Transcript Slide 1

SIPAT SUPER THERMAL POWER PROJECT
SIPAT STAGE # 1 BOILER
ECONOMISER TO 1 ST PASS TOP HEADERS :
ECO. O/L LINKS
OUTLET HEADERS
VERTICAL
WALL
INTERMITTENT
HEADERS
ECO. JUNTION
HEADERS
ECO. MIXING
PIECE
SPIRAL WALL
ECONOMISER
BOTTOM RING HEADER
ECO I/L HDR
ECONOMISER :
COUNTER FLOW
4 BANKS
163 ASSEMBLIES
4 JUNCTION HEADERS
224 HANGER TUBES
ECO OUTLET HEADER
SA 106 C ; SA 210 C
SPIRAL AND VERTICAL WALLS :
TOTAL SPIRAL TUBES : 440 (102X2 FRONT & REAR; 108X2
LEFT & RIGHT)
SPIRAL TO VERTICAL RATIO = 1:3
FRONT VERTICAL TUBES: 336
SIDE WALL TUBES: 648
REAR SCREEN TUBES : 280
REAR HANGER TUBES : 56
TUBES : T22
HEADERS : P12
START UP SYSTEM :
SEPERATORS I/L
LINKS
1ST PASS ROOF O/L
HEADERS
SEPERATOR TANKS
STORAGE TANK
WR
ZR
BCP
TO ECONOMISER
UG
MIXING
PIECE
FLASH
TANK
CONDENSER
FEED WATER LINE
BOILER FILL LINE
2ND PASS STEAM FLOW :
1ST PASS ROOF I/L HDR
EXTENDED WALL :
BACK PASS ROOF I/L HDR
BACK PASS TOP LHS HDR
BACK PASS TOP RHS HDR
EXTENDED
WALL
EXTENDED WALL
HDR
BACK PASS BOTTOM
RING HDR
BACK PASS WALLS & HEADERS :
FURNACE FRONT ROOF : 168
BACK PASS ROOF : 111
BACK PASS REAR WALL : 111
BACK PASS SIDE WALL : 328
BACK PASS FRONT WALL : 167
BACK PASS SCREEN : 167
TUBES : T12
HEADERS : P12
EXTENDED WALL :
EXTENDED WALL FLOOR : 142
EXTENDED SIDE WALL : 142
TUBES : T12
HEADERS : P12
FLUID COOLED SPACER TUBES: 3
BACK PASS WALLS & HEADERS :
START UP SYSTEM :
LINK PIPES
: P12
LINK PIPES
SEPERATORS &
STORAGE TANK
: SA 302C
SEPERATORS &
STORAGE TANK : SA 302C
: P12
DIVISIONAL PANEL :
II ND PASS TOP RHS HDR
DIV. PANEL I/L HDR
FROM II nd PASS BOTTOM
RING RHS HDR
DIV. PANEL O/L HDR
DIV. PANEL O/L HDR
DIV. PANEL I/L HDR
II ND PASS TOP LHS HDR
FROM II nd PASS BOTTOM
RING LHS HDR
SH DIV. PANEL TUBES : 480
TUBES : T23; T91
HEADERS : P12; P23
DIV. PANEL
FLUID COOLED SPACER TUBES : 6
DIV. PANEL
PLATEN AND FINAL SH :
PLATEN TO FINAL SH LINK
DIV. PANEL TO PLATEN LINK
TO HP TURBINE
PLATEN
I/L HDR
PLATEN
O/L HDR
FINAL SH O/L
HEADERS
DIV. PANEL I/L HDR
FINAL SH
I/L HDR
DIV. PANEL O/L HDR
DIV. PANEL O/L HDR
DIV. PANEL I/L HDR
PLATEN ASSEMBLIES : 20
NO OF TUBES : 480
TUBES : T12; T23; T91
HEADERS : P12; P23
PLATEN COILS
FINAL SH COILS
COUNTER FLOW DIRECTION
NO OF STAGES : 2
ASSMBLIES : 2X55
NO OF TUBES : 935
TUBES : T23; T91
HEADERS : P23; P91
TO IPT
REHEATERS :
TO IPT
NO OF BANKS : 3
NO OF TUBES : 111
TUBES : SA 210C; T12; T23
HEADERS : SA 106C; P12
LTRH BANKS
FINAL RH
FROM CRH
NO OF ASSEMBLIES : 41
NO OF TUBES : 615
TUBES : T23; T91; SUPER 304H
HEADERS : P12; P91
FROM CRH
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
FEATURES OF SUPER CRITICAL BOILER :
1. ONCE THROUGH OPERATION :
FEED
WATER
PUMP
ECONOMISER
WATER WALL/
EVAPORATOR
RECIRCULATION
PUMP
SEPERATOR
SUPERHEATER
STORAGE
TANK
CONSTANT WATER WALL FLOW
(below 30% load)
FEED
WATER
PUMP
ECONOMISER
WATER WALL/
EVAPORATOR
SEPERATOR
ONCE THROUGH FLOW OPERATION
(above 30% load)
SUPERHEATER
2. CONSTANT PRESSURE OPERATION :
Above 90% & below 30%
3. SLIDING PRESSURE OPERATION :
B/W 30% & 90%
ADVANTAGES OF SLIDING PRESSURE OPERATION
1. No additional pressure loss between boiler and turbine
2. Low Boiler Pr. at low loads
- Less fatigue of Pr. part components
- Longer life of all components, Less wear of components
- Less Maintenance
3. Lower thermal stresses in the turbine during load changes
4. Control range of RH temp is extended
5. Overall reduction in power consumption and improved heat rate
660MW PARAMETERS :
DESCRIPTION
UNIT
660 MW AT BMCR
T/HR
2225
KG/CM2
256
SH STEAM TEMP
0C
540
RH STEAM FLOW
T/HR
1742
0C
299
0C
568
KG/CM2
46.61
0C
289.64
SECONDARY AIR FLOW
T/HR
1732
PRIMARY AIR FLOW
T/HR
946
TOTAL COAL FLOW
T/HR
472
S/H STEAM FLOW
SH
STEAM PR
RH STEAM TEMP
INLET
RH STEAM TEMP OUTLET
RH STEAM PRESS OUTLET
FEED WATER TEMP
FEATURES OF 660 MW- STEAM QUALITY PARAMETERS
STEAM QUALITY AT SG
OUTLET
S.NO.
PARAMETER
1
TDS
20
2
2
SILICA
20
2
3
SODIUM
10
2
4
CHLORIDES
0
2
5
COPPER
20
1
6
IRON
10
5
7
8
CATION
CONDUCTIVITY
PH
DURING START UP
<0.2 to 0.25 micro
siemens /cm
DURING
NORMAL
OPERATION
<-0.2 micro
siemens / cm
6~8
COMMISSIONING
NETWORK
MS Line HT
CRH Line HT
HRH Line HT
MS Line Welding
Completion
CRH Line Welding
Completion
HRH Line Welding
Completion
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
SG ECW SYSTEM
ID FAN # 1A TRIAL RUN
FD FAN # 1A TRIAL RUN
SAPH # 1A TRIAL RUN
BRP TRIAL RUN
SACNNER AIR SYSTEM
READINESS
Temporary Piping Completion
FURNACE READINESS
FUEL OIL SYSTEM
READINESS
AUX PRDS READINESS
Boiler Light Up & Steam Blowing
ACW System
CHEMICAL CLEANING OF
BOILER
COMPRESSED AIR
SYSTEM READINESS
MDBFP Trial
CW SYSTEM READINESS
CEP Trial
GATES, DAMPERS /
VALVES
TG :
TG ECW System
SG :
MFT CHECKING
DDCMIS
FSSS READINESS
HOT Well Readiness
LIST OF APPROVED PROCEDURES
Boiler Commissioning is carried out based on the guide lines of
Corporate commissionin groups. OS) These are the list of
approved commissioning procedures which are followed in sipat
commissioning activities
1. BOILER HYDRO TEST
2. OIL FLUSHING OF ROTARY MACHINES
3. BOILER & DUCTS AIR TIGHTNESS TEST (ATT)
4. ESP AIR IN LEAK TEST
5. ESP GAS DISTRIBUTION (GD) TEST
6. BOILER CHEMICAL CLEANING
7. BOILER COLD AIR VELOCITY TEST
8. CLEAN AIR FLOW TEST
9. LDO & HFO SYSTEMS COMMISSIONING
10. BOILER & AUX LINES STEAM BLOWING
COMMISSIONING MILE STONES
1. BOILER HYDRO TEST :
HP SYSTEM : Hydro test done on 20.12.2006
HP system hydro test is done at 410 KSC. HP system consists of Economiser,
boiler 1st & 2nd pass, divisional panel, platen & final super heater upto boiler
stop valves.
MP SYSTEM : Hydro test done on 26.03.2008
MP system hydro test is done at 80.1 KSC. MP system consists of CRH isolator
to LTRH, Final Reheater upto HRH isolators.
2. BURNER TILT, OIL GUNS & IGNITOR CHECKING :
Checking is completed on 24.12.2007
Burner tilt checking is done from inside the boiler in which burner limits +300 &
- 300 angles adjusted. Oil guns & ignitors clearances are checked inside the
boiler.
3. FD, ID & PA FANS COMMISSIONING :
FD Fan # 1A trial run taken on 03.03.2010
ID Fan # 1A trial run taken 15.03.2010
PA Fan # 1A trial run taken 18.03.2010
COMMISSIONING MILE STONES
3. FD, ID & PA FANS COMMISSIONING :
FD Fan # 1B trial run taken on 22.06.2010
ID Fan # 1B trial run taken 21.06.2010
PA Fan # 1B trial run taken 22.06.2010
Fans commissioning involves following steps:
 Lube oil flushing of lube oil skid, lube oil lines with flushing oil (32 grade)
(bearings bypassed) (Completion criterion is Moisture & Mechanical impurities
should be below 100 ppm)
 Lube oil flushing through bearings (32 grade)
 Lube oil flushing through bearings (68 grade oil)
 Blade pitch commissioning & discharge gate commng.
 Cooling water lines flushing & charging
 Fan trial
4. AIR PREHEATERS COMMISSIONING :
SAPH # 1A trial run taken on 27.03.2010
SAPH # 1B trial run taken on 20.04.2010
4. AIR PREHEATERS COMMISSIONING :
PAPH # 1A trial run taken on 29.03.2010
PAPH # 1B trial run taken on 20.04.2010
Air Preheaters commissioning involves following steps:


Lube oil motors & main motor no load trial
Lube oil flushing of Support & Guide bearings with 32 oil (Completion criterion
is Moisture & Mechanical impurities should be below 100 ppm)

Lube oil flushing through bearings (32 grade)

Lube oil flushing through bearings (680 grade oil)

Air motor service air line blowing

Cooling water lines flushing & charging

Air preheater trial with air motor & electrical motor
4. BOILER & DUCT ATT :
Secondary air duct ATT is completed on 01.04.2010
Primary air duct ATT is completed on 05.05.2010
Flue gas air duct ATT is completed on 24.04.2010
Furnace ATT completed on
 ATT of boiler & ducts is done at 150 mm of water column.
 Secondary air duct & boiler pressurisation is done by FD Fan.
 Primary air duct pressurisation is done by PA fan.
 Flue gas duct pressurisation is done by using temporary blowers
5. ESP COMMISSIONING :
ESP Air In Leak test: All passes air in leak test completed on 09.11.2008
The test is done to prove that air in leak into ESP is with in guaranteed value of
1% of design gas flow rate.
ESP Rapping system commng. : All passes rapping systems commng.
completed on 21.07.2010
Each Pass has 18 nos. collecting electrodes rapping system, 18 nos emitting
electrode rapping system & 2 nos. gas distribution plates rapping system.
5. ESP COMMISSIONING :
ESP Fields charging
ESP GD test completed on 25.08.2010
This is done to verify uniform flow distribution inside the ESP Chambers.
6. BOILER CAVT :
CAVT (Cold Air Velocity Test) is completed on 03.09.2010
This test is done to check flue gas flow patterns inside the boiler.
7. AIR BALANCE TEST (ABT):
8. BOILER CHEMICAL CLEANING :
Boiler Chemical cleaning is completed on 30.09.2010
Chemical cleaning involves following steps:
 Flushing
 Acid Cleaning
 Rinsing
 Pre Neutralization
 Neutralization
 Passivation
 Main chemicals used are formic acid (10%), sorbic acid, coronil 200S
 Boiler chemical cleaning is completed in 7 days.
9. BRP (Boiler Recirculation Pump) COMMISSIONING :
BRP trial completed on 13.10.2010
BRP commissioning involves following steps:
 Cavity filling line flushing (until Conductivity & Turbidity reaches required
parameters)
 Flushing through motor cavity & through cooler
 ECW lines water flushing
 Pump trial
10. BOILER LIGHT UP :
Boiler is Lighted Up on 27.10.10
Boiler is lighted up with LDO and all 4 corner oil guns were proven.
11. STEAM BLOWING : It has following steps
PRE STEP1:
Separator
Superheater
Main Steam Line
Main Stop Valve
Temporary Piping
Temporary MOV
Tailpipe to atmosphere
Blowing is done from 40 KSC to 20 KSC
11. STEAM BLOWING :
Steam blowing consists of following steps:
PRE STEP 2:
Separator
Superheater
Main Steam Line
HP Bypass Valve
Cold RH line backward flush through drain pot near RH inlet
header
Temporary Piping
tailpipe to atmosphere
Blowing is done from 40 KSC to 20 KSC
MAIN STEP 1:
Separator
Superheater
Main Steam Line
Main Stop Valve
Temporary Piping
Temporary MOV
Non-return Valve
Cold
Reheat Line
Reheater
Hot Reheat Line
IPT Stop Valve
Tailpipe to atmosphere
Blowing is done from 80 KSC to 40 KSC
MAIN STEP 2:
Separator
Superheater
Main Steam Line
Main Stop Valve
Temporary Piping
Temporary MOV
Non-return Valve
Cold
Reheat Line
Reheater
Hot Reheat Line
LP Bypass Valve
Tailpipe to atmosphere
Blowing is done from 80 KSC to 40 KSC
11.PF SYSTEM COMMISSIONING:
(a) Seal air fan & its dampers
(b) Mills commissioning:


Lube oil pumps load trial
Lube oil flushing of oil line with 32 oil bypassing gear box & bearings
(Completion criterion is Moisture & Mechanical impurities should be below
100 ppm)

Lube oil flushing through bearings & gear box(32 grade)

Lube oil flushing through bearings (320 grade oil)

Cooling water lines flushing & charging

Roller & Bowl gap adjustment

Spring tension adjustment

P&I checks & Mill solo run.
11.PF SYSTEM COMMISSIONING:
(C) RC Feeders
 Motor checks


P&I checking
Feeder belt trial with clean out conveyor.
(D)Commissioning of gates & dampers
 Commng of HAD, CAD, HAG, CAG, BIG, MDV from remote
(E) Clean air flow test of mills as per approved procedure
PROBLEMS &
MODIFICATIONS
1. Provision of manholes in ducts & hoppers
2. Oil gun cleaning system
3. BRP fill line from boiler fill pump
4. FD, ID & PA fans blade pitch local indication
5. Black Start Up line in unit # 1
6. Additional vents are provided in SGECW system
7. Boiler headers & links replacement
BOILER HEADERS REPLACEMENTS
 Some of the super heater headers were replaced with higher grade
materials.
 5 nos. of headers & link pipes of Gr P23 were replaced with Gr P91.
 This material replacement is done to avoid probable material failure in
the pipes and fittings of the boiler subjected to very high temperature
and pressures.