Transcript Document

Adani Power Limited
Power Business Goal - 20,000 MW
ADANI POWER AT A GLANCE
• Power Business Goal - 20,000 MW BY 2020
• MUNDRA– 330MW X 4 + 660MW X 5
• TIRODA– 660MW X 5
(UNDER COMMISSIONING)
• KAWAI– 660MW X 2
(UNDER ERECTION)
• BITTA– 40MW BIGGEST SOLAR IN INDIA
ACHIEVEMENTS
• INDIA’S FIRST 66O MW SUPER
CRITICAL UNIT SYNCHRONISED BY
ADANI POWER LTD, MUNDRA IN OCT
2010 IN RECORD TIME OF 36
MONTHS.
• COMMISSIONED 4Nos. 660MW UNITS
IN A YEAR.
• ADANI IS THE FIRST COMPANY IN
INDIA TO EARN CARBON CREDIT.
WELCOME
TO
PRESENTED BY
B.K.PANDEY
APML, TIRODA
START-UP SEQUENCE
• BOP SYSTEM READYNESS
• BOILER FLUSHING: COLD/HOT
• BOILER LINE UP AND LIGHT UP.
• TURBINE LINE UP.
• TURBINE ROLLING.
• SYNCHRONISATION
• PHASE CHANGE OVER
• FULL LOAD
START UP MODES
• COLD START UP:HP & IP SHAFT METAL
TEMP <204°C
• WARM START UP: HP & IP METAL TEMP IN
BETWEEN 204 TO 400°C
• HOT START UP :HP & IP METAL TEMP
>400°C
Boiler
FCS
Economiser
11+1
8
HPT
IPT
LPT A
3
HPH - 2
HPH - 1
RH
2x7
2x7
8
1
7
5
6
LPT B
7
8
8
7
5
LPH -7A
LPH -8A
7
8
LPH -7B
LPH -8B
Condensor
(HP)
Deaerator
6
Condensor
(LP)
EXT From
CRH
(MD BFBP 1x35%)
HPH -3
TDBFP 2X50%
CEP
3x50%
1994 TPH
GSC
CPP
1482 TPH
LPH -5
LPH -6
PRE STARTUP READYNESS
• HT/LT POWER SUPPLY READINESS
• WATER SYSTEM: FIRE WATER,SERVICE WATER,DMP,CW &
ACW.
• CCCW SYSTEM
• COMPRESSOR SYSTEM
• AUXILIARY STEAM. (S/B UNIT OR AUX BOILER).
• START CEP AND MDBFP.
• CHECK THE BCP SYSTEM IS READY.
WHY BCP ?
• TO ASSIST CIRCULATION IN BOILER WATER WALL
• TO INCREASE THE CIRCULATION VELOCITY
• TO AVOID DNB (Departure from Nucleate Boiling) IN LOW LOAD.
• TO REDUCE THE OVER HEATING AND UNDUE STRESSES ON
WATER WALL TUBES.
• TO AVOID DRY OUT OF WATER WALL TUBES WHEN LOAD IS
REDUCED.
BCP FILLING ,PURGING & FLUSHING
• PURPOSE- TO FILL THE MOTOR CAVITY.
• RECOMMENDED MOTOR FILLING WATER QUALITY
CONDUCTIVITY <1 µs/cm
- BOILER FEED WATER
TEMP.<= 45 OC
CL- <= 50 PPM
pH >= 6.5
SUSPENDED SOLIDS <= 5 PPM
• FILLING,PURGING & FLUSHING WATER REQUIREMENT
-
MOTOR INITIAL FILLING FLOW RATE
: MAX. 5 L/MIN
PRE BOILER FLUSHING
• START CEP.
• FILL & DRAIN FROM DEAERATOR UNTIL
REQUIRED WATER QUALITY IS ACHIEVED.
( Fe<500 Ppb.)
• START MDBFP.
• START THE BOILER COLD/HOT FLUSHING
TO REDUCE THE Fe & SiO2 CONTENT IN
FEED WATER.
Boiler flushing
SP SP
START-UP
LINE
Sampling Fe+
Below
Above
500ppb
500ppb
MIXER
BCP
WW
ECO
CW
LINE
HOTWELL
BOILER COLD FLUSHING
COLD FLUSHING
• WATER WALL TEMP REQUIRED 105-120 DEG.C
(TEMP MAINTAINED BY DEAERATOR PEGGING
STEAM)
• COLD OPEN FLUSHING QUALIFIES
Fe
< 500PPB
SiO2 < 100PPB
• THEN CPU WILL BE TAKEN IN SERVICE TO REDUCE WATER
LOSS AND IMPROVE QUALITY.
• COLD CYCLIC FLUSHING QUALIFIES
(ALL ANALYSIS FROM SEPARATOR DRAIN)
Fe < 100PPB
SIO2 < 50PPB
BOILER HOT FLUSHING
HOT FLUSHING
•
WATER WALL TEMP REQUIRED 150-190 DEG.C (TAKE
OIL GUNS OF BC ELEVATION)
• HOT OPEN FLUSHING START UP CRITERIA
•
IF HOT CYCLIC FLUSHING CRITERIA IF
• HOT CYCLIC FLUSHING QUALIFIES IF
FE
SIO2
> 100PPB
> 50PPB
FE
< 100PPB
SIO2 < 50PPB
FE
< 50PPB
SIO2 < 30PPB
• AFTER COLD FLUSHING START BCP WITH MINIMUM 30%
FEED FLOW & THROTTLE FRS VALVE.
BOILER LINE UP AND LIGHT UP
•
FUEL OIL SYSTEM: LDO/HFO PUMPS
•
ESP HEATERS & RAPPERS
•
AIR FLUE GAS SYSTEM: APH,IDF, FDF &
SCANNER FAN.
•
MAINTAIN AIR FLOW : 30% - 40%.
•
FURNACE PURGE: 300 Sec.
•
LIGHT UP BOILER WITH OIL GUNS AT BC (LDO)
ELEVETION.
•
CONTINUE HOT FLUSHING UNTIL REQD.WATER
QUALITY IS ACHIEVED
•
THEN TAKE CD ELEVETION GUNS. IF REQUIRED
TAKE 2 NO. GUNS IN AB ELEVETION.
BOILER LINE UP AND LIGHT UP
• CONTINUOUS APH SOOT BLOWING TO BE DONE AT THE
TIME OF OIL FIRING.
• PR RISING RATE- 0.05 MPA/MIN. BETWEEN 0-1 MPA
• PR RISING RATE 0.1 MPA/MIN. BETWEEN 1 – 2 MPA
• PR RISING RATE 0.2 MPA/MIN. ABOVE 2 MPA
•
FURNACE EXIT GAS TEMP MUST BE BELOW 538°C FOR
REHEATER PROTECTION (UNTIL HP-LPBP IS CHARGED).
• CLOSE SH DRAINS AND VENTS AFTER ACHIEVING DEGREE
OF SH 50 °C ( CLOSE IT AFTER CHARGING HP-LP BYPASS).
LDO/HFO GUN
Fuel
Light Oil
Fuel Pressure
0.8MPa-2.0MPa
Fuel Flow
500kg/h -3000kg/h
Atomizing Air Pressure
0.6MPa-1.2MPa
Atomizing Air Flow
100-600kg/h
Ignition Method
HESI (20 joules/spark)
Fuel
Heavy Oil
Fuel Pressure
0.8MPa- 2.0MPa
Fuel Flow
1000-4000 kg/h
Atomizing Steam Pressure
0.8MPa-1.2MPa
Atomizing Steam Flow
100-400kg/h
Ignition Method
HESI (20 joules/spark)
TURBINE LINE UP
• ENSURE:
• LUBE OIL SYSTEM: IN SERVICE (0.8 MPA)
• JACKING OIL SYSTEM:IN SERVICE ( 14 MPA)
• TURBINE BARRING GEAR: 3-4 RPM
• SEAL OIL SYSTEM: AIR & H2 SIDE. CHARGED
• STATOR AND H2 COOLING WATER SYSTEM:CHARGED TEMP CONTROL
IN AUTO)
• H2 FILLED IN GENERATOR AND MAINTAIN PR 0.35 MPA.
• EH OIL SYSTEM: IN SERVICE (14 MPA)
TURBINE LINE UP
• ENSURE TDBFP IN BARRING.
• GLAND STEAM CHARGING: ENSURE STEAM TEMP. IS 56°C
- 111 °C MORE THAN ROTOR TEMP & DEGREE OF SH >
50°C.
• CHARGE THE GLAND SEAL SYSTEM OF TDBFP.
• START THE VACUUM PULLING WITH VACUUM PUMP.
MAINTAIN VACUUM -0.9 KG/CM2.
• CHARGE THE HP-LP BYPASS SYSTEM .MAINTAIN THE MS
STEAM PRESSURE AND FIRING RATE FOR ACHIEVING
TURBINE ROLLING PARAMETERS.
COLD START UP CURVE
HOT ROLLING
MS TEMP
RH TEMP
SPEED
MS FLOW
LOAD
MS PRESS
PRE HEATING OF HP CASING.
• PREHEATING OF HPT REQUIRED WHEN INNER METAL TEMP <150°C.
• CRH PR 0.5-0.7 MPA/220-380°C.
• OPEN PRE HEATING VALVE (REVERSE FLOW VALVE) GRADUALLY.
• OPEN BDV VALVE FULLY.
• OPEN CRH DRAIN BEFORE NRV AND HPT-IPT CASING DRAINS.
• HEATING RATE SHOULD NOT BE MORE THAN 50°C PER HR.
• HP CASING TOP-BOTTOM & INNER-OUTER WALL METAL TEMP
DIFFRENCE SHOULD BE WITHIN 50°C.
• AFTER ATTAINING THE CASING TEMP > 150°C CLOSE THE RFV
VALVE AND OPEN HP CYLINDER VENTILATION VALVE TO
CONDENSOR.
TURBINE WARM UP OPERATION
MS
HPBP
HPT
CRH NRV
RFV
IPT
Ventilator valve
TO CONDENSER
BDV
TO CONDENSER
CRH LINE
TURBINE STARUP PROCEDUR
TURBINE ROLLING
• AS PER REQUIREMENT OF START UP CURVE, FIRING TO BE
INCREASED.
• REQUIRED
–
–
-
STEAM PARAMETERS BEFORE ROLLING
MS PR: 8.73 MPA, TEMP: 330-380 °C
RH PR: 1.1 MPA , TEMP: 330°C
THE DEGREE OF SUPER HEAT > 56°C.
• AFTER LATCHING THE TURBINE, START IP ROLLING WITH HP VENT
TO CONDENSER IN OPEN CONDITION TO KEEP THE HPT IN
VACUUM.
• MSV 1&2 AND RSV 1&2 ARE IN OPEN CONDITION.
• GIVE THE SPEED SET POINT TO 600 RPM
• CHECK THE TURBINE SUPERVISORY INSTRUMENT PARAMETER.
• THE ECCENTRICITY SHOULD BE LESS THAN 0.076 MM.
TURBINE ROLLING
• SELECT TARGET SPEED 1500 RPM WITH RAMP RATE OF 100
RPM/MIN.
• ENSURE ALL HP CV’S OPENS TO 12% TO WARM UP THE HP
CASING.
• WHEN HP CASING TEMP >320°C.CLOSE THE HP CV’S.
• SOAK THE TURBINE FOR 4 HRS ACCORDING TO THE START UP
CURVE.
• CHARGE THE LP HEATER 5 & 6 BEFORE 3000 RPM
• SELECT TARGET SPEED TO 3000 RPM WITH RAMP RATE OF 100
RPM/MIN.SOAK IT FOR 30 MIN AS PER S/U CURVE.
• AS PER PROCEDURE SYNCHRONISE THE UNIT.
LOADING
• AFTER SYNCHRONISATION INITIAL LOAD WILL BE 30 MW.HOLD IT
FOR 30 MIN AND CHEK THE VIBRATION, BEARING TEMP, DIFF
EXPANSION, CASING EXPANSION.
• CHARGE EXTRACTION STEAM TO DEAERATOR.
• TAKE MORE OIL GUNS IN EF/AB ELEVETION.
• TAKE PA FANS & SEAL AIR FAN.
• AFTER ACHIEVING FURNACE TEMP. MORE THEN 450°C. TAKE COAL
MILL-B AT. STEAM T/PR 380°C/8.7 MPA.
• INCREASE FUEL FLOW MAINTAINING STEAM TEMP.& RAISE LOAD
• AT 70 MW IP TO HP CHANGE OVER. CV’S WILL START OPENING,
CLOSE THE BDV AND VENTILATING VALVE.
• INCREASE THE LOAD AT 3MW/MIN
• CLOSE THE HP-LP BYPASS GRADULLY.
660
LOAD
(MW)
350
660 MW
495
330MW
330
198MW
165
60MW
33MW
400
450
500
MINUTES
550
600
650
MILL-F CUT IN (540MW)
MILL-E CUT IN (430MW)
MILL-D CIT IN (300MW)
OIL GUN CUT OUT (260MW)
MILL-A CUT IN(210MW)
WET TO DRY CHANGE OVER
2ND TDBFP CUT IN(180MW)
HPH CHARGED(150 MW)
MILL-C CUT IN AT 100MW
IP TO HP CHANGE OVER (70MW
MILL-B CUT IN
SYNCHRONISE
&CHARGE D/A
LPT A
2nd
LPT B
FROM IPT EXHAUST
2nd
5th
5th
6th
6th
5th
4th
4th
5th
6th
6th
LP HEATER 7A
LP HEATER 7B
LP HEATER 8A
LP HEATER 8B
CONDENSER
CONDENSER
HP HEATER
LP HEATER 5
5
HP HEATER
LP HEATER 6
6
TDBFP START UP
• TAKE ONE TDBFP IN SERVICE( CHANGE OVER WITH MD BFP) WHILE
DRIVING STEAM IS AVAILABLE. SECOND TD BFP WILL BE TAKEN AT
180 MW.
• WARM UP THE TURBINE.
• SLOWLY OPEN THE AUX STEAM MOV TO TURBINE.
• PARAMETERS FOR ROLLING TDBFP.
STEAM PRESSURE: 0.6～1.3MPA, STEAM TEMP: 50 DEG C MORE THAN
CASING TEMP.
• ROLL THE TDBFP AS PER PROCEDURE.
• GIVE THE TARGET SPEED 500 RPM AND THAN TO 1000 HOLD FOR 40
MIN.CHECK THE TSI PARAMETER
• WHEN SPEED REACHES 2840 RPM, GIVE REQUEST COMMAND FROM
FW MENU. THEN SELECT CCS CONTROL IN FROM MEH MENU.
TDBFP STEAM SOURCES
HP
IP
1.12 Mpa
378 ºC
1.3 MPa
350 ºC
Aux. Steam
Header
To
CRH
M
Changeover Valve
E
M
M
M
M
From
CRH
E
M
M
4 MPa
315.3 ºC
TDBFP-B
To
Condenser
Deaerator
TDBFP-A
Booster
pumps
LOADING
• TAKE THE MILL-C IN SERVICE AT 100 MW. STEAM T/PR:400°C/8.7
MPA.
• GRADUALLY WITH DRAW THE OIL SUPPORT AS PER THE FLAME
CONDITION.
• INCREASE THE LOAD TO 150 MW AND TAKE THE HPH-3, HPH-2 &
HPH-1 IN SERVICE. MS T/PR 410°C/8.7 MPA.
• AT 180 MW TAKE SECOND TDBFP IN SERVICE.
MS LINE
HRH LINE
IP EXHAUST
CRH LINE
9th stage
5th stage
TDBFP A
HP HEATER
1
HP HEATER
2
HP
HP HEATER
HEATER
33
DEAERATOR
TDBFP B
PHASE CHANGE FROM WET TO DRY MODE
• DURING LOAD RAISING >25% BMCR, THE BCP FLOW AND FEED
WATER FLOW TO BE MONITORED CLOSELY.
• THE BCP FLOW NEED TO BE ADJUSTED W.R.T SEPERATOR TANK
LEVEL AND THE SAME FLOW TO BE ADJUSTED IN FEED WATER FLOW
TO MAINTAIN TOTAL FEED WATER FLOW TO ECONOMISER
CONSTANT.
• WHEN BOILER STEAMING RATE RISES TO >30% BMCR, W.R.T FUEL
FIRING, THE SEPERATOR LEVEL REDUCES .
• ONCE THE CONDITION FULFILLS THE BCP STOPS AND FEED FLOW
CONTROL CHANGES OVER FRS.
• AFTER STOPPING BCP IT ACTS AS SUB-CRITICAL ONCE THROUGH“.
• WHEN THE STEAM PR REACHES 22.1 MPA IT IS IN “SUPERCRITICAL
ZONE”
LOADING
• TAKE MILL-A AT 210 MW.
• CUT THE OIL SUPPORT AT 260 MW AS PER THE FLAME CONDITION.
• TAKE MILL-D AT 300 MW. MS T/PR 475°C/10 MPA.
•
TAKE MILL-E AT 430 MW. MS T/PR 566°C/17 MPA.
• TAKE MILL-F AT 540 MW. MS T/PR 566°C/24.1 MPA.
• INCREASE THE LOAD TO “FULL LOAD 660 MW” GRADUALLY.
Boiler Design Parameters
NO.
Parameters
1
100% BMCR Coal consumption (Design)
Unit
390.37
t/h
2
Design fuel
3
Superheated steam flow
2111
t/h
4
Superheater outlet pressure
25.4
MPa
5
Superheater outlet temperature
569
℃
6
Reheated steam flow
1749.1
t/h
7
Reheater inlet pressure
4.73
MPa
8
Reheater outlet pressure
4.49
MPa
9
Reheater inlet temperature
324
℃
10
Reheater outlet temperature
569
℃
Feedwater pressure
28.8
MPa.g
11
Feedwater temperature
280
℃
12
Separator’s steam temperature
421
℃
153.3
℃
147.2
℃
13
14
Air preheater’s outlet air temperature, uncorrected
After correcting
Calculating thermal efficiency of boiler
Indian coal
87.19%（BMCR）
TURBINE PARAMETERS
Steam Admission Parameters at Turbine Inlet
HPT
IPT
LPT
Pressure (MPa)
24.2
3.961
1.12
I/L Temp (Deg C)
566
566
378
O/L Temp(deg C)
315.3
378
Steam Flow (tph)
1959.25
1649
TURBINE HEAT RATE( KCL/KWH) 1885
No of Stop valves
2
2
No of Control valves
4
4
TURBINE AT FULL LOAD
3.96MPa / 566°c
HRH
24.2MPa/566ºC
1.12MPa / 378°c
RSV
MS LINE
MSV
CV
CV
CV
TO BLR RH
CV
CRH
HPT
IPT
LPT
#1
LPT #2
CRH
RCV
CV
CV
RCV
CV
CONDENSOR A
MSV
MS LINE
HRH
CV
CV
RSV
RSV
CONDENSOR B
GEN
SHUT DOWN
• EXCEPT IN AN EMERGENCY, LOAD SHOULD BE REDUCED
GRADUALLY.
• CUT THE MILL-F AT 540 MW.
• CUT THE MILL-E AT 470MW.
• CUT THE MILL-D AT 300 MW.
• TAKE OIL SUPPORT FOR FURNACE STABILITY ( AT THE TIME OF 3
MILL OPERATION).
• CUT THE MILL-A AT 210 MW.
• TAKE THE HPH-1,2,3 OUT OF SERVICE.
• WHEN THE LOAD < 30% BOILER COMES IN WET MODE FROM
DRY MODE. START THE BCP AND MAINTAIN THE SEPEARTOR
LEVEL.
SHUT DOWN
• WHEN THE LOAD HAS DECREASED TO 20% OF RATED LOAD TRIP
THE TURBINE ON TURBINE PROTECTION. THIS CLOSES THE
THROTTLE VALVES, GOVERNOR VALVES, REHEAT STOP VALVES AND
INTERCEPTOR VALVES
• CHECK DRAIN VALVES OPENS IN AUTO.
• HP LP BYPASS VALVE OPENS TO MAINTAIN THE FLOW.
• REDUCE THE BOILER LOAD GRADULLY.
• TRIP THE BOILER.
• THE VACUUM BREAKER VALVES SHOULD NOT BE OPENED UNTIL THE
TURBINE UNIT HAS COASTED DOWN.
• VACUUM SHOULD BE KILLED BEFORE GLAND SEALING STEAM IS
SHUT OFF.
• AUX OIL PUMP STARTS IN AUTO AT 2850 RPM.
• JOP START IN AUTO AT 1200 RPM.
SHUT DOWN
• WHEN THE VACUUM REACHES ZERO, SHUT OFF THE SEALING STEAM
TO THE GLAND STEAM CONTROL VALVES.
• SHUT DOWN THE GLAND STEAM CONDENSER EXHAUSTER. SHUT
DOWN CONDENSATE PUMP.
• SHUT DOWN THE VACUUM PUMP.
• SHUT OFF THE COOLING WATER SUPPLY TO THE GENERATOR
HYDROGEN COOLERS.
• ENSURE THAT BARRING GEAR HAS CUT IN.
SHUT DOWN CURVE
COOL DOWN CURVE
THANK YOU