Transcript Slide 1
Devdeep Bose DGM ( Commng & Testing) • INTRODUCTION TO SUPER CRITICAL UNI - POINTS OF DISCUSSION SUB CRITICAL & SUPER CRITICAL BOILER SIPAT BOILER DESIGN SIPAT TURBINE DESIGN DESIGN PARAMETERS COMMISSIONING PRE COMMISSIONING PROBLEMS POST COMMISSIONING PROBLEM COMPARISION OF 660 MW Vs 500 MW BOILER Description unit 660 T/HR 2225 1625 KG/CM2 256 179 0C 540 540 T/HR 1742 1397.4 0C 303.7 338.5 RH STEAM TEMP OUTLET 0C 568 540 RH STEAM PRESS INLET KG/CM2 51.17 46.1 FEED WATER TEMP 0C 291.4 255.2 S/H STEAM FLOW SH STEAM PR SH STEAM TEMP RH STEAM FLOW RH STEAM TEMP INLET 500 Tonnage Comparison Description 660 MW 500 MW Structural Steel Erection 7383 9200 Boiler Proper & Accessories (Pre. Parts) 7080 5300 Refractory, Insulation & Cladding 1410 2000 Power Cycle Piping 3032 2200 54 76 Coal Firing System 3573 2000 Draft System 5275 5200 62 200 Miscellaneous System 130 280 Electrical & Instrumentation 282 380 28281 26836 Soot Blowing System Fuel oil system TOTAL Material Comparison Description 660 MW 500 MW Structural Steel Alloy Steel Carbon Steel Water wall T22 Carbon Steel SH Coil T23, T91 T11, T22 RH Coil T91,Super 304 H T22, T91,T11 LTSH T12 T11 Economizer SA106-C Carbon Steel Welding Joints (Pressure Parts) 42,000 Nos 24,000 Nos Structural Comparison Slno 660 MW 1 STRUCTURALS 500 MW a b. Remarks Entire structural is bolting typeentire structure is bolted. Holes are drilled on the columns and gusset plates, and supplied with matching plates. Structural is assembled at site with welding Advantages (660MW) of Bolting structure: oFast in erection. oClean environment oNo Welding network required oSafety at site oPainting finish is good o( No Weld surface) No Welding work involved in assembly/ Erection , except Walkway rail post welding Assembly is carried out with Welding Can be dismantled if required ( For Maintenance purpose) Material supply is tier wise including staircases, railing, gratings etc. Material is supplied as per the erection sequence. Erection completion tier wise, including gratings, platforms , staircases etc. c COST COMPARISON 1 Cost of SG Package 1970.73 Cr 1020.54 Cr with ESP 2 Cost of ESP 183.54Cr 3 Total cost of Boiler + ESP 2154.27 Cr 1020.54 Cr 4 Cost of Boiler per MW with ESP 1.09 Cr 1.02 Cr 5 Cost of TG for entire stage 1204.72 Cr 634.31 Cr 6 TG cost per MW 0.6Cr 0.63 Cr BOILER SPECIFICATION Description unit S/H STEAM FLOW T/HR 2225 KG/CM2 256 0C 540 T/HR 1742 0C 303.7 RH STEAM TEMP OUTLET 0C 568 RH STEAM PRESS INLET KG/CM2 51.17 FEED WATER TEMP 0C 291.4 SH STEAM PR SH STEAM TEMP RH STEAM FLOW RH STEAM TEMP INLET = Boiler Efficiency Quoted Turbine Heat Rate 100% TMCR 86.27% 100% Load 1904 Kcal / KWH 80% TMCR 86.60% 80% Load 1924 Kcal / KWH 60% TMCR 86.68% 60% Load 1973 Kcal / KWH 50% TMCR 86.91% 50% Load 2065 Kcal / KWH Net Plant Heat Rate = NTRH = 2207 KCal / KWHR ( at 100% TMCR) 80% TMCR 60% TMCR 50% TMCR = 2222 Kcal / KWHR = 2276 Kcal / KWHR = 2376 Kcal / KWHR Plant Efficiency at 100% TMCR = 38.96% 80% TMCR = 38.7 % 60% TMCR = 37.78% 50% TMCR = 36.19% Supplier : M/s DOOSAN Erection By : M/s L&T UNDERSTANDING SUPER CRITICAL TECHNOLOGY When Water is heated at constant pressure above the critical pressure, its temperature will never be constant No distinction between the Liquid and Gas, the mass density of the two phases remain same No Stage where the water exist as two phases and require separation : No Drum The actual location of the transition from liquid to steam in a once through super critical boiler is free to move with different condition : Sliding Pressure Operation For changing boiler loads and pressure, the process is able to optimize the amount of liquid and gas regions for effective heat transfer. SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration 1 3 568’C 540’C TEMP 600 500 Steam flow :2225 T/Hr Steam temp : 540 ‘c Steam Pres : 256 kg/cm2 RH pre : 51.6 Kg/cm2 RH Temp : 568’c Feed water Temp : 291’c 2 400 300 200 100 5 4 0 ENTROPY 540°C, 255 Ksc 568°C, 47 Ksc 492°C, 260 Ksc 457°C, 49 Ksc FUR ROOF I/L HDR ECO HGR O/L HDR HRH LINE MS LINE 411°C, 277Ksc 411°C, 275 Ksc SEPARATOR G LPT C O N D E N S E R LPT FINAL SH FINAL RH DIV PANELS SH LTRH PLATEN SH VERTICAL WW ECO JUNCTION HDR 305°C, 49 Ksc S T O R A G E T A N K IPT HPT ECONOMISER ECO I/L FEED WATER BWRP 290°C, 302 KSC FUR LOWER HDR FRS Steam Partial Steam Generation Steam Complete or Once-through Generation Water Heat Input Heat Input Water Water Boiling process in Tubular Geometries SIPAT SUPER CRITICAL BOILER BOILER DESIGN PARAMETER DRUM LESS BOILER : START-UP SYSTEM TYPE OF TUBE Vertical Spiral SPIRAL WATER WALL TUBING Advantage Disadvantage over Vertical water wall Vertical Tube Furnace To provide sufficient flow per tube, constant pressure furnaces employ vertically oriented tubes. Tubes are appropriately sized and arranged in multiple passes in the lower furnace where the burners are located and the heat input is high. By passing the flow twice through the lower furnace periphery (two passes), the mass flow per tube can be kept high enough to ensure sufficient cooling. In addition, the fluid is mixed between passes to reduce the upset fluid temperature. Spiral Tube Furnace The spiral design, on the other hand, utilizes fewer tubes to obtain the desired flow per tube by wrapping them around the furnace to create the enclosure. This also has the benefit of passing all tubes through all heat zones to maintain a nearly even fluid temperature at the outlet of the lower portion of the furnace. Because the tubes are “wrapped” around the furnace to form the enclosure, fabrication and erection are considerably more complicated and costly. SPIRAL WATER WALL ADVANTAGE Benefits from averaging of heat absorption variation : Less tube leakages Simplified inlet header arrangement Use of smooth bore tubing No individual tube orifice Reduced Number of evaporator wall tubes & Ensures minimum water flow Minimizes Peak Tube Metal Temperature Minimizes Tube to Tube Metal Temperature difference DISADVANTAGE Complex wind-box opening Complex water wall support system tube leakage identification : a tough task More the water wall pressure drop : increases Boiler Feed Pump Power Adherence of Ash on the shelf of tube fin BOILER OPERATING PARAMETER FD FAN 2 No’S ( AXIAL ) 11 kv / 1950 KW 228 mmwc 1732 T / Hr PA FAN 2 No’s ( AXIAL) 11 KV / 3920 KW 884 mmwc 947 T / Hr ID FAN 2 No’s ( AXIAL) 11 KV / 5820 KW TOTAL AIR 2535 T / Hr SH OUT LET PRESSURE / TEMPERATURE / FLOW 256 Ksc / 540 C 2225 T / Hr RH OUTLET PRESSURE/ TEMPERATURE / FLOW 46 Ksc / 568 C 1742 T / Hr SEPARATOR OUT LET PRESSURE/ TEMPERATURE 277 Ksc / 412 C ECONOMISER INLET 304 Ksc / 270 C MILL OPERATION 7 / 10 COAL REQUIREMENT 471 T / Hr SH / RH SPRAY 89 / 0.0 T / Hr BOILER EFFICIENCY 87 % 3020 T / Hr Coal Analysis Unit Design Coal Worst Coal Best Coal Young Hung #1,2(800MW) Tangjin #5,6(500MW) kcal/kg 3,300 3,000 3,750 6,020 6,080 Total Moisture % 12.0 15.0 11.0 10.0 10.0 Proximate Volatile Matter Analysis Fixed Carbon % 21.0 20.0 24.0 23.20 26.53 % 24.0 20.0 29.0 52.89 49.26 % 43.0 45.0 36.0 13.92 14.21 Fuel Ratio (FC/VM) - 1.14 1.00 1.21 2.28 1.86 Combustibility Index - 2,067 2,353 2,476 2,781 3,492 Carbon % 39.53 31.35 40.24 63.03 62.15 Hydrogen % 2.43 2.30 2.68 3.60 3.87 Nitrogen % 0.69 0.60 0.83 1.53 1.29 Oxygen % 6.64 5.35 8.65 7.20 7.80 Sulfur % 0.45 0.40 0.60 0.72 0.68 Ash % 43.00 45.00 36.00 13.92 14.21 Moisture % 12.00 15.00 11.00 10.00 10.00 HGI 50 47 52 45 48 - Hi–Vol. ‘C’ Bituminous Hi–Vol. ‘C’ Bituminous Hi–Vol. ‘C’ Bituminous Midium Vol. Bituminous Hi–Vol. ‘C’ Bituminous Parameter High Heating Value Ash Ultimate Analysis Grindability ASTM Coal Classification 1. High erosion potential for pulverizer and backpass tube is expected due to high ash content. 2. Combustibility Index is relatively low but combustion characteristic is good owing to high volatile content. Ash Analysis Unit Design Coal Worst Coal Best Coal SiO2 % 61.85 62.40 61.20 57.40 57.40 Al2O3 % 27.36 27.31 27.32 29.20 29.20 Fe2O3 % 5.18 4.96 5.40 4.40 4.40 CaO % 1.47 1.42 1.52 2.70 2.70 MgO % 1.00 1.03 0.97 0.90 0.90 Na2O % 0.08 0.08 0.08 0.30 0.30 K2O % 0.63 0.32 1.22 0.70 0.70 TiO2 % 1.84 1.88 1.80 1.30 1.30 P2O5 % 0.54 0.55 0.44 - - SO3 % 0.05 0.05 0.05 - - Others % - - - 3.10 3.10 Initial Deformation o C 1150 1100 1250 1200 1200 Softening o C - - - Hemispheric o C 1400 1280 1400 Flow o C 1400 1280 1400 Ash Content kg/Gcal 130.3 150.0 96.0 23.12 23.37 Basic / Acid B/A 0.09 0.09 0.10 1.63 1.63 Parameter Ash Analysis Ash Fusion Temp. (oC) (Reducing Atmos.) Young Hung Tangjin #1,2(800MW) #5,6(500MW) 1. Lower slagging potential is expected due to low ash fusion temp. and low basic / acid ratio. 2. Lower fouling potential is expected due to low Na2O and CaO content. BOILER LOAD CONDITION Constant Pressure Control Above 90% TMCR The MS Pressure remains constant at rated pressure The Load is controlled by throttling the steam flow Below 30% TMCR the MS Pressure remains constant at minimum Pressure Sliding Pressure Control Boiler Operate at Sliding pressure between 30% and 90% TMCR The Steam Pressure And Flow rate is controlled by the load directly CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC Boiler Load % 20 40 Efficiency Change % +1 0 -1 -2 -3 -4 Variable Pressure 60 80 100 Benefits Of Sliding Pressure Operation ( S.P.O) Able to maintain constant first stage turbine temperature Reducing the thermal stresses on the component : Low Maintenance & Higher Availability No additional pressure loss between boiler and turbine. low Boiler Pr. at low loads. WHY NOT S.P.O. IN NATURAL/CONTROL CIRCULATION BOILERS Circulation Problem : instabilities in circulation system due to steam formation in down comers. Drum Level Control : water surface in drum disturbed. Drum : (most critical thick walled component) under highest thermal stresses LMZ (LENINGRADSKY METALLICHESKY ZAVOD) K STANDS FOR KLAPAN LTD.,BULGARIA WHICH SUPPLIES TURBINE,NOZZLES,DIAPHRAGMS, SEALS,BLADES ETC. 1.TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE COLUMNS (T1 – T26). 2.TG HALL IS CONSTITUTED OF 3 MAINS ROWS OF COLUMNS – A,B ,C ROW AND TWO BAYS – AB BAY AND BC BAY. THE WIDTH OF AB BAY IS 36m AND BC BAY IS 12m 3.CONDENSER TUBE BANKS (CW PATH) HAS AN INCLINATION OF 40. 4.THERE ARE TWO MAIN EOT CRANES FOR TG HALL.EACH EOT CRANE IS HAVING A CAPACITY OF 200t FOR MAIN HOIST AND 20t FOR AUXILIARY HOIST. 35.5m IS THE MAXIMUM VERTCAL DISTANCE A HOIST CAN TRAVEL.TANDEM OPERATION OF TWO EOT CRANES ARE ALLOWED. IP Turbine LP Turbine Ext. No Source Of Extraction Destination Equipments 1 13th stage of HPT HPH-8 2 CRH HPH-7 3 3rd stage of IPT HPH-6 * 3 3rd stage of IPT TDBFP 4 6th stage of IPT DEAERATOR 5 8th stage of IPT LPH-4 6 11th stage of IPT LPH-3 7 2nd stage of LPT LPH-2 8 4th stage of LPT LPH-1 Condenser • • • Design Design CW Flow Vacuum • • No. of passes Total no. of tubes • • • Tube material Rated TTD DT of CW LMZ 64000 m3/hr 77 mm Hg (abs) at 33 0C 89 mm Hg (abs) at 36 0C 1 22.225 (OD)x0.71 (t) - 29920 22.225 (OD)x1.00 (t) - 2080 ASTM A-249 TP 304 3.40C 100C Condensate Extraction Pump • • • • • • • • Design flow rate Discharge pressure Shut off head Pump speed Power input No. of stages Type of first stage impeller Depth 238.75 Kg/s 32.15 Ksc 395 m 1480 rpm 972.3 KW 6 double entry 7.43 m MDBFP • • • • • • • • • • • • • • • Pump flow Suction temp BP Suction pr. BFP Suction pr. 21.01 BFP Discharge pr. BFP Discharge temp. BP Discharge pr. Shut off head BFP Speed BP Speed Normal R/C flow220 HC Rated O/P Speed Outer casing type No. of stages BFP warm up flow 769.950 186.2 14.05 ata 335.78 187.9 22.01 4830 6275 1490 TPH 6505 barrel 7 15 TPH 0C ata ata 0C ata m rpm rpm rpm TPH TDBFP • • • • • • • • • • • • • • • Pump flow Suction temp BP Suction pr. BFP Suction pr. BFP Discharge pr. BFP Discharge temp. BP Discharge pr. Shut off head BFP Speed BP Speed Normal R/C flow HC Rated O/P Speed Outer casing type No. of stages BFP warm up flow 1283.14 186.2 14.10 28.24 335.83 187.8 29.06 4580 4678 2098 365 6505 barrel 7 20 TPH 0C ata ata ata 0C ata m rpm rpm TPH rpm TPH Drip Pump • • • • • • • • Design flow rate Discharge pressure Shut off head Pump speed Power input No. of stages Type of first stage impeller Depth 324.509 TPH 43 ata 306.7 m 1486 rpm 310.1 KW 5 centrifugal, single entry 1090 mm RATED CONDITIONS • • LOAD BEFORE HP STOP VALVE • • • • 660MW : : : 247KSC 5370C 2023.75T/HR : : 48KSC 298.710C : : 43.2KSC 5650C 1681.12T/HR. 0.105KSC (abs.) 64000M3/HR 286.350C 47.5 – 51.5 Hz AFTER HPC • • • STEAM PRESSURE STEAM TEMPERATURE STEAM FLOW : STEAM PRESSURE STEAM PRESSURE BEFORE IP STOP VALVE • • STEAM PRESSURE STEAM TEMPERATURE • • • STEAM FLOW TO REHEATER DESIGN CONDENSER PRESSURE COOLING WATER FLOW : : : • FINAL FEED WATER TEMP. : • FREQUENCY RANGE : STEAM TURBINE • • • • • • Generator rated speed Generator manufacturer No. of bleedings Length of the turbine No. of stages HPT IPT LPT-1 LPT-2 Total Turbine Governing system Mode of Governing Type Control fluid Normal Operating Pr. Capacity Fluid pump motor rating Filter material Mesh size 3000 Electrosila 8 36.362 rpm m 17 11x2 5x2 5x2 59 Nozzle E/H Firequel-L make Supresta-USA 50 Ksc 600 lpm 200 KW Ultipor 25 µ Turbine Protections Turbine protection system consists of Two Independent channels, each operating the corresponding solenoid (220V DC) to trip the Turbine in case of actuation of remote protection Hydraulic Protection: Apart from the Electrical Trip, Turbine is equipped with the following Hydraulic Protections: 1. Local Manual Trip (1V2) 2. Over speed Trip #1 at 110% of rated speed 3. Over speed Trip #2 at 111% of rated speed 4. Governing oil pressure < 20 Ksc Contd.. 5.Axial shift Very High (2V3) [-1.7mm, +1.2mm] 6.Turbine bearing vibration : Very High (2V10 including X & Y directions)* >11.2mm/sec (Td=2 sec) 7.Lube oil tank level very Low (2V3)* Td=3sec (Arming with two stop valves open) 8.Lub oil pressure Very Low (2V3) < 0.3 Ksc; Td =3 sec (Arming with two stop valves open) 9.Condenser pressure Very High (2V3) > - 0.7ksc (Arming with condenser press < 0.15 ksc Abs) Contd 10.M.S. temp Very Low (2V3) < 470 deg C (arming > 512 deg C)* 11.M.S. temp Very High (2V3) > 565 deg C* 12.HRH temp Very Low (2V3) < 500deg C (arming > 535 deg C)* 13.HRH temp Very High (2V3) > 593deg C* 14.HPT outlet temperature Very High (2V4) > 420 deg C Contd… 15.Gen seal oil level of any seal oil tank Very Low (2V3)* < 0 mm;Td=15 sec (Arming with any two stop valves open) 16.All Generator seal oil pumps OFF (3V3)* Td: 9 sec (Arming with any two stop valves open) 17.Generator Stator winding flow Very Low (2v3) < 17.3 m3/hr; Td =120 sec (Arming with any two stop valves open) 18.Generator hot gas coolers flow Very LOW (2V3)* : <180m3/hr; Td=300sec(Arming with any two stop valves open) 19.Generator cooler hot gas temp. Very High(2V4) > 85 deg (Td = 300sec Contd 20.MFT operated: (2V3) 21.Deareator level Very High (2V3) > 3400 mm* 22.HP heater level protection operated (2V3)* 23.Generator Electrical protection operated (2V3) 25.Turbine over speed protection operated (114%) 26.Turbine Controller failure protection operated (2V3) OF SIPAT SUPER CRITICAL UNIT 1ST UNIT SYNCHRONIZED AT 1ST UNIT FULL LOAD ACHIEVED AT : 18.02.2011 : 2nd UNIT SYNCHRONIZED AT 2ND UNIT FULL LOAD ACHIEVED AT : 03.12.2012 : 24.12.2012 PRE – COMMISSIONING ACTIVITIES CHEMICAL CLEANING OF BOILER : REQUIRED FOR Maintaining steam quality at the turbine inlet. Minimizing corrosion of the metal surface of boiler. DETERGENT FLUSHING OF PRE-BOILER SYSTEM To remove dirt ,oil ,grease etc., from Condensate ,Feed water, Drip and Extraction steam lines of HP and LP heaters prior to putting these systems in regular service. This is to ensure flow of clean condensate and feed water to the boiler. STEAM BLOWING OF POWER CYCLE PIPING : The purpose of steam line blowing is to remove pipe slag, weld bead deposits and other foreign material from the main and reheat steam systems prior to turbine operation. The cleaning is accomplished by subjecting the piping systems to heating, blowing steam and cooling cycles in sufficient number and duration until clean steam is obtained. SAFETY VALVE FLOATING PRE – COMMISSIONING CHECKS All commissioning procedure should be finalized. P&I Drawings should be finalized and available with site engineer Different systems check list should be finalized with all concerned agencies All Field quality checks should be completed. P&I Checks should be finalized. Start – Up procedure should be finalized COMMISSIONING SEQUENCE OF TG SIDE 1.Commissioning of stator water cooling system for HV testing before generator rotor insertion. a) Stator water pump trial run. b) Flushing of the system bypassing winding. c) Flushing of the system through the winding. 2.Commissioning of MCW,ACW and DMCW system. a) Trial run of pumps. b) Flushing of the system. 3.Detergent Flushing of pre boiler system (Feed water ,condensate ,HPH and LPH drip system) a) Cold water flushing until turbidity comes below 5NTU. b) Hot water flushing (600C) with 2 hrs circulation of each circuit. c) Raising water temperature to 600C and addition of Detergent d) (Coronil 100%) e) Circulation through each circuit for 2 hrs. f) Hot draining of the system g) DM water rinsing of each circuit until conductivity comes below 5µs/cm and oil content BDL. h) Passivation with ammonia and hydrogen peroxide solution at a temperature of 400C. i) Draining of the system. 4. Lube oil flushing of MDBFP lube oil system. 5.Trial run of MDBFP. 6.Lube oil and seal oil flushing of main TG. 7.CF system flushing. 8.Condenser flood test. 9.Trial run of CEPs 10.Commissioning of generator gas system. 11.Generator ATT. 12.Calibration of HPCVs and IPCVs 13.Putting turbine on barring. 14.Vacuum pumps trial run. 15.Commissioning of seal steam system. 16.Commissioning of HP and LPBP system. 17. Vacuum pulling. 18.Lube oil flushing of TDBFP. 19.Steam blowing of TDBFP steam line. 20.Commissioning of TDBFP. MS Line HT CRH Line HT HRH Line HT MS Line Welding Completion ( 30 Pen) CRH Line Welding Completion ( 12 Pen) HRH Line Welding Completion (34 Pen) MS Line Hanger Erection Cold Setting CRH Line hangers Cold Setting HRH Line Hangers Cold Setting MS Line Insulation CRH Line Insulation HRH Line Insulation STATOR COOLING WATER FUR DRAFT SYSTEM SEC AIR SYSTEM TG ON BARRING BRP TRIAL RUN TG LUBE OIL / GEN SEAL OIL SYSTEM POWER CYCLE PIPING STEAM BLOWING FURNACE READINESS FUEL OIL SYSTEM READINESS CHEMICAL CLEANING OF BOILER AUX PRDS READINESS UNIT SYNCHRONIZTION CONDENSER VACCUM SYSTEM COMPRESSED AIR SYSTEM READINESS MDBFP Trial CEP Trial CW SYSTEM READINESS TG SEAL STEAM SYSTEM GATES, DAMPERS / VALVES TG : TG CONTROL FLUID SYS SG : (13 / 190 ) MFT CHECKING DDCMIS FSSS READINESS TG GOV SYSTEM GEN GAS SYSTEM Discussion Questions Please Enlighten Us Evaporator – heat absorption Reduced number of evaporator wall tubes. Ensures minimum water wall flow. SPIRAL WALL ARRAMGEMENT AT BURNER BLOCK AREA : Support System for Evaporator Wall • Spiral wall Horizontal and vertical buck stay with tension strip • Vertical wall Horizontal buck stay