of the concentrated tank to drain sludge to the sludge pool of the ash removal system at the same time. Operation and supervision of the wastewater treatment equipment a) Sample and analyze turbidity, COD, BOD5 and PH before drainage of treated wastewater and wastewater can not be drained until every indicator is qualified. b) Strengthen inspection of every rotary mechanical equipment during operation of the wastewater equipment. c) Inspect and supervise PH valve of the drainage constantly during operation of equipments. d) Ensure that the liquid level of acid and alkaline metering tank and solution tank and others is more than one third, and prepare it in a timely manner if it is insufficient. e) Check if cooling water of every pump is smooth or not. f) Idler running of every mechanical mixer is strictly prohibited when there is no liquid. g) Backwash when inlet and outlet pressure difference of the activated carbon filter is more than 0.1MPa according to the manual in the water generation manual.
7.4 Common faults, judgment and Treatment of wastewater station and wastewater system 1) Unqualified pH of water outlet of wastewater station a) Reason: On-line PH meter fails. Treatment: Contact a thermal control person for repair. b) Reason: Acid can not be added due to abnormal acid dosing pump. Treatment: Contact the relevant person for repair. c) Reason: Alkali can not be added due to abnormal alkali dosing pump. Treatment: Contact the relevant person for repair. d) Reason: Excessive or insufficient acid or alkali dosage. Treatment: Adjust acid or alkali dosage. 2) Unqualified turbidity or chromaticity of water outlet of wastewater station a) Reason: Large drainage quantity and poor quality of wastewater of desulphurization specialty. Treatment: Dilute and circulate until water is qualified. b) Reason: Abnormal sludge scraped from flocculation tank and clarification tank. Treatment: Contact an electrical repairer. c) Reason: Sludge in flocculation tank and clarification tank can not be discharged. Treatment: Wash pipelines with industrial water and contact the relevant person for repair. d) Reason: The dosing pump of flocculation tank is dosed abnormally. Treatment: Adjust dosage of coagulating agent. e) Reason: The dosing pump of coagulant aid is dosed abnormally. Treatment: Adjust dosage of coagulant.
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8 Hydrogen Generation Plant Operation Manual 8.1 General descriptions of hydrogen plant and hydrogen system 8.1.1 General descriptions of hydrogen generation system The system includes auxiliary hydrogen generation and supply equipments of 4X300MW Project of Vietnam Quang Ning Power Plant. It consists of three sets of HM water electrolysis and hydrogen generation equipments of 8.4m3/h, three sets of medium-pressure and high-pressure compressor systems, three sets of medium-pressure drying systems, one set of closed cooling water device, medium-pressure cache equipment, high-pressure storage equipment, hydrogen distribution device and auxiliary water tank, vacuumization device, nitrogen system and control system used for blowing and cleaning. 8.1.2 Operational principle Water will be decomposed to hydrogen and oxgyen when DC passes through potassium hydroxide solution and its chemical reaction is as follows: Cathode: 2H2O +2e H2+ 2OHAnode: 2OH-2e H2O + 1/2O2 Power-on: 2H2O = 2H2+ O2 In general, electrolyte used in the HM system is KOH solution whose weight ratio is 25% and the corresponding specific gravity is 1.23620. 8.2 Technical norms of equipments Serial No. 8.2.1 1) 2) 3) 4) 5) 6) 7) Item Hydrogen generator Hydrogen quantity treatment Nm3 h MPa mg/m 3 8.4 0.7 99. 8 99.5 0.049gH2O/N.Cu.m3 35 Unit Data Remark
Working pressure Purity of outlet hydrogen Purity of outlet oxygen Humidity of outlet hydrogen Temperature of outlet hydrogen Requirements of cooling water Cooling water quantity PH value Soluble solids
m3h
2.64 7
ppm
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Serial No.
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Item Unit ppm 1 Data Remark
Rigidity Calculated by CaCO3 8.2.2 1) 2) 3) 8.2.3 1) 2) 3) 4) 8.2.4 1) 2) 3) 4) 5) 6) 7) 8) 8.2.5 1) 2) 3) 4) 5) 6) Busbar Working pressure Quantity Producer Pure water tank Volume Outer diameter Quantity Producer Hydrogen compressor Hydrogen quantity Inlet pressure Outlet pressure Working temperature Working voltage Outline dimension Quantity Producer Storage tank Type Design pressure Working pressure Design temperature Working temperature Volume generation
MPa Set
0.7 1 Beijing CEC
m3 mm Box
0.219 2700*1800*2270 1 China Power New Energy Group 0.820 1.0 50 -15.0 -3650 380 550300700 6 Beijing Tiangao Company
Nm h MPa MPa V(DC) mm Compressor
Vertical MPa MPa m3 15.5 14.0 50 -36~50 0.51
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Serial No. 7) 8) 9) 10) 11) 12) 8.2.6 1) 2) 3) 4) 5) 6) 7) Diameter
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Item mm mm mm Unit 457 22 3810 16MnR Tank 27 Kaiyuan Chemical Machine Co., Ltd & CLZ-100 cooling water T/h T/h MPa m
3
Data
Remark
Wall thickness Total height Material Quantity Producer Desalinated water cooling device Model Closed flow
10 25 0.2-0.6 1.4 8 1
Industrial cooling water flow Closed cooling pressure water
Volume of reflux water tank Power Quantity
kW Set
8.3 Equipments operation 8.3.1 Startup and shutdown of hydrogen plant and hydrogen system 8.3.1.1 Startup and shutdown of hydrogen generation equipment 8.3.1.1.1 Preparation before startup of the hydrogen generator 1) Carry out hydrostatic test of 1.5MPa and airtight test of 1.0MPa for 30 minutes respectively before startup of the inspected hydrogen generation equipment system and electrolytic tank, and check if there is no leakage or not with soap solution; tests are qualified if there are no bubbles and pressure drop of the pressure gauge. 2) Measure insulation degree of every part with 500V Meg-ohmmeter before startup of the repaired the electrolytic tank and treat instantly if there is any unconformity until it is qualified. 3) Clean electrolytic tank, pure water tank, pressure adjuster, washer and separator with condensation water and analyze water quality. 4) Check if valves and switches in all systems are flexible and pressure gauge is normal or not. 5) Prepare for sufficient nitrogen cylinders, carbon dioxide cylinders and potassium hydroxide and potassium dichromate and so on for replacement. 6) Clean the maintenance equipments and the electrolytic tank to guarantee there is no seeper on the ground. 7) Inject electrolyte and take inspection.
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8) Open water inlet valve of water supply pump to inject water. 8.3.1.1.2 Startup of the hydrogen generator 1) It is required to adopt equipment power and water supply during operation of the system. 2) Close the main loop breaker connected to the power supply to receive power energy, and the programmable controller must be in operation mode. 3) Turn on control switch of the power contactor to power on two control loops of the generator and power supply. 4) Press touch switch of Alarm to reset on the parking screen and then Generator is ready is displayed; the system will begin to run after pressing touch switch of startup/reset. 5) Blow and clean the pipe valve system at the side of the generator oxygen by blowing and cleaning with nitrogen for 30 seconds after operation of the system; the pipe valve system has also been pre-pressed to the required pre-pressure with the development of blowing and cleaning. When the hydrogen pressure begins to rise, the oxygen pressure will rise correspondingly and maintain a pressure difference of 3Psi to 10Ps on the blowing and cleaning screen of the generator; when the hydrogen pressure reaches 20Psig (namely, 1.4kg/cm2), the pre-pressure period of 15 minutes begins and the countdown of 900 seconds is shown on the pre-pressure screen. 8.3.1.1.3 Shutdown of the hydrogen generator 1) From operation to standby: Internal pressure of the system will begin to rise due to no air supply, and air will not be generated when pressure reaches 115Psig (namely, 8.1kg/cm2). 6# lamp on controller module of 2# slot will be off. The system will remain pressure and be in standby status and be ready for air supply according to nees. Touch screen will display Generator is in standby status of hydrogen and oxygen pressure, and air will be generated again when internal pressure of the system drops to the rated system pressure. 2) Shutdown: Hydrogen generator will stop automatically by contacting Generator has stopped.; press the pressure release switch to release pressure automatically if releasing pressure 3) Automatic shutdown and protection of the unit: Shutdown conditions Alarm input Setting point High temperature of KOH High liquid level of KOH LS2 Low liquid level of KOH LS1 90 seconds FS1 10l/min Low flow of KOH High hydrogen pressure PT1 120Psig PT1 120Psig Low hydrogen pressure PT12 115Psig High oxygen pressure PT12 39Psig Low oxygen pressure 3Psig Low differential pressure PT1-PT2 5Psig Low pre-pressure PT1 High temperature pressure in oxygen TC3-TC4 200 Power alarm Low water supply resistance FQM 200-cm
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External alarm Power failure PLC 50 High ambient temperature TC4 Low ambient temperature TC4 5 Drying circulation trouble PT3, PT4 Drying & blow-cleaning trouble PT3, PT4 8.3.1.2 Startup and shutdown of the diaphragm compressor 8.3.1.2.1 Prepare before boot-strap 1) Clean equipments; 2) Check if all valves are closed tightly or not; 3) Check if the pointer of the pressure gauge returns to zero position or not; 4) Check if lubricating oil in crankcase is qualified or not. Check if oil level is between the upper and lower scribed lines of the oil leveler or not. 8.3.1.2.2 Startup 1) Open the valve of the exhaust pipe, and turn to open bypass vent pipe if there is air pressure in the externally connected pipeline; 2) Rotate the fly wheel for several circles; 3) Start up the diaphragm compressor so that rotary speed of the crankcase can reach the rated rotary speed, when the oil pressure in the oil cylinder will rise gradually to 3.6 MPa to 3.8 MPa; 4) Open the valve of the air inlet pipe slightly and then close the air release valve of the exhaust pipeline quickly; 5) Operate under low load for ten minutes and then operate under full load. 8.3.1.2.2 Shutdown 1) Close valves of the air inlet or exhaust pipeline in sequence; 2) Stop the diaphragm compressor; 3) Open the air release valve of the exhaust pipes to release air pressure in every cylinder; 4) Open meter valve below oil-pressure gauge and release oil pressure in every cylinder; 5) Close all valves tightly. Note: Diaphragm compressor can not be started or stopped frequently. In general, the interval between shutdown and boot-strap shall be not less than 2 hours (and it can be shortened properly if the ambient temperature is less than 10). 8.3.2 Adjustment in operation of hydrogen plant and hydrogen system 8.3.2.1. Adjustment in operation of the hydrogen generator 1) Indicator of ampere meter shall be 50A to 280A according to user demand during operation period; the corresponding voltage shall be determined according to the specification of the electrolytic tank and several operation factors. Voltage of the electrolytic tank shall be within the scope of following table. Voltage of the electrolytic tank at 250A Specification of the electrolytic tank Voltage scope HM 50 54-65
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2)
3)
4)
HM 100 108-125 HM 125 135-160 HM 150 162-190 HM 200 215-250 KOH temperature without heat exchanger (TC1) shall be within permissible KOH temperature control scope during operation of the system. The temperature regulator shall control the initially prepared program according to proportion so that KOH temperature can be 64. Temperature regulator (BV1) will be opened or closed according to demand. The valve position and temperature of electrolyte can be monitored on screen of temperature control valve position which is selected from system information of the display. Water supply system is replenished with water intermittently and supply water flows to a storage tank periodically during the ordinary operation, as shown 3# input lamp of 1# slot and 1# and 3# output lamps of 2# slot which are all on. Water supply shall be shown by injection image of touch display for 30 seconds. Water supply frequency depends on consumption rate and it changes with air outlet and electrolytic rate. Water quality monitor shall indicate the permissible green lamp for the minimum electric resistivity of 200-cm. Temperature rise of hydrogen in oxygen during operation of the generator and under almost full load shall be less than 20. It will increase greatly when the system is in standby mode.
Sensor of hydrogen in oxygen needs a constant oxygen flow of 100CC/min. 5) The pressure gauge of at least one drier shall be under pressure during ordinary operation. Drier program can be monitored by pressing touch switch of drier program on the screen which displays Generator is in operation. 4# output lamp of 6 # slot module shall be on before switchover of drying except pre-pressure period for 30 minutes to indicate that blow-cleaning valve of the drier is on. 2# or 3# lamp shall be on according to the program timing to indicate that the heater of the drier is in operation. 6) Data and working days shall be assigned to the generator so that documents can verify the daily operation data. The recorded data can provide useful information to daily maintenance and general diagnosis of operation problems, and such information shall be recorded within 24 hours. 8.3.2.2 Adjustment in operation of the diaphragm compressor Take the subsection and boost lifting pressure and turn to trial operation under rated exhaust pressure gradually after normal operation without load. It is required to lift the suction pressure in sections and then lift the exhaust pressure gradually. (Please refer to Table 2 for details.) Table 2 Serial No. 1 2 3 Suction pressure, MPa 0 0.4 0.7 Exhaust pressure, MPa 1.0 2.5 3.2 Operation period, min 10 10 80
8.3.2.2.1. Operation and adjustment: 1) Inspection of oil supply pump Oil supply pump will operate normally by touching oil exit pipe manually or it is required to find
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out reasons in Table 5. 2) Removal of gas in pressure measurement pipes in the oil cylinder Unscrew the tightening bolt on the meter valve slightly, and screw down tightening the bolt if there are no bubbles in fluids to flow out of the oil pipe. 3) Adjustment of oil-pressure gauge of the oil cylinder Pointer of the oil-pressure gauge of the oil cylinder shall swing slightly and the swinging scope is suggested to be between two minimum scales. Handle of the meter valve can be screwed or unscrewed for adjustment due to excessive or insufficient amplitude of the swing. 4) Lifting pressure Boost suction or exhaust pressure in sections according to requirements in the table. Oil pressure will rise correspondingly after the exhaust pressure rises, and it shall be always higher than the exhaust pressure by 10% to 20%. Note: Oil pressure will not decline due to effect of the check valve below, and the oil-pressure gauge will not drop when the exhaust pressure drops, and at the time the actual valve can be gained by operation according to the above (3). 5) Thermal stable status Operate continuously for 60 minutes when the suction or exhaust pressure can reach the rated pressure so that the machine can be in the thermal stable status to facilitate inspection and find out problems. 8.3.2.2.2. Water quality requirements of the cooling water of the diaphragm compressor are as follows: 1) The suspended matter content of organic and mechanical sundries shall be less than 100mg/L and the oil content can be less than 5mg/L 2) Cooling water is almost neutral. That is, PH indicator of hydrogen ion is suggested to be between 6.5 and 9.5; It has thermal stability and the temporary rigidity is less than 10. (Note: rigidity 1 is equivalent to 10mg CaO or 7.19mg MgO in every liter of water.) It is required to filter and purify if the water quality can not meet the above requirements. Urban drinking water is permitted to use as the cooling water. Inspect and clean the oil filter when the oil pressure is less than 0.15MPa, and then inspect the gear pump if there is still no effect. 8.3.2.2.3. Items to be inspected itinerantly during operation as follows: 1) Check if the operation of the suction valve, exhaust valve, oil supply pump, pressure regulation valve and gear pump and others is normal or not; 2) Check if there is leakage from the oil or air pipeline or not; 3) Check if the connecting rod bearing, copper bush, bearing and plunger and others are overheated or not; 4) Oil temperature of the crankcase shall not exceed 70; 5) Exhaust temperature can not exceed 140, It is required to stop for inspection instantly if there is any abnormal equipment. 3)
8.4 Common faults, judgment and Treatment of hydrogen station and hydrogen generation system 8.4.1 Treatment under emergent conditions 8.4.1.1 Cut off the silicon rectifier power quickly for treatment if there is any emergent condition. 1) Short-circuit, fire-fighting and fulmination of the electrolytic tank 2) The pressure of the hydrogen generation system rises rapidly and is invalid after adjustment
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3) Severe leakage of gas or alkali of hydrogen generation system 4) Severe scorched flavor and short-circuit of the silicon rectifier 5) Circulation shutdown of the electrolyte 8.4.1.2 Fire and explosion in the hydrogenation station It is required to cut off DC and AC power supply of the silicon rectifier instantly and solve problems if there is any emergent condition. Record the Treatment result on the operation log after the event happens; and report it to the chemical worker and leader on duty. 8.4.2 Treatment of common troubles during operation 8.4.2.1 Unqualified purity of hydrogen and oxygen Reason Diaphragm ruptured Severe electro corrosion which may cause corrosion and perforation of pole plate Large water level difference of pressure adjuster of hydrogen and oxygen Too dirty electrolyte or too low concentration of electrolyte in electrolytic tank Deposits in electrolytic tank Reason One-phase quick fuser is fused. One phase of silicon rectifier fails. Treatment Overhaul the electrolytic tank if it exceeds the overhaul term. Adjust hydrogen or oxygen discharge vale to guarantee normal water level. Re-fabrication of electrolyte Shutdown and backwashing of electrolytic tank Treatment Notify the electrical maintenance personnel to replace quick fuser. Electrical maintenance personnel shall find out trouble points and solve problems and record in guard records. Treatment expansion or uneven Strengthen operation and supervision and prevent alkaline liquid from splitting and hurting people Reduce startup times and decrease load slowly
8.4.2.2 The maximum current of the electrolytic tank only rises to 220A.
8.4.2.3 Severe leakage of alkali and gas from the electrolytic tank Reason Frequent startup, shrinkage
The electrolytic tank has operated for a long time to damage leakproofness Corrosion on the surface of pole plate or diaphragm frame Damaged insulation cushion Ruptured coil spring 8.4.2.4 Sudden shutdown of electrolytic tank Reason Power failure caused by vibration of connecting points of mercury relay of silicon rectifier blower Sudden power failure of the plant
Replace insulation cushion, pole plate, diaphragm frame and coil spring and so on during overhaul and shutdown
Treatment Inspect silicon rectifier then start up it for operation if there are no other troubles. Contact integrated control guard for power
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL supply.
Trouble of silicon rectifier and protection motion
Notify the electrical maintenance personnel to solve problems.
8.4.2.5 Large temperature difference of positive and negative poles and hydrogen-oxygen outlet of electrolytic tank Reason Jammed filter and unsmooth circulation of acid and alkali Jammed air outlet pipe or alkaline liquid hole of electrolytic tank Uneven opening of cooling hydrogen-oxygen separator water of Treatment Clean or close inlet and outlet valves of filter and open bypass valve for operation Stopping the tank for backwashing Check if concentration of alkaline liquid is normal or not. Adjust water inlet quantity of cooling water of hydrogen-oxygen separator. Treatment Check if outlet valve of hydrogen pressure regulator is closed or not and remove water in the U-type pipe. Close main valve of condensing water and open water inlet valve and blowdown valve of water tank to release partial condensing water in the water tank. Inspect water inlet valve if there is leakage in the valve.
Too high or low concentration of electrolyte 8.4.2.6 Water tank which is full of water Reason Misuse of water inlet valve of water tank
Internal leakage of water inlet valve of the water supply tank
Hydrogen system pressure is more than pressure in water tank
8.4.2.7. System pressure is more than pressure of hydrogen storage tank by 0.003MPa of gauge pressure Reason Jammed valve or pipe before hydrogen storage tank Frozen outdoor valve or pipe to hydrogen storage tank Jammed float connecting rod of pressure regulator Large reserve pressure of the check valve Treatment Dredge jammed pipe valves Unfreeze outdoor pipe valves by steam Fluctuate water level of pressure regulator for several times Correct and evaluate pressure difference of the check valve again Treatment Find out leakage positions carefully and solve problems.
8.4.2.8. Unbalanced water levels of hydrogen and oxygen sides before startup of electrolytic tank Reason Leakage of hydrogen or oxygen system
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Open automatic water supply valve again to check if it is closed tightly or not. Take measures to start up the electrolytic tank normally and adjust balanced water levels of two sides. Treatment
Automatic water supply valve of water tank is not closed tightly with internal leakage.
8.4.2.9. Variable pressure of hydrogen system during operation and noise in the hydrogen cooler Reason Check if drainage quantity of blowdown valve on the bottom of the hydrogen cooler exceeds the normal scope. Check if there are bubbles in industrial water from peephole of cooling water of cooler or not. Check if there is no noise in the cooler or not by ears. The hydrogen cooler is sinked in industrial water for severe corrosion and perforation.
Stop the electrolytic tank instantly if there are any phenomena, and release the system pressure to 0.02MPa and replace H2 system by N2.
Detach and overhaul the hydrogen cooler and replace the serpent-type pipe.
8.5 Special safety cautions of hydrogen generation station and hydrogen generation system 1) Repair and maintain relevant devices and instruments of hydrogen generation station periodically to guarantee normal operation so as to ensure that purity and humidity of hydrogen can meet requirements. 2) Fireworks of equipments with hydrogen in and out of hydrogen supply station are strictly prohibited. It is strictly prohibited to place inflammables and explosives. It is required to hang an alarm board with No smoking and enclosure around the hydrogen storage tank (namely, within 10m) and prepare for necessary firefighting equipments in the hydrogen supply station. 3) Irrelevant people are strictly prohibited to enter into the hydrogen supply station. 4) Fire operation or jobs with spark is strictly prohibited in the hydrogen supply station. Staff can not wear shoes with nails. Measure hydrogen content in advance if it is required to weld or carry out fire operation to validate that hydrogen content in the air within work area is less than 1% and the staff can not work until examination and approval of the chief engineer. Unfreeze pipe valves or other equipments in the hydrogen supply station by steam or hot water and it is strictly prohibited to fire. Check if there is hydrogen leakage of every connecting pipe or not by instruments or soap water and it is strictly prohibited to inspect by fire. 5) Partition repair part and connecting part and install a tight block plate then replace the hydrogen by air before repair of hydrogen storage equipments (including pipe system) and hydrogen-cooled system of generator. 6) Open valves on equipments evenly and slowly when discharging hydrogen with pressure or dumping hydrogen to release gas slowly and it is strictly prohibited to release gas rapidly to avoid spontaneous combustion caused by friction. 7) Erect gas bottles on the support vertically and avoid heat and direct solar radiation. Coat white on the surface of storage tank and inspect safety valve on the hydrogen storage tank
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8)
9) 10) 11) 12) 13) 14) 15)
periodically to guarantee excellent motion. It is required to cut off electrical equipments and power instantly to release system pressure and extinguish fire by carbon dioxide when hydrogen supply station. Extinguish fire by carbon dioxide and caulk leakage by asbestos cloth to guarantee no hydrogen emission or preclude gas source by other methods if fire is caused by hydrogen leakage. It is strictly prohibited to use tools which may cause spark and it is suggested to use tools which are made of copper during repair and operation of hydrogen system. Hydrogen supply station shall adopt explosion-proof electrical devices. Mixed hydrogen and oxygen has explosion danger and upper limit is 96% of hydrogen and 4% of oxygen and lower limit is 5% of hydrogen and 95% of oxygen. It is not allowed to repair equipments in the hydrogen supply station during operation and it is required to stop equipments then repair according to relevant manual if they must be repaired. Operators are not suggested to wear work clothes which are made of synthetic fiber and wool. Freshmen shall be familiar with system operation of hydrogen supply station and they can not work individually until passing examinations. Door of hydrogen supply station shall be closed constantly and operators shall submit kindling and register before entering into the hydrogen supply station.
9. Circulating Water System & Auxiary Cooling Water System Operation Manual 9.1 Equipment Technical Specification
NUMBER 1
NAME
MODEL AND UNIT NUMBER MANUFACTURE SPECIFICATION 1# 2# 2 CHANGSHA WATER PUMP CO.,LTD
REMARK
CLOSED CYCLE MODEL NUMBER: SET 2 COOLING 20SAP-10 WATER PUMP Q=2000m3/h H=45mH2O MOTOR MODEL NUMBER: SET 2 YKK4504-6 400kW 6600V 980rpm
SUPPLIED WITH PUMP SHANGHAI POWER EQUIPMENT CO.,LTD JINAN PRESSURE VESSEL CO.,LTD
CLOSED CYCLE MODEL NUMBER: SET 2 COOLING SJ-1530-1 WATER COOLER HEAT EXCHANGE AREA: 1580m2 CLOSED CYCLE VOLUME: 30m3 COOLING WATER EXPANSION TANK SET 1
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NUMBER 4 NAME
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL MODEL AND UNIT NUMBER MANUFACTURE SPECIFICATION 1# 2# MODEL NUMBER: SET 2 28SAP-25 Q=3600m3/h H=12mH2O MODEL NUMBER: SET 2 Y2-355L2-10 160kW 400V 590rpm MODEL NUMBER: SET 2 50CYL25-8 25 m3/h 8mH2O 2 CHANGSHA WATER PUMP CO.,LTD
REMARK
OPEN CYCLE WATER PUMP
MOTOR
SUPPLIED WITH PUMP ZHENGJIANG CHANGKAI MECHANICAL EQUIPMENT CO.,LTD SUPPLIED WITH PUMP
CIRCULATING WATER PIT BLOWDOWN PUMP MOTOR
MODEL NUMBER: SET 2 Y2100L2-4 3kW 400V 1450rpm
9.2 Circulating Water System 9.2.1 Inspection and Adjustment before Startup a) Examination and repair is complete, working order form is filled; safety measures have removed and site has cleaned completely; b) C&I group shall be informed to apply operating power source and gauge power for circulating water pump control panel; to check the gauges operate normally. c) Motor insulation of circulating water pump and hydraulic control butterfly valve oil pump are qualified; interlock protection test is qualified. d) Open the water filling valve of cooling water manifold. e) Open water inlet valve of condenser cooling water. f) Open water outlet valve of condenser cooling water g) Close outlet/inlet drain valve of condenser circulating water.. h) Open vent valve of inlet water chamber and then it shall be closed after continuous water discharging. i) Cooling water shall be opened to circulating water pump A&B and electromotor cooling water inlet valve, and then to adjust the opening of valves (rubber bearing shall be filled with water for 20mins washing in the first startup). j) To adjust lube cooling water pressure of circulating water pump A&B until achieving normal condition.
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Lube oil level and quality of Motor bearing of circulating water pump A&B is normal with oil temperature not less than 15; oil level of hydraulic control butterfly valve shall be at 1/21/3, Interlock switching of circulating water pump set at CUTTOFF position, and then power supply will be provided to circulating water pump. Circulating water pump protection shall be put into service. Startup of Circulating Water Pump Operate rotary filter screen continuously, pressure difference before/after filter screen shall be <100mm. Circulating pump is provided with startup condition. Press SEQUENCE STARTUP button of circulating water pump. Hydraulic control butterfly valve at the outlet is opening gradually, and then circulating water pump starts up when the valve opens to 15. Hydraulic control butterfly valve at the outlet opens keep opening and will be fully open in 25s. Current, circulating water manifold pressure and pump and electromotor bearing of circulating water pump are normal; When the pressure difference before/after rotary filter screen is <100mm, then filter screen can be shutdown if no sundries being filtered off. Circulating Water Pump Shutdown Press SEQUENCE STARTUP button of circulating water pump Hydraulic control butterfly valve at the outlet is closing gradually, and then circulating water pump shutdown when the valve closes to 15. Hydraulic control butterfly valve at the outlet opens keep closing without circulating water pump inversion. Idle circulating water pump will be on standby or maintained according to the actual situation. Circulating Water Pump Shifting Standby circulating water is provided with startup condition. Startup standby circulating water pump according to startup sequence of circulating water pump; attention shall be paid to the pressure changing of circulating manifold. Standby pump starts normally; Operating pump shall be stopped according to the shutdown sequence of circulating water pump; attention shall be paid to the pressure changing of circulating manifold; pump shall not operate inversely after shutdown. Idle circulating water pump will be on standby or maintained according to the actual situation. Operating Maintenance of Circulating Water Pump Pump current and water outlet pressure is normal during operating. Lube oil level of from bearing on the circulating water pump Motor is at 1/2-2/3; oil quality and cooling water flux is normal;
l)
9.2.2 a) b) c) d) e) f) g) 9.2.3 a) b) c) d) 9.2.4 a) b) c) d)
e) 9.2.5 a) b)
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e) f) 9.2.6 a) b) c) d) e) f)
g)
Water level difference before/after filter screen of cleaning machine shall be less than 400mm. Bearing temperature of running circulating water pump electromotor shall not be higher than 70(alarm warning at 70, protection will act at 80); thrust bush temperature shall not be higher than 75(alarm warning at 95); winding temperature of Motor stator winding shall not be higher than 80(alarm warning at 110 and protection will act at 120) Upper and lower shaft vibration of running circulating water pump Motor shall not be larger than 0.06mm. Adjustment shall be carried out when the cooling water pressure decreases to 0.1MPa. Startup and Shutdown of Rotary Filter Screen All gauges completed and power is available normally; Lube oil quality of lube components is qualified; lube level is normal; Tightness degree of chain is appropriate, main axis is level; Alarm device is available; Rotary filter screen shall be accepted by manual inching test and no-load test before operation. Auto startup of rotary filter screen 1) Flushing water pump will startup automatically when the water level difference before/after the filter screen achieved 100mm(adjustable); to open motorized valve of flushing water, the rotary filter screen will startup automatically after 10s(adjustable) 2) Rotary filter screen will be shut down after 15mins (adjustable) continuous flushing and the water level difference before/after the rotary filter screen lower than 50mm; and then close to close motorized valve of flushing water, finally to shutdown flushing water pump. 3) If the water level difference is still more then 50mm within the specified 15 mins flushing time, the flushing will be go on until the water level difference before/after the rotary filter screen lower than 50mm.Meanwhile, alarm signal will be sent to the shifting room(or control room). 4) If the water source is clean which results in the water level difference before/after filter screen cannot achieves 100mm, rotary filter screen and flushing water pump will be operated 15min(adjustable) automatically each 8 hours; 1-1.5 rounds will be applied to each operation flushing. 5) Alarm signal will be sent to control room immediately when the water level before/after filter screen achieves or more than 400mm. Rotary Filter Screen Startup in Manual Way: 1) When the rotary filter screen fails to operate, manual running will be applied; manual running shall be carried out twice during each shift according to the start up sequence of: flush pump electric valve filter screen, shutdown will base on the sequence of filter screen electric valve flush pump;
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h)
i)
9.2.7 a) b) c) d) e) f) g) h)
2) Manual way will apply when the rotary filter screen meet the startup condition with large filter screen differential pressure; 3) Flushing water pump starts up by opening the outlet manual valve and the electric valve of corresponding rotary filter screen water source; pump outlet pressure is 0.3~0.5 MPa; 4) Switching sets at manual position, then startup rotary filter screen to check if the rotation parts is operating normally; attention shall be paid to the operating sound and vibration as well as heating of each parts; relevant flushing water will be provided and drained to sewer tunnel outlet; 5) Rotary filter screen operates stably without blockage and serious twist; 6) Sewage in the cleaning groove shall be removed by flushing water. Rotary Filter Screen Shutdown: 1) Rotary filter screen can be shutdown when the pressure difference is small; 2) Cutoff the power for Motor, power gauge shown zero; 3) Rotary filter screen stops operating without abnormity; 4) Shutdown flush pump. Operating Maintenance of Rotary Filter Screen 1) Sewage cleaning shall be carried out in time according to the original water; sewage cleaning shall be strengthen continuously; for the cleaning water source, filter screen shall be runned 1-1.5 round in each 8 hours; 2) Nozzel shall be checked and cleaned termly to improve cleaning quality; 3) Safety device shall be inspected frequently to ensre safety operation; 4) According to the alarm signal for chain loosening, chain shall be calibrated in time; 5) Inspection and repair shall be carried out if the chain or screen plate being blocked during operating; Condenser Rubber Ball Cleaning System Ensure circulating water system and outlet siphon are normal, and outlet/inlet water valve of condenser is open; Ensure the differential pressure before/after ball collector is normal, then operator records the vacuum, TTD/DCA and temperature increasing of condenser; Check the rotor plate of rubber ball cleaning pump to ensure normal bearing oil level and quality. Overall inspection of condenser; Rubber collector A&B set at ball collecting position; Add 700 balls with 29 into ball chamber A&B respectively; Open water inlet/outlet valve of rubber ball pump, water outlet valve and vent valve of ball chamber; Apply rubber ball cleaning procedure and startup rubber ball pump; vent valve of ball chamber will be closed automatically after water drain off;
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i)
Water outlet valve of ball chamber shall be opened adequately and screen plate of ball chamber shall be opened; rubber balls shall be checked to ensure they are into main system completely; j) Screen plate of ball chamber sets at balls collecting position after 24 hours operation; balls collecting time will be 30 mins; k) Close outlet valve of rubber ball pump, and then shutdown the pump and the water outlet valve of ball chamber; l) Water drain and vent valve of ball chamber will be opened for water drain and pressure releasing; hand hole will be opened to count the rubber after complete water draining; ball return rate shall be more than 95%; m) Ball collector on water outlet pipe of circulating water shall set at FLUSHING position after cleaning according to the real situation. 9.2.7.1 Condenser Isolation Cleaning and Leakage Checking (Half) a) Ball cleaning device of the part to be shutdown shall finish ball collecting, balls stop running, then ball cleaning procedure will be exited; meanwhile power for rubber ball pump will be cut of; b) Shifting engineer is informed to loading down below 75% according to the unit vacuum situation; c) Water inlet/outlet of condenser circulating water operated side shall be opened properly; d) Close isolation valve from shutdown side to vacuum pump inlet; e) Close condenser exhaust vacuum isolation valve of shutdown side; f) Close inlet/outlet valve of condenser shutdown side and to open drain valves on inlet/outlet pipe; g) Vent valve of condenser shutdown side shall be opened adequately to destroy its outlet siphoning; h) Drain valve of condenser shutdown side water chamber shall be opened for water drain and pressure releasing; i) Cutoff the power for the following devices: 1) condenser pump inlet/outlet electric valves 2) Rubber ball pump. 3) Electric inlet/outlet valve of rubber ball pump. j) After water pressure decreased to zero, manhole of shutdown side shall be opened slowly for cleaning and leakage checking; condenser vacuum shall be checking during isolation procedure, If vacuum drops, operation shall be stopped immediately to recover the vacuum; 9.2.8 Condenser Recovery after Isolation Cleaning. a) Condenser overhaul is complete; personnel leave site complete, tools and waste are removed completely; holes and valves are closed, and then power shall be provided to the following devices: 1) Inlet/outlet electric valves of condensers. 2) Rubber ball pump.
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3) Rubber ball pump inlet/outlet electric valve. b) Close all drain valves of condensate circulating water. c) Circulating water outlet valve opens 10% d) Open condenser water inlet valve gradually; e) Vent valve on circulating water inlet/outlet pipes shall be closed after water is drain off; f) Open electric valve of circulating water outlet gradually; g) Water outlet valve on two sides of condenser circulating water shall be adjusted to ensure average water temperature; h) Condenser vacuum valve of shutdown side shall be opened slowly to adequate opening after water side of condenser circulating water working normally; i) Open water inlet valve of water chamber vacuum pump; to open the isolation valve form reported water chamber to inlet of water chamber vacuum pump according to the actual need; j) Unit load will be recovered according to the condenser vacuum if necessary, or to carry out cleaning of the other side; k) Condenser rubber cleaning device procedure can be applied according to the actual need. 9.2.9 9.2.9 chlorine feeding system of circulating water 9.2.9.1 Adjusting the Dosing Flow 9.2.9.1.1 Increasing the dosing flow a) Open the flap b) Turn hand wheel slowly to the left c) Close the flap 9.2.9.1.2 Decreasing the dosing flow a) Open the flap b) Turn hand wheel slowly to the right c) Close the flap 9.2.9.2 Switching between Automatic and Manual Adjusting of the Dosing Flow 9.2.9.2.1 Switching from manual to automatic adjusting of the dosing flow a) Open the flap b) Turn hand wheel totally to the right c) Press hand wheel upwards until upper limit is reached d) Close the flap 9.2.9.2.2 Switching from automatic to manual adjusting of the dosing flow a) Open the flap b) Pull hand wheel down c) Close the flap 9.2.9.3 Switching on 9.2.9.3.1 Close rate valve 9.2.9.3.2 Close shut-off valve at the injection unit 9.2.9.3.3 Open motive water valves
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9.2.9.3.4Switch on booster pump 9.2.9.3.5 Open valve of the gas container 9.2.9.3.6 Slowly open the rate valve until the desired gas flow is displayed by the measuring tube 9.2.9.4 Switching off 9.2.9.4.1 Emergency Stop a) Put on safety equipment! b) Immediately close all container valves c) Let the plant run until all parts are evacuated from the dosing medium d) Swith off the plant as described in the following 9.2.9.4.2 Short-term Stop(up to 6 hours) a) Close rate valve b) Switch off booster pump c) Close motive water valves d) Close shut-off valve at the injection unit 9.2.9.4.3 Long-term Stop While the plant is still running: a) Close all container valves b) Let the plant run until the measuring tube shows no more gas flow c) Close rate valve d) Switch off booster pump e) Close motive water valves f) Close shut-off valve at the injection unit 9.3 Auxilary Cooling Water System 9.3.1 Open Cooling Water System 9.3.1.1 Startup of Open Circulating Cooling Water Pump a) Inspection and repair for opened cooling water system have completed; working order form is finished; safety measures is removed; Construction site is cleaning; C&I instrument are complete, instruction valves are open. Oil level of bearing shall be at 1/2-2/3 with normal quality. b) Confirm that the circulating water system operates normally. c) Clean the filter screen of opened circulating cooling watr , and then to close the drain valve. d) Open water inlet valve of opened circulating cooling water pump. e) The vent valve of open circulating cooling water pump shall be opened, and then it shall be closed after air exhausting completely. f) Open water outlet valve of opened circulating cooling water pump. g) Open the inlet/outlet valve of closed water heat exchanger which to be started (two sets operating and one set standby in total 3 heater exchangers A, B and C); to open water side vent valve of closed water heat exchanger, and then it shall be closed after water drain off continuously. h) Power will be supplied to opened circulating cooling water pump after insulation of Motor is qualified; Motor power shall be provided to the test position for the first startup after
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overhaul, and switch static open/close test is accepted; Motor operates normally without coupling. i) Close outlet valve of opened pump and the cooling water control switch; if water pump and Motor operate in good condition, outlet valve of open circulating water will be opened. j) Bypass electric valve shall be opened before opened circulating cooling water pump shutdown. 9.3.1.2 Shutdown of opened circulating cooling water pump a) Bypass operates in good condition b) Close outlet valve of open circulating cooling water pump slowly, and then open circulating cooling water pump shall be shutdown if the closed heat exchanger operates normally. c) If opened circulating cooling water pump need to be shutdown or bypass need to be closed, the system shall be checked to ensure that no system users operate. 9.3.1.3 Operation Maintenance of Open Circulating Cooling Water Pump a) Current and outlet water pressure of operating pump are normal. b) Motor, bearing temperature and gland water return shall be normal; c) Operating pump and Motor bearing vibration shall be normal; d) No alarm warning for pressure difference of opened circulating water filter screen; filter screen shall be cleaned termly according to the working requirement; e) When opened circulating water pump tripped or pressure decreased to 0.18MPa, bypass operation shall be adjusted to ensure normal working condition for closed circulating water heat exchanger. In the normal operation, a group of device will be standby while the other group puts into service. 9.3.2 Closed Cooling Water System 9.3.2.1 Startup of Closed Circulating Cooling Water Pump a) Inspection and repair have completed; working order form is finished; safety measures is removed; Construction site is cleaning; C&I marks is complete, instruction valves are open; the inlet/outlet valve of Motor cooler shall be closed if no pressure in the Motor. b) to open the isolation valve form condensate transferpump to closed expansion water tank, to close inlet valve of closed water pump; drain valve shall be opened to wash the expansion water tank, and then water level of expansion water tank shall be filled to the overflow pipe after water is qualified, and then to closed the tank. Condensate is accepted to apply in the above procedure, but condensate shall not used as make-up water during normal operation to avoid water quality affected by different water. c) Vent valve after closed circulating water outlet valve shall be closed after water is draining off continuously. d) Open the water inlet valve of closed cooling water pump A&B e) to open the van valve of closed circulating water pump A &B, and then close after air exhausting completely; pressure difference before/after closed pump inlet filter is normal; f) Open water outlet valve of closed cooling water pump A&B.
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g) h) i) j)
k) l) 9.3.2.2 a) b) c)
d)
9.3.2.3 a) b) c) d) e) f) g) h) i) j) k) l)
Sampling valve before water outlet valve of closed cooling water pump A&B shall be closed. Open closed inlet/outlet valve, pressure governor valve and front/back electric butterfly valve of two heat exchangers; close drain valve and vent valve. At least a group of cooler is put into service. Power will be supplied to opened circulating cooling water pump after insulation of Motor is qualified; Motor power shall be provided to the test position for the first startup after overhaul, and switch static open/close test and interlock loop test is accepted; Motor operates normally without coupling. Controlling switch of closed circulating water pump shall be closed to check if the water pump and Motor operate normally. Standby pump interlock shall be set at INPUT position. Shutdown of Closed Cooling Water Pump Shifting engineer, shifting personnel of Chemical, FGD and boiler group shall be informed before closed circulating pump shutdown. Interlock of standby closed circulating cooling water pump shall be cutoff. Closed circulating cooling water pump shutdown without inversion operation, or the water outlet valve of inversed operate water pump shall be closed immediately; startup is forbidden when water pump is inversion operating to avoid equipment damage. If both the closed circulating cooling water pumps need to be shutdown, the system shall be checked to ensure that no any user; if cooling water is required by chemical and FGD, it shall be provided from adjacent units. Closed Heat Exchanger Shifting (e.g.: Operation changed from A to B) Closed water pressure, water level of water tank shall be recorded and shifting engineer shall be informed before closed heat exchanger shifting; Close bottom water drain valve of closed heat exchanger B; Open water inlet valve of closed heat exchanger B slightly for water filling. Vent valve of closed heat exchanger B opens slightly, and it shall be closed when water comes out. Water inlet valve of closed heat exchanger B opens slowly to observe water level changing of closed water tank. Open cooling water inlet valve of closed heat exchanger B. Cooling water side vent valve of closed heat exchanger B is closed. Cooling water side drain valve of closed heat exchanger B is closed. Open cooling water outlet valve of closed heat exchanger B. Water outlet valve of closed heat exchanger B shall be opened slowly and attention shall be paid to the closed water pressure changing. Cooling water outlet vale of closed heat exchanger B shall be adjusted to maintain the temperature of closed water less than 38. Water inlet valve of closed heat exchanger A shall be closed slowly and attention shall be paid to the changing of closed water pressure.
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m) Close water outlet valve of closed heat exchanger A. n) Close cooling water inlet valve of closed heat exchanger A. o) Close cooling water outlet valve of closed heat exchanger A. p) Open the cooling water drain valve on two ends of closed heat exchanger A. q) Shifting engineer inform chemical group to test the hardness of closed water. r) To record the shifting time of closed heat exchanger. 9.3.2.4 Operation Maintenance of Closed Circulating Cooling Water Pump a) Water level of expansion water tank is normal; water level adjustment system of expansion water tank shall put into service. b) Outlet pressure of operating pump shall not be less than 0.5MPa. c) Operating pump current and outlet water pressure are normal. d) Motor and bearing temperature of operating pump is normal; e) Motor and bearing vibration of operating pump is normal; f) When closed circulating cooling water pump trips or manifold pressure of closed circulating cooling water decreased to 0.3MPa, standby closed circulating cooling water pump will startup automatically and alarm warning; g) When water level of water tank achieves 1800mm, High water level switch will act to alarm at control room; when water level of water tank decreased to 1500mm, low water level switch will act to alarm, meanwhile, water makeup governor valve of expansion water tank will be fully open; when water level of water tank decreased to 500, LL water level switch will act to alarm in the control room. h) After closed cooling water pump trips, and standby cooling water pump fails to act in 3 secs. Shutdown protection pump will startup automatically; water source of shutdown protection pump is induced from condensate storage tank; attention shall be pay to the water level, if shutdown protection pump fails to startup or trips automatically after startup, manual cooling water inlet valve from expansion water tank and boiler-water circulating pump. Meanwhile, attention shall be paid to other temperature changing.
10 ESP System & Deslagging and Ash Handing System Operation Manual 10.1Scope The standard provides for the principles, methods and steps of startup, stop, operation and maintenance, control and adjustment, maintenance, trouble removal and others of gas electrostatic precipitator (ESP), deslagging and ash removal system in Vietnam Quang Ninh Thermal Power Co., Ltd. 2 300MW generating units. Personnel at all levels engaging in ESP and ash system operation, equipment maintenance and production technology management of Vietnam Quang Ninh Thermal Power Co., Ltd. 2 300MW generating units must be familiar with all or relevant parts of the standard and strictly implement them.
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10.2
Specific quoting documents The provisions contained in the following standards and adopted by the manual are the provisions of the manual. When the manual is promulgated, all the shown standards are valid. All the standards will be revised, and all parties using the manual should explore the possibility of using the following standards with the latest versions and their latest versions apply to the manual. Symbol of standard No. 277 electricity safety 1994 DL408-91 Name of Standard Rules of work of electric job securitythermal-mechanical part Rules of work of electric job security (Power plant and substation electrical part Technical agreements and equipment data of Quang Ninh Power Plant
S/N 01 02 03
10.3Principal specification of system 10.3.1 Overview Vietnam Quang Ninh Thermal Power Co., Ltd. 2 300MW generating units are provided with double-arched W flame single hearth and one-time middle reheating, forced circulation and sub-critical steam drum furnace. Solid deslagging method is used and ash residue at the furnace bottom is discharged to a residue slurry tank via slag crusher and hydraulic ejector. ESP uses double-room four-electric-field electrostatic precipitator and negative pressure ash removal system. The fly ash collected from the air heater, economizer and ESP is delivered to large ash silos (the volume of each of two ash silos is 2500 m3), and dry ash is further mixed through ash and water and sent to the residue slurry tank, and then is transported to the ash yard by mortar pump (meanwhile dry ash retains the way of comprehensive utilization). Each generating unit consists of two negative pressure delivery subsystems. Four separate subsystems (1A, 1B, 2A and 2B) can at the same time automatically (or manually) run and sent out the ash in their respective ESP ash buckets, economizer ash bucket and air preheater bucket through the negative pressure fan. The production systems of three negative pressure fans of each generating unit run the necessary vacuum, of which two run and the other one is for standby. The two ash silos can at the same time receive ash from four transportation subsystems. Four subsystems include their respective independent and specialized pipeline and respective ash silos, and each generating unit contains two pipelines. ESP ash bucket is provided with a gasification system, which transports continuous and stable compressed air provided by the ash bucket gasification fan and heated to the ESP ash bucket, enabling ash in the ash bucket to remain dry and flow, so that ash in the ash bucket can smoothly flow to the pipeline while the fly ash system is running. The dust collection equipment is installed on the top of the ash silo and includes 2 sets of bag filter dust collectors, each of which is equipped with two gas lock valves. The bag filter dust collector includes an automatic injection bag filter attached with relevant instruments. The bag filter can filter fly ash and prevent dust from entering into the negative pressure fan. The ash collected in the bag collectors in the role of their own gravity goes into the ash silos through four air lock valves (each ash collector is equipped with two air lock valves). The air lock
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valve is used to ensure the fly ash falls smoothly into the ash silos but the system in operation will not be interrupted. Ash is temporarily stored in the ash silos until fly ash is discharged and finally handled through the unloading devices. A ventilation filter is arranged on top of each fly ash silo. Air is replaced out when the system runs and the ash silos discharge ash is filtered and then discharged into the atmosphere by the ventilation filter. Each fly ash silo is equipped with an air chute. The air chute can evenly distribute the gasification air in the silo and cause ash to flow toward the discharge mouth. Gasification air is from three sets of ash silo gasification fans and is heated by air circulation heater installed on the gasification pipeline to make the gasification air keep dry. The ash silo gasification device is designed to the continuous operation mode. 10.3.2 Technical specification of major equipment 10.3.2.1 Electrostatic precipitator 1 2 3 4 5 6 7 8 Model Quantity Set furnace 2 450/400 221/224 4 15 480C m 4.55Single electric field BS Barbed Wires of the first and second electric field; high chrome high nickel stainless steel spiral line of the third and fourth electric field Lateral transmission vibration Lateral transmission vibration D of the top transmission Setset m/s
Distance between mm the same poles Number of channel Number of electric field Height of electric field Type plate of anode PCS PCS m
Length of electric field Type of cathode wires Cathode vibration type Anion type vibration
9 10 12 13 14 15
Groove type polar plate system Electric field wind speed Number buckets of
ash pcs/electric field
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16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4
Number of power pcs/electric supply regions field Design pressure Body resistance efficiency of dust collection Manufacturer Model/specification Quantity AC input voltage AC input current AC input power DC output voltage DC output current DC output power Rectifier system Cooling pattern Manufacturer Girder heater electric Fujian Longking Environmental Protection Co.Ltd. setset V A kVA kV A kW Single-phase full-wave high-pressure output bridge type, negative 72 1.2 Pa Pa Shanghai Metallurgical Mining Machinery Plant GGAJ021.2A/72kV 3 380 271
Ceramics axis electric heater Ash bucket electric heater Ash bucket level gage
10.3.2.2 Negative pressure fan S/N 1 2 Item name Model Maximum working pressure Flow Quantity Motor model Motor power Rated current Rated voltage kW A V 400 Unit BK9020 kpa 49 m3/min Set 69 3 QA280M4A 90 Design data
3 4 5 6 7 8
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9 S/N 1 2 3 9 Manufacturer Item name Model Filter area Efficiency of dust collection Manufacturer
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL China Diamond Power Machine (Hubei) Co. Inc. Unit m
2
10.3.2.3 Combination bag type ash collector Design data DMD250 90 99.95 China Diamond Power Machine (Hubei) Co. Inc.
10.4Startup, operation and maintenance and stop of ESP system 10.4.1 Interlocking and Protection 10.4.1.1 If the security interlocking key of the ESP is disconnected, the silicon rectifier transformer of the corresponding electric field can not be put into operation; when the ESP runs, if the interlocking key is disconnected, the silicon rectifier transformer of the corresponding electric field will trip. 10.4.1.2 If the lock switch of the switch cabinet valve of the silicon rectifier transformer is disconnected, the silicon rectifier transformer of the corresponding electric field can not be put into operation; when the ESP runs, if the lock switch is disconnected, the silicon rectifier transformer of the corresponding electric field will trip. 10.4.1.3 Silicon rectifier transformer is provided with gas protection: light gas alarm and heavy gas tripping. 10.4.1.4 Silicon rectifier transformer is provided with the oil temperature protection, and it will alarm if the oil temperature is more than 80 (ambient temperature +30 to 40 ) and it will trip if the oil temperature is more than 85 (as is commissioned and set on the site). Alarm oil temperature signal is in parallel connected with light gas signal and tripping oil temperature signal is in parallel connected with heavy gas signal. 10.4.1.5 Silicon rectifier transformer is provided with input over-current, load open circuit, load short circuit, SCR short circuit, SCR open circuit and partial excition protection. 10.4.2 Preparation and inspection of pre-operation 10.4.2.1 ESP body and relevant electrical parts are all repaired, all components fully inspected are qualified, the inside is clean without person, debris and others, manholes are closed and locked tightly, mechanical and electrical work sheets are ended, and the idle load pressure build-up test is qualified. 10.4.2.2 All the equipment parts are complete, equipment signs are clear and correct, all manholes are sealed well, heating devices of girders, insulators and ohters are intact, and each part provides complete thermal insulation. 10.4.2.3 All the temporary grounding wires inside the electric field are disassembled and the ESP body is grounded well. 10.4.2.4 The grounding resistance of the ESP body should be no more than 1, and the shells of all electric field, low-voltage distribution devices, control cabinets and motors as well as high-voltage isolation switch grounding ends and others must be reliably grounded.
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10.4.2.5 The motor connections of all the rotating equipment are correct firm with complete appearance, and the direction is right after commissioning; the local switch is at the cabinet posiiton and the power switch in the control cabinet is closed. 10.4.2.6 The oil of all the rotating equipment (including reducers) is qualified, the oil level is normal, there is no oil leakage, the protection covers are intact, the arming pins are firmly connected, and the transmission mechanisms do not fall off.. 10.4.2.7 The rectifier transformers have no oil infiltration or leakage, the oil is qualified, the oil level is normal, the silica gel inside the respirator is blue, high and low-voltage cables are not damaged, high-voltage cable joints have no flashover traces, and the grounding wires of transformer shells are complete and firmly. 10.4.2.8 The isolation switch of the rectifier transformer is at the closing position of electric field and contacts well, cabinet valves are well locked, insulation porcelain pieces are clean without crack and discharge traces, and damping resistors do not fall off and fracture; ash bucket ;evel switches, insulators, porcelain axis electric heaters and their temperature measurement devices are installed firmly and connections are intact. 10.4.2.9 The switches of high-voltage control cabinets and low-voltage control cabinets as well as meters are complete and integral, all brakes are operated flexibly, indicaiton locations are correct, connections do not fall off, and the power supply of low-voltage busbar at the PC section is turned on. 10.4.2.10 The security interlocking cabinet keys inside the low-voltage cabinets are complete and are placed to Turn-on, the low-voltage power switch and the power control switch of the control cabinet are closed, the control the power switch button on each control cabinet panel is pressed, and then the low-voltage power and power control indicator lights on the panel are on. (Operate intelligent monitoring instruments of control cabinets in No. 3 to 6 generating units: close the power supply of all electric field intelligent monitoring instruments, and the intelligent monitoring instruments after completion of their self-inspection should show CCCC; check whehter all parameters of the intelligent monitoring instruments are set up correctly, and sparks setting operation mode under normal circumstances should be used in the high-voltage electic field.) 10.4.2.11 The insulation resistance of high-voltage coil, rectifier component and high-voltage ceramic casing in the high-voltage electic field. tested with 2500V megohm meter is no less than 1000M, the insulation resistance of the electric field is no less than 500M; the insulation resistance of the vibration motor, electric heater and their cables (380V and below electrical equipment) tested with 500V megohm meter is no less than 0.5M, and the insulation resistance of the low-voltage coils and low-voltage ceramic casing of the silicon rectifier transformer is no less than 300M. 10.4.2.12 The dust removal transformer and dust removal PC section operate normally. 10.4.2.13 The fly ash system is in the standby status, ash bucket electric heater, ash bucket gasification fan and ash bucket level meter all can work properly. 10.4.2.14 ESP stairs and platform are solid and clean, with adequate lighting and complete fire prevention facilities.
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10.4.2.15 The upper PC of the system operation control is normally put into operation. 10.4.2.16 All the remote monitoring equipment (meters) are intact, the measured values are correct and the alarm system is intact. 10.4.3 Commissioning and operation of the ESP 10.4.3.1 The ESP operates in priority in the PC and can also be operated on the control cabinet on the site, and the switch of the on-site control cabinet is placed at the on-site position in the implementation process of the on-site operations of the on-site control cabinet. 10.4.3.2 Close the switches of the power supply and the control power supply inside the high-voltage control cabinet and low-voltage control cabinet, and the power switches of electric heater and vibration motor inside the low-voltage cabinet, and th indicator lights show correctly without warning and it is confirmed that all the set parameters are right. 10.4.3.3 Before the boiler is ignited, ceramics axis, insulator (porcelain sleeve), girder, ash bucket and others are input for heating in 12 to 24 hours (18 to 24 hours optional in the rainy season mostly and 12 to 18 hours optional in the dry season), and the electrostatic precipitator body and the ash bucket are preheated. 10.4.3.4 Before the boiler is ignited, input all the electric field ash bucket gasification fans in 2 to 4 hours, and put the vibration motor into operation in 1 to 0.5 hours. 10.4.3.5 After the boiler with coal dust input operates stably (usually, there are two sets of milling systems of the boiler in operation, there are not more than four oil guns for fuel, and the inlet gas temperature of the ESP under normal circumstances should be more than 110 and the minimum should be not less than 95), the leader on duty notices the ESP to be put into operation. When operating the on-site control cabinet, press the Reset button, and then press the Startup button to commission and operate the high-voltage electric field (the electric field is input in order according to the inverse direction of flue gas flow direction, and 300MW generating unit ESP is first input into electric field and then into , , electric field). If there is still oil gun in operation in the boiler burning, boost in the Manual mode, and adjust the secondary voltage to 40kV in operation; after the withdrawal of all oil guns for the boiler burning, the secondary voltage is adjusted to the normal best state and the operation switch is set to Automatic position. After each field is put into operation, a period of time to observe and stability (5 to 10 minutes) should be provided, to verify whether their work is normal, and the problems found should be timely examined, analyzed and treated. 10.4.3.6 Adjust the operating mode and setting values of high-voltage parameters according to the secondary voltage and current value, the operating conditions of the boiler and load of the generating unit . 10.4.4 Stop the ESP 10.4.4.1 While the boiler stops, after the oil gun is put into operation, when the exhaust gas temperature drops to below 100 , the operation of high voltage electric field can be gradually cease. 10.4.4.2 After stopping the ESP upon the command of the leader on duty, start to stop the high-voltage electric field, and operate in priority the upper PC and also operate the on-site control cabinet.
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10.4.4.3 When stopping the high-voltage electric field in the inverse direction of flue gas flow likewise, that is, start with the last electric field in series to stop it. In the process of stopping, adjust first the secondary voltage and current to the minimum, and then stop it. 10.4.4.4 When stopping on the on-site control cabinet, adjust first the secondary voltage and current to the minimum, press Reset button on the control panel and then press the Shutdown button. 10.4.4.5 Shut off the main circuit switch of the high-voltage control cabinet. 10.4.4.6 Under normal circumstances, after the high-voltage field stops, maintain the vibration device to continue to operate for four to eight hours and then stop it. 10.4.4.7 If the boiler stops in two days and the ESP is not repaired, the girder, cermics axis and other heating devices will not stop. If they need to be disabled due to maintenance or other inspections, testing and so on, stop them according to the normal stop operation and take the power outage and other related security measures. 10.4.4.8 If the boiler has stopped for more than two days, the heating device should be suspended and the power switches and the control power switches and others of all branches of the low-voltage cabinet are disconnected. 10.4.5 Inspection in operation and contents of maintenance 10.4.5.1 The vibration device is installed firmly and its anchor bolts are not loose; the motor is in normal operation, turns correctly and has no abnormal sound; the motor surface temperature can not exceed the ambient temperature 45, its vibration is no more than 0.08mm, and the fan is in normal operation; the maximum motor bearing temperature is not allowed to be more than the ambient temperature 45 ; the reducer lubricates well, with adequate lubricant, and no oil permeability exists on all vent caps and oil discharge mouthes. 10.4.5.2 The arming pins of the transmission mechanism are intact, shift forks are not fractured, and the vibration sound inside the ESP is normal. 10.4.5.3 Each manhole of ESP body, insulator room valve and vibration axis penetration body should be closed and seamless, and the ash bucket outputs ash normally. 10.4.5.4 Check that the on-site control cabinet of the vibration motor is normal and under emergency circumstances, stop the vibration motor through the on-site cabinet control switch. 10.4.5.5 After the anode vibration motor stops, the corresponding electric field continues to run for a peirod time that should not exceed 24h. 10.4.5.6 After the cathode vibration motor stops, when the secondary current is less than 100mA, it should be suspended, and the corresponding electric field continues to run for a peirod time that should not exceed seven days. 10.4.5.7 The oil level of the high-voltage silicon rectifier transformer is one second to two thirds, and oil is transparent without debris and oil leakage; the transformer has no abnormal sound and smell, no abnormal increase in oil temperature occurs, silica gel inside the respirator is blue, the isolation brake is in the electric field, the red indicator light is on, and the ceramic casing has no climbing electricity and discharge phenomenon.
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10.4.5.8 The primary and secondary voltage and current of the high-voltage cabinet should be lower than the rated values, otherwise they should be adjusted or the reasons are identified and eliminated. 10.4.5.9 The operating indicator light of the high-voltage cabinet control panel is on, with no fault alarm, and the cooling fan of the high-voltage cabinet SCR operates normally. 10.4.5.10 The vibration motor of the low-voltage cabinet and electric heater have no fault alarm, and the displayed temperature value of the electric heater is in the set scope. 4.5.11 There is no abnormal sound, smell and smoke phenomena in the cabinet, each meter and indicator right show normally, the switch position is correct, and the cabinet valve is locked. 10.4.6 Operation of ESP and Attentions to Maintenance 10.4.6.1 ESP uses high-voltage DC power supply, so the relevant provisions of Safety should be strictly enforced in the process of operation and maintenance, with particular attention to personal safety and equipment. 10.4.6.2 The rectifier transformer is not put into operation in the boiler-fuel stage and can be appropriately input in the co-combustion of coal oil stage when the fuel is very little. 10.4.6.3 Before commissioning and operating the high-voltage electric field, the temperature of the ceramics axis, insulator and others heated should be more than the smoke dew point (normally 70 to 80) temperature of 20 to 30 and the inlet smoke temperature of the ESP exceeds 95 (less than 160 ). 10.4.6.4 It is prohibited in operation that the manholes of the ESP body, ceremics axis and insulator room are opened and the isolation switches must be locked; it is prohibited in the operating process of the rectifier transformer to operate the high voltage isolation switch or directly cut off the power supply. 10.4.6.5 If the operations inside the ESP are necessary, the operations must be conducted after the boiler stops and cools down, the outlet temperature of the ESP drops to below 40, the ESP body is reliably grounded by inspection, and the power off and other security measures are prepared and it is confirmed that the content of the internal toxic gas meets labor protection requirements. If it is urgent to operate the ESP inside, after the boiler stops for eight hours, open the manhole of ESP body and start a guide ventilatorto speed up the cooling. 10.4.7 Common faults and trouble shooting of ESP 10.4.7.1 The primary and secondary voltmeter and ammeter of ESP have no significant display values -- Reasons The power supply of the power circuit of the rectifier transformer is disconnected; The automatic adjustor is powered off. -- Treatment Check the power circuit; Check the control power supply of the automatic adjustor. 10.4.7.2 The primary voltage of the ESP is very low, its current is large, its secondary voltage is close to zero and the secondary current is very large
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-- Reasons The high-voltage isolation switch is placed on the Ground; High-voltage cable is broken down or terminal joint insulator is damaged to cause short circuit; The electric field ash bucket is seriously accumulated with dust to cause short-circuit between the anode and the cathode; The broken cathode line causes short circuit; The rotational ceramics axis of the cathode vibration device is damaged or the ceramics axis box is seriously accumulated with dust, causing short circuit to earth; The damping resistor at the top of electric field falls off to the ground; There is a metal foreign body between two poles to cause short circuit; The high-voltage insulator is damaged or quartz casing is condensed or has ash, causing the short circuit. -- Treatment The high-voltage isolation switch is placed on the Electric field position; Treat or replace cables and terminal joints; Reduce the fouling inside the ash bucket as soon as possible; Stop the boiler and treat the broken line; Replace the rotation axis or remove the fouling; Restore or replace the damping resistor; Stop the boiler and treat the foreign body; Replace the damaged insulation porcelain pieces, remove the fouling and improve the heating temperature. 10.4.7.3 The secondary voltage of the ESP is normal and its secondary current is small -- Reasons Corona is closed; The vibration effect is bad, resulting in weighty corona line or anode plate with too thick fouling. -- Treatment Understand the boiler load, and observe whether it is relieved in low load; Input the continuous vibration or adjust the vibration cycle. 10.4.7.4 The switch inside the ESP control cabinet trips or trips again after it is closed -- Reasons There is a foreign body in the electric field, causing double-pole short circuit; The cathode line is broken or components fall off, causing double-pole short circuit; The ash bucket is full of ash, causing the cathode short-circuit to earth; The heating device of the insulator room at the top of the cathode fails or thermal insulation is bad, causing the insulator surface to be condensated and flashover resulted from insulation; The fouling surface on the insulator at the top of the cathode discharges and is broken down. -- Treatment
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Stop the boiler and treat the debris; Stop the boiler and treat the broken line or components; Reduce the fouling inside the ash bucket; Restore thermal insulation or heating devices; Swab the insulator. 10.4.7.5 Light and heavy gas alarm happen in the gas relay of ESP rectifier transformer -- Reasons Rectifier transformer fails inside -- Treatment Check whether the abnormal temperature of the outage rectifier transformer rises, check and confirm the nature of the gas inside the gas relay, and inform the maintenance staff to check and test insulating oil. 10.5Startup, operation, maintenance and stop of negative-pressure ash removal system 10.5.1 Interlocking and permision conditions Before the system vacuum breaker valve is closed, the system must form a single and smooth negative pressure air flow channel. While the system is running, only an ash bucket material transport valve (H-type valve) is allowed to be opened. Before the ash removal procedures of the system ash transport pipeline start, all H-type valves must be closed. Before the negative pressure fan is allowed to commence, there must be a single and smooth transport channel to form. Before H-type valve is allowed to be opened in automatic ash transport mode during the operation, the value of negative pressure the system must meet the minimum allowable transmission value of PSML. Before the upper valve of the gas lock valve is allowed to be opened, the lower valve of the gas lock valve must be fully closed. Before the lower valve of the gas lock valve is allowed to be opened, the upper valve of the gas lock valve must be fully closed. If the ash warehouse provides the alarm condition of the material level of the ash warehouse is high, the system associated with the ash warehouse could not be activated. However, when the relevant ash warehouse provides the alarm condition of the material level of the ash warehouse is high after the system has begun to operate, the system continues to run (only alarm). Before the electric gasification air heater of the ash bucket (the ash warehouse) is put into operation, the gasification fan of the corresponding ash bucket (the ash) must have been put into operation normally. Before the electric gasification air heater of the ash bucket (the ash warehouse) commences, it must be ensured that the outlet pipeline valve has been opened and a smooth air flow channel has formed. 10.5.2 Inspection and preparation before commissioning and operation
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The maintenance of all equipment of the negative pressure pneumatic ash removal system is all over, and the work sheet ends and passes the acceptance. Check whether there is no debris inside the ash bucket. Check that the appearance of the on-site control box is intact and the switches and buttons in the disc are complete and are operated flexibly. Contact a heat engineer to connect the PLC program-controlled power supply of the ash removal system, and the indicator light shows correctly, without alarm. Check that the pneumatic and manual valves for all instruments are at the full position, and adjust the gas pressure for the instruments to be 0.4 to 0.6 Mpa. Click, open and close all pneumatic valves on the CRT one by one, and observe that the actual location is consistent with the position of the CRT and the on-site control panel on the site and the pneumatic implementing mechanism switch is flexible and in place and is not jammed. Check that the appearance of the bag-type dust collector is intact, the outlet mesh grid is intact, the general compressed air valve is open, the pressure is about 0.6Mpa, without air leakage phenomenon, the power switch inside the on-site control cabinet is closed, the indicator light shows right and all the switches are flexible. The manhole of the ash warehouse is closed, the appearance of the vacuum pressure release valve is intact, the connections of the level meter and material level switch do not fall off, the indication is correct, and the CRT has no wrong alarm. The inlet and outlet manual valve of the gas storage cylinder in the ash warehouse are both opened, and the pressure is 0.4 to 0.6 Mpa. The pneumatic and manual valve of the pneumatic valve at the top of the ash warehouse for the electromagnetic valve control cabinet is opened, the switch location is right and the control power supply is closed. Open the manual dry ash valves of each ash bucket to the full open status. Open the manual isolation valve of each branch pipeline of the gasification fan of the ash bucket to the full open status. Deliver the power supply of the gasification fan, ash warehouse and gasification fan heater of the ash bucket, and gasification fan heater of the ash warehouse. Check and set the temperature (120) of the gasification fan electric heater of the ash bucket (the ash warehouse) correctly, and set the control mode of the heater to the position of Remote control. 10.5.3 Startup of the gasification system of the ash bucket and air warehouse 10.5.3.1 Check and confirm that the isolation valve of each branch of the ash bucket (the ash warehouse) gasification fan has been opened. 10.5.3.2 Open the outlet pneumatic valve of the gasification fan of the ash bucket (the ash warehouse) until the Full open feedback signal is sent out. 10.5.3.3 Start the gasification fan of the ash bucket (the ash warehouse). 10.5.3.4 Delay three minutes and then start the gasification fan electric heater of the ash bucket (the ash warehouse). 10.5.4 Commissioning and operation of the negative pressure ash removal system
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10.5.4.1 Start the ventilation filter of the ash warehouse. 10.5.4.2 Complete the following options based on the operating control station CRT of the ash removal system: Select the ash bucket of each ESP, air preheater and economizer until COLLECT status is through the BYPASS - COLLECT selection button) Select the ash removal subsystem A and B to AUTO status (relative MANUAL) According to the standby status of the negative pressure dedusting fan, select two fans on work. 10.5.4.3 Press START button of the system 10.5.4.4 Observe that the system should run in accordance with the following procedures: 10.5.4.4.1 The filter dust collector of the ash warehouse A begins to circulate, and its impulse control timer is excited (powered on) so that the bag-type filter starts to work. The upper and lower valve of the corresponding air lock valve combined with the balance valve begin to open and close circulatorily. At the same time the fluidization electromagnetic valve of the filter dust collector is excited (powered on) and is open. When the lower valve of the air lock valve is open, its fluidization electromagnetic valve is excited and is open, and the fluidization electromagnetic valve is de-excited (powered off) and is closed when the lower valve is closed. 10.5.4.4.2 The opening/closure of the following system isolation valve can form a separate ash transport channel and vacuum channel through the filter dust collector A: The vacuum fan isolation valve is adjusted to the correct channel. The first branch pipe isolation valve of the ESP ash bucket is opened. Check the procedure logic and make sure that the ash warehouse is not in the high material level, and a separate smooth transport channel has been established (through the limit switch of the valve). The vacuum breaker valve is excited (powered on) and is closed. 10.5.4.4.3 Startup of vacuum fan A. 10.5.4.4.4 When all the ash bucket relief valves (H-type valves) are closed after the fan commences, the vacuum degree of the system will rise. When the vacuum degree reaches the set point PSML, PLC will send signals so that the most remote ash bucket relief valves (H-type valves) in the first column of the ESP ash bucket are opened. If it can not reach the set point of PSML in the scheduled time, it will send a warning signal low vacuum (FLY ASH SYSTEM VACUUM LOW). The phenomenon is likely resulted from the vacuum leakage of the pipeline system or an H-type valve not closed. When the H-type valve is opened after receiving the signal, the timer begins to work. In the scheduled time, the vacuum degree of the system must decline to the set point PSL below, otherwise it will trigger the high vacuum alarm (FLY ASH SYSTEM VACUUM HIGH). (Usually, the time set by the timer is determined based on the time for dumping the entire ash bucket). Before the end of the timer delay, if the vacuum degree of the system declines to the PSL below, the timer returns to zero (reset).
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When the ash in the ash bucket is discharged into the flying ash pipeline, the vacuum degree of the system will increase to the set point PSH, and at the time, the E-type valve that is currently open receives the signal and is closed to prevent the pipeline from over load. When the H-type valve is closed, as no more ash is discharged into the pipeline, the vacuum degree of the system will gradually drop to PSMH, and at this time, the H-type valve receives the signal and is re-opened. As ash in the ash bucket is gradually discharged, the vacuum degree of the system will gradually decline. When the vacuum degree of the system declines to the set point of PSL, the ash bucket is basically emptied, and thus the H-type valve of the ash bucket receives the signal and is closed. The closure of the H-type valve leads to the vacuum degree of the system to rise again, when the vacuum degree reaches the set point of PSML, PLC sends signals to open the H-type valve of the selected next ash bucket in the ash collection order. 10.5.4.4.5 Repeat the operation order in the above steps from C to E for every ash bucket in the column. 10.5.4.4.6 When the vacuum degree of the system declines to PSL in the operation process of the chosen last ash bucket in the column, or the fourth ash bucket, its H-type valve is closed. 10.5.4.4.7 The branch pipe isolation valve of the ash bucket in the second row receives signals and is opened, and meanwhile branch pipe isolation valve of the ash bucket in the row that has completed ash output receives signals and is closed. 10.5.4.4.8 The order of ash output and the operation process of the ash bucket in the second row are completely the same as the ash bucket of the row completed. 10.5.5 Inspection of the negative pressure ash removal system in operation 10.5.5.1 The gasification fan and vacuum fan of the ash bucket (the ash wareshoue) are in normal operation, without abnormal sound, the vibration is less than 0.08mm, the bearing temperature is less than 80 , and belts slack appropriately, without fault; oil of the lubricating parts is good, transparent and colorless, the oil level is one third to two thirds, without oil leakage. 10.5.5.2 The combination faces of all air pipelines and pipeline flanges have no air or ash leakage. 10.5.5.3 Ammeter three-phase of the electric heater control cabinet is uniform, the voltage is around 380V, the indicator light is right and can automatically start and stop according to the set temperature, there is no burnt flavour inside the cabinet, and the SCR cooling fan is in normal operation. 10.5.5.4 The ash transport pipeline has no vacuum leakage and each ash bucket discharges ash normally; 10.5.5.5 The compressed air pressure of the system is normal, withotu air leakage phenomenon, all the pressure gauges show correctly, the pneumatic valve operates flexibly and is not jammed, and the on-site switch position is the same as the indicated on the CRT and on-site disc; 10.5.5.6 Check the ash discharge pressure curve of each ash bucket timely, analyze the ash discharge status, and confirm the alarm in the larm column after it is analyzed.
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10.5.5.7 The electromagnetic valve of the bag-type dust collector works properly, the effect of pulse vibration is good, and the air exhaust does not output ash. 10.5.5.8 The on-site state of all remote control equipment and valves are consistent with the CRT. 10.5.6 The negative pressure ash removal system stops normally: 10.5.6.1 The pulse injection timer of the filter dust collector still remains the working condition, and the upper and lower valve of the corresponding air lock valve continue to circulate for a scheduled period of time to ensure that the filter bag is clean and the filter dust collector is completely emptied. 10.5.6.2 After a delay for cleaning the transmission pipeline, the running vacuum fan receives signals and stops. Before the fan stops (about 2 seconds), the corresponding vacuum breaker valve is powered off and is opened. 10.5.6.3 The branch pipe isolation valve of the ash bucket and the isolation valve of the fan are closed. 10.5.6.4 The operating process of ash removal ends. 10.5.7 Common faults and trouble shooting of negative pressure ash removal system When there is an alarm signal, press (ACK) button first of all; after eliminating the alarm situations, press (RESET) to remove the alarm display. (For the critical alarm signal of the system, the system must be reset before it is allowed to restart.) 10.5.7.1 Low vacuum of fly ash system Reason: A low vacuum alarm signal lasts more than 30 seconds. The possible reason is that the material transport valve of the ash bucket can not be closed or the pipeline is damaged. System response: the system stops at the current ash bucket because the vacuum degree of the system fails to rise to PSML, it can not be transferred to the next ash bucket. Treatment: check whether H-type valve of the current ash bucket moves normally, and find the leakage point and eliminate it 10.5.7.2 High vacuum of fly ash system Reason: the vacuum value continues to maintain the set point of PSMH for more than 15 minutes. The possible reason is that the ash bucket is blocked or the material transport valve of the ash bucket can not be opened. System response: the system stops at the current ash bucket because the vacuum degree of the system fails to decline to PSL, the current H-type valve maintains open. Treatment: switch the status of the ash bucket to the BYPASS status, and check whether the manual lower ash valve of the ash bucket is opened, and treat the blocked ash of the ash bucket. 10.5.7.3 High temperature outlet of negative pressure fan A (B) Reason: the outlet temperature of the negative pressure fan is high, and the possible reasons include the bad lubrication or the fan has mechanical failure. System response: the transportation system is shut down Treatment: the system is put into operation again after switching the standby fan 10.5.7.4 High pressure difference of filter dust collector A (B or C)
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Reason: the differential pressure switch senses the high differential pressure inside and outside the cloth bag, and three times of this situation within 10 minutes appear continuously. Possible reason is that the cloth bag is blocked or the cloth bag cleaning equipment fails. System response: when the cloth bag dust collector alarms for the first time due to the high differential pressure of the cloth bag, the current H-type valve should be closed and the system vacuum breaker valve is powered off and is opened. The on demand ash removal control procedures of the filter dust collector continue to operate, and the air lock valve below the dust collector runs circulatorily for a scheduled period of time (about two minutes). The vacuum breaker valve is powered on and is closed, and the current H-type valve is re-opened so that the system resumes operating. If the dust collector cloth bag has high differential pressure for three times continuously within 10 minutes, an alarm signal appears, and the system starts to stop normally. (After cleaning the pipeline, before the system stops, the pulse injection control procedures of the filter dust collector and the circulation procedures of the air lock valve continue to run for 5 to 10 minutes). Treatment: check the pulse electromagnetic valve of the cloth bag dust collector and check the pressure of the gas source for the cloth bag dust collector. 10.5.7.5 The cloth bag A (B) of the filter dust collector is broken Reason: the determined significant changes in dust grain flow are detected by the dust monitor installed on the front air inlet mother tube at the entrance of the negative pressure fan and this situation continues for a scheduled period of time. The reason is usually that the cloth bag of the filter dust collector is damaged or the cloth bag falls off. System response: the system alarms. Treatment: stop the system to check the cloth bag dust collector and calibrate the dust detector. 10.6Startup, operation, maintenance and stop of the hydraulic deslagging system 10.6.1 Interlocking and protection 10.6.1.1 After the slag crusher is overload, it stops and sends out fault alarm signal. 10.6.1.2 A, B slag bucket of each boiler are at the same time not allowed to discharge slag, and two boilers discharge slag alternately. 10.6.1.3 When the liquid level of the front buffer tank of the slurry pump of No.1, 2 generating unit (the front tansfer warehouse of the slurry pump for No. 3 to 6 generating unit) is too low value, the operation pump stops; when it is low value, the slurry pump is locked and is allowed not to start. If the high-pressure pump at this time is in operation, the water replenishing valve is opened; when it is the normal value, the water replenishing valve is closed, and when it is high value, the slurry pump should be start or continue to run; when the liquid level of the front buffer of the slurry pump is low value and the high-pressure water pump does not run, the water replenishing valve is not closed. (No. 3 to 6 generating unit is yet not provided wih logical chain, so the low value is 1.5m in the actual operation and the too low value is provided by 0.5m) 10.6.1.4 When the liquid level of the front buffer tank of the slurry pump of No.1, 2 generating unit
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is too low value, the washing valve of the slurry pump is opened, the inlet valve is closed, and the slurry pump stops and the washing valve is closed after washing for some time. 10.6.1.5 When the high, medium and low-pressure water pump begin to be put into operation, the electric bypass valve is opened first automatically, the bypass valve is closed after the pump operates stably, and when the pressure of the mother tube is high in the course of running, the bypass valve is opened to relieve pressure. 10.6.1.6 The overflow pump and sewage discharge pump start under the high water level signal sent by the liquid level meter, and they stop when it is low water level " signal. 10.6.1.7 When the water storage tank sends low water level signal, the water replenishing electric valve is opened to supply water to the water storage tank, until the water level is normal before the water replenishing electric valve is closed. 10.6.2 Preparation and inspection prior to commissioning and operation 10.6.2.1 Confirm that the maintenance of all the equipment of the system is all over and the work sheets are ended and pass the acceptance. 10.6.2.2 The manholes of the slag bucket are closed tight, overflow pipes are smooth, there is no slag deposition in the overflow water tank, each manual valve of water seal slot and sight glass washing valve are opened, the slag discharge gate and each aerodynamic nozzle vavle are closed, sight glass is intact, and all the pipelines are connected tightly. 10.6.2.3 The water storage tank for controlling the slag discharge valve of the slag bucket is filled with water by 15 to 25cm, and its water inlet valve, overflow water valve,and the water discharge valve at the bottom and the control emptying valve at the top are all closed, without water and air leakage. 10.6.2.4 The appearance of the slag crusher is intact, the anchor bolts are connected tightly, the shaft seal water is normal, the oil level of the reducer is one second to two thirds, and oil quality is good, without oil permeability and leakage, the transmission chain is appropriate elastic with good lubrication, the shield is solidly installed, the hydraulic injector is smooth, and the inlet and outlet flange are connected tightly. 10.6.2.5 The liquid level of the water storage tank is normal and the liquid level indicator shows correctly. 10.6.2.6 The anchor bolts of high and medium pressure water pumps are connected tightly, the inlet manual valve and bypass manual valve are open, the shaft seal water and bearing cooling water are appropriately adjusted, the oil level is one second to two thirds, and the oil quality is good, without oil permeability and leakage, and the coupling shield is installed firmly. 10.6.2.7 The anchor bolts of low-pressure water pumps are connected tightly, the inlet manual valve and bypass manual valve are open, the bearing lubricant is good, the belt is intact and is appropriately elastic, and the shield is installed firmly. 10.6.2.8 Start a slag bucket cooling water pump to supply the corresponding the water seal groove at the bottom of the boiler with water before 1h when the boiler is ignited. 10.6.2.9 The anchor bolts of the overflow pumps are connected tightly, the bearing lubricant is good, the belt is intact and is elastic appropriately, the shield is installed firmly, and the shaft
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seal water is appropriately adjusted. 10.6.2.10 There are no big blocks of slag deposition, debris and others inside the slag bucket buffer pool (transfer warehouse), and the liquid level shows correctly. 10.6.2.11 The anchor bolts of the slurry pump are connected tightly, the inlet manual valve and outlet manual valve are open, the shaft seal water and bearing cooling water are appropriately adjusted, the oil level is one second to two thirds, and the oil quality is good, without oil permeability and leakage, and the coupling shield is installed firmly. 10.6.2.12 Contact a heat engineer to connect the PLC power supply, open the pneumatic and manual valve of the slag bucket for the electromagnetic on-site cabinet instrument, close the control power supply, and the indicator light shows correctly and the switch is placed at the Remote position. 10.6.2.13 Close the power supply inside the on-site control cabinet of the slag crusher, and the indicator light shows correctly and the switch is placed at the Remote position. 10.6.2.14The air pressure of the instrument is 0.4 to 0.6 Mpa, all the pressure transmitting instruments and pressure switches are input, the pressure gauge is intact, the pneumatic valve and electric valve switches are flexible and the feedback signals are correct. 10.6.2.15 The ash water recycling system is in good standby status. 10.6.3 Startup and stop of slag bucket cooling water pump 10.6.3.1 Operation steps of starting the slag bucket cooling water pump 10.6.3.1.1 According to the operating conditions of the generating units, open the general electric valve of the low-pressure water replenishment and the manual valve of each branch line (appropriate opening). 10.6.3.1.2 Open the electric bypass valve of the low-pressure water pump. 10.6.3.1.3 Press Start button of the low-pressure water pump, observe that the outlet pressure gauge of the low pressure water pump is normal, and open the electric valve of the low-pressure water pump. 10.6.3.1.4 After the low-pressure water pump works normally, close the electric bypass valve of the low-pressure water pump, and adjust the electric outlet valve according to the water replenishing status of the boiler water seal. 10.6.3.2 Operation steps of switching slag bucket cooling water pump (switching the high and medium pressure water pump by reference to the operation steps) 10.6.3.2.1 Report to the leader on duty before switching. 10.6.3.2.2 Start the standby pump. 10.6.3.2.3 Open the exit valve of the standby pump and close the exit valve of the operating pump, and at this time pay attention to the changes in the outlet mother tube pressure and the overflow water. 10.6.3.2.4 Stop the original operating pump after the startup pump is operating normally. 10.6.3.3 Operation steps of stopping the slag bucket cooling water pump 10.6.3.3.1 Stop the slag bucket cooling water pump when the leader on duty orders to stop the slag bucket cooling water pump. 10.6.3.3.2 Press Stop button of the low-pressure water pump to stop it.
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10.6.3.3.3 Close the inlet and outlet valve, and shaft seal water and bearing cooling water.after the low-pressure water pump stops 10.6.4 Startup and stop of overflow pump 10.6.4.1 Operation steps of starting the overflow pump 10.6.4.1.1 Check whether the overflow pump and its motor have the startup conditions, connect the power supply and confirm the power current and the control power supply are normal. 10.6.4.1.2 Confirm that the slag bucket cooling water pump is running normally, the overflow of the water seal slag discharge groove is normal and the water level of the overflow water tank is normal. 10.6.4.1.3 When the water level of the overflow water tank is high, start the overflow pump on the CRT, open the electric outlet valve of the overflow pump in the interlocking or manual mode, and confirm on the site that the overflow pump starts normally. (When the water level high signal of the overflow water tank is sent, the overflow pump should be interlocked and start automatically) 10.6.4.1.4 After the overflow pump is running, pay attention to the changes in the outlet pressure of the overflow pump and the water level of the overflow water tank. 10.6.4.2 Operation steps of stopping the overflow pump 10.6.4.2.1 When confirming that the water level of the overflow water tank is low, the overflow pump can be suspended. (When the overflow water tank sends a low water level signal, the overflow pump should chain and automatically stop, and the electric inlet valve will shut down automatically). 10.6.4.2.2 Press stop button of the overflow pump on the CRT to stop operating the overflow pump, and close its electric outlet valve. 10.6.4.2.3 If the overflow pump stops for a long time and there is no water in the overflow water tank, close the manual water valve of shaft seal of the overflow pump. 10.6.5 Startup and stop of deslagging water pump 10.6.5.1 Operation steps of starting the deslagging water pumps 10.6.5.1.1 Check whether the liquid level of the water storage tank is normal; 10.6.5.1.2 Check that the deslagging water pump and its motor are provided with startup conditions, connect the power supply, and confirm that the power supply and the control power supply are normal. 10.6.5.1.3 Open the electric bypass valve of high-pressure water pump. 10.6.5.1.4 Press Start button of the deslagging water pump on the CRT, observe the outlet pressure gauge of the deslagging water pump shows normally, and open the electric outlet valve of the deslagging water pump, when the changes in the outlet pressure of the deslagging water pump and the water level of the water storage tank should be paid attention to. 10.6.5.1.5 Close the electric bypass valve of the deslagging water pump after opening the inlet and outlet valve of the slag discharge hydraulic ejector. 10.6.5.2 Operation steps of stopping the deslagging water pump 10.6.5.2.1 Confirm that the slag discharge out of the slag bucket ends.
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10.6.5.2.2 Press Stop button of the deslagging water pump on the CRT 10.6.5.2.3 Close the electric outlet valve of the deslagging water pump 10.6.5.2.4 Confirm that the deslagging water pump stops running. 10.6.5.2.5 Close the shaft seal water valve and bearing cooling water valve of the deslagging water pump. 10.6.6 Operations of slag bucket slag discharge 10.6.6.1 Place the switches of the electromagnetic valve control cabinet and slag crusher on-site control cabinet to Remote position. 10.6.6.2 Open the outlet pneumatic valve of the hydraulic ejector. 10.6.6.3 Open the inlet pneumatic valve of the hydraulic ejector. 10.6.6.4 Start the deslagging water pump. 10.6.6.5 Start the front-wall slant nozzle of the slag bucket. 10.6.6.6 Start the slag crusher and open the back dilution valve of the slag gate and the slag discharge gate. 10.6.6.7 When slag in the slag bucket is emptied basically (time to be determined after commissioning) , close the front-wall slant flush valve of the slag bucket, open the outer slant flush valve, rinse it for 2 to 3 minutes and then close it, open the lower oblique flush valve inside the slag bucket for 2 to 3 minutes and then close it, open the upper oblique flush valve inside the slag bucket for 2 to 3 minutes and then close it, open the front-wall slant flush valve of the slag bucket for 2 to 3 minutes and then close it, and open the emergency flush valve of slag bucket gate for 1 to 2 minutes and then close it. 10.6.6.8 Close the slag discharge gate. Open the upper oblique flush valve inside the slag bucket to inject water to the slag bucket for 20 minutes and then close it. 10.6.6.9 Stop the slag crusher. 10.6.6.10 Open the outlet pneumatic valve of the hydraulic injector of another slag bucket. 10.6.6.11 Open the inlet pneumatic valve of the hydraulic injector of another slag bucket. 10.6.6.12 Repeat Item 6.6.5 to 6.6.9 and discharge slag out of another slag bucket 10.6.6.13 Stop the deslagging water pump after the end of discharging slag out of the slag bucket 10.6.6.14 Close the inlet valve of the hydraulic injector. 10.6.6.15 Close the outlet valve of the hydraulic injector. 10.6.7 Startup and stop of slurry pump 6.7.1 Operation steps of starting the slurry pump 10.6.7.1.1 Check that the liquid level of the slurry buffer tank or transfer warehouse is normal, and wash the slurry pumps of No. 1 and No.2 generating unit and close the electric valve. 10.6.7.1.2 Confirm that the slurry pump and its motor are provided with startup conditions, connect the power supply, and confirm the power supply and the control power supply are normal. 10.6.7.1.3 Start the inlet valve of the slurry pump, press Startup button of the slurry pump and observe that the outlet pressure gauge of the slurry pump shows normally (more than 0.4Mpa), and open the exit valve of the slurry pump (but a slurry pump should be avoided from transporting to two slag pipes at the same time, and two slurry pumps are prohibited to transport to a slag pipe at the same time), when the changes in the outlet
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pressure of the slurry pump and the water level of the slurry buffer tank should be paid attention to. 10.6.7.1.4 The inspection on concentration of slag water, size of slag grain, pressure of slag pipe and others of the slurry pump during operation should be strengthened to prevent the slurry pump from being jammed, overflowing or the slag pipe from being blocked as well as unusual situations from occurring. 6.7.2 Operation steps of stopping the slurry pump 10.6.7.2.1 When it is confirmed that sediment in the slag bucket at the bottom of the furnace or in the slurry buffer tank has been transported cleanly, the desulfurization and ash warehouse stop discharging gypsum (mortar) and the liquid level of the slurry buffer tank or transfer warehouse reduces to the low value, open the backwashing valve at the entrance to the slurry pump, close the inlet valve of the slurry pump and rinse the slag pipe for 15 minutes. 10.6.7.2.2 Press Stop button of the slurry pump to stop operating the slurry pump. 10.6.7.2.3 Close the outlet valve of the slurry pump. 10.6.8 Inspection of commission and operation and contents of maintenance 10.6.8.1 All the slag buckets, pipelines and valves have no water leakage, the fire holes are not ruptured, and the positions of the valves are correct. 10.6.8.2 There is no abnormal sound from the slag crusher in operation, shaft seal is supplied with water normally, vibration is less than 0.08mm, bearing temperature is no more than 80, and the chain transmission is normal. 10.6.8.3 Water storage tank provides normal liquid level and has no water or gas leakage phenomenon. 10.6.8.4 The outlet pressure of the hydraulic ejector in the process of discharging slag increases abnormally, the water output of the slag pipe becomes small, the slag discharge gate of the slag bucket should be timely closed and the slag pipe is washed. 10.6.8.5 The liquid level of the water storage tank and slurry buffer tank is normal, the float valve sends signal right in time, and water supply is input in a timely manner. 10.6.8.6 The sound of the water pump is normal in operation, and the pump body does no leak and the shaft seal drips normal. Bearing temperature does not exceed 80, vibration is less than 0.08mm, water of the shaft seal is properly adjusted, the belt does not skid or is not broken, and the outlet pressure is normal. 10.6.8.7 The indicator lights of all on-site control cabinets are right, the air pressure for instruments is 0.4 to 0.6Mpa, the pipeline does not leak, and all the pressure gauges and pressure transmitting instruments are input normally. 11 FGD and Limestone Supply System Operation Manual 11.1 SCOPE This standard prescribes the principle, method and procedure for the start up, shut down, operation & maintenance, control & regulation, dead status upkeep, accident handling and so on of the 2x300MW power generation unit flue gas desulfurization (FGD) system in Vietnam
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Guangning Power Corporation, Ltd. The 2x300MW power generation unit FGD system operation, equipment maintenance and production technical management staff at all levels engaged in Vietnam Guangning Power Corporation, Ltd. must acquaint themselves with entire or related parts and carry through strictly. 11.2 NORMALIZED DOCUMENT QUOTATION The terms in the documents listed below become the terms of this standard through quotation. For every dated quotated documents, all subsequent revision sheets or versions shall not be applicable. However, it is encouraged that all parties who come into agreement on this standard can investigate the workablity of the latest versions of these documents. For every undated qutoted documents, the latest version shall be applicable under this standard. S. No. 01 02 03 Standard Code Name DL277-94 DL408-91 Standard Title Working Regulation of Power Safety (Thermal Mechnical Part) Working Regulation of Power Safety (Power Station and Substation Electrical Part) Shanghai Shichuan Island Guangning Desulfurization System Operation And Maintenance Manual
11.3FGD SYSTEM QUIPMENT SPECIFICATION 11.3.1 General Vietnam Guangning first phase 2x300MW coal firing generation units consist of 2 sets of subcritical drum boiler with controlled circulation, single drum, one regenerative stage, W flame combustion (middle storage, hot air powder feeding, third air not entering the furnace), balanced ventilation, solid deslag, open arrangement and complete steel suppension structure. The raw flue gas shall be dedusted by ESP. The FGD is set at the furnace rear area after the ID fan. The limestone-gypsum wet full flue gas desulfurization method shall be used under BMCR operation conditions by FGD project. The design efficiency is 93% and the guarantee desulfurization efficiency is not less than 90%. Desulfurization process shall use limestone-gypsum wet desulfurization method. The spray empty absorber towers are adopted. One absorber tower is set for each boiler. The wet milling proposal is used in limestone preparation system which is design into two sets. One set of the milling machine shall meet the 100% limestone consumption requirement by 2 boilers under BMCR operation conditions. The Gas-Gas-Heater (GGH) is used. The monitoring and control of FGD are set in Ash Control Building. One DCS system is adopted for control of 2 boilers FGD and common systems. The desulfurization sewage treatment system is not given in this project temporarily. The desulfurization sewage is discharged into the plant ash slurry reservoir directly. 11.3.2 Project Design Conditions 11.3.2.1 Boiler Survey 11.3.2.1.1 Major design parameters for boiler Equipment Parameter Unit Value
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Type SUBCRITICAL NATURAL CIRCULATION, W FLAME, DRUM BOILER 996.33 2 130~145 2 DOUBLE ROOM FOUR FIELDS ESP >99.1 Static blade adjustable axial draft type 2 258.7
Boiler
Deduster
MCR Quantity Actual coal consumption Quantity (per boiler) Type efficiency Type
t/h set t/h set %
Quantity (per boiler) set Air quantity (T.B) m3/s Air pressure (T.B) Pa height m 200 Inner diameter at outlet m 4600 chimney Internal anticorrosive material 11.3.2.1.2 Parameters for flue gas and its ducting Item Unit Value Flue gas speed (design flow) m/s ID fan outlet flue duct dimension (steel structure) mm R=4500 ID fan outlet flue duct central line elevation m 2.9 11.3.2.1.3 Flue gas parameters at FGD system inlet Boiler BMCR Operation Conditions Flue Gas Analysis (Design coal, Standard conditions, Actual O2) Item Unit Dry basis Wet basis Remark CO2 Vol% 13.26 12.57 =1.477 O2 Vol% 6.85 6.49 N2 Vol% 79.84 75.67 SO2 Vol% 0.06 0.053 H2O Vol% 4.98 5.2176 Boiler BMCR Operation Conditions Flue Gas Parameters remark Design coal ID fan Nm3/s ID fan outlet flue gas quantity(BMCR) Nm3/s Nm3/h Nm3/h
Dry basis, =1.447 Wet basis, =1.447 Standard conditions, Dry basis, =1.4 Standard conditions, Wet basis, =1.4
ID fan outlet flue gas temperature Pa BMCR Operation ID fan outlet flue gas Conditions pressure ID fan outlet flue gas quantity and temperature under different loads Item Unit RO 75%RO 65%RO 30%RO Nm3/h ID fan outlet dry flue gas quantity
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ID fan outlet wet flue Nm3/h gas quantity ID fan outlet flue gas temperature Boiler BMCR Operation Conditions Flue Gas Pollutant Analysis(Standard conditions, Dry basis, 6%O2) Item Unit Design coal Min Max 3 SO2 mg/Nm 934 573 1504 SO3 mg/Nm3 Cl(HCl) mg/Nm3 F(HF) mg/Nm3 Soot (ID fan outlet) mg/Nm3 400 400 400 11.3.2.2 Fuel No. I Components Heating values High heating value Low heating value Proximate analysis 1 2 3 4 5 6 7 8 Total moisture (as received) Surface moisture Inherent moisture Air-dried moisture Fixed carbon (as received) Volatile matter (as received) Ash content (dry) Ash content (as received) Total Ultimate analysis 1 2 3 4 5 6 7 Carbon (as received) Hydrogen (as received) Oxygen (as received) Nitrogen (as received) Sulphur (as received) Ash (as received) Moisture (as received) Total Physical criteria 1 2 Hardgrove Grindability Index Dust coal (0-15mm) +10 mm size 5-10 mm size particle size % % 6.16 - 17.5 9.89 - 18.3 45 - 70 47 100 10.53 14.22 Car H N S A
ar ar
Symbol HHV LHV War W W W Cf V A A

s in ad
Unit kcal/kg kcal/kg % % % % % % % %
Range Data 4680 - 5300 4490 - 5157 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
Design Data 4980 4790 9.00 7.63 1.48 1.39 53.68 6.83 33.5 30.49 100.00
ar
ar d ar
% % % % % % %
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 9.00 100.00
ar or
ar
ar ar
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No. Components 2.5-5 mm size
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Symbol Unit % % % % % degree Symbol Unit % % % % % % % % % % % % % g/cm R cm
3
Range Data 15.60 - 21.71 8.73 - 13.76 12.36 - 18.13 6.80 - 14.45 11.47 - 31.47 0.92 - 1.10 33 - 39 Range Data 57.60 - 64.10 23.3 - 28.64 4.26 - 6.16 0.018 - 0.028 0.50 - 0.91 0.30 - 0.77 0.67 - 1.42 3.35 - 4.70 0.15 - 0.55 0.19 - 0.30 0.251 - 0.481 0.006 - 0.050 0.00 0.224 - 0.370 301x10 603x102 1210 - 1280 1430 - 1600 1530 - 1600
2
Design Data 18.62 10.97 14.89 10.02 20.77 1.00 37 Design Data 62.83 24.76 5.41 0.026 0.68 0.44 1.11 3.64 0.48 0.24 0.341 0.043 0.00 100.00 0.291 525x102
1.25-2.5 mm size 0.63-1.25 mm size 0.315-0.63 mm size - 0.315 mm size 3 4 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 Density Angel of repose Components Ash content SiO2 Al2O3 Fe2O3 V2O5 TiO2 CaO MgO K2O Na2O P2O5 SO3 MnO Others Total Ash density Ash resistivity (for reference only) Ash Fusibility 1 2 3 Initial deformation temperature Hemispherical temperature Fluid temperature softening T1 T2 T3
0 0
C C C
1250 1570 1600
11.3.2.3 Water Conditions The process water comes from plant industrial water with temperature less than 35 and pressure of 0.20.5MPa(g). The cooling water sources from the process water and circles within the process system. It is not returned. The quantity is included in the process water. The industrial water analysis is as follows: Item Value Colour: No Smell: CO2 (Concentration): No 2.64 mg/l
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Value 0.10 me/l 0.17 mol/l 0.175 mol/l 1.80 mg/l 50 mg/l Weak Unit wt % wt % wt % wt % wt % KWh/Mt Kg/m mm
3
11.3.2.4
Item Total hardness: Total Cation: Total Anion: SiO2: Total sludge: Mean Corrosiveness: Limestone Conditions Parameter CaCO3 content Analysis: MgO Fe2 O3 SiO2 Al2 O3 Bond work index
Value 92 95 0.19 - 2 0.1 - 1.2 0.16 - 0.6 0.14 - 2.0 10 (estimated) 2400 - 2600 0 - 20 or more
Solid limestone (dense) Solid limestone size
11.3.2.5 FGD Design Guarantee Value 11.3.2.5.1 Once the FGD is in commercial operation, the FGD utilization ratio shall be not less than 98% of the boiler ESP operating time, the definition is as the below formula: AB A 100% Utilization ratio = Here: A- hours with FGD device in-operation conditions B- forced shut down hours with FGDs causes 11.3.2.5.2 Desulfurization efficiency, SO2 emission density Under the conditions of no excessive limestone, process water and power consumptionns, firing the coal provided by client (sulfur 0.27%-0.66%) and handling complete flue gas under BMCR operation comditions, the guarantee desulfurization effciency is over 90% so that the FGD outlet SO2 density shall not exceed max permissible density 150mg/Nm3 (Dry basis, 6%O2). 11.3.2.5.3 FGD gypsum slurry quality Item Unit Value - purity - pH - density - smell - average particle diameter - MgO(water soluble) - Na2O(water soluble) mass-%dry / mg/m / / mass-%dry mass-%dry
3
90 5.5~7.5 1 Nil 40 0.021 0.035
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Item - K2O
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Unit mass-%dry mass-%dry mass-%dry Value 0.07 0.01 0.35
- Cl(water soluble) - CaSO31/2H2O(as SO2) - (Oxidable organics) - soot -Al2O3 -Fe2O3 -SiO2 -CaCO3 -K2O
mass-%dry mass-%dry mass-%dry mass-%dry mass-%dry mass-%dry
1.32 0.26 0.10 0.70 2.9 0.07
11.3.2.5.4 Flue gas emission When the coal sulfur content comes up to 200% of the design value, the polutant emission density shall not exceed: SO2: 150 mg/Nm3(Dry basis) HCl: 1 mg/D.Nm3 Soot: <100mg/Nm3(Dry basis) 11.3.2.5.5 Limestone consumption Ca:S1.03 When S content = 0.66%, average limestone consumption5.7 t/h. When S content = 0.41%, average limestone consumption3.3t/h. 11.3.2.5.6 Water consumption Max: 100 t/h (When S content = 0.66%) Normal: 80 t/h (When S content = 0.41%) 11.3.2.5.7 Steam consumption Under the boiler rated loading and worst conditions, FGD maximum steam consumption is 5.5 t/h. The superheated steam used by desulfurization island comes from the main power house with quality of: 1.2Mpa, 300. 11.3.2.5.8 Power consumption The desulfurization island total power consumption is 5800 Kw. 11.3.2.5.9 Flue gas temperature at chimney inlet and mist content at mist eliminator outlet The chimney inlet flue gas temperature is not less than 82 (boiler BMCR operation conditions), the water drop carried by the flue gas shound be less than 100mg/Nm3(dry). 11.3.3 Production Process 11.3.3.1 The FGD system consists of the following subsystems: Sorbent Preparation and Supply System; Flue Gas System; So2 Absorbing System;
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Common System; Electrical System. 11.3.3.2 FGD System Process Flow 11.3.3.2.1 Absorber The flue gas exhausted by ID fan flows into the bottom of the absorber under the function of boost fans, 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 process that gas passes through absorber and absorbs the acidity content, it is vaporized by the water in slurry to saturation condition, and 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. 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. Flue gas Section On the upper part of the absorber, the flue gas passes through the two-stage roof type mist eliminator to minimize the droplets. The start-up of washing program for mist eliminator is controlled by the slurry level.
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11.3.3.2.2 The oxidization air Three sets of oxidization fans are adopted for two absorbers, 2 working 1 stand by. The oxidization fan is Roots fan. Three sets of mixers are set per absorber. The oxidization air is fed into the absorber slurry reservoir through the front nozzles. And then the mixers shall distribute the bubbles equally in the reservoir. The oxidization air can be well distributed among the slurry, so that the SO3 can be oxidized into SO4. 11.3.3.2.3 Flue gas reheat system During the desulfurization, the flue gas is cooled to adiabatic saturated temperature by circulating slurry. The flue gas is reheated before entry into the existing chimney to prevent the condensation in the chimney. The flue gas reheat system major equipments include gas gas heater (GGH) and its auxiliaries. Gas gas heater (GGH) To use the heat of the untreated flue gas from the boiler, one set of rotary GGH is adopted. The clean flue gas at the absorber outlet is heated by this device. The flue gas uplift floatage in and at the outlet of the chimney is increased so that it can prevent the chimney corrosion bought by condensate maximumly. The GGH device has increased the power consumption and maintenance expense of the FGD, but it is a must. The philosophy of GGH (like air preheater) is as follows: 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. The GGH has higher and stricter requirements than boiler air preheater in aspects of sealing, leakage, flue gas contacting surface anti-corrosion, sweeping and etc. The anti-leakage control system is arranged to bring the leakage of original gas to clean gas down to the minimum. That is to say some clean gas is extracted and charged to the heating elements between clean gas and original gas. Because the pressure of seal gas is higher than original gas, the leakage of original gas to clean gas is prevented maximumly. Auxiliaries for reheater The reheater is mate with one set of cleaning device for removing the dust on the heating surface. The steam and pressure water is used as cleaning medium in the device. The steam sweeping is in use under normal operation. When the device is operating up to some time (preliminary fixed as five days, or according to the pressure drop between the GGH inlet & outlet), the HP water is used. After the system stop operation, the LP water is used. 11.3.3.2.4 Boost fan system To compensate the pressure lost because of the absorber, GGH and flue duct, the boost fan is installed at the upriver of the original flue gas side. The boost fan is of static blade axial fan. 11.3.3.2.5 Flue gas duct system There is main flue gas duct connection between the flue gas duct system and boiler ID fan outlet. There is bypass flue gas damper set at the section connecting main flue gas duct and chimney. FGD device is equipped with independent flue duct system, consisting of:
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Original flue gas duct, from the main flue gas duct with original flue gas damper to the absorber inlet through boost fan. Clean flue gas duct, from the absorber outlet, GGH, through main flue gas duct with clean flue gas damper, to the chimney. Partial original flue gas duct and all clean flue gas duct is lined with anti-corrosion (glass scale) protection. The flue gas duct system is equipped with double layer damper. The damper sealing fan system will provide sealing air to these dampers to fulfill zero leakage. 11.3.3.2.6 Limestone storage, milling and slurry supply system The limestone (0-20mm) is transported to the site by truck. Two unloading fuel hoppers are used in this project. Heavy grating is set at each unloading fuel hopper to prevent large size material from entering the downriver equipment. One set of dedusting system is adopted to eliminate the dust in the unloading room and around to the minimum. The limestone is conveyed on the ripple belt conveyor through the bottom of the unloading hopper by the vibrating feeder and then fed into the two limestone storage silo. The conveying system is designed to be of close negative pressure which can decrease the fly ash to the minimum. One scale weighing fuel feeder is set at the bottom of the limestone silo which sends the limestone particle. There is air locking device at the milling fuel adding hole. The limestone preparation system shall be two sets (one working one stand by). Each set is equipped with one scale weighing feeder, one wet miller with slurry tank, two slurry pumps and one group of limestone swirling machine. The scale weighing feeder sends the middle silo limestone particle into the wet miller for milling. Single wet miller is of 75% FDG-BMCR. The limestone slurry after milling overflows into the wet milling slurry tank. Then it is centrifuged in limestone swirling machine with fineness of 90% of the particle can pass through screen of 0.045 (325) and quality of smooth overflow into the buffer tank. The unqualified particle returns to the wet milling for remilling through the bottom of the swirling machine. The limestone slurry preparation system automatically make limestone and water into 30% density slurry which is sent into absorber through two stage pumps (buffer pump and slurry supply pump). 11.3.3.2.7 Process water system The process water system is mainly used for absorber mist eliminator cleaning (absorber make up), pipe cleaning, GGH HP & LP cleaning. The process water for FGD comes from the plant industrial water system. 1x150m3 water tank as middle storage tank supplies continuous make up water to maintain the normal operation of the system. The FGD island industrial water and process water system shall common pump delivery and network system. In FGD system, the major process water consumption includes flue gas evaporation, waste water drainage and etc. 11.3.3.2.8 Industrial water system The industrial water is mainly for high quality consumer, including milling oil station cooling, pump mechanical sealing water, rotary equipment bearing cooling water and so on. The water supply system is the same as in process water system.
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Most part of the industrial water is circulating within the FGD system. 11.3.3.2.9 Instrument air system There is one set of instrument air tank for two units in the FGD island which is mainly used for bypass flue gas damper actuator and instrument cleaning in FGD island. 11.3.3.2.10 Auxiliary steam system The auxiliary steam is of GGH cleaning with steam. The auxiliary steam comes from the plant hot and cool section. 11.3.3.2.11 Vent, discharge system The vent system consists of emergency slurry tank, ground channel and pit. When FGD in normal operation, the overflow slurry or water and water shall be collected in the pit and then sent. Emergency is used for storage of the slurry during the absorber overhauling and for emergency storage. After FGD system into operation, the cleaning of the absorber and connecting network among all parts of the water drainage system will be done manually. Therefore, there will be few times in actual application. All overflow water in the system, except of the life sewage, will be recovered into the system. The discharge system mainly consists of gypsum discharge pump, absorbing area pit pump, emergency slurry return pump. When the circulating slurry PH and density in the absorber reaches the discharge requirements, the gypsum discharge pump will start and discharge part of the slurry into the reservoir. 11.3.4 Major equipment specifications 11.3.4.1 Boost fan Item Parameters 1. Equipment type TB - Fan efficiency - Axial power - Fan total weight(exclusive of motor) - Fan speed - Shell material - Blade material - Front/rear guide plate material - Wheel hub material - Axis material 2. Motor type - Rated power 86.3% 1999kW 75000kg 480r/min Q235 16MnR Q235/Q345 16MnR 35CrMo YKK series 2100kW Spraying nickel based carbon wolfram Spraying nickel based carbon wolfram Type Remark
BMCR 85.7% 1489kW
ECR
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- Rated voltage - Rated voltage
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL 6kV 480r/min IP54 Air-air cooling Nil Form13 series Type
- Shell protection degree - Cooling mode 3. Gearbox type 4. Coupling type 11.3.4.2 Item 1.GGH proper parameters: Type Speed(working/cleaning) Effective anti-leak system type Pressure drop design GGH
Type
Remark
Rotary GGH 1.2/0.6rpm Double channel sealing structure, low leaking system Raw flue gas terminal (design value): 462Pa Clean flue gas terminal (design value): 450Pa Low carbon steel+enamel 23500 m2(both sides) 780 mm Q235-A Scale resin, 1.52.0mm CORTEN CORTEN 15KW 11.6KW 380V 1500rpm Oil-bath Gear driven B4VV09 or related model of indicated FLENDER
Heat exchange element Material Heat exchange surface Total height Shell Material Lining material and thickness Rotor Main shaft material Cubicle frame material Motor and its driven device Motor capacity Rotary power consumption (shaft power consumption) Rated voltage Motor rated speed Cooling mode Gear box mode Gear box model
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Item Coupling type Coupling model Sealing pad Material Guiding bearing Bearing type and model Lubrication mode Supporting bearing Bearing type and model Lubrication mode 2.Soot blower and compressing system Soot blower Operating duty Installation quantity Installation location Air consumption LP water consumption LP water pressure 3.Sealing fan Type and model Quantity Flow Pressure Shell/impeller material Medium Motor type Motor capacity Motor insulation degree Motor protection degree 4. Purifying fan Type and model
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Type Type brand Flexible coupling Undetermined 316L.TEFLON SKF Double row bearing/23060(CCK/W33 ) Oil-bath SKF Thrust rolling bearing/29488E Oil-bath its air rolling Remark
Online intermittent operation 2X2 Raw flue gas upper and lower 5.5t/hr 45t/h 0.30.5Mpa Centrifugal fan /GMB16 2X2 7500 Nm3/hr 5000Pa Carbon Steel/Carbon Steel Air 18.5kw F(check as per B) IP55 HMB 40
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Item Quantity Flow Pressure Shell/impeller material Medium Motor type Motor capacity Motor insulation degree Motor protection degree 5.HP flush water pump Type and model Quantity Flow Pressure Shell/impeller material Motor type Motor capacity Motor insulation degree Motor protection degree
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Type 1X2 63000Nm3/hr 6500Pa 316L Clean flue gas 185kw F(check as per B) IF55 Ram pump GP5136 1 160 L/min 13Mpa Cast steel/cast steel 50KW F(check as per B) IP54 Cylinder/stainless steel Unit set Type Remark
Inlet screen type and material 11.3.4.3 Slurry circulating pump Item -Quantity -Type -Shell material -Impeller material -Anti abrasion material -Axis capacity -Motor rated power -Suction screen -Suction side pressure -Head -Volume flow -Solid content in medium -Sealing system type -Sealing medium
(3+1)2 Centrifugal pump Anticorrosive alloy or lining rubber Anticorrosive alloy Anticorrosive alloy or carborundum
kW kW Yes/no kPa kPa m3/h %
225/255/285/315 260/300/330/370 Yes 52 15/17/19/21 4254 20 Mechanical sealing SiC
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Spheroidal graphite cast iron+EPDM/stainless steel Spray tower Reverse 1,258,254 1,304,741 5000 2.5 13.4 3.94 2.9 1.03 15/25 <20 4.5~6.0 11.6 7.5 11.6 5.3 4.8/5.3/5.8 560 28.2 Carbon steel/1.4529 C276 clad plate/2/6.8 FRP/SiSic DIN1.4529/DIN1.4529 DIN1.4529 4/2.0 68 Screw /air awl 3 22 0.11 3
-Suction side valve material Absorber -Absorber type -Flow direction(direct/reverse) -Flue gas quantity before absorber (standard conditions, wet basis, Actual O2) -Flue gas quantity after absorber (standard conditions, wet basis, Actual O2) -Design pressure -Stop time for slurry circulation -Time for all slurry discharge -Flue gas speed -Time for flue gas in the absorber -Chemical measure ratio CaCO3/removed SO2 -Slurry reservoir solid content: Min/Max -Slurry Cl content -Slurry pH -Absorbing area diameter in absorber(or length x width) -Absorbing area height in absorber -Slurry reservoir diameter(or length x width) -Slurry reservoir height -Slurry reservoir level normal/max/min -Slurry reservoir capacity -Total height of absorber -Material Absorber shell/internal lining Inlet flue gas duct material/thickness/length Spray layer/nozzle Mixer shaft/impeller Oxidization air duct/nozzle -Spray layer number/layer space -Nozzle number per layer -Nozzle type -Mixer or mixing device quantity -Mixer or mixing device power -Mixer specific power -Oxidization air nozzle quantity -Absorber insulation Thickness Material External layer material Flue gas resistance in absorber(including mist eliminator) Mist eliminator -Location -Stage number -Height -material -Mist eliminator cleaning nozzle number 11.3.4.4
Nm 3/h Nm3/h Pa min h m/s s mol/mol Wt% g/l m m m m m m3 m -/mm/m
pic/tower kW kW/m3 mm Pa
1190 Inside tower Two 3.65 polypropylene 420
pic/tower
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Pa l/min m3/hset m3/hset Pa set kPa kW kW Nm3/h % 26.46 190 12+1 Roots 88 113 128 3364 10 130 Sound absorbing pipe type Sound absorbing pipe type (1+1)2 Centrifugal pump Anticorrosive alloy or lining rubber Anticorrosive alloy Anticorrosive alloy 7.7 11 Yes 50 40 60 Mechanical sealing SiC 1 90 Carbon steel 7 5 16Mn Screw unloading 1+1 Silo top type/1 2 Electromagnetic 2 0.210^6 polypropylene 63 intermittent 1
-Nozzle pressure -Nozzle material -Nozzle flow -Cleaning mode(constant/intermittent) -Average cleaning water consumption -Instantaneous max cleaning water consumption -Flue gas resistance in mist eliminator 11.3.4.5 Oxidization fan -Quantity -Type -Head -Shaft power -Motor rated power -Inlet flow (per set) -Flow allowance -Outlet oxidization air temperature - Fan inlet strainer type - Fan inlet & outlet silencer type 11.3.4.6 Slurry discharge pump -Quantity -Type -Shell material -Impeller material -Anti-abrasion material -Shaft power -Motor rated power -Suction side screen -Suction side pressure -Head -Volume flow -Sealing type -With/without sealing material 11.3.4.7 Limestone silo -Quantity -Effective volume -Material -Height -Diameter -Anti-abrasion material -Discharge type -Discharge outlet Quantity -Limestone silo top deduster Type/Quantity 11.3.4.8 Metal separator -Quantity -Type 11.3.4.9 Crusher -Quantity
Set
kW kW Yes/no kPa kPa m3/h
pic m3 m m
-/set set
set
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Hammer type 1015 80 22 30 2 5~15 0.5 3.7 2 Wet type horizontal ball miller 100 7 2.5x7.5 Rubber lining 380 0.63/90
-Type -Capacity -Inlet particle size -Outlet particle size -Shaft power -Motor power 11.3.4.10 Scale weighing belt conveyor -Quantity -Capacity -Accuracy -Motor power 11.3.4.11 Wet type ball miller -Quantity -Type -Rating per set -Handling capacity per set -Shell size -Anti-abrasion component -Shaft power -Motor rated power -Output size 11.3.4.12 Gypsum slurry cyclone Gypsum slurry cyclone -Cyclone Quantity -Cyclone Quantity per set -Standby Cyclone Quantity -Cyclone material -Feeding material solid content -Overflow solid content -Bottom flow solid content 11.3.4.13 Gypsum miller slurry circulation tank -Quantity -Effective volume -Material -Anti-corrosion material -Mixer Quantity -Mixer Material (Impeller/shaft) -Mixer power 11.3.4.14 Miller slurry circulation pump -Quantity -Type -Head -Capacity -Medium solid content -Sealing type -shaft power -Motor rated power 11.3.4.15 Limestone slurry reservoir
t/h mm mm kW kW set t/h % kW
% t/h mm kW kW mm/%
12 12 Carbon steel+Rubber lining/ polyurethane 30 20 35 2 50 Carbon steel Rubber lining 1 Carbon steel Rubber lining 5.5 1+3 Centrifugal pump 200 90 30 Mechanical sealing 6.5 7.5
% % % set m3 set kW set kPa m3/h % kW kW
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL set m3 m m set kW Set 1 200 6.77 6 Synthetic resin 1 Rubber lining 22 2+2 Centrifugal pump Anticorrosive alloy or lining rubber / Anticorrosive alloy 30 450 30 20 Mechanical sealing SiC 6.5 7.5 1 100 5.8 4.5 Carbon steel+Synthetic resin lining 1+1 Centrifugal pump Spheroidal graphite cast iron Spheroidal graphite cast iron 26 30 No 30 400 120 Mechanical sealing SiC 12 Centrifugal pump Cast iron Cast iron 30 45 Yes
-Quantity -Effective volume -Diameter -Height -Anti-corrosion material -Mixer Quantity -Mixer material (Impeller /shaft) -Mixer power 11.3.4.16 Limestone slurry pump -Quantity -Type -Shell /Impeller Material -Suction side pressure -Head -Capacity -Medium solid content -Sealing type -Sealing material -Shaft power -Motor rated power 11.3.4.17 Process water tank -Quantity -Effective volume -Diameter -Height -Material 11.3.4.18 Process water pump -Quantity -Type -Shell material -Impeller material -Shaft power -Motor rated power -Suction screen -Suction side pressure -Head -Volume flow -Sealing type -Sealing material 11.3.4.19 Mist eliminator cleaning pump -Quantity -Type -Shell material -Impeller material -Shaft power -Motor rated power -Suction screen
kPa kPa m3/h % kW kW Set m3 m m
set
kW kW Yes/no kPa kPa m3/h
set
kW kW Yes/no
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL kPa kPa m3/h 42 60 156 Mechanical sealing SiC 1 560 9 9 Synthetic resin 1 Anticorrosive alloy or carbon steel+lining rubber / Anticorrosive alloy 22 1 Centrifugal pump Anticorrosive alloy or carbon steel+lining rubber / Anticorrosive alloy 520 200 60 20 Mechanical SiC/alloy 6.5 7.5 12 17 Concrete Synthetic resin lining 1 Anticorrosive alloy or carbon steel+lining rubber / Anticorrosive alloy 3.7 4 Vertical pump 200 60 4.8 5.5 1 17
-Suction side pressure -Head -Volume flow -Sealing type -Sealing material 11.3.4.20 Emergency slurry reservoir -Quantity -Effective volume -Diameter -Height -Anti-corrosion material -Mixer Quantity -Mixer material (Impeller /shaft) -Mixer power 11.3.4.21 Emergency slurry return pump -Quantity -Type -Shell /Impeller material -Suction side pressure -Head -Flow -Medium solid content -Sealing type -Sealing material -Shaft power -Motor rated power 11.3.4.22 Absorber water discharge pit -Quantity -Effective volume -material -anti-corrosion material -Mixer Quantity -Mixer material (Impeller /shaft)
set m3 m m set
kW set
kPa kPa m3/h % kW kW set m3 set
-Mixer power kW 11.3.4.23 Absorber water discharge pit pump -Quantity set -Type -Head kPa -Capacity m3/h -Shaft power kW -Motor rated power kW 11.3.4.24 Limestone slurry preparation area water discharge pit -Quantity set -Effective volume m3
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Concrete Synthetic resin lining set 1 Anticorrosive alloy or carbon steel+lining rubber / Anticorrosive alloy -Mixer power kW 2.2 11.3.4.25 Limestone slurry preparation area water discharge pit pump -Quantity set 1 -Type Vertical -Head kPa 300 -Capacity m3/h 30 -Shaft power kW 3.0 -Motor rated power kW 3.7 11.3.4.26 Instrument air tank -Quantity set 1 -Volume m3 3 -Diameter m 1.4 -Height m 2.8 -Working pressure MPa 1 11.3.4.27 Miscellaneous use air tank -Quantity set 1 -Volume m3 4 -Diameter m 1.6 -Height m 2.8 -Working pressure MPa 1 11.4START-UP OF DESULFURIZATION SYSTEM 11.4.1 Acceptance and test after maintenance 11.4.1.1 Acceptance after overhaul 11.4.1.1.1 After overhaul of the desulfurization devices, institute responsible for the overhaul work should offer overhaul summary, acceptance report, deviation report of the equipment and detailed explanation to the operation department. 11.4.1.1.2 The operation department should organize its managing and operating personnel to attend the overhaul acceptance above level 2; to attend every stand-alone and system pre-commissioning of main and auxiliary equipment, and record various primary data, confirm the data is right in the range regulated by the specification; to attend pre-commissioning, test and confirm the DCS control system is in right logical relation while having normal protection and interlock movement. 11.4.1.1.3 The entire acceptance file before start-up should be kept in generating department as file materials. 11.4.1.2 Inspection and acceptance after overhaul 11.4.1.2.1 Once the overhaul work finished, overhaul personnel and tools should be evacuated from the operating field, safeguard measures cancelled, false work cancelled, no sundries can be saw on the equipment, ambient environment, passway and the lighting should be satisfying.
-Material -anti-corrosion material -Mixer Quantity -Mixer material (Impeller/shaft)
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11.4.1.2.2
Foundation bolts and coupling wheel screw of rotating equipment should be tightened, hood of the coupling wheel should be complete and tightly installed; qualified lubrication, oil level is above oil gauges centerline but between the upper limit red line and lower limit red line, no leakage in the oil system, clear and complete oil gauge and oil level mirror, try the oil tank heater and confirm its in normal operating; clear, unblocked and controlled shaft cooling water; complete inlet/outlet damper(valve) with flexible switches on close position; complete and tight grounding of the motor; and no things around is to interfere the start-up. 11.4.1.2.3 No deviation for the equipments appearance, good insulation, correct and clear equipments name plate, color ring on the pipe, rotating direction and mediums flowing direction. 11.4.1.2.4 Inspect the flue duct, absorber, mist eliminator, each water tank and pit, reservoir, boost fan, GGH, and make sure it is clean inside without foreign matters & medium along with intact anti-corrosion layer. After inspection, manhole and vent valve is tightly closed. 11.4.1.2.5 All manual, pneumatic, motorized air doors and valve should be tight, flexible in switch, complete in travel and of no leakage on dynamic & static sealing area. The local switch indications of all pneumatic and motorized valves are in line with the displays of DCS, which are at the off position. 11.4.1.2.6 The tightness of al mechanical driven V shape belt is appropriate. 11.4.1.2.7 Upon the completion of DCS commissioning, the configuration parameters are correct and all instrument power supply is put in use. All automatic, protection and alarming device is correctly launched after commissioning. The installation of local instruments and testing point finishes with firm wiring and correct position. The measuring and testing of transmitters and transformers are in normal conditions. All testing data and acceptance procedures are complete. 11.4.1.2.8 The local control cabinet is in normal operation and the indication light testing is in order. 11.4.1.2.9 The gauges for distribution device are complete, intact and verified. The terminal, plug and socket are of no abnormal looseness and mobilization. 11.4.1.2.10 All switches and contactors are of clear and correct switch-in & off indication. They are qualified in switch-in & off testing with switch at testing positions. 11.4.1.3 Testing after overhaul 11.4.1.3.1 Trial operation of mechanical equipment z The trial operation of mechanical equipment is to confirm that there is no abnormal condition before the formal operation of the FGD system. The inspection and measuring of the current, vibration, temperature and sound of the motor and mechanical equipments as well as the performance of the design values are done in this trial operation. Any abnormal conditions are to be eliminated before normal start-up. At the same time of trial operation , the inspection and testing for equipment
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z z
11.4.1.3.2 z
z z z
start up, shut down, interlock procedure, sequence, time, alarm and trip preset values shall be done. Before trial operation of all mechanical equipments, the motors should be independently operated for 1-4 hours with unfastened coupling connecting screw. After confirmation on correction of its vibration, temperature rise, current and direction, the coupling connecting screw should be connected. The rotor is in normal operation under related torque without stuck, unsmooth or abnormal sounds. The insulation resistance should be confirmed qualified before trail operation and power supply of the motors. The trial operation of conveyor belt and feeder should be conducted with no load. The trial operation of steel ball crusher should be done in phased manner from no load to full load gradually as per the requirements in the manual and the retightening of its steel tiles should be done by the installation workers during the process. The trial operation of the rotary machinery should continuously operate for 1-4 hours in principles. The operation can be extended if the person in charge thinks it is necessary, but the reasons and results for doing the same should be clearly noted down. During the trial operation period, the engaged equipments should be regularly inspected, measured and recorded: motor current (on/off load), bearing temperature, bearing vibration, noise, inlet & outlet pressure, rotary speed, current & its flow curve generated by damper (air door, valve) open degree variation, equipment interlock, alarm & protection, and to confirm whether they are in the normal value range. The remote control of all air door, damper, pneumatic & motorized valve should be agile in action and properly switched to on/off positions. During the trial operation, the thermal control persons should inspect, check and modify the travel & torque of motorized actuator; the accordance between the actual open degree of valve & air door damper and the display on DCS screen; the correctness of interlock logic; the correctness of protection action. During the trial operation, the electrical persons should observe and inspect the operation conditions of the transformer, switches & motors, record all data; examine and check the protection setting, electrical interlock & emergency switch. Preparation before equipment trial operation Examine & test the start up/shut down circuit, interlock circuit and control circuit to make sure they are in normal conditions; the testing of overload relay and earthing relay drivers is done; Test the insulation resistance of motors & cables and supply the power after resistors qualification; Supply power for the thermal instruments & meters and check whether they are in normal operation; The cleaning work of miscellaneous and instrument air pipes is done, and the internal & external obstacle are completely removed;
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z
z z
z 11.4.1.3.3 z
z z z z
The water tank and reservoir is internally clean with industrial water fed at indicated level (above permitted start up level), confirm the accordance between the level gauge and actual testing value, and no leakage; The lubrication oil for all rotary equipments are qualified in testing; the lubrication oil level for all equipments is normal; all cooling water can go smoothly; the oil temperature of start up oil tank heater or start up oil cooler is in the prescriptive range; The on/off speed correction of pneumatic valve regulated by speed controller is done; its operation normality is confirmed by using manual switch; For belt driven equipments, the adjustment & correction of the capstan and the follower is done; the qualified belt has been installed; the belt tightness is suitable; the tightness should be measured again and adjusted after completion of the machinerys trial operation; The control relay has been set to standard values. Matters to be taken care in trial operation When start the rotary equipments, besides the regular protection measures, the commissioning persons should stand at the shaft direction position of the equipments to avoid accidental injury. In the specific time period, the start up times of HV motors can not exceed the provision in the regulation. The on load start up times of AC motors should be in line with the products technical regulation. If there is no clear regulation in products technical conditions, the following Manual shall be followed: The start up can be done twice in cold state, with interval not less than 5 mins. The start up can be done once in hot state; when in accident handling & the start up time for big motors is less than 2-3s, it can be restarted again. Prevent the body and the tools from contact with the rotary parts. Before the trial operation, the handling preparative proposals for abnormal interlock or protection action conditions should be though over carefully to insure the equipment and personal safety. The trial operation should be stopped when after start up obvious abnormal conditions and high possibility of equipment damage & personal injury occur. During the machinery trial operation, if there are abnormal sounds or vibration or temperature rise, the measures such as inspection, retighten foundation bolts, appropriate addition or change of lubrication oil and so on should be done, under the premises of personal & equipment safety and the monitoring of the progress should be kept on. If it is still abnormal, the fault equipment should be stopped. The equipment can not restart for trial operation until the reasons are found out and the problem is solved. After the completion of the trial operation, all left medium in equipment and pipes should be discharged as much as possible. If the equipments shall not be in
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11.4.1.3.4 z
11.4.1.3.5 z
operation right after trial operation, the power supply of motors and other electrical equipments should be cut off and necessary maintenance is to be done. Testing items for equipments trial operation The time period from start-up to back and the current value under no-load and load changing conditions of the large-scale HP motors and equipments should be measured and recorded when start-up for the first time. The start-up, operation and shut down of the motors and equipments should follow the orders of the personnel who measure the current. Inspect and record interlocking action sequence and time of equipments; inspect and test the alarm and interlock protection setting value; inspect and test emergency button. Check whether the current value is in the regulated range; whether the vibration and temperature rise of the machinery and motors is in the regulated range; whether the noise is normal; whether there is peculiar smell, leakage of gas or fluid; whether the changes of the water level of the water tank and pond is in the regulated range; whether the operation of the motorized or pneumatic valves are normal; record with details. Normal operation standard of motors and mechanical equipments The operation time of motors and mechanical equipments is 1-4 hours, during which: bearing temperature rise: gliding bearing temperature should not exceed 80 ; rolling bearing temperature should not exceed 95. No unexpected noise should occur during the operation of the machinery; machinery vibration should be in the normal range. Synchronous (r/min) speed 3000 0.05 1500 0.085 1000 0.10 750 and below 0.12
Double amplitude value mm z z
The motors operation current should exceed the rated value on the name plate. If there is specific regulation of the above parameters from the manufacturers, then these Manual will be followed. 11.4.1.4 Simulative test of water circulation 11.4.1.4.1 Aim of the water circulation test: using water instead of limestone slurry and gypsum slurry, simulative operations will be carried out to all equipments of FGD system, inspecting and confirming the system rigour and stability, as well as the desulfurization control system, start-up and shut down sequence, related interlock and protection, so that the potential equipment defects and errors might occur after formal start up of FGD system can be discovered in advance. 11.4.1.4.2 The scope of water circulation tests: equipments and systems for handling limestone slurry and gypsum slurry. 11.4.1.4.3 The qualified standard for water circulation test:
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z z z z 11.4.1.4.4 z z z z z z 11.4.1.4.5 z
11.4.1.4.6 z
To conduct preliminary modifications for control system and confirm the correctness of the logic relationship; To confirm the control system, its start-up & shutdown operation sequence, related working parameters, interlocks and protection in normal conditions; The equipments are in normal operation without leakage and the system is water balanced; To confirm the flow characteristic curve of all control valves. The preparation of water circulation test Sufficient qualified water source; DCS system is qualified with application conditions; All instruments correction, testing & interlock, protection examinations are completed; The trial operation of all pumps and mixers machinery related to water circulation are accomplished; The dampers of original and clean flue gas are insulated from the control system; The water circulation system is qualified with all start-up conditions. Matters to be taken care of during water circulation test: The water circulation tests should not influence the boiler safety operation. The bypass damper fixings should be all open. The dampers of original and clean flue gas should be closed. Its sealing fans should be operating. The FGD system is insulated from the boiler flue gas system. The levels of absorber, limestone slurry tank and filtrate tank should be closed monitored during water circulation tests. Due to different liquid densities, the level displayed by DCS might be a little bit higher than the actual level in absorber and other equipments. The operating personnel should master the actual level of the absorber in line with various situations. The start-up operation of water circulation tests and operations requiring water circulation tests: Injecting the water till normal level for the following equipments: Equipment name Absorber Limestone slurry reservoir Industrial water tank Gypsum buffer tank Filtrate tank Unit m m m m m
When there is no system and equipment fault, maintenance, cleaning signals, all liquid levels are in line with start up requirements, all inlet and outlet doors are at the pre-start state, individual equipment can meet the start up requirements after inspection, the following equipments will be started in DCS system: Industrial water pump; Absorber mixer;
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Filtrate tank mixer; Limestone slurry tank mixer; Absorber pit mixer; Gypsum slurry buffer tank mixer; Absorber gypsum discharge pump; Gypsum eddy station charge pump; Sewage eddy station charge pump; Absorber slurry discharge pump; Absorber slurry circulation pump; z The control room operators should get the permission from the local inspection and side station monitoring personnel before start up the above equipments in sequence. z After the normal start up completion of each equipment, the related inlet & outlet doors should be opened and stopped at the required positions through automatic or manual remote operation. Until inspectors confirmation on the successful start up and normal operation of this equipment, can the start up of the next equipment be arranged. z After all equipments normal start up, the operating conditions at every positions should be regulated so that the flow, water level and pressure correspond to the system water balance requirements and the machinery is in sound operation. z After completion of the testing, the testing equipments should be stopped one by one in the sequence which is reverse of the start up and the related valves should be closed. z Each characteristic curve and words obtained in the testing should be recorded and kept in files. 11.4.1.5 Major equipment emergency button test 11.4.1.5.1 After the overhaul of FGD system, the emergency buttons of each major equipment in FGD system shall be tested to examine and ensure the operation withdrawals under emergency conditions. 11.4.1.5.2 Test procedure: z Pull the switches of the engaged equipments to the testing positions; z Enforce all related conditions in DCS manual manner to meet the start up requirements of the testing equipments; z Close the switches of all individual 6KV equipments on CRT; z Press the emergency button close to the equipment; z Observe the equipment switch which should be normally disjunct; z Resume all related forced conditions in testing to the normal original state. 11.4.1.6 Flue gas test 11.4.1.6.1 Test purpose z The initial flue gas test is to conduct simulative operation of all equipments in flue gas system and absorber system, inspecting and confirming the system rigour and
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11.4.1.6.2 z
z z z z z 11.4.1.6.3 z z z z z z z z z 11.4.1.6.4 z
equipment reliability as per the design requirments, as well as onece more examination of the desulfurization control system, start-up and shut down sequence, related interlock and protection, so that the potential equipment defects and errors might occurr after formal start up of FGD system can be discovdered in advance. Particularly, a preliminary estimation of each flue gas dampers reliability, fexibility, rigour & influence to the boiler & unit and the standardrization & check of each instrument testing point as well as a comparison with the design values can be done through the test, making good preparation for the system commissioning and normal placing in operation in future. Test conditions FGD system has passed the water circulation test: each tank, reservoir, pipe, valve and all equipments are qualified without leakage, and environment, passage, illumination and communication conditions can meet with the requirements; Each equipment in FGD system has been proved to be qualified in individual tests; Each subsystem in FGD system instruments, control sequence, thermal signals, interlock protections has been installed well and tested to be qualified; Common systems can be normal operating and standby, including water, power, steam, air and etc; The absorber is ready with gypsum slurry; the limestone slurry reservoir is ready with enough slurry of qualified density; The FGD system has been proved to be qualified in emergency shut down button test. Test procedure Report to the operating manager and obtain the permission; Start cleaning pump, compressing air system, GGH system with its sealing fans successively; Start gypsum discharge pump and limestone slurry pump for circulation; Start slurry circulation pumps (two sets at least) and oxidization air system; Close the evacuation door on the top of the absorber and open the clean flue gas damper; Start the original flue gas damper; Start the boost fan; Adjust the boost fan guiding blades, and slowly close the bypass damper door depending on the situations; Put mist eliminator cleaning, PH device cleaning and limestone slurry feeding system in service. Test items Inspect, measure and correct the site obtained values with the display values on CRT including flue gas system inlet oxygen content, SO2, flue gas temperature, flue gas flow, dust content, inlet pressure and etc;
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z
Inspect, measure and correct the site obtained values with the display values on CRT including flue gas system outlet oxygen content, SO2, flue gas temperature, pressure differential & temperature between GGH original flue gas side & clean flue gas side, GGH outlet pressure and etc; z Inspect, measure and correct the site obtained values with the display values on CRT including slurry PH in the absorber, process water consumption, limestone consumption, power consumption, the influence of open degrees of all damper doors & boost fan guiding blades to the boiler & desulfurization system and etc; z Dynamically verify the bypass damper door quick open function when the boost fan trip. 11.4.1.6.5 Matters to be taken care of in the test z Conduct accident anticipations and measures to keep the accidents away for the boost fan, inlet & outlet damper doors of FGD system; the boiler operating personnel should conduct accident anticipations when the testing bypass damper door is closed, and the test personnel should take other measures to ensure the quick open action of the bypass damper door; z Adjust slowly the boost fan guiding blades to reduce the negative influence on boiler negative pressure; z Record the site measured and control displayed parameters on time; z Reinforce the going-around inspection and monitoring of the system trial operation; z Each characteristic curve and words obtained in the testing should be recorded and kept in files. 11.4.2 Inspection and preparation before start up of FGD system 11.4.2.1 Cold standby state start up: when desulfurization device in operation for the first time after installation, or long time shut down for overhaul or other reasons, all the chemical tanks are without absorbent and water, all the mechanical equipments are out of operation, and all the operations start from OFF state. 11.4.2.2 Hot standby state start up: when desulfurization device experiences short time shut down for debugging maintenance or other reasons, flue gas removing system is not in operation, and the other systems are under start-up operation of standby or operating state. 11.4.2.3 Inspection before start up of FGD system 11.4.2.3.1 After confirming the accomplishment of the maintenance and operation orders, safety measures are removed; field sundries be cleared up with unblock passages, sufficient illumination, safe & stable handrails & stairs, clean channels, floors & equipments, and complete covers. 11.4.2.3.2 For each rotary equipment, the oil level is normal with good quality oil, clear & intact oil gauge & oil level mirror and no leakage; the cooling water is unblocked and the water temperature is normal.
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11.4.2.3.3
11.4.2.3.4
11.4.2.3.5
11.4.2.3.6 11.4.2.3.7
11.4.2.3.8
11.4.2.3.9
11.4.2.4 11.4.2.4.1 11.4.2.4.2 11.4.2.4.3 11.4.2.4.4 11.4.2.5 11.4.2.5.1
11.4.2.5.2
All signs and marks for the revisions of the equipment name, serial number, color ring, medium flow direction, due to the maintenance, changes of the equipments or system, or other reasons, should be clear, intact and correct. Inner space of the flue duct, earth pit, channel, tanks, towers, bunkers and GGH should be cleaned already; intact anti-corrosion layer; no left over; manholes are closed after inspection; intact insulation of the flue duct and the pipes. Put the DCS system in operation and the power supply for each instrument in operation; the parameters are correct in each group and state; the measuring indications and regulating actions are normal; field testing points, instruments, transmitters and sensors are in good operation state and at the right positions. Measure the insulation resistance of the electrical equipment and supply the power after a qualified test result. Mechanical and electrical equipment having normal appearances with foundation bolts, motor connection and grounding wiring in safe and stable state, complete shield, normal installation of connector and fasteners. Normal air compressing system of FGD system with pressure of 0.5--0.8MPa. Make sure that all the steam source doors of the start up actuators are at open position. Switches of air doors and valves should be flexible and on the right position. Inspect each air door and valve of every system according to the requirements before the start up of the FGD system, and then adjust the doors & valves to the specified position. The following conditions should be satisfied before the start up of the FGD system: Qualified crystal seeds have been injected into the absorber. The limestone slurry preparation system is under normal operation and can produce qualified limestone slurry. The unit is under normal operation with ESP, whose outlet flue gas turbialty can meet the requirements of the FGD system. The water level of the process water tank is normal and can guarantee the constant water supply of the process water. Absorber slurry crystal seeds make up & install conditions and slurry charge method: The process water pump can work properly and the process water tank is filled with water. The commissioning of each protection and interlock in process water system has completed. To check whether the absorber level gauge is at the pre-start up position. Inspect the inside of absorber, emergency slurry reservoir (tank) and its water discharge pit is clean without sundries. Each manhole is tightly closed. The evacuation valve door to the earth pit is closed. Suitable screen (over 6mm can not pass) is installed at the emergency slurry reservoir earth pit inlet to prevent the entry of caking gypsum or sundries. Instruments should be prepared simultaneously including measuring bottle, density meter, gablock and etc. The
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trail operation of emergency slurry tank discharge pit pump and emergency slurry tank discharge pump have been finished. The commissioning of protection and interlock has completed. 11.4.2.5.3 The air pressure of the compressing air tank is normal. The commissioning of each manual and pneumatic door has been completed and doors can work properly. 11.4.2.5.4 The trial operation of slurry circulation pump, gypsum discharge pump and oxidization fan have completed. The commissioning of the protection and interlock has finished. All mixers have accomplished the trial operation. 11.4.2.5.5 The clean industrial water is injected into the emergency slurry reservoir from the absorber up to around 4 meters. The emergency slurry reservoir mixer should be started. 11.4.2.5.6 Check the valve from the gypsum slurry discharge pump to ash slag front reservoir is closed, the absorber earth pit pump outlet manual door is closed, the valve to emergency slurry reservoir is closed and the circulation pipe manual door of the gypsum slurry discharge pump is open. 11.4.2.5.7 The gypsum crystal seed which is 10% of the gypsum is fed into the emergency slurry reservoir uniformly to keep the density of slurry at around 10%. 11.4.2.5.8 Start the gypsum slurry discharge pump, open the valve from the gypsum discharge pump to emergency slurry reservoir and inject water into the emergency slurry reservoir slowly. 11.4.2.5.9 Check the valve from the emergency slurry pump to the ash slag reservoir is closed and the shaft sealing water is normally put into service. 11.4.2.5.10 Start the emergency slurry pump, open the outlet door manually and inject the gypsum crystal seed slurry into the absorber. 11.4.2.5.11 When the absorber level is above 3 meters, the 4 mixers should be started successively. 11.4.2.5.12 Inject the water continuously and inject the gypsum crystal seeds uniformly at the rate of 10% gypsum into the emergency slurry reservoir, keeping the slurry density at around 10%. Maintain the emergency reservoir level higher than the trip position of mixer and emergency slurry pump until the absorber level reaches 9.63 m, then stop injecting the gypsum crystal seeds & emergency slurry pump and close its outlet door. 11.4.2.5.13 Discharge the gypsum crystal seeds in the emergency slurry pump pipe completely and conduct reverse cleaning when necessary. 11.4.2.6 The FGD system whole set start up 11.4.2.6.1 To shorten the start up time as much as possible, several function groups should be started in parallel and operated under standby state. The FGD system device should be put in service as per the following order: (If the system starts after a short time shut down and the process water pump and mist eliminator cleaning water pump do not stop during the short shut down, the related steps can be skipped.)
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z z z z z z 11.4.2.6.2
Process water pump; Mist eliminator cleaning water pump; Absorber slurry circulation pump; Flue gas duct; Oxidization fan; Limestone slurry conveying system. The positions of the related manual valves should be checked as per the following table before put the system in service: Special name KKS Action The switch should be flexible Open Open Close Close Open (circulation pump in operation Open (circulation pump in operation Open (circulation pump in operation Open (circulation pump in operation Close Close Close Open Open Open Close Close Close Close Close
Limestone slurry supply system drawing 06019S-J-03-13 (absorber area slurry supply pipe part) Limestone slurry non return valve Limestone slurry regulating valve up stream isolation valve Limestone slurry regulating valve down stream isolation valve Limestone slurry regulating valve bypass orifice plate inlet isolation valve Limestone slurry regulating valve bypass orifice plate outlet isolation valve Slurry supply pipe outlet to circulation pipe 2# inlet isolation valve Slurry supply pipe outlet to circulation pipe 1# inlet isolation valve Limestone slurry to circulation pipe 2# inlet isolation valve Limestone slurry o circulation pipe 1# inlet isolation valve *HTK71 AA901 *HTK71 AA501 *HTK71 AA502 *HTK71 AA503 *HTK71 AA504 *HTK71 AA510 *HTK71 AA511 *HTK71 AA520 *HTK71 AA521
Absorber system drawing 06019S-J-03-02 & 06019S-J-03-03 Absorber level gauge cleaning isolation valve *HTD10 AA213 *HTD10 AA214 *HTD10 AA214 *HTD10 AA303 *HTD10 AA304 *HTD10 AA305 *HTD10 AA202 *HTD10 AA203 *HTD10 AA204 *HTD10 AA205 *HTD10 AA206
Absorber level gauge isolation valve Absorber evacuation valve Absorber evacuation tank cleaning valve Absorber lower mixer cleaning pipes isolation valve
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Special name KKS *HTD10 AA204 *HTD10 AA205 *HTD10 AA206 *HTD10 AA301 *HTD10 AA302 *HTD10 AA211 *HTD10 AA212 *HTL11 AA401 *HTL11 AA501 *HTL13 AA501 *HTL30 AA501 *HTL30 AA511 *HTL30 AA512 *HTF11 CP301 *HTF12 CP301 *HTF13 CP301 *HTF11 CP510 *HTF12 CP510 *HTF13 CP510 *HTG11 AA510 *HTG12 AA510 *HTG11 AA901 *HTG12 AA901 *HTG50 AA501 *HTG51 AA501 Close Close Close Open Open Close Close Close Open Close Open Open Action
Absorber low position mixer cleaning pipe isolation valve Mist eliminator pressure differential measuring pipe isolation valve Mist eliminator pressure differential measuring pipe cleaning pipe isolation valve Gypsum slurry sampling valve Absorber to gypsum slurry buffer tank Absorber to emergency tank isolation valve Gypsum slurry PH value measuring bypass outlet manual valve PH gauge 1 cleaning pipe inlet isolation valve PH gauge 2 cleaning pipe inlet isolation valve Circulation pump inlet pipe pressure gauge isolation valve Circulation pump outlet pipe pressure gauge isolation valve Oxidization air system 06019S-J-03-10 #1 oxidization fan outlet manual valve #2 oxidization fan outlet manual valve #1 oxidization fan outlet non return valve #2 oxidization fan outlet non return valve Oxidization air main pipe to absorber manual valve Oxidization air main pipe to GGH dry manual valve Instrument valves temperature gauges 11.4.2.6.3 z z for each pressure,
Open
Open
Open Open Flexible open Flexible open Open Close Open
Put the process water system in service Check and ensure the process water tank is not less than 3.0 m; Check the related system valves is at the required positions as per the following table: Special name KKS Open Close Position
FGD process water inlet master valve Process water tank water discharge valve
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Special name KKS Open Open Open Open Open Open Open Open Open Close Close Close Open Open Open Open Close Close Close Open Close Close Close Open Position
#1 process water pump inlet isolation valve #2 process water pump inlet isolation valve #1 process water pump inlet isolation valve #2 emergency process water pump inlet isolation valve #1 process water pump outlet isolation valve #2 process water pump outlet isolation valve #1 process water pump outlet isolation valve #2 emergency process water pump outlet isolation valve Master water supply valve to emergency slurry tank area Emergency slurry return pump cleaning valve Emergency slurry mixer cleaning valve Emergency slurry tank area ground cleaning valve Turn-off valve of water supply to Limestone slurry tank area Mater valve of other water supply to milling & preparation workshop Master water valve at dehydration process building first floor Water supply valve for vacuum pump unit groups Desulfurization sewage treatment hydrochloric room water valve system
Desulfurization sewage treatment dosing unit area master water valve Cleaning valve at neutralization, coagulation aids and precipitation tank Mater cleaning valve at gypsum eddy station sewage eddy pump Master water valve for absorber area slurry pump, mixers and etc Cleaning turn-off valve to GGH LP water Cleaning turn-off valve to absorber mist eliminator Water supply valve to GGH HP cleaning water pump z z 11.4.2.6.4 Start #1 or #2 process water pump; Put the standby pump interlock in service; Start up of mist eliminator cleaning water pump:
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z z
Check and ensure the process water tank is not less than 3.0 m; Check the related valves is at the required positions as per the following table: Special name KKS Position Open Open Open Open Close Close Open Open
#1 mist eliminator cleaning water pump inlet isolation valve #2 mist eliminator cleaning water pump inlet isolation valve #1 mist eliminator cleaning water pump outlet isolation valve #2 mist eliminator cleaning water pump outlet isolation valve #1 mist eliminator cleaning water pump inlet isolation valve evacuation valve #2 mist eliminator cleaning water pump inlet isolation valve evacuation valve Master door from mist eliminator cleaning water pump to #1 FGD mist eliminator Master door from mist eliminator cleaning water pump to #1 FGD mist eliminator z z 11.4.2.6.5 z z z a) b) c) 11.4.2.6.6 z a) b) c) d) e) z z
Start #1 or #2 mist eliminator cleaning water pump; Put the standby pump interlock in service; Put the absorber slurry circulation pump in service: Check and ensure the absorber level is not less than 5.0m; Check and ensure the start up interval with other 6Kv equipment in the system is over 60s; Invoke the slurry circulation pump start up function group or operate as per the following sequence: Close the slurry circulation pump evacuation door and ensure the action completeness; Start the slurry circulation pump inlet motorized door and ensure the action completeness; Start the slurry circulation pump in 60s delay manner and observe the current which should return to the normal value in time. Put the flue gas system equipment in service: The following conditions have to be fulfilled before put the flue gas system in service: The boiler ESP has been put in service normally; The boiler ID fan is operating normally; The boiler combustion is normal without heavy oil aiding; The limestone slurry preparation system can normally supply the limestone slurry continuously; The absorber system has qualified conditions for put in service and 2 sets or above slurry circulation pump is in operation. Invoke the flue gas system start up function group or operate as per the following sequence: Start the GGH sealing fan;
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z z z z z z z z z z z a) b) c) d) e) f) g) z z z z z
Start the GGH major or standby driven motor and wait for the return of signal for normal GGH speed; Open the low leakage fan inlet damper; Close the low leakage fan outlet damper; Start the low leakage fan; Open the low leakage fan outlet damper; Put the GGH rotor low speed signal interlock in service; Open the clean flue gas damper; Close the motorised absorber evacuation buffer fly valve; Open the original flue gas damper; Put the boost fan static blade actuator at the manual position and adjust its open degree to less than 10%; Check and ensure the following start up permission conditions are fulfilled: The clean flue gas damper is open; The original flue gas damper is open; GGH is in normal operation with speed not less than 0.75 r/min; 2 sets or above slurry circulation pumps are in operation; The temperature of boost fan bearing is less than 70; The temperature of boost fan main motor bearing 1# and 2# is less than 75; The main motor winding temperature is normal; Start 1# or 2# bearing cooling fan; Start boost fan main motor; Increase the open degree of static blade manually depending on the boost fan inlet negative pressure situation after return of boost fan main motor current; Close the bypass damper gradually and adjust the open degree of static blade manually to maintain the boost fan inlet pressure around -200Pa; Set the boost fan pressure close circuit control setting value (bypass damper pressure differential is zero or the boost fan inlet pressure is -200Pa) and put the boost fan static blade automatic control mode in service. Put the oxidization fan in service Check and confirm all manual valves on air duct from the oxidization fan outlet to absorber are open; Open the oxidization fan bypass unloading valve; Open the oxidization fan sound arresting covering fan; Start the oxidization fan and observe the current to return in 20-6S normally; Close the oxidization fan bypass unloading valve. Put the limestone slurry supply system in service Check the related valves is at the required positions as per the following table: Special name KKS Position Open Open
11.4.2.6.7 z z z z z 11.4.2.6.8 z
Isolation valve before limestone slurry supply pipe density gauge Isolation valve after limestone slurry supply pipe density gauge
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Special name KKS Position Close Close Open Open Close Open Open
Limestone slurry supply pipe density gauge bypass valve Limestone slurry supply pipe density gauge valve group evacuation valve Isolation valve before absorber slurry charge regulating door group Isolation valve after absorber slurry charge regulating door group Absorber slurry charge regulating door group bypass valve Absorber slurry charge regulating door group evacuation valve Primary door for all measuring instruments z z z z z z z
Close the motorized evacuation valve at the limestone slurry pump inlet; Set the open degree of the absorber slurry charging regulation door below 30% manually; Close the motorized cleaning valve on the limestone slurry pump outlet pipe; Start the limestone slurry pump; Start the limestone slurry pump outlet motorized door; Put the standby limestone slurry pump interlock in service; Set the absorber slurry PH automatic control setting value at 5.6 and put the absorber gypsum slurry PH valve close circuit control.
11.5MONITORING AND REGULATION IN FGD SYSTEM OPERATION 11.5.1 Major purpose and task of monitoring and regulation The major purpose and task of monitoring and regulation is to ensure the continuous steay operation of the FGD system, the qualified desulfurization efficiency, the long term application life of the equipments, the safe operation of the equipments under accident conditions, and maintain the FGD system in favourable working conditions through corrrect monitoring and regulation of the FGD system and the equipments. 11.5.2 Crucial control parameters and limitations in the FGD system 11.5.2.1 Absorber inlet flue gas density control As per the design requirement, the soot density at the FGD system inlet should be controlled below 370mg/Nm3, (i.e. the dust content of the flue gas at the inlet). If the dust content is too high, the system working conditions shall deteriorate and the SO2 absorbing efficiency shall decrease with occurrence of abnormal conditions such as the belt conveyor dehydration difficulty, influencing the quality and utility value of the desulfurization gypsum. Therefore, the dust content variation should be strictly watched over in operation regulation. When the system dust content gose above the normal scale seriouly, the unit operating personnel should be contacted in time and the operation of the FGD system should be stopped without delay. 11.5.2.2 Fan inlet air pressure control To ensure the safe and steady operation of the boiler, the flue gas presssure is controlled by regulating the open degree of the boost fan guiding blades and the boost fan inlet pressure stablization is maintained. In order to obtain the better dynamic features, the boiler loading and ID fan situatin singals are led in as subsidiary signals. During the process of putting the FGD flue gas
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in service, the open degrees of the flue gas bypass damper door and the boost fan guding blades should be controlled coordinately, maintaining the pressure stablization at the boost fan inlet. When the bypass damper door is closed to certain degree, the preesure control close circuit will be put in service and the bypass damper door will be closed. In the operation process, the boost fan inlet pressure should be closely watched over. If there is big variation in boost fan inlet pressure, the open degree of the boost fan moving blades should be manually regulated in good time to keep the boost fan inlet pressure stable. 11.5.2.3 Absorber slurry PH control The PH value of the absorber slurry should be controlled within the specific arange. If it is very low, the slurry will lose the absorbing capability, influencing the SO2 removing rate and by product desulfurization gypsum quality. Simultaneously, high PH value will bring the consequences of scaling and jam to the system. The stability of PH is maintained by the online dynamic regulating the open degree of the limestone slurry regulation door to control the limestone slurry supply quantity. The best PH value for single circuit absorber is controlled between 4.5 and 5.8. 11.5.2.4 Absorber level control The absorber level varies due to the changes in factors such as the control of the absorber limestone slurry supply quantity, the gypsum slurry discharge quantity, the flue gas inlet quantity and etc. Based on the measured level value, the filtrate pipe regulation valve and the time interval for mist eliminator cleanings are controlled to keep the level stable. The level of absorer should be controlled at 13.50.5m. If the level is at14.00m or above, the operation is forbidden to avoiding GGH heat exchange surface pollution by gypsum slurry overflowing through the absorber inlet glue gas duct. 11.5.2.5 Absorber gypsum slurry density control The density of the absorber gypsum slurry should be controlled within the specific range. If the density is too low, it will result in the slurry gypsum crystalization difficulty and belt dehydration difficulty. If the density is too high, the system abrasion, the slurry circulation pump power consumption and risks of system scaling will be increased. The FGD absorber density should be controlled between 10501150Kg/m3. The absorber gypsum slurry density is controlled through regulation of the gypsum slurry quantity discharged to the ash and slag system. When the density of the absorber gypsum slurry reaches 1100Kg/m3, check and confirm the ash and slag system is ready with necessary conditions to receive gypsum slurry; To control the absorber gypsum slurry discharge quantity through regulating the open degree of the slurry discharge pneumatic door from the absorber to the front slurry reservoir by absorber gypsum slurry density close circuit control or manual control, and keep the absorber gypsum slurry density relatively stabilize at 10501150Kg/m3. 11.5.2.6 Absorber slurry Chloridion content control To protect and reduce the corrosion of the equipment and system pipes, ensure the normal operation of the FGD sewage system and maintain the suitable sewage discharge quantity, the asborber slurry Chloridion content should be controlled below 10000ppm. When the Cloridion is relatively high, the slurry discharge quanaity to the ash and slag system should be increased and the absorber level should be maintain by increasing the absorber process water make up quantity.
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11.5.2.7 11.5.2.8
To ensure the limestone reaction activity, the CaO ore of good quality and qualified fineness is generally used. The SO2 content in outlet flue gas should be strictly watched over. When deviation occurs, comprehensive analysis of the boiler loading, inlet SO2 density, circulation pump operation conditions and slurry PH should be conducted and suitable counter measurement should be adopted. Comparison Table of Parameters and Power Consumption Influencing SO2 Desulfurization Efficiency Value SO2 desulfurization efficiency Power consumption
Absorber flow PH
circulating
CaCO3 in absorber Limestone activity Flue gas flow SO2 density at FGD inlet Cl content in flue gas
11.5.3 Major operation control parameters limitation 11.5.3.1 Flue gas system KKS *HTA10 CP001 *HTA10 CP002 *HTA10 CP003 Specification Boost fan untreated pressure Boost fan untreated pressure Boost fan untreated pressure Range From To 40 Unit Operatin Valu Min/Max g value e -5 Action
up stream flue gas -40 up stream flue gas -40 up stream flue gas -40
mbar
40
mbar
-5
40
mbar
-5 Bypass protectio XXX n start up > Max X *HNA50 AA601
*HTA10 CP901
Boost fan up stream untreated flue gas logic pressure (two values out of 3) FGD device up stream untreated flue gas temperature
*HTA10 CT001
350
< 180
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KKS *HTA10 CT002 *HTA10 CT003
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Specification Range From 0 To 350 Unit Operatin Valu Min/Max g value e < 180 Action
FGD device up stream untreated flue gas temperature FGD device up stream untreated flue gas temperature FGD device up stream untreated flue gas logic temperature (two values out of 3)
350
< 180
*HTA10 CT901
350
< 180
> Max1 140
Bypass damper protectio >Max 2 180 n start up *HNA50 AA601 Bypass damper protectio 120 n start up *HNA50 AA111 Sending out signals for starting 120 up of treated flue gas damper *HTA50 AA601
<Min1
>Min1
<Min 2 110 *HTA20 CQ001 *HTA20 CQ002 FGD device up stream untreated flue gas SO2 content FGD device up stream untreated flue gas O2 0 21 0 5000 mg/m dry basis %
3
<3605
>Max1 3605
6-8
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KKS
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Specification Range From To Unit Operatin Valu Min/Max g value e Action
content *HTA30 CT001 Absorber (inlet) up stream untreated flue gas temperature 0 200 <120 Failure alarm
Max1 *HTA50 CP001 *HTA50 CP002 *HTA50 CP003 *HTA50 CP901 FGD device down stream -10 treated flue gas pressure FGD device down stream -10 treated flue gas pressure FGD device down stream -10 treated flue gas pressure Absorber down stream treated flue gas logic temperature (two values out of 3) FGD device down stream treated flue gas SO2 content FGD device down stream treated flue gas NOX content FGD device down stream treated flue gas O2 content FGD device down stream treated flue gas ash content FGD device down stream treated flue gas moisture content Down stream treated flue gas temperature GGH rotary body speed <0.7 rpm 0 200 0 21 0 1000 mg/m dry basis
3
125
40 40 40
mbar mbar mbar
+5 +5 +5
> Max 1 10
> Max2 *HTA50 CQ001 *HTA50 CQ002 *HTA50 CQ003 *HTA50 CQ004 *HTA50 CM001 *HTA50 CT010 *HUD10 CS901 0 500 <150
40
mg/m3 dry basis % dry basis mg/m3 dry basis %
<1000
<50
> Max1
50
100
<12
200
>=80 FGD device 0.2 flue gas pipe
rpm
< Min1
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KKS
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Specification Range From To Unit Operatin Valu Min/Max g value e Action failure *HTAOO EG001 Flue gas ready to 0.7 receive *HTA00 EG002
*HUD10 CS902
GGH rotary body speed <1.2 rpm
rpm
< Min1
11.5.3.2 KKS *HTC10 AA001
Boost fan Specification Boost fan static blade actuator Range From 0 To 100 Unit % >max1 -40 +40 mbar >max2 5 10 Warning Alarm Warning Alarm Warning Alarm Warning Alarm Alarm Alarm Alarm Trip Alarm Trip Alarm Trip Alarm Alarm Alarm Alarm Trip Alarm Operatin Min/Ma Valu g value x e Action
*HTA10 CP901 Boost fan inlet pressure (see flue gas system) *HTC10 CP001 Boost fan pressure outlet
<min1 -15 <min2 -18 >max1 30 35 -5 40 >max2 <min1 <min1
-40
+40
mbar
<min2 -10 *HTC10 CF901 *HTC10 CT001 *HTC10 CT002 *HTC10 CT011 *HTC10 CT012 *HTC10 CT051 *HTC10 CT052 Flue gas flow signa calculated from the 0 pressure differential of *HTC10 CP003 Boost fan front bearing -25 temperature Boost fan front bearing -25 temperature Boost fan middle bearing -25 temperature Boost fan middle bearing -25 temperature Boost fan rear bearing -25 temperature Boost fan rear bearing -25 temperature
150
40-120
>max1 120 >max1 >max2 >max1 >max2 >max1 >max2 >max1 >max2 >max1 >max2 >max1 >max2 85 95 85 95 85 95 85 95 85 95 85 95
120 120 120 120 120 120
C C C C C C
<70 <70 <70 <70 <70 <70
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KKS *HTC10 CT031 *HTC10 CT032 *HTC10 CT031 *HTC10 CT032 *HTC10 CT021 *HTC10 CT022 *HTC10 CT023 *HTC10 CT024 *HTC10 CT025 *HTC10 CT026 *HTC10 CY301 *HTC10 CY302 *HTC10 CP301 11.5.3.3 KKS
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Specification Range From To 120 120 120 120 Unit
o
Operatin Min/Ma Valu g value x e <70 <70 <70 <70 <125 >max1 >max2 >max1 >max2 >max1 >max2 >max1 >max2 75 80 75 80 75 80 75 80
Action Trip Alarm Alarm Trip Trip Alarm Alarm Trip Alarm Trip Alarm Trip Alarm Trip Alarm Trip Alarm Trip Alarm Alarm Trip Alarm Alarm Trip Alarm60S unrelease d Trip
Boost fan motor front -25 bearing temperature Boost fan motor front -25 bearing temperature Boost fan motor rear -25 bearing temperature Boost fan motor rear -25 bearing temperature Boost fan motor stator winding temperature Boost fan motor stator winding temperature Boost fan motor stator winding temperature Boost fan motor stator winding temperature Boost fan motor stator winding temperature Boost fan motor stator winding temperature Boost fan vibration value Boost fan vibration value bearing bearing
C C C C C C C
>max1 125 >max2 130 >max1 125 >max2 130 >max1 125 >max2 130 >max1 125 >max2 130 >max1 125 >max2 130 >max1 125 >max2 130 >max1 6.3 >max2 7.1 >max1 6.3 >max2 7.1 Signal spark
<125 <125 <125 <125 <125
mm/s mm/s
<5 <5
Boost fan surging alarm GGH Specification Range 02 Unit
Operatin Less/mo Value g value re than 11.5
Action Normal operating speed
GGH rotor speed *HUD10 *HUD10 CS001003 (2 CS901 out of 3) GGH speed<0.2rpm GGH speed <0.7rpm
rpm
<Min1 <Min1
0.2 0.7
Alarm, stop rotor driver Stop HP
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KKS
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Specification Range Unit Operatin Less/mo Value g value re than Action water cleaning procedure
GGH speed <1.0rpm *HUD10 Guiding bearing 0 CT001 lubricating oil temperature 200
<Min1
1.0
Alarm
60
>Max1 >Max2
Alarm
*HUD10 Supporting bearing CT002 lubricating oil temperature
>Max1 >Max2 Stop steam cleaning
*HUG01 Cleaning steam pressure CP001 *HUG20 Cleaning steam drainage CT001 discharge temperature 3HUQ01 HP cleaning water pump CP002 up stream pressure
bar
10
<Min1
300
<Min1
250 Stop HP water cleaning procedure
bar
<Min1
3HUQ01 HP cleaning water pump CP005 outlet pressure *HUW01 Positive pressure sealing CP001 fan down stream pressure 11.5.3.4 KKS *HTD10 CL001 Absorber Specification Range From To Unit
bar
>Max1
Stop HP water 100 cleaning procedure
mbar
Operatin g value 13500
Min/Ma x >MAX2
Value
Action Absorber inlet PO, 2 out of 3 Upper mixer PO, 2 out of 3
1# absorber level
14300
<MIN4
10000
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Circulatio n pump PO, 2 out of 3 Mixer PO, 2 out of 3 Gypsum discharge pump PO, 2 out of 3 Absorber inlet PO, 2 out of 3 Upper mixer PO, 2 out of 3 Circulatio n pump PO, 2 out of 3 Mixer PO, 2 out of 3 Gypsum discharge pump PO, 2 out of 3 Absorber inlet PO, 2 out of 3 Upper mixer PO, 2 out of 3 Circulatio n pump PO, 2 out of 3 Mixer PO, 2 out of 3
<MIN7
3000
<MIN9
1800
<MIN1 1
1200
>MAX2
14300
<MIN4
10000
*HTD10 CL002
2# absorber level
13500
<MIN7
3000
<MIN9
1800
<MIN1 1
1200
*HTD10 CL003
3# absorber level
13500
>MAX2
14300
<MIN4
10000
<MIN7
3000
<MIN9
1800
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Gypsum discharge pump PO, 2 out of 3 Alarm, mist eliminator sequence group control stop Stand by signal Close circuit control start up cleaning Alarm, upper mixer PO Release connectin g upper mixer Release connectin g circulatio n pump Alarm circulatio n pump PO Alarm mixer PO Release connectin g mixer
<MIN1 1
1200
*HTD10 CL901
Absorber level
logic
>MAX1
14000
>MIN1
<MIN2
12700
<MIN3
10500
>MIN3
10500
>MIN5
3500
<MIN6
3000
<MIN8
1900
>MIN8
1900
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Release connectin g gypsum discharge pump Alarm gypsum discharge pump PO
>MIN9
1800
<MIN1 0 11.5.3.5 KKS 0HTK60 CL901 Limestone slurry supply system Range Specification Limestone slurry tank level Fro m 0 To 500 0 Unit MM Operatin Less/Mor Valu g value e than e 2000-4 500 More than More than 480 0 450 0
1700
Action High level alarm
Unconditional start slurry preparation terminal procedure Conditional start slurry preparation procedure Conditional start slurry preparation terminal procedure Start slurry preparation procedure Low level alarm Allowing start up mixer
More than More than
420 0 300 0
Less than Less than More than More than Less than
200 0 180 0 150 0 150 0 100 0
Allowing limestone slurry pump start up Stop mixer, alarm limestone slurry pump stop
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Less than 400 Stop limestone slurry pump
11.5.3.6 KKS
Process water system Specification water Range From To Unit mm Operating value Continuous 5800 5500 >Max2 High alarm level Min/Max Value Action
0HTQ10 Process CL901 tank level
>Max1
Make up valve close (0HTQ10 AA101) Make up valve open (0HTQ10 AA101) Allowing process water pump activation Low alarm level
3000 <MIN1
3000 >MIN1
<MIN2
2000 1000
<MIN3 0HTQ15 Process water AA091 return pressure stabilizing valve *HTQ50 Absorber mist AA090 eliminating cleaning pressure relief valve 11.5.3.7 KKS Emergency slurry system Specification Range From To Unit Operating Min/Max value 13500 MAX1 Value MPa 0.65
Stop all process water pumps
MPa
0.21
Action
Emergency slurry tank 0HTT10 CL001 Emergency slurry tank level mm 13000 High alarm level
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KKS
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Specification Emergency slurry tank level Range From To Unit mm Operating Min/Max value MIN1 Value 3000 Action Allowing mixer activation Alarm mixer termination Stop mixer Alarm emergency discharge pump termination Stop emergency discharge pump High alarm level
mm mm mm
MIN2 MIN3 MIN4
2000 1800 1200
mm
MIN5
1000
Absorber earth pit *HTT41 CL001 Absorber earth pit level mm mm 1300 MAX2 MAX1 2800 2300
Allowing earth pit pump activation Allowing mixer activation Stop earth pit pump (level protection) Stop mixer Stop earth pit pump protection High alarm level
mm mm
MIN1 MIN2
1400 1300
mm mm
MIN3 MIN4
1100 500
Unloading room earth pit 0HTT51 CL001 Unloading room earth pit level mm 700 MAX2 800
mm mm 11.5.4 Inspection in FGD system operation
MAX1 MIN1
600 200
Activated earth pit pump Stop earth pit pump
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Equipment name Boost fan auxiliaries and
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Inspection item and requirements its For all rotary parts, current, vibration and sound are normal; machinery and motor bearing temperatures are normal; cooling water flow and temperature are normal; lubricating (hydraulic) oil pressure, temperature, quality and level are normal; all connectings, including guiding blade actuator and air dampers, are firm without deformation, bending and rip; no leakage points; CRT displays of outlet pressure and flue gas flow are normal. For all rotary parts, current, vibration and sound are normal; machinery and motor bearing temperatures are normal; outlet pressure value is normal; inlet screen is clean. For all rotary parts, current, vibration and sound are normal; machinery and motor bearing temperatures are normal; cooling water flow and temperature are normal; lubricating (hydraulic) oil pressure, temperature, quality and level are normal; driven belt tightness is suitable, without distortion and abrasion is within the normal standard; inlet and outlet pressure are normal; non return valve and pipes have no self-sustained oscillation or syntony appearance; inlet strainer is clean; all connectings are firm without deformation and bending; all valves are at the right positions; no leakage points. For all rotary parts, current, vibration and sound are normal; machinery and motor bearing temperatures are normal; lubricating oil level is normal and quality is good; all connecting bolts and nuts are firm; no leakage points. Without blockage; open degrees of valves are normal; inlet flow is normal; no leakage points.
Sealing fan
Oxidization fan and all types of pumps
Mixer
Hydraulic cyclone
Gypsum separator and For all rotary parts, current, vibration and sound are normal; machinery vacuum dehydration and motor bearing temperatures are normal; gypsum conveying belt conditions and the gypsum lump thickness are normal; the open degrees of valves and the solenoid valve action frequency are normal; the roller and its driven device works normally; the filter cloth is without blockage, broken holes or rip; cleaning conveying nozzle is without blockage conditions; water cleaning filter cloth is clean; the vacuum conditions is suitable; the gypsum splattering conditions are normal; local instruments indications are right; no leakage points. Rotary heat exchanger GGH For all rotary parts, current, vibration and sound are normal; machinery and motor bearing temperatures are normal; the cleaning water pressure is normal; lubricating oil level and quality are normal; sealing air pressure is normal; no leakage points. The open degree of dampers are right, drivers for air cylinder are normal; sealing air pressure and flow is normal; sealing components
Dampers with sealing device
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Absorber
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL are without leakage. Absorber level is within the normal range; current, vibration and sound of rotary parts, including circulation pump, mixer and so on, are normal; machinery and motor bearing temperatures are normal; the open degrees of valves and automatic valves are normal; PH gauge pipe is without blockage; there is no abnormal vibration and sound in the area; local instruments indications are right; no leakage points. and All water tank levels are within the normal range; the open degrees of valves and instrument valves are right; there is no abnormal vibration and sound in pipes; equipments and its auxiliaries in the system area are without leakage. The level gauge indications of limestone lump bunker and powder bunker are right; all instruments indications are within the normal range; the valve open degrees and pipe vibration are normal; the fluidizing device works properly; no leakage points. All indication values are within the design range; all interlocks and protections are normally put in service; no alarm signals; the operators on duty records on time.
All water tanks slurry tanks
Silo
CRT
11.5.5 Maintenance During the FGD System Operation 11.5.5.1 GGH Cleaning. To prevent the scaling inside GGH, the online cleaning must be adopted to GGH when the pressure difference enlarges in a faster speed or exceeds the designed value. During the normal operation of GGH (rotary proper of GGH: rotating speed n1.5), the steam cleaning should be carried out every 8 hours and the entire process (1 time) lasts for about 2.3 hours. The process is manually started by operators. When pressure difference (P) of GGH rises to ~1.5 P under clean conditions, alarms shall reminder the operators to start-up HP water cleaning. The intending frequency of HP water cleaning: during the normal operation of GGH, the system shall be cleaned once a week, or during the GGH system shut down process. The entire process lasts for about 9 hours. This process can only be manually adopted upon the operators request. The process is to be automatically accomplished by GGH soot blowing local control cabinet (including feedback of fault signal), and only remote start and stop signal will be issued by the operator. 11.5.5.1.1GGH steam cleaning Check and confirm the start-up conditions of GGH steam cleaning are fulfilled (not interlocked). GGH system is in operation and the rotor speed n1.5 (min 1). Upper and lower soot blowers are at the outer side. Air valve is closed. HP nozzle cleaning valve is open. Invoke GGH steam cleaning start-up function group to start GGH steam cleaning.
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11.5.5.1.2GGH HP water cleaning Check and confirm the GGH water cleaning conditions are fulfilled (not interlocked). GGH system is in operation. HP pump is not in operation. Chief water valve is closed. Invoke GGH HP water cleaning group to start GGH HP water cleaning. HP water cleaning procedure specification: During the HP water cleaning, GGH rotating speed is changed to low rotating speed of 0.75n. Start HP water cleaning procedure, which is controlled by soot blower control cabinet and the start & stop signals are sent out by DCS. Monitoring of HP water cleaning. The HP water procedure should be stopped when the following signals occurring: HP water pressure P>100 bar (3HUQ10 CP310), max 1. 11.5.5.2 PH gauges cleaning and correction 11.5.5.2.1Absorbing tower has two PH gauges, clean them alternately in the specific sequence. When the fault value and large warp alarm occur, it is necessary to start the cleaning device manually. The PH gauges should not be in operation during the cleaning. 11.5.5.2.2The results of manual analysis and online measurement should be compared at least once a week, and the online PH gauge should be adjusted when there is difference in the comparison. 11.5.5.3 Cleaning of oxidization air pipe 11.5.5.3.1To prevent blockage, every oxidization air pipe is equipped with a cleaning pipe, and every oxidization air pipe should be cleaned sequently every week. 11.5.5.3.2Each oxidization air pipe should be cleaned as per the following procedure: Check if the cleaning water pump is in normal operation. Slowly close separate valve of branch oxidization air pipe, wait until the oxidization air pipe pressure gauge turns to ZERO. Open the cleaning water separate valve of the oxidization air pipe, clean it and monitor the pressure gauge. Close the cleaning water separate valve of the oxidization air pipe after the cleaning. Slowly open the cleaning water separate valve of the oxidization air pipe. 11.5.5.4 The complete discharge and cleaning of the centrifugal pump for limestone and gypsum slurry transportation and the pipes after shut down 11.5.5.5 Periodic test for bypass damper door 11.6SHUT DOWN OF THE FGD SYSTEM Due to periodic overhaul or tear of the system, the FGD system will shut down after transacting the shut down procedure. Only after the operator managers approval can the FGD system be shut down. During the shut down process, the relative operations especially the flue
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gas system should be operated in stable order by closely contacting the operators, so as to guarantee the boiler safe operation and safe shut down of the FGD system. The methods of the equipments putting in service vary due to the different shut down methods of the FGD system. 11.6.1 Preparation before shut down of the FGD system 11.6.1.1 As each slurry pump is to be cleared and cleaned after shut down of the FGD system, the water level of absorber should be lower properly to keep the normal low level operations of the absorber discharge pit and emergency slurry reservoir. 11.6.1.2 Before shut down of FGD system, GGH should be cleaned by online steam or HP water. 11.6.2 FGD system from operating state to hot standby state The shut down of FGD system means that the FGD system changes from the operating state to the hot standby state; or after shut down of the boiler, the FGD system changes from the operating state to the hot standby state. This operation is accomplished by running flue gas system stop function group and absorbers stop function group, or by the remote sequent control of FGD system centralized controller. 11.6.2.1 Discuss with operator manager and chief operator to request for shut down of this units FGD system. After receiving the approval of the operator manager, invoke the flue gas system stop function group and absorber stop function group or manually stop the FGD system as per the following procedures: 11.6.2.2 Open the bypass damper z Manually open the bypass damper, add 5% extent for each time. Add with the same extent till 50% opening of the damper when the booster air fans inlet pressure reaches to a stable state. z Change the booster air fans automatic control to manually controlling state. z Add 5% extent to the opening of bypass damper while manually reducing boost fans static blade opening. After maintaining the boost fans inlet pressure, add bypass dampers opening to 100% by adding 5% opening extent. 11.6.2.3 Stop the boost fan z Make sure that the bypass damper opens to 100%. z Close the boosters static blade until the opening is under 10%. z Stop the operation of boost fans main motor. 11.6.2.4 Close the original flue gas damper 11.6.2.5 Close the clean flue gas damper 11.6.2.6 Start 1 set damper airproof fan z Start damper airproof fan z Start the electrical door at damper airproof fans inlet 11.6.2.7 Open the drainage door at the top of absorber 11.6.2.8 Shut down the GGH low leakage fan z Close the electrical door at outlet of low leakage fan z Shut down the low leakage fan z Close the electrical door at inlet of low leakage fan
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11.6.2.9 Close the limestone slurry feeding door to opening 0. 11.6.2.10 Shut down the absorbers slurry circulation pump by sequence z Make sure that the conditions for slurry circulation pumps shut down are fulfilled(boost fan is shut down, original flue gas damper and clean flue gas damper are closed) z Shut down the slurry circulation pump z Close the electrical door at slurry circulation pump inlet after a 120s delay. z Make sure that the water level at absorbers drainage pit is not high. z Start the drainage electrical door at the shut down slurry circulation pumps inlet z Close the drainage electrical door at the shut down slurry circulation pumps inlet after a 300s delay. 11.6.2.11 Shut down the oxidation fan z Open the bypass discharge valve of oxidation fan z Shut down the oxidation fan z Close the bypass discharge valve of oxidation fan z Shut down the sound proof fan of oxidation fan z Close the main humid adding door of oxidation air 11.6.2.12 Stop the gypsum slurrys PH gauge at absorber z Close the manual sampling door for PH measuring of gypsum slurry at absorber. z Open the drainage door at PH measuring slots bottom of gypsum slurry and drain the gypsum slurry inside. z Open the measuring loop of PH measuring of gypsum slurry and flush the manual door for 5 minutes. z Close the drainage door at PH measuring slots bottom of gypsum slurry and drain the gypsum slurry inside z Close the gypsum slurrys PH measuring loop and flush the manual door after treatment liquid is fulfilled in the PH measuring slots bottom of gypsum slurry. 11.6.2.13 Shut down GGH z Cancel the low rotating speed interlock of GGH stand by motor z Stop the GGH driven device z Stop GGH sealing fan 11.6.2.14 Shut down the limestone slurry pump z Shut down the limestone slurry pump z Open the flush door of limestone slurry feeding pipe and flush the feeding pump 11.6.2.15 Main equipments state under hot and stand by state of FGD system System Absorber system Description of main auxiliaries Boost fan Original flue gas damper door of FGD Clean flue gas damper door of FGD Bypass flue gas damper door of FGD State Stopped Closed Closed Open
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System
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Description of main auxiliaries Absorber ventilation door Absorber circulation pump Gypsum drainage pump Absorber mixer Oxidation fan Absorber PH control Mist remover flush system Absorber water level control Damper airproof fan Absorber pit pump Absorber pit mixer Soot blower Main and supplement drive motor GGH airproof fan GGH low leakage fan Low leakage fan inlet door GGH soot blower airproof fan Limestone slurry pump State Open Stopped In operation In operation Stopped Manually Stopped Automatic In operation According to the pit water level According to the pit water level Stopped Stopped Stopped Stopped Adjusted position Stopped In operation In operation Automatic Automatic According to Milling districts pit water level According to Milling districts pit water level In operation In operation In operation In operation According to the emergency slurry pools water level Stopped to corresponding
GGH system
Limestone slurry tank mixer Limestone slurry tank feedwater flow control Limestone slurry tanks water level control Milling district pit pump Milling district pit mixer Flush water system
Auxiliary system
Closed cooling water system Multi use air system Instrument air system Emergency slurry pool mixer Emergency slurry pump
Emergency pool
slurry
11.6.3 FGD system changes from hot standby state to cold standby state When the FGD system requires overhaul and the shut down mood need to be changed into cold standby state, it demands that each system should shut down, drain the slurry from tanks and pools into emergency slurry pool for storage and keep the emergency pool mixer on running.
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11.6.4 Matter to be taken care of after shut down of the FGD system 11.6.4.1 All the gypsum, limestone slurry transporting pump and pipe should be drained and flushed after the shut down operation 11.6.4.2 Mixers of tanks containing slurry should maintain constant operation mood. 11.7 FGD SYSTEM FAULT AND ACCIDENT HANDLING 11.7.1 FGD system fault and general principles for accident treatments 11.7.1.1 When FGD system has faults or emergencies, the operator manager and chief operator should lead all the operators to deal with the accidents according to Manual. Otherwise its harmful to personnel and equipments safety; all the orders should be followed. 11.7.1.2 When FGD system has faults or emergencies, the operators should report to chief operator, operator manager and relative leaders, and adopt effective and doable methods to prevent the accidents extend, restrict the accidents scope, clear up the causations and resume the operation of the FGD system. Under emergency conditions, the treatment comes first and then report to the leaders. 11.7.1.3 The main equipments of FGD system should be stopped and treated when they can not fulfill the operation conditions and can threaten operators and equipments safety. 11.7.1.4 The operators should immediately and positively adopt solutions by personal experience and judge for accidents not listed in this specification. 11.7.1.5 After treating accidents, the operators should record the time, accident, treatment process and solutions on the duty relay recording notebook and submit the raw report to the safety department of the plant. 11.7.1.6 When the accident occurred during the duty relay time, duty deliver that has not finished duty relay should go on for work and treat the accidents with duty relay personnel. The duty can only be relayed when the accident treatment is over or stopped for a rest time. 11.7.1.7 When noticing the FGD systems flue gas system shut down due to accidents, check if the bypass damper door is automatically opened or press the quick open button on the bypass damper, then report to operator manager and contact boiler operators to ensure the safety operation of boiler. 11.7.1.8 The consideration equipment scope of FGD systems accident treating does not only including the main equipments and systems inside the FGD system, but also the effects to the other service systems; take the possible secondary pollutions into consideration and avoid them. 11.7.2 Emergency shut down of the FGD system 11.7.2.1 Emergency shut down conditions of FGD system The FGD system should be immediately shut down when comes to the following conditions. If the system can not be shut down, the bypass damper should be opened manually and shut down the FGD system. z Boost fan trips z Less than 2 sets of operating slurry circulation pumps in operation z Flue gas temperature at inlet of boost fan is over 180
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Operating original flue gas damper or clean flue gas damper are closed due to faults z Boiler MFT z ESP fault trips or less than 2 flue gas channels are flowing to electric field. z GGH operation motor trips and the stand by drive motor can not be connected to start, leading to the shut down of GGH. 11.7.3 FGD system shut down due to not emergent faults The FGD system should be shut down when comes to the following conditions, but the department leaders agreement is the precondition. z 2 sets of absorber mixers out of operation z Operators should shut down the FGD system when the soot concentration at the inlet of FGD system. z The limestone slurry producing equipments and feeding system can not supply slurry to the absorber, and PH value of slurry insider the tower is under 4.0 and keep on dropping. z Density of gypsum exceeds 1200Kg/ m3 and can not be reverted to normal in short time. z The accidents occur at producing field and control room threaten personnels and equipments safety. z FGD systems controlling system can not monitor the faults. z GGH pressure difference can not be treated by the operators and keeps on enlarging. 11.7.4 Systems common fault treatment The following should be carried out when the DCS alarms for faults: z Make sure of the operation state of FGD system; z Find out the causes of alarming; z Adjusting operation should be done to remove the fault. z Revert and back to operation, resume the FGD system to normal operation. 11.7.4.1 Causations and solutions for the decreasing efficiency of FGD system:
z
Causations Limestone slurrys supply can be fulfilled inside the absorber Not exact data for PH online measuring, which leads to low measuring(control value) of actual PH level inside the absorber
Appearance and analyzing results Low control level of PH value
Solutions Improve the PH control level properly and increase the limestone slurrys supply
Compare the test result with online Mark the PH gauge measuring value manually to find out the comparatively and periodically. existing difference
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Blockage inside the spraying pipes or nozzles Flue gas increases flow
QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL Slurry circulation pumps flow(current) decreases and outlet pressure increases Deal when shut down
Online measuring indicates the increasing Add a spray coat if possible of flow and each sections resistance of the flue gas system increases at the same time Flue gas online measuring indicates that Add a spray coat if possible the density of SO2 increases and the boilers coal consumption increases Enlarge the sewage drainage flow
Density of SO2 inside flue gas increases Quality of slurry turns down and the densities of Cl, dust and heavy metal are too high Measuring value of online measuring gauge is not exact due to faults, which leads to wrong calculation of FGD efficiency
SO2 value at the inlet of online measuring Calibrate the online gauges absorber is different(less) with SO2 value contained inside the coal; SO2 value at the outlet of online measuring absorber is larger than the actual value.
11.7.4.2 Tripping during boost fans operation z Appearance --Boost fans current on the DCS screen turns to 0, inlet pressure turns to positive, and motors screen turns from red to green. --Bypass damper opens automatically, inlet and outlet dampers close automatically, ventilation damper of absorber opens automatically, and boilers induced fan may have short time positive pressure. --FGD system shut down automatically. z Treatment process --Make sure the flue gas bypass damper is already open, or open it by other means. --Report to operator manager and chief manager of centralized control about the boost fans tripping. --Check whether the operation of absorbers circulation pump, oil temperature of boost fans bearing and motors bearing and the fans vibration are normal. Make sure if they are the causations for the tripping. --Check the operation of electrical and thermal protection and compare with the field equipments operation, then contact the maintaining personnel to check the validity of the protecting operation and reset the protection after handling the problems, check the insulating resistance of the boost fans motor, booster motor
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proper and oil station, make sure of the causation of tripping and deal with it. --Check the overall equipments of FGD system and turn them into hot standby state. --If the causation of the fault can be found and treated in short time, then restart the FGD system. 11.7.4.3 Blackout of treatment liquid z Appearance Treatment liquid sends out alarm signals Blackout of treatment water at production fields. z Treatment procedure Check the operation state of operating pump, and if there is abnormality, start the stand by pump (start the coupling pumps when the treatment liquid pressure is under 300 kpa). Check the water level of the treatment liquid tank and make sure that the makeup water of treatment liquid is normal; When the blackout can not be renewed for a short time, then request the long time shut down of FGD system; Drain the slurry pipe, try to renew the water source as soon as possible, then flush the pipe and restart the FGD system. 11.7.4.4 Large GGH pressure difference z Appearance Alarming for large GGH pressure difference Treatment procedure Increase the times of soot blowing and reduce the time space of soot blowing. Start HP water pump when the treatments above are of no effect. Reduce the opening of the boost fan, reduce the systems air flow and renew the system after treating to normal state. 11.7.4.5 Complete shut down of slurry circulation pumps z Appearance Complete shut down the operating slurry circulation pumps, switch of the DCS system turns to green, current changes into ZERO and alarm rings. Shut down of FGD system. z Treatment procedure Make sure that the boost fan is tripped, manually stop the boost fan when necessary and shut down the FGD system; Check if the absorber level is in the normal scope; Contact the thermal control personnel and check if there are abnormal conditions in absorber level control system, the level indicator is right or not, and clean or correct the level indicator depending on the actual conditions; Send a notice to the electrical maintenance personnel to check whether the slurry circulation pump motor, cable and switch cabinet are in normal operation; check
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whether the electrical protection is in action; After eliminating the defects, restart up. 11.7.4.6 Abnormal in absorber level z Cause Absorber level gauge out of order or metering error; Absorber slurry circulation pipe leakage; All valves which is connected to the absorber inside leakage; Absorber leakage; Absorber level control module failure; Mist eliminator cleaning water cutoff or nozzle blockage. z Treatment procedure Check and adjust the level gauge indication; Check and repair the leaking pipe; Check the valves inside leakage conditions, and change the related leaking valves; Check the discharging doors at the absorber proper and the bottom. 11.7.4.7 Accident trip of the FGD flue gas system z Appearance DCS alarm signal sent out; Boost fan trip; Bypass damper open, original and clean flue gas damper door close; z Cause Boost fan failure trip; GGH driven motor speed less than 0.5r/min; Less than 2 sets of absorber circulation pumps in operation; Clean flue gas damper closed; The FGD system main power supply failure trip. z Treatment procedure Closely adjust and monitor each slurry tank and absorber slurry level, consistency and density after the FGD system trip; If the FGD system main power supply trip, then it should be treated as equipment shut down; After finding out the failure causes and eliminating the defects, restore the FGD system operation. 11.7.4.8 FGD system other defects causes and treatment methods Defect type Defect cause 1. Limestone powder feeder blockage 2. Powder bridging in the powder bunker 3. Valve control out of order Treatment methods 1. Clean up the powder feeder 2. Adopt all clean up measurements, to increase the powder bunker discharge quantity 3. Inspect and repair the valves
Limestone slurry density decrease
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL 4. Limestone slurry tank over water feeding 1. Valve blockage 2. Relative valve out of order 3. Flow gauge out of order 4. Limestone slurry pump failure 5. Relative valve can not open or close to the right positions 1.PH gauge slurry supply quantity is not enough 2.PH gauge slurry supply mixed with cleaning water 3. Gauge not correct 4. Inspect relative pipes and valves 1. Clean up the pipe 2. Inspect, clean and repair the relative valves 3. Inspect or change the flow gauge 4. Change to stand by pump 5. Inspect and correct the valves 1. Inspect and correct the valves, and inspect whether the slurry discharge valves are at the right positions 2. The cleaning water valve has leakage or not, examine by cleaning and comparison with the standard liquid 1. Contact the centralized control operating manager, to know the boiler operation adjusting conditions and coal combustion analysis; 2. Inspect the circulation slurry pump operation conditions and put 1 more circulation slurry pump in service when necessary; 3. Inspect and restore the limestone slurry density; 4. Correct the gauge. 1. Treat after find out the reasons 2. Check the pressure differential and treat 3. Contact to conduct boiler modification
Limestone slurry flow decrease
Inexact PH gauge indication
Absorber SO2 increase
1. Absorber circulation slurry quantity decrease outlet 2. Limestone slurry quantity density decrease 3. Limestone slurry density decrease 4. Gauge not correct
1.GGH rotation not in good Absorber inlet flue conditions gas temperature 2.GGH blockage high 3. FGD system inlet flue gas temperature high GGH outlet flue gas temperature high GGH outlet flue gas temperature low Mist eliminator pressure differential high Oxidization air flow abnormal All absorber circulation pumps shut down 1.GGH blockage 2. FGD system inlet flue gas temperature low 1. Elements blockage 2. Gauge not correct 1. Pipe or oxidization fan inlet blockage
The temperature rises to the specific value. 1. Check the pressure differential and treat 2. Contact to conduct boiler modification when it is lower than the specific value 1. Inspect the blockage, adjust mist eliminator cleaning flow and time intervals 2. Correct the pressure gauge 1. Inspect the oxidization fan inlet filter and clean the air duct up to the absorber
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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW BOP OPERATION MANUAL 2. Oxidization fan failure or pipe leakage 2. Inspect the oxidization fan or pipe Inspect the inlet filter, clean or change
Limestone silo fluidizing fan 1. Inlet filter blockage output pressure low
11.7.4.9 The FGD system shall shut down due to failure interlock when with the following conditions: 11.7.4.9.1There are less than 2 absorber slurry circulation pumps in operation; 11.7.4.9.2The FGD system inlet temperature is over the maximum value permitted; 11.7.4.9.3The inlet temperature is below the minimum value permitted; 11.7.4.9.4The boost fan is not in operation; 11.7.4.9.5The GGH is not in operation; 11.7.4.9.6Boiler MFT (2 boilers MFT of 2 boilers +1 absorber or boiler MFT of 1 boiler+1 absorber); 11.7.4.9.7The main power supply fails. 11.7.4.10 The FGD system shall shut down due to the non interlock failure when with the following conditions, and the approval of the department leaders should be obtained before the shut down: 11.7.4.10.1 The operators should shut down the system when 2 sets out of 4 absorber mixers are shut down; 11.7.4.10.2 The operators should shut down the system when the FGD system inlet soot density is over 300mg/Nm3. 11.7.4.10.3 The operators should shut down the system when original damper for 2boilers+1absorber or 1boiler+1absorber is closed; 11.7.4.10.4 The operators should shut down the system when the clean flue gas damper is not open thoroughly. 11.7.4.10.5 When the FGD system outlet flue gas temperature is less than 80 and the adjustment is not effective, the operators should shut down the system after obtaining the approval. 11.7.4.10.6 The instrument air system failure and the pressure can not be kept; when it can not meet the FGD systems requirements, the operators should shut down the system; 11.7.4.10.7 The system should be shut down when the FGD system parameters are seriously deteriorating and can not maintain the normal operation; 11.7.4.10.8 When accidents happen at the site and in the control room, and personal and equipments safety are in danger, the system should be shut down; 11.7.4.10.9 When the control system of the FGD system fails and can not conduct the normal monitoring, the system should be shut down;
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11.7.4.10.10 When the GGH pressure differential is high, and continuously increase after ineffective treatment conducted by the operators, the system should be shut down. 11.8 OPERATION OF LIMESTONE SUPPLY SYSTEM 11.8.1 Start up of the limestone preparation system 11.8.1.1 To choose the start up of the wet miller LP lubricating oil pump on the local control panel, and set the interlock of wet miller LP lubricating oil pump A & B when the lubricating oil pressure is more than 0.4MPa. 11.8.1.2 Start the wet miller spray fan. 11.8.1.3 Start the wet miller ejecting oil pump. 11.8.1.4 Start the wet miller gear box oil pump; if the oil pressure is over 0.5bar, start after a time delay of 120s. 11.8.1.5 Start wet miller LP oil pump (jacking); if the oil pressure (is over 3.0MPa) does not establish, then wet miller can refuse to start. 11.8.1.6 The wet miller main motor can only start after the wet miller slow driven device trips. 11.8.1.7 Start the limestone miller process water inlet motorized door, and set the wet miller inlet water recovery regulation door at the automatic mode to mix water as per the limestone quantity so that the wet miller slurry density can be controlled. 11.8.1.8 Start the scale feeder, when the limestone quantity is around 12t, lower the feeder at the setting necessary quantity after half an hour. (Considering that: at the initial stage of start up, the wet miller is on zero load, and large quantities of materials are needed to counteract the grinding consumption between the steel balls.) 11.8.1.9 Start the wet miller slurry tank mixer. 11.8.1.10 Add materials and water into the wet miller to control the wet miller recirculation slurry tank (through level mode) at the setting value of 1500mm; (stabilization at this level is a little bit inclined to the upper limit). 11.8.1.11 Start wet miller slurry recirculation pump, adjust the frequency up to 40-50Hz, and regulate the limestone slurry eddy station inlet pressure. 11.8.1.11.1 Choose the wet miller recirculation pump A or B, (please pay attention to the corresponding relationship). 11.8.1.11.2 Invoke the wet miller recirculation pump cleaning sub function group. 11.8.1.11.3 Open the wet miller recirculation inlet door, close the wet miller slurry pump outlet door and manually close the discharge door. 11.8.1.11.4 Open the process water cleaning door. 11.8.1.11.5 A time delay of 300s. 11.8.1.11.6 Close the wet miller slurry inlet door. 11.8.1.11.7 Open the wet miller slurry outlet door. 11.8.1.11.8 A time delay of 300s. 11.8.1.11.9 Close the wet miller slurry pump outlet door, close the process water cleaning door; control the outlet pressure (the setting value is around 200kPa) to discharge to the limestone slurry eddy station (close the outlet door initially and open the overflow outlet after the fineness is qualified).
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11.8.1.12 Send the samplings for chemical examination. 11.8.1.13 After the start up of the wet miller slurry pump, open the wet miller slurry pump outlet door, adjusting the frequency up to 50Hz, so that the limestone slurry eddy station inlet pressure can be regulated over 200kPa or 2 eddy in the limestone slurry eddy station are in operation. 11.8.1.14 The slurry enters the buffer tank after pass the chemical examination with qualified results. 11.8.1.15 After confirmation of slurry tank level reaches 5.5m, start all slurry supply pumps to supply slurry to the each absorber. 11.8.2 Upkeep of the wet miller 11.8.2.1 During the long time shut down, the bowl shall cool and shrink gradually, and the journal will slip on the bearing bushing. To reduce the friction and the axial tensile force induced by the bowl shrink, the LP oil pump should automatically supply oil for 3mins in every other 30mins after 24hr shut down so that a certain oil membrane thickness can be maintained between the journal and the bearing bushing. 11.8.2.2 During the shut down in winter, the cooling water in the water cooler should be discharged entirely to avoid pipe frozen and split. 11.8.2.3 Generally, the material feeding should be stopped before shut down and stop the wet miller operation as soon as possible. 11.8.2.4 If the wet miller will shut down for a long time, the steel balls should be spilled out to prevent the bowl from deformation. 11.8.2.5 The operators should comply with and pay attention to the following matters during normal operation: 11.8.2.6 The wet miller can not operate for long without feeding so as not to damage the lining plate and consume the medium (otherwise there should be water in the milling bowl). 11.8.2.7 To feed equally is the one of the most important conditions for the wet miller to achieve the most working efficiency, so that the operators should ensure the feeding equality of the materials. 11.8.2.8 To exam the friction conditions of the lining plate and the medium inside the wet miller bowl, change the lining plates which has been worn and split in time, to screw and exchange the bolts which are not firm and fractured to prevent bowl from being worn out. 11.8.2.9 Inspect and ensure from time to time each lubricating point (including the main shaft bearing sealing ring) has enough and clean lubricating oil (fat); to clean the oil station return oil strainer once every month at least; to examine the lubricating oil quality every half a year and replace by the new oil when necessary. 11.8.2.10 To inspect the wet miller big & small gears mesh conditions and the junction bolt tightness, and there is no abnormal vibration and sounds in gear box operation. 11.8.2.11 To regulate the steel ball quantity and stage configuration based on the milling materials and products granularity requirements; to add steel balls into the wet miller in time so as to keep the best state of the steel balls in the wet miller; the steel balls added
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should be of the maximum size of the initial adding (but if there is long time without adding new balls, smaller size balls can be added). 11.8.2.12 The protective cover for wet miller coupling & clutch and other safety protection device should be intact and caution boards should be hung at the dangerous area. 11.8.2.13 Any proper disassembly or maintenance work is forbidden when the wet miller is in operation. When it is necessary to enter the bowl, the operation order sheet should be applied & issued, the safety measurements have been strictly followed and the monitoring measurements have been handled well. 11.8.2.14 During the inspection and maintenance of the wet miller and its auxiliaries, the LP illumination equipments should be used. When conduct welding to the parts on the wet miller, necessary earthing protection should be noticed to avoid current burning gear surface and bearing bushing surface. 11.8.2.15 The cooling water temperature and flow for the main shaft and each oil station should be meeting with the requirements that the bushing temperature does not exceed the permitted temperature and can be adjusted appropriately. 11.8.2.16 Periodic inspection Manual should be worked out during the application procedure, and the equipments maintenance should be conducted. 11.8.2.17 To upkeep the equipments carefully, clean the ambience, and ensure there is no water leakage, slurry leakage, oil pollution, screw untightness and sundries next to the equipments. 11.8.3 Shut down of the limestone preparation system 11.8.3.1 Stop the scale feeder. 11.8.3.2 Adjust the setting values of the 2 recover water doors at the wet miller inlet and slurry tank to 0m3/h and then close the doors. 11.8.3.3 Adjust the wet miller recirculation slurry tank to the normal and maintain the wet miller slurry pump operate for some time to dilute the pipe density. 11.8.3.4 To adjust the wet miller slurry tank level to the low position and ensure the wet miller inside materials decrease obviously. 11.8.3.5 Start P oil pump (jacking oil pump with establishment of oil pressure), stop wet miller and then stop the jacking oil pump after 3-5min. 11.8.3.6 Stop the wet miller big gear ejecting oil pump and spray fan. 11.8.3.7 Stop the bearing lubricating system. (Keep the lubricating oil system in operation in winter) 11.8.3.8 Invoke the cleaning function group when shut down the wet miller recirculation pump: 11.8.3.8.1Stop the wet miller recirculation pump. 11.8.3.8.2Close the wet miller recirculation pump outlet door. 11.8.3.8.3Open the wet miller recirculation pump cleaning door. 11.8.3.8.4Close the wet miller recirculation pump cleaning door and close the inlet door. 11.8.3.8.5Confirm the limestone eddy station is clean after cleaning. In 10.5.3.3 the wet miller slurry discharge dilatation has been conducted, but manual cleaning shall be conducted again when necessary.
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11.8.3.8.6The limestone slurry reservoir mixer can shut down only when the tank level is at 2.0m, otherwise it can not be stopped. 11.911.9 LIMESTONE HANDLING SYSTEM DESCRIPTION Limestone with particle size of 5-20mm will be supplied by the Owner through barges of 100-200T capacity near to the plant limestone unloading station. The limestone consumption for both phases (4x300 MW) has been assessed as about 120,000 t/year. The scope of work start from Limestone unloading from the barge, conveying to Limestone storage shed (common for 4 Units), further conveying to limestone Silo. The limestone supply system shall include but not be limited to the following: Common unloading facility (4 Units) at jetty complete with bucketed rotary crane of capacity not less than 70 T/Hr with bucket of capacity 2 m3. One (1) limestone storage shed having storage capacity of twelve (12) days (about 6000 tons) consumption with the worst sulfur coal at BMCR for 4 Units. Bridge type grab crane with the capacity of 60 T/Hr will be provided for the limestone storage shed. One (1) 100% duty limestone supply conveyor system common for 4 Units. The specification of belt conveyor from unloading station to limestone storage shed and to the limestone Silo is of width B=500mm, speed v=1.0m/s, capacity 60t/h, All Conveyors will be one streams,. For the flow diagram of limestone handling system see DWG F4091S-M0104-02. 11.9.1 Startup of limestone belt conveyor 11.9.1.1 All belt conveyors are started in reverse flow sequence. 11.9.1.2 The changeover switch on local control & operating box is place at Local position, interlock switch is place at correct Interlock position, startup of belt conveyor is strictly prohibited without turning on interlock. 11.9.1.3 Ring the alarm bell before startup. After 30 seconds, startup operations are performed by pressing Start button. If the startup is failure, the reason shall be found out immediately. Startup again is permitted only after the fault is removed. Interval between two operations must not be less than 15 minutes. 11.9.1.4 After limestone loading is finished, press Stop buttons on various belt conveyors in forward limestone flow sequence to stop the belt conveyors. 11.9.1.5 On-load start or stop of belt conveyor is forbidden except for special condition. 11.9.1.6 If the belt conveyor is stopped due to tripping, the reason shall be found out. Startup again is permitted only after the fault is removed. Press Start button, the conveyor will operate and operating indicator is illuminated after sound-light alarm device sounds for 30 seconds. 11.9.2 Shutdown of limestone belt conveyor 11. 9.2.1 Shutdown operations may be performed only if shutdown instruction has been received after local test is finished. 11.9.2.2 Press Stop button, the belt conveyor will stop, stop indicator is illuminated . 11.9.2.3 After confirming the stop of belt conveyor, place the selector switch on local control box at Remote Control position. 11.9.2.4 After confirming the test run of belt conveyor is satisfactory, equipments are ready
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for operation. 11.9.3 Notices for operation 11. 9.3.1 During operation of the equipments, any maintenance and defect elimination jobs must not be carried out. 11.9.3.2 During operation, changes in current indicator of all operational equipment shall be monitored closely, the limit must not exceeded. 11.9.3.3 During operation of the equipments, care shall be taken to watch operating conditions of all rotational equipments, and oil level in reduction gearbox shall be normal. Temperature shall be 75,vibration 0.01mm,all bearing temperatures 85. If the above data is approached or reached, the shift supervisor shall be reported promptly to take preventive measures. 11.9.3.4 The belt conveyor shall be free from serious misalignment, slippage, tearing etc. All idler and roller shall be flexible in rotation, free from jamming and abnormal sound.
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12 Air Compressor System Operation Manual 12.1 Direction for use of control panel stop button 1) startup button The three indicator lamp indicates: ---operating ---fault ---power supply The operating indicator lamp and power indicator lamp are on in normal operation, and the fault indicator lamp is on when fault happens in operation. 2) Emergency button: the red button below the display panel a) Press the button when fault appears to emergently stop the air compressor; the fault lamp is on; b) The reset screen appears when the emergency button is pulled out; press F3 to reset. 3) Modify the high/low limit of the pressure a) Press F1 and the main menu (meau) screen appears; b) When the main menu appear after pressing F1 button, press the down arrow until the Modify Params appears; press the horizontal arrow until Parameters appears, and then press the horizontal arrow again to modify the low limit of the pressure. c) Press F2 button to carry out modification; use up and down arrow to modify the low limit, and press F1 to confirm; then press F1 to return. The high limit is preset by the manufacturer, and is not allowed to be modified. d) Continuously press the F1 button can return to the main menu (meau) screen, and F3 button can also be pressed to reset 4) Press F1 button and up, low and horizontal arrow for browsing the main menu, check the startup times, operation time, oil temperature, differential pressure and other parameters. 12.2 Instrument-use air compressor operation 1) The high limit of pressure of No.1 to four air compressor is set as 0.8MPa, and the low limits are set as 0.7MPa, 0.69MPa, 0.68MPa and 0.67MPa in sequence. 2) In normal operation and conditions, No.1 air compressor (with the high limit of 0.8MPa and the low limit of 0.7MPa) and No. 2 air compressor (with the high limit of 0.8Mpa and the low limit of 0.69MPa) are in operation, and the No.3 and No. 4 air compressor are in reserve. No. 1 air compressor will automatically stop when the system compress air pressure is higher than 0.8Mpa; when the system compress air pressure is lower than 0.8Mp, No.1 air compressor is automatically started; when the system compress air pressure is lowered to 0.69Mpa, No.2 air compressor is started and operates in synchronization with No.1 air compressor; and the rest may be deduced by analogy. Air compressor operation maintain 1) Check the room temperature and the ventilation before starting the air compressor, and the room temperature should be less than or equal to 46 degrees Celsius. 2) Check whether the oil level is normal or not, and whether the automatic water discharge valve is open or not. 3) Check oil leakage inside the air compressor and whether the machine has abnormal noise or not after the air compressor is started.
12.3
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4) Frequently open the manual water discharge valve and check discharge water content and oil content. 5) Periodically clean the filter according to the differential pressure (not more than 0.08Mpa) in the air compressor. 6) The red emergency shutting down button should not be pressed randomly unless emergency happens. 7) When the air compressor is shut down, the outlet valve of the air compressor should be closed, the manual water discharge valve should be opened and the remained water inside the air compressor should be drained completely. 12.4 Air compressor shutdown protection 1) Main motor overload protection. 2) Emergent shutdown protection. 3) Fan overloads protection. 4) High oil temperature protection (alarms at 100 degrees Celsius and shut down at 110 degrees Celsius).
12.5 Air compressor dryer operation maintain 1) Dryer startup and shutdown operation a) Switch the startup-shutdown position to the startup position, and when the dryer is normally started, the local operation indicator lamp is on (green). b) When trying to stop the dryer, switch the startup-shutdown position to the shutdown position while the pressure of the two dryer tank is balanced as much as possible, and then the dryer is shutdown.. 2) Dryer maintenance a) The dryer should be started or shutdown at pressurized conditions. b) The filter indicated P8P is used for dedust; the filter indicated P8C is used for oil removal. c) The dryer filter should be periodically blowdown; the cartridge of the filter should be replaced when the differential pressure gauge is more than 0.1MPa (the gauge shows red color) d) In the operation process of the dryer, the dryer tank has pressure, while the regeneration tank is pressure free. The two tanks are shifted every five minutes. 13 Fire-fighting System Operation Manual 13.1 Overview Fire-fighting water system comprises a fire-fighting pump, stabilized pressure pump, fire-fighting pool, high and low pressure fire-fighting pipe network, invalve and outvalve fire-fighting hydrants, sprinkler extinguishment facilities and others, and also provides foam fire-fighting water to the oil depot region. Fire-fighting pump only provides high-pressure fire-fighting water. 13.2 Startup mode of fire-fighting pump In addition to the self startup according to the chain conditions, the fire-fighting pump can start and stop by the remote controller of the CRT in the chemical control room (the switch of the fire-fighting pump of the local control panel is placed on the remote control position) and can also
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start and stop on the site (the switch of the fire-fighting pump of the local control panel is placed on the local position). 13.3 Operation mode of fire-fighting pump At present the operation mode of the fire-fighting pump is that the stabilized pressure pump operates for a long term to maintain the pressure of the high and low pressure fire-fighting pipe network (the stabilized pressure pump is switched per week regularly), and the fire-fighting pump will automatically start and stop according to the chain conditions when the pressure of the fire-fighting pipe network declines. 13.4 Chain conditions of fire-fighting pump 1) The pressure of the fire-fighting system is maintained at 1.06 MPa (adjustable) by the fire-fighting atmospheric pressure stabilizer. 2) When the pressure of the high-pressure fire-fighting pipe network is less than 0.8Mpa (adjustable), the electric fire-fighting pump is input. 3) When the electric fire-fighting pump fails, the diesel fire-fighting pump is automatically input. 4) When the pressure of the high-pressure fire-fighting pipe network is more than 1.06Mpa, the fire-fighting pump stops. 5) When the liquid level of the fire-fighting pool is below 1.5 m, two fire-fighting pumps and two stabilized pressure pumps stop. 13.5 Diesel fire-fighting pump system Diesel fire-fighting pump body includes a diesel engine, heat exchanger, expansion water tank, cooling pipeline, flexible coupler, water pump, diesel tank, storage batteries and control panel and other equipments. Water pump is connected with the diesel engine through the flexible coupler directly. 13.5.1 Preparations for operation and use 1) Make preparations for operating and using the supporting equipment of the diesel engine pumping group, such as: oil, water and electricity are in the proper state. 2) Ensure that all cable connections are correct and various switches of the control screen are in the correct position before operation. 13.5.2 Startup of diesel fire-fighting pump 1) The diesel fire-fighting pump control panel is powered on 2) After the preparatory work is completed, turn on the Power switch on the panel (DC control power supply, or switch from zero position to manual or automatic position), when the DC control circuit of the diesel engine is powered on, the power indicator light is on, and at the same time the monitor will display the rotation speed, water temperature, oil temperature and pressure of the diesel engine. 3) Start the diesel fire-fighting pump manually a) Place the Manual\automatical switch on the panel to the Manual position, when the diesel pump group enters into the manual control state. b) Preheating: when the weather is cold, the pump is preheated prior to startup, the preheating switch is connected, the preheating indicator light is on, the cooling water of the diesel engine begins heating, and there is a temperature switch of the water heater,
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and the water temperature can be controlled to a certain range. The diesel engine stops heating if the preheating switch is disconnected. c) EDC power supply: press EDC Power Supply button before starting the pumping group, when EDC power supply indicator light is on and an electric spraying controller is powered on. (Note: the follow-up operations will not be conducted only until EDC power supply indicator light is on) d) Startup: press No.1 Battery Startup button of the diesel engine, and the startup contact of No.1 Battery is pulled in, when the No.1 Battery provides power supply; if the No.1Battery lacks of electricity, press the No.2 Battery Startup button, when the No. 2 Battery starts and the contact is connected, the No.2 Battery provides power supply, a motor starts to drive the diesel engine to rotate, and then the operation light is on after the diesel engine starts successfully. The startup button can be released at this time, a second startup operation is conducted after the interval of 5 to 10 seconds, and the appropriate inspection should be carried out if three consecutive startups fail. e) Speedup: press the Speedup button after the diesel engine starts, and the diesel engine will operate at high speed, and the rotation speed of the diesel engine through the potentiometer of the screen is adjusted to operate in the rated state or the necessary rotation speed. f) Idle speed: press the Idle speed button to allow the diesel engine to operate at idle speed. g) Stop: press the Stop button after it operates at idle speed for three minutes, and theStop light is on, the diesel engine stop and then the button is released. 13.5.3 Automatic control of diesel fire-fighting pump 1) The control panel automatically works if Manual/automatic switch is placed on Automatic position. 2) In the automatic mode, the controller gives out No.1 Battery Startup order of diesel engine when there is automatic startup signal, and meanwhile EDC power supply is automatically connected so that the diesel engine starts, the controller can give out three consecutive No.1 Battery Startup orders if it fails to start, the controller gives out No.2 Battery Startup order to activate the diesel engine if it is not successful in the three times, the controller can give out three consecutive No.2 Battery Startup orders if the activiation fails, and the controller gives out sound and light alarm signal due to failing in activiation if the activiation is unsuccessful. After the activiation is successful, the controller will control the diesel engine to run at idling speed for about five seconds, and then give out idle speed order, so that the diesel engine operates at the rated rotation speed. 3) During operation of the diesel engine, the controller will give out idle speed order if it receives automatic shutdown signal, to make the diesel engine run at idle speed for about three minutes, and then the controller will give out shutdown order so that the diesel engine stops completely.
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13.6 Descriptions of fault and alarm of diesel engine fire-fighting pump 1) In operation, if the cooling water temperature, oil temperature, oil pressure and rotation speed of the diesel engine are beyond the limits, the control panel will give out sound and light alarm signal and the alarm signal light will give out flashing bright, and at the same time a flashing LED on the corresponding digital display corresponding to the overranging parameters is also on, indicating the parameters are beyond the limits. After pressing Silencer button, the sound alarm signal disappears, the light alarm signal is converted to matt indication and always maintains until the parameters have resumed to the normal. When the overranging parameters are up to the stopping values, the controller will give out sound and light alarm signal while giving out stopping signal so that the diesel engine stops emergently due to failure. At this time, the sound alarm signal can be eliminated by pressing Silencer button; as the light alarm signal has memory function, it will remain until the failure is eliminated, and it will disappear after pressing Reset button. 2) In standby, the alarm signal of a storage battery with low voltage is given out if the voltage of the storage battery is low. 3) In operation, the sound and light alarm signal of the liquid level is given out if the liquid level is low. 4) In standby, the alarm signal of charging failure is given out if the charger has no DC rechargeable power output. 13.7 Descriptions of function buttons 1) Reset: When there is fault alarm and the diesel engine stops working, the diesel engine fails and need be ruled out; press first Reset button after the person on duty troubleshoots when re-starting the generating unit, so that the control screen undoes the alarm signal and is in the alarm state. In addition, when the control power supply is just connected or the diesel engine starts, if there are any unusual characters to appear on the digital display, the control panel is not working properly, this is usually caused by excessively low voltage of the control power supply, and the control screen can work properly by pressing the Reset button. Note: it is prohibited to press the Reset button during normal operation of the diesel engine. 2) Self-check: press the Self-check button, when the control screen implements the self-check program. The control screen will simulate the change in the parameters of all working conditions in the self-check process, and a sound and light alarm and stopping signal is given out when reaching the overranging alarm and stopping value, and the sound and light alarm signal can be eliminated by pressing the Silencer button and thus light alarm becomes smooth light. Accordingly, users can check whether the overranging fixed value is correct and the protection functions meet the requirements. 3) Silencer: the control screen can shown a sound and light alarm signal after there are all kinds of faults. The sound alarm disappears after pressing the Silencer button, and all the light alarms turn into smooth light and continues to work normally. 4) Time: when pressing the Time button, the total operation time will be shown on the location of speed display and the original speed display will restore after several seconds.
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13.8 Inspection items in the operation of diesel pump group 1) Check whether the connecting studs of the diesel engine, water pump and public base are loose; 2) Check whether the connecting studs and screws of all connecting parts are loose; 3) Check whether the liquid level of the fuel tank is normal and there is leakage in the system; 4) Check whether the liquid level of the oil pan maintains the normal; 5) Check whether the lubrication pre-heating device works normally; 6) Check whether the pressure of the lubrication pre-supply pump in operation is normal; 7) Check whether the water level height of the expansion water tank is normal; 8) Check whether the cooling water preheating device works normally; 9) Check whether there is leakage phenomenon in the cooling water system; 10) Check whether the storage battery starts normally, its voltage is adequate and the charging device works properly; 13.9 Regular maintenance of diesel pump group 1) Regular maintenance a) Start the machine once every two weeks and operate it for 15 minutes to check whether the machine set and all devices maintain still a good state, and conduct a simulation test of the automated devices to check whether they maintain still a good state. b) Pay attention to heat preservation of diesel engine and water pump in the cold season to prevent the equipment from being frozen badly due to low water temperature.. The room temperature should maintain 5 above. c) Before the storage battery is used for the first time, it is charged after the battery liquid is filled. d) Check the voltage of the diesel engine for starting the battery and the height of storage battery electrolyte. Maintain the storage battery, storage battery terminals and wiring to be clean and contact well. e) Check the siliencer and exhaust pipeline, remove carbon deposition and prevent sparks from generating. f) Check whether the water pump packing seal is worn, and replace it timely if necessary. Check whether the lubricating resin of the water pump is consumed. g) The fuel storage tank should always be full as much as possible but be definitely not less than 50% of the fuel tank capacity. When refueling, it should be ensured that moisture content and impurities are excluded. 2) Switching and maintenance mode a) When it can not automatically be put into operation and the fire-fighting water is required for fire, the startup mode should first be switched to the manual mode. The pump selection switch turns to the pump to be activated and then the startup button is pressed. b) Trial run # 1 and # 2 electrical fire-fighting pump every Monday on day shift. Trial run the diesel fire-fighting pump on the 10th and 25th day monthly.
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14 Appendix 14.1 Twenty-five Key Requirements to Prevent Serious Accident and Failure in Electric Power Operation (Chemical Part) Issued by China Grid 14.1.1 Prevention from large area corrosion 1) Be in accordance with Quality Criterion of Water and Steam for Generating Unit and Steam Power Equipment (GB121451999), Guide for Chemical Supervision of Water and Steam in Thermal Power Plants (DL/T5611995), Opinions of Corrosion of The condenser Copper Alloy Tube of Thermal Power Plant and Correction Measures and Requirements to Prevent Corrosion of the boiler Structure in Power Plant and other relevant Manual strictly and strengthen chemical supervision. 2) Unqualified water is strictly prohibited to enter into the boiler and unqualified steam is strictly prohibited to mix. Acid wash water-cooled wall in a timely manner if deposit can meet pickling requirements to avoid corrosion or hydrogen brittleness. Stop and protect boiler according to requirements of Guide for Lay-up of Thermal Power Equipment in Fossil Fuel Power Plant (SD2231987) to avoid shutdown and corrosion of furnace tubes. 14.1.2 Prevention from tube explosion of pressure vessel Color of gas bottles in use is strictly prohibited to change to avoid misuse. Take measures to not dump gas bottles and place steel cylinders containing liquid chlorine horizontally and temperature of locations to place liquid chlorine or ammonia shall meet requirements. 13.1.3 Prevention from motor damage Water quality of water-internal-cooling generator shall be within regulated scope and it is allowed to add corrosion inhibitor in water during operation of units whose power is equal to or less than 125MW to slow up copper tubes but PH value must be more than 7.0. 14.2 General Principle of Electrical Part and Pump 14.2.1 Inspection items before power on the motor are as follows: 1) Inspect integrity of electrical loop and equipments with terminated work order and put them into protection devices. 2) Fix connecting wires of the motor and cable shell firmly. 3) Fix protective cover of cable head of the motor and blower cover firmly. 4) Check if there is oil in the startup device of wire wound the motor with normal oil level or not. 5) Guarantee no water in the cold air chamber if the motor is cooled by air. 6) The motor and mechanical equipments shall be intact without startup obstacle so that they can meet startup conditions. 7) Guarantee sufficient oil in the bearing oil level and cover then place the oil system into operation if it belongs to reinforced lubrication. It is also required to open cooling water if bearing is cooled by water. 8) Supply cooling water if the motor is cooled by air cooler. 14.2.2 Inspection items during operation of the motor are as follows: 1) Fix connecting wires of shell and protective cover of cable head firmly. 2) Check if there is spark for slip ring or commuter of DC the motor and cover protective cover of commuter and slip ring and handle of slip ring can not exceed dangerous mark.
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3) 4)
5)
Guarantee no obstacle in ventilation hole of the motor and normal operation of air cooler without water leakage. Guarantee no accumulated ash and water on the motor and remove sundries such as ash, powder and water vapor and so on which may enter into the motor and startup devices in a timely manner. Monitor and compare temperature of the motor shell and bearing under the same ambient temperature and find out reasons if there is abnormal temperature rise and take measures to strengthen ventilation and monitoring and reduce load if necessary. The maximum monitoring temperature of the motor coil and iron core can not exceed the temperature under any circumstance according to the Manual of manufacturer and it can not exceed 105 and temperature rise can not exceed 65 if there are no Manual of manufacturer. The maximum temperature of sliding bearing can not exceed 80 (and temperature rise can not exceed 40) and that of rolling bearing can not exceed 100(and temperature rise can not exceed 60). In general, the motor shall operate within variation scope of 5 to 10 of rated voltage with constant rated output (which is between 5.7kV and 6.6kV and voltage is between 360V and 420V). Unbalanced value of voltage in phases during operation under rated output can not exceed 5% and pay attention to heating and vibration and so on of the motor during unbalanced operation period of voltage. Current of the motor can not exceed 5 of rated value during normal operation and guards shall strive to reduce it to rated current within 15 minutes if it is exceeded by 5 to 10. Measured amplitude of every bearing during operation of the motor can not exceed following values: Rated (r/min) rotary speed 3000 0.05 1500 0.085 1000 0.10 750 and below 0.12
6)
7)
8)
Amplitude dual-amplitude (mm)
14.2.3 Inspection items during operation of cables are as follows: 1) Guarantee intact cover plate of cable trench and no water, oil or other sundries in the cable trench. 2) Check if pavement with laid cables is normal or not. Check if stakes are intact without excavation trace or not. 3) It is not allowed to pile rubbles, slag, building materials, lumpish matters, acid or alkaline excrement or stack swallow hole and so on along cable lines. 4) Check if cable head is not heated without casing rupture and discharging trace or not. 5) Guarantee intact ventilation, drainage and lighting facilities and so on in cable trench or cable channel and check if fire prevention facilities are intact or not. 6) Temperature of cable sheath can not exceed permissible normal value and load current can not exceed permissible value. 7) Pay attention to water level of cable trench in summer or thunder storm season.
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13.2.4 General operation requirements of the motor 1) Guards of mechanical equipments driven by every motor shall master power supply mode of the motor and operation mode of relay protection and automatic device. 2) Every motor shall have rated nameplate of original manufacturer on the shell and repair personnel shall supplement nameplates in a timely manner if they are lost. 3) Paint on shell of the motor, ventilation pipes and metallic structure and name and enumerate equipments according to the unit. 4) The motor and machines shall have arrow marks to indicate rotation direction. 5) Outgoing lines of the motor and cable heads and exposed rotary parts shall have firm barrier or protective guard. 6) Shell of the motor and startup device shall be grounded according to the Manual of Technical Specifications of Grounding and it is strictly prohibited to work on grounding body of the motor in operation. 7) Standby the motor shall be started at any time and it is required to prepare for periodic chart of shifting operation or trial operation of the motor. Every guard shall operate the motor according to periodic chart of shifting operation or trial operation strictly. 8) The motor with normal switchover and startup conditions shall be started according to switchover cycle and measure insulation resistance if volume of the motor without startup conditions is more than 50kW and it is stopped for 10 consecutive days or it is necessary to measure insulation resistance before startup. (There is no need to measure insulation resistance with normal heater input of the motor with moisture-proof heater but repair personnel must measure insulation resistance after repairing the motor or cables.) 9) Put standby the motor into trial operation for every 10 days to prevent it from being affected with damp if it is installed in wet locations. 14.2.5 Measurement Manual of insulation resistance of the motor are as follows: 1) Insulation of high-voltage the motor shall be measured by magneto-ohmmeter of 2500V and insulation resistance can not be less than 1 mega ohm for every 1000V and that of low-voltage the motor whose voltage is equal to or less than 380V shall be measured by magneto-ohmmeter of 500V and insulation resistance can not be less than 0.5 mega ohm for every 1000V. (Insulation resistance of DC the motor can not be less than 0.5 mega ohm.) 2) Insulation resistance of the motor must be measured under cold standby status of loop. 3) Insulation resistance must be measured after the motor is affected with damp, smoked by steam or poured by water. 13.2.6 Operation principle of power failure and supply of the motor: 1) Supply power to the motor by primary loop and operate according to sequence of power knife switch and switch and operate according to reverse sequence during power failure. 2) Check if control fuse is placed in its accurate position or not during power supply. That is, check if green lamp is on or not then take control fuse down during power failure. 3) Selection switch shall be in remote control position according to operation mode of switch panel of the motor. 4) It is strictly prohibited to use gauge and indicator light as the only judgment basis of opened or
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closed switch. 5) Close knife switch and inspect whether blade is in closing or opening position if applicable. 6) Remote operators can not start the motor until contacting local guards if its knife switch is closed remotely. Local guard shall keep the motor until its rotary speed can increase to rated rotary speed. Monitor startup process according to ampere meter if applicable and inspect the motor body according to detailed conditions after startup. 14.2.7 Permissible startup times of the motor with squirrel cage type rotor shall be in accordance with following Manual strictly. 1) The motor whose volume is equal to or more than 100kW is allowed to start up twice continuously under cold condition and once under hot condition. 2) The motor whose volume is less than 100kW is allowed to start up for three times continuously under cold condition and twice under hot condition. 3) Startup times of the motor with accident treatment whose startup time is not more than 3 seconds can be increased by one. 13.2.8 Definition of the motor status: 1) Cold condition means that stalling time of the motor is equal to or more than 30 minutes. 2) Thermal condition means that stalling time or attenuation time of startup current of the motor is less than 30 minutes. 3) Attentions to startup of motors as follows: 4) Start up the motor one by one and it is usually not allowed to start up two or more the motors with large volume on one bus at the same time. It is required to contact integration control personnel to adjust bus voltage before startup of the motor with large volume. 5) It is strictly prohibited to close the knife switch again under normal conditions if switch can not be closed or before finding out tripping reasons during startup of the motor. It is required to open power switch of the motor and find out reasons if startup time exceeds general startup time of the motor and current has not been attenuated to normal value. 6) Open power switch of the motor and find out reasons instantly if the motor has noise without rotation or it can not reach normal rotary speed after closing knife switch of the motor. 14.2.9 Common faults, judgment and treatment of electrical equipments 14.2.9.1 Stop the motor instantly if there is any circumstance: 1) Instant personal injury caused by accident of the motor if necessary; 2) Strongly vibrated or damaged motor or mechanical parts; 3) Fired or scorched motor; 4) Rapid temperature rise of the motor or bearing which has exceeded limit and rapid declination of rotary speed; 5) The motor. flooded 14.2.9.2 The motor does not start up 1) Possible reasons a) Inaccurate position of conversion switch; b) Inaccurate interlocked position under program control status; c) No reposition after protection motion of the motor;
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d) Power failure or broken fuse protector; e) Damaged contact point of AC contactor which can not be suction. 2) Treatment method a) Turn interlocked switch to the correct position. b) Ask local personnel to check if the motor is excellent or not. c) Supply power after resetting for thermo-couple motion. d) Ask repair personnel to inspect and treat for other electrical protection motions. e) Replace fuse or supply power again. f) Find out reasons and remove mechanical faults. 14.2.9.3 Trip during operation of the motor 1) Possible reasons a) Excessive current and over load; b) Failure of startup switch; c) Unclosed outlet valve or excessive opening; d) Broken phase of three phases of grounding wires; e) Abrasive or jammed rotary parts; f) Friction between impeller and pump shell; g) Bent shaft and damaged bearing; h) Vane jammed by sundries; i) Power failure. 2) Treatment method a) Startup of standby motor; b) Load adjustment; c) Repair and treatment. 14.2.9.4 Larger noise during operation of the motor 1) Possible reasons a) Single-phase operation; b) Unbalanced three-phase current of the motor; c) Uneven air gap between stator and rotor of the motor; d) Collision or sundries between blower and cover; e) The motor is installed roughly or loose foot screw; f) Bearing problem. 2) Treatment method: Stop operation instantly and contact repair personnel for treatment. 14.2.9.5 Excessive temperature rise of the motor or burnt winding 1) Possible reasons a) Overload for a long time; b) Trouble of heat engine; c) Broken one-phase fuse; d) Poor ventilation and heat elimination; e) Local short-circuit or grounding of stator winding; f) Other reasons such as inflexible driving mechanism;
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2) Treatment method: Stop operation instantly and contact repair personnel for treatment. 14.2.9.6 Heated bearing of the motor 1) Possible reasons a) Incorrect installation and excessive vibration; b) Inconsistent gap between crankshaft, bearing and end cover or improper installation and excessive axial float. c) Poor lubrication or incorrect oil quality. 2) Treatment method: Stop operation instantly and contact repair personnel for treatment. 14.2.9.7 Air switch of main power which can not be closed 1) Possible reasons a) Emergency stop button not reset; b) Damage trip coil or not voltage; c) Damaged tripping mechanism not reset. 2) Treatment method: Contact repair personnel for treatment. 14.2.9.8 Large noise after closing knife switch of main power switch 1) Possible reasons a) Insufficient voltage of trip coil; b) Unadjusted tripper and excessive gap between suctioned armature iron; c) Obstacle to armature iron after tightening switch cover. 2) Treatment method: Contact repair personnel for treatment. 13.2.9.9 Noise after suctioning contactor 1) Possible reasons a) Insufficient suction of coil; b) Poor suction problems such as blocked armature iron or inaccurate alignment; c) Ruptured short-circuit ring; d) Excessive axial offset. 2) Treatment method: Contact repair personnel for treatment. 14.2.9.10 Electric leakage of shell 1) Possible reasons a) Low insulation resistance of the motor; b) Rupture or aging of outgoing lines or connection between connecting plug and shell; c) Damaged bottom plate of terminal or local connection in the winding; d) Poor grounding of shell. 2) Treatment method: Contact repair personnel for treatment. 14.2.10 Operation of the water pump 14.2.10.1 Inspection before startup of the water pump 1) Finish repair and work order with written records for repair equipments. 2) Supply power to electrical valve of pump inlet and guarantee intact valve and normal operation without leakage. 3) Guarantee intact water pump without foreign matters which may obstacle operation. 4) Check if manual segregation valve is in correct position or not according to conditions of the
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water pump. 5) Check if bearings can be connected firmly with intact protective cover and firm fixation without loss foot screw or not. 6) Guarantee intact gauges in pump outlet and manual valve of the pressure gauge is in closed position and indicators of flow and pressure converters are zero. 7) Guarantee firm supply of water supply pipes of the water pump and intact insulation layer. 8) Bearing oil level of the water pump shall be between 1/2 and 2/3 and oil shall be transparent without sundries. 9) Guarantee sufficient lighting on the site and excellent ventilation and complete fire prevention measures. 14.2.10.2 Operation during operation of the water pump 1) Guarantee normal operation sound and excellent integrity during operation of the water pump without leakage of the water pump. 2) Bearing temperature of the water pump can not exceed ambient temperature which is 35 and the maximum temperature can not exceed 85 and vibration shall be less than 0.08mm. Flange temperature shall be the same to that of pump body and drainage pipes shall be smooth after dripping water for 10 to 20 drips for every minute. 3) Guarantee firm tightening piece and intact protective cover and foundation bolt can not be loose. 4) Operation of remote and local gauges shall be normal and pressure shall be within the scope of regulated pressure and current is less than rated value. Flow shall be within the regulated scope and flow, pressure and current shall correspond mutually. 5) Guarantee correct position and indication of every valve ad excellent appearance of valve without water leakage or misplacement. 6) Guarantee normal operation of pressure and flow converters and correct fixation of connecting wires without water leakage. 7) Guarantee no inversion for standby pump. 8) Erect support of water supply pipes without distortion or deformation of expansion joints and guarantee excellent insulation layer without water leakage for system pipes. 14.2.10.3 Common faults, judgment and treatment of the water pump 14.2.10.3.1 Abnormal sound of the water pump 1) Possible reasons a) Damaged impeller, bearing or loss rotary parts. b) Foreign matters suctioned into the water pump. c) Operation under overload. 2) Treatment method a) Integral load; b) Stop the water pump and contract repair personnel for treatment. 14.2.10.3.2 Large vibration of the water pump 1) Possible reasons a) Air in the water pump or insufficient opening of outlet valve;
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b) Loose foot screw; c) Unbalanced motor and axial line and severely abrasive bearing and rotary parts. d) Loose or damaged parts of rotary parts; e) Operation under overload. 2) Treatment method a) Remove air in the water pump and open the valve of large opening; b) Operate under reduced load; c) Contact repair personnel for treatment. 14.2.10.3.3 No water outlet or reduce water supply quantity of the water pump 1) Possible reasons a) Non-hermetic water absorption pipes with air; b) Unexhausted air in the water pump; c) Jammed water passageways; d) Low rotary speed and reverse direction of the motor; e) Damaged impeller key; f) Water source problems (such as low water level and so on); g) High pressure of main pipe and little water consumption; h) Unopened inlet valve or shed core. 2) Treatment method a) Gas-tight pipes; b) Startup again after exhausting air; c) Inspection and dredging of passageways; d) Inspection of power lines; e) Repair and treatment; f) Sufficient water source; g) Some pumps are out of operation; h) Open the inlet valve or contact repair personnel for repair. 14.2.10.3.4 Overheated bearing or with noise 1) Possible reasons a) Poor quality or low oil level; b) Improper gap between bearings; c) Abrasive bearing; d) High oil level; e) Operation under overload. 2) Treatment method a) Turn down outlet valve and reduce the load; b) Stop the water pump and replace or add oil; c) Contact repair personnel for repair. 14.3 General Principle of Chemical Technology Supervision 14.3.1 Guidelines of chemical technology supervision Chemical supervision is one of important links to guarantee safe, economic and stable
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operation of power supply equipments and its main task is to take detection measures which can adapt power generation development and scientific management method in a timely manner to strength quality supervision of water, steam, gasoline, hydrogen and fuel and so on to avoid and slow up corrosion, scale, salt accumulation and inferior oil quality during operation, shutdown and standby period of thermodynamic equipments. It is required to find out latent troubles of oil-filled electrical equipments in a timely manner and strengthen fuel supervision to coordinate with economic and safe combustion of the boiler to increase efficiency of the unit and find out and solve hidden troubles caused by chemical problems in a timely manner to avoid occurrence of accidents. 1) Insist in guideline of precaution primary and quality first and realistic and scientific attitude for chemical supervision and research continuously and take new technology to enhance supervision level. 2) Be in accordance with relevant Manual of management during system design, installation, debugging, operation and repair phases for chemical supervision to guarantee health unit. 14.3.2 Chemical supervision during startup phase of unit 1) Operation department shall wash the condenser, water supply system and boiler in sections by desalinated water of regulated PH value after adding ammonia and chemical deoxidizer before startup of the unit. Next system can not be washed until every washed section is qualified and ignition is not allowed until water quality of the boiler is qualified. Carry out hydrostatic test after repairing boiler and it is required to use chemical desalinated water of a certain quantity of ammonia and deoxidizer. 2) Wash samplers during startup of the unit and adjust flow according to the Manual so that sample flow can be between 500 mL/min and 700 mL/min and temperature shall be less than 30. 3) Add deoxidizer for heating and adjust steam exhausting opening during startup of the unit to guarantee qualified oxygen dissolved in the water supplied to boiler. 4) Strengthen sewage treatment and charging treatment during startup of the unit and unqualified condensing water and drained water can not be recycled and unqualified steam can not be washed and rotated. Strengthen sewage treatment treatment after startup of the boiler if the boiler water is turbid and take measures such as limiting load, reducing pressure and replacing water and so on if necessary until boiler water is clear. 5) Wash silicon according to requirements strictly when boosting the pressure of the boiler and pressure of silicon dioxide in boiler water can not be boosted until meeting requirements of next phase. Reduce pressure for operation if silicon dioxide in boiler water exceeds limit. 6) Startup time shall be calculated according to startup standard from watering of the unit to 8 hours after synchronization and result after 8 hours shall be recorded into the operation data for statistics of chemical specialty. 14.3.3 Normal operation management of the unit 1) Please refer to the manual for quality supervision items of water vapor and control standard and times of operation unit and water treatment system and add analysis times and items according to detailed conditions if there is abnormal operation or during startup of the unit.
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Chemical operator shall fill in the daily chemical operation report every day and report it to supervisor and chemical engineer after manual analysis and confirmation of items which exceed the standard. Contact chemical examination group for validation if chemical operation can not define accuracy of chemical examination result and chemical examination group shall examine water supply and water vapor systems once every week and report it to chemical operator and engineer if standard is exceeded so that chemical operator can treat and report it to supervisor for treatment if unit operation needs coordination. Definite the technical disclosure of requirements which can not be treated by the construction team with next construction team and make records at the same time. It is required to report it to chemical engineer, assistant branch manager and manager when it reaching the primary treatment value and report it to chemical engineer, assistant branch manager, manager and vice general operation engineer when it reaching the secondary treatment value and report it to chemical engineer, assistant branch manager, manager, vice general operation engineer and vice general production manager when it reaching the tertiary treatment value and people of various levels shall treat according to treatment principle of abnormal water vapor in three levels. 3) Wash sampler periodically during operation and sample periodically to remove copper and iron according to the Manual. 4) Strengthen quality supervision of drained water and returned water and it can not enter into the system directly without treatment. It is required to control water vapor loss in the plant and it shall meet following requirements. 5) 300MW Unit Not more than 1.5% of rated evaporation rate 6) 135MW Unit Not more than 2.0% of rated evaporation rate 7) Take effective measures scientifically to enhance boiler water quality and reduce blow-down rate but it can not be less than 0.3% by considering various indicators of energy-saving supervision and chemical technological supervision comprehensively. 8) Water and vapor quality standard issued by electricity authority refers to controlled limit value (namely, normal value) to maintain reliable and stable operation for a long time. 50% to 70% of limit value shall be regarded as the control value of actual operation in accordance with Manual of electricity authority to guarantee safe and economic operation of the unit on the basis of enhanced integral level of the equipments. 9) Switch over operation equipments periodically and notify defects of equipments to maintenance department for treatment in a timely manner to ensure that equipments can operate normally at any time. 10) Fossil-fired power plant must have necessary on-line chemical instruments to enhance reliability, timeliness and continuity of quality supervision of water vapor. Supplied water and boiler water shall have PH, conductivity and phosphate radical tables and supplied water (namely, water outlet of deoxidizer) and condensing water shall have dissolved oxygen table and supplied water and condensing water shall have conductivity table (of hydrogen sensing). Main stream shall have silicon and sodium tables and supplied water shall have conductivity table (of hydrogen sensing). Prepare for other instruments one after the other according to
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detailed conditions and instruments used in the laboratory shall meet requirements in Compilation of Testing Methods, Standards and Manual of Water Vapor of Fossil-fired Power Plant and they shall be examined periodically and used within the period of validity. 11) Analyze technology and economy of chemical specialty and save medicines to reduce material consumption. 14.3.4 Abnormal quality management of water vapor Report deteriorated water vapor quality to leaders in a timely manner and find out reasons for treatment and treat according to following tertiary treatment principle if water vapor continues to deteriorate. That is, the primary treatment begins from deteriorated water vapor quality (which exceeds the standard) and abnormal conditions shall be restored within 72 hours. Secondary treatment shall be restored within 24 hours and tertiary treatment shall be restored within 4 hours. Stop the boiler for treatment instantly if deteriorated water vapor quality can not be restored normally on time. It is required to take measures of a higher level for abnormal treatment method if deteriorated water vapor quality can not be restored normally within regulated time. Normal values of drum boiler can be restored by pressure drop and it is required to stop boiler emergently when PH of the boiler water is less than 7.0 and sodium content in the condensing water is more than 400gL. Tertiary treatment value is as follows: Water sample Item Sodium: Normal value g/L 10 Treatment value Primary 1020 0.30.4 <8.8 or >9.3 <9.0 or >9.6 0.30.4 7 9.0 0.40.65 20 8.5 0.65 8.0 Secondary 2035 0.40.5 Tertiary 35 0.5
Condensing water Electric 0.3 conductivity: s/cm pH(25) Supplied water With 8.89.3 copper Without 9.09.6 copper
8.0
Electric 0.3 conductivity:s/cm Dissolved oxygen: 7 g/L
Boiler water
PH
(25)
910
Stop boiler instantly when PH of supplied water is less than 7.0 or sodium content in condensing water is more than 400ug/l. Note: Measure Cl-, Na+, conductivity and alkalinity of the boiler water when water quality is abnormal to find out reasons and take measures for treatment. 12) Chemical specialty shall analyze accuracy of data and representation of sample firstly when abnormal water vapor quality can reach the primary treatment value and report it to supervisor instantly after comprehensive analysis and confirmation. Supervisor shall organize
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investigation and notify corresponding departments for treatment. (Ask integration control personnel for system adjustment and ask maintenance department to solve equipment problems.) In the meanwhile, it is required to add testing times and strengthen supervision until it can be qualified. Supervisor shall report it to division heads and chemical supervision engineer if abnormal water vapor quality can not be qualified after treatment of the staff. 13) Report detailed conditions to supervisor, chemical supervision engineer and relevant division heads in a timely manner after confirmation of chemical specialty that water quality of supplied water, boiler water or condensing water can reach secondary treatment value with impossibility of restoration. The supervisor shall take corresponding measures for treatment according to the detailed conditions of the unit and report it to leaders of the company if abnormal water quality can not be qualified after treatment of the staff. 14) Report it to supervisor, chemical supervision engineer and relevant department managers instantly when water quality of supplied water, boiler water or condensing water can reach the tertiary treatment value, the supervisor and chemical supervision engineer shall report it to leaders of the company at the same time and above people shall rush to the site instantly after receiving the report and leaders of the company shall command uniformly and take emergent measures. 15) Report it to the supervisor, chemical supervision engineer and relevant department managers instantly if the condenser leaks or quality of condensing water or supplied water can exceed the standard. Supervisor and chemical supervision engineer shall report it to leaders of the company at the same time and above people shall rush to the site instantly after receiving the report. Leaders of the company shall command uniformly and caulk in a timely manner and strengthen sewage treatment of the boiler and monitor variation of PH value of the boiler water. It is necessary to take measures such as reducing pressure and limiting load even emergent shutdown measures to protect equipments and avoid accidents if the condenser continues to leak and water quality deteriorates rapidly. 16) Stop equipments emergently for treatment without request if there are accidents which may endanger safety of people and equipments and report it to relevant leaders instantly after the event. 14.3.5 Supervision during repair phase of the unit 1) Responsible person of chemical supervision shall propose inspection items and requirements with regard to water vapor quality before repairing thermodynamic equipments and inspect, record, sample and analyze them with relevant personnel after inspection and disassembly of equipments for comprehensive judgment and propose correction opinions by aiming to existing problems. Sediments in the equipments can not be removed and it is not allowed to repair in such parts before inspection of chemical supervision. 2) Inspect scale and corrosion of deoxidizer, economizer, water-cooled wall, super-heater, impeller of turbine, baffle and copper tube of condensing tube and measure scale quantity. 3) Antisepsis management during shutdown and standby phase of the unit 4) Take corresponding antisepsis measures during overhaul, minor overhaul, temporary inspection or standby periods of the unit and record detailed operation methods in the
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integration control and chemical manuals. Record antisepsis date, method and supervision control indicators and operation department shall be responsible for it is discharging water by hot boiler with protection of ammonia injection and hydrazine and nitrogen-filling protection operation and equipment maintenance department shall be responsible for system installation. Take antisepsis measures for equipments to prevent steam, water and oil in adjacent boiler or public system from mixing and entering into the standby unit.
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Bop Operation Manual Qn1 Sec G 04 TP 005 (195) Dang

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BOP Operation Manual

Model Screw type oil unload pump

Heavy oil, oil temperature 50 70%

95 m3/h limit value is 6 m, guaranteed value is 5.5 m

) Speed 1450 r/min

Shaft power Voltage

400 V AC Arrange ment mode Lift Outdoor submersibl e pump

Model Submers ible pump for wastewa ter with oil

Motor model Efficienc y Rated power

YB90S-4(expl osion-proof motor ) 40 0.9 KW

NPSHr Shaft power

1450 r/min 400 V AC

Front screen of heavy oil unload pump

Heavy oil Screen paramet ers

Oil temperature 25~50

Inlet/outl et pipe diameter

Inlet/outlet operating pressure difference

Fuel oil heater

Horizontal type U-tube

Inlet oil temperatur e Operating oil pressure

Fuel oil flow

< 5 MLC (On shell side) Flow rate Lift

26.5 m/h 100m

Mechanical acceleration clarification tank Clear pump water

Lift pump of filtered water Electric fire-fighting pump

Living water pump

Set 2 Set 2 Set 2 Set 2 1 Set 1 Set 2

Cleaning station chlorination equipment Filter chamber backwashing pump

One is in operation and the other is for standby

sludge accumulates at the recycling part

4.4.6 Alum floats on the clarification tank

4.4.7 Unqualified effluent turbidity of the filter chamber

Filling Grain diameter mm 0.8~1.6

001X7 Multi-plane ball

strong acid anion exchanger

2.5m Cation =500mm Anion =1000mm

Hydrochloric acid storage tank Alkali tank storage

Acid mist absorber with 2 filling Hydrochloric 1

DN500 Cation 2.6t/h(0.4mpa)

acid metering boxcation 15 Hydrochloric acid metering boxMixed 1

Mixed bed Anion bed Mixed Mixed

Outlet water of active carbon filter

sodion Outlet water of cation exchanger

silicon dioxide Electroconductivity silicon dioxide Electroconductivity

g/L s/cm g/L s/cm

100 0.2 20 0.2

Backwas hing influent valve

Backwas hing drainage valve

Exha ust valve

backwash ing pump

Pre-commissi oning Operation Drainage

Scrubbing Back washing Positive washing

Note means that the valve starts or the pump operates

Postitive discharge valve

Middle discharge valve

Mixer outlet valve

Acid inlet Metering valve of tank regenerated outlet liquid valve

Raw water pump

Self-use desalination water pump

Acid metering pump

Note means that the valve starts or the pump operates

Backwashing influent valve