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SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY

2 × 300 MW – Anthracite Coal Fired Power Station

BOILER & AUXILIARIES

Maintenance Manual

Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

Rev. : A

SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

INDEX

1 MAIN TECHNICAL SPECIFICATIONS AND STRUCTURE OF BOILER ( TAKING SG-995/17.3-MMX BOILER AS EXAMPLE)

-

1 -

1.1 GENERAL

 

- 1 -

1.2 TECHNICAL SPECIFICATION OF THE BOILER

- 1 -

1.3 BOILER STRUCTURE

 

- 2 -

2 BOILER PROPER

-

4 -

2.1

DRUM

- 4 -

2.1.1 SPECIFICATION OF DRUM

2.1.2 EQUIPMENT INSIDE THE DRUM

2.1.3 DRUM MAINTENANCE INSPECTION

- 4 -

- 4 -

- 4 -

2.2

LOWER DRUM

- 9 -

2.2.1 LOWER DRUM TECHNICAL SPECIFICATION

2.2.2 MAINTENANCE OF LOWER DRUM

- 9 -

- 9 -

2.3

WATER WALL

- 11 -

2.3.1 TECHNICAL SPECIFICATION OF WATER WALL, STEAM-WATER CONNECTION PIPE, WATER WALL HEADER. - 11 -

2.3.2 MAINTENANCE OF WATER WALL AND HEADER

2.4 SUPERHEATER, REHEATER AND HEADER

2.4.1 SPECIFICATION AND STRUCTURE OF SUPERHEATER AND REHEATER

2.4.2 MAINTENANCE OF CONVECTION SUPERHEATER

2.4.3 MAINTENANCE OF PLATEN SUPERHEATER

2.4.4 MAINTENANCE OF FURNACE TOP AND ENCLOSURE SUPERHEATER

2.4.5 MAINTENANCE OF CONVECTION REHEATER

2.4.6 MAINTENANCE OF RADIANT REHEATER

2.4.7 MAINTENANCE OF PLATEN REHEATER

2.4.8 MAINTENANCE OF HEADER

2.5 ECONOMIZER

2.5.1 TECHNICAL SPECIFICATION OF ECONOMIZER TUBE, ECONOMIZER HEADER

2.5.2 MAINTENANCE OF ECONOMIZER

2.6 BURNER

2.6.1 TECHNICAL SPECIFICATION OF BURNER

2.6.2 MAINTENANCE OF BURNER

2.7 ROTARY AIR PREHEATER

2.7.1 TECHNICAL SPECIFICATION OF ROTARY AIR PREHEATER

2.7.2 MAINTENANCE OF ROTARY AIR PREHEATER

2.8 DESUPERHEATER

2.8.1 TECHNICAL SPECIFICATION OF DESUPERHEATER

2.8.2 MAINTENANCE OF DESUPERHEATER

- 11 - - 14 - - 14 - - 19 - - 23 - - 23 - - 23 - - 28 - - 28 - - 28 - - 29 - - 29 - - 29 - - 33 - - 33 - - 33 - - 34 - - 34 - - 35 - - 56 - - 56 - - 56 -

Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

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Rev. : A

SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

2.9

BOILER WATER CIRCULATING PUMP

- 57 -

2.9.1

TECHNICAL SPECIFICATION OF BOILER WATER CIRCULATING PUMP

- 57 -

2.9.2

STRUCTURE OF BOILER WATER CIRCULATING PUMP

- 58 -

2.9.3

MAINTENANCE OF BOILER WATER CIRCULATING PUMP

- 58 -

2.10

HYDRAULIC PRESSURE TEST OF BOILER

- 62 -

2.10.1 CLASSIFICATION OF HYDRAULIC PRESSURE TESTS

 

- 62 -

2.10.2 QUALIFIED CRITERIA OF HYDRAULIC PRESSURE TEST

- 62 -

2.10.3 CONDITIONS OF HYDRAULIC PRESSURE TEST

- 62 -

2.10.4 HYDRAULIC PRESSURE TEST

- 63 -

2.11

MAINTENANCE OF BOILER STEEL FRAME, PLATFORM HANDRAIL AND MANHOLE

- 65 -

2.11.1 STRUCTURE OF BOILER STEEL FRAME

 

- 65 -

2.11.2 MAINTENANCE OF BOILER STEEL FRAME, PLATFORM HANDRAIL AND MANHOLE

- 65 -

2.12

SPECIAL TOOLS AND SPARE PARTS AND MATERIAL FOR MAINTENANCE OF BOILER PROPER

- 67 -

3 VALVE, WATER LEVEL GAUGE, PIPE AND ACCESSORIES

 

-

68 -

3.1

MAINTENANCE OF SAFETY VALVE

- 68 -

3.1.1 STRUCTURE OF SAFETY VALVE

 

- 68 -

3.1.2 MAINTENANCE OF SAFETY VALVE

- 69 -

3.2

MAINTENANCE OF SOLENOID RELIEF VALVE

- 80 -

3.2.1

MAINTENANCE OF SOLENOID RELIEF VALVE

- 80 -

3.3 MAINTENANCE OF WATER LEVEL GAUGE

 

- 85 -

3.4 MAINTENANCE OF DESUPERHEATING CONTROL VALVE

- 90 -

 

3.5 VALVES

- 92 -

3.5.1 MAINTENANCE OF HP GATE VALVE

 

- 92 -

3.5.2 MAINTENANCE OF HP STOP VALVE

- 95 -

3.6

BLOWDOWN FLASH TANK

- 96 -

3.6.1 TECHNICAL SPECIFICATIONS OF BLOWDOWN FLASH TANK

 

- 96 -

3.6.2 MAINTENANCE OF BLOWDOWN FLASH TANK

- 97 -

4 COAL PULVERIZING SYSTEM

-

100 -

4.1

STEEL BALL COAL MILL

- 100 -

4.1.1 STEEL BALL COAL MILL TECHNICAL SPECIFICATIONS

- 100 -

4.1.2 MAIN TECHNICAL PERFORMANCE

- 101 -

4.1.3 STEEL BALL COAL MILL MAINTENANCE

- 104 -

4.2

COAL FEEDER

- 124 -

4.2.1 COAL FEEDER TECHNICAL SPECIFICATIONS

- 124 -

4.2.2 COAL FEEDER MAINTENANCE

- 125 -

4.3

MAINTENANCE OF THE AUXILIARY EQUIPMENT OF THE COAL PULVERIZING SYSTEM

- 128 -

4.3.1 MAINTENANCE OF THE RAW COAL BIN AND PULVERIZED COAL BUNKER

- 128 -

4.3.2 COARSE /FINE PULVERIZED-COAL SEPARATOR

- 132 -

4.3.3 MAINTENANCE OF WOODBLOCK SEPARATOR

- 135 -

4.3.4 MAINTENANCE OF WOOD SCRAPS SEPARATOR

- 136 -

4.3.5 AIR LOCKER MAINTENANCE

- 138 -

Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

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SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

4.3.6 COAL GATE MAINTENANCE

 

- 139 -

4.3.7 EXPLOSION DOOR MAINTENANCE

- 139 -

4.4

MAINTENANCE OF PULVERIZED FUEL FEEDER

- 140 -

4.4.1 TECHNICAL SPECIFICATIONS OF PULVERIZED FUEL FEEDER

 

- 140 -

4.4.2 MAINTENANCE OF IMPELLER PULVERIZED FUEL FEEDER

- 142 -

4.5

PULVERIZED COAL CONVEYER MAINTENANCE

- 148 -

4.5.1

PULVERIZED COAL CONVEYER TECHNICAL SPECIFICATIONS

- 148 -

4.5.3

PULVERIZED COAL CONVEYER TROUBLE SHOOTING

- 154 -

4.5.4

OPERATION AND REPAIR

- 156 -

4.6

JET LUBRICATION UNIT MAINTENANCE

- 158 -

4.6.1 JET LUBRICATION UNIT TECHNICAL SPECIFICATIONS

 

- 158 -

4.6.2 JET LUBRICATION UNIT MAINTENANCE

- 159 -

4.7 MAINTENANCE OF PRIMARY AIR PIPE

- 160 -

4.8 MAINTENANCE OF BAG-TYPE DUST COLLECTOR

- 161 -

5 PRIMARY AIR FAN (MILL FAN), FORCE DRAFT FAN , INDUCED DRAFT FAN

-

162 -

5.1

PRIMARY AIR FAN (MILL FAN)

- 162 -

5.1.1 TECHNICAL SPECIFICATIONS OF PRIMARY AIR FAN

 

- 162 -

5.1.2 MAINTENANCE OF PRIMARY AIR FAN

- 163 -

5.2

FORCE DRAFT FAN

- 170 -

5.2.1 TECHNICAL SPECIFICATIONS FORCE DRAFT FAN

 

- 170 -

5.2.2 TECHNICAL SPECIFICATIONS OF FORCE DRAFT FAN OIL STATION

- 173 -

5.2.3 MAINTENANCE OF FORCE DRAFT FAN AND HYDRAULIC FLUID STATION

- 173 -

5.3

INDUCED DRAFT FAN MAINTENANCE

- 183 -

5.3.1 TECHNICAL SPECIFICATIONS OF INDUCED DRAFT FAN

 

- 183 -

5.3.2 FUNCTION DESCRIPTION

- 187 -

5.3.3 PARTS DESCRIPTION

- 190 -

5.3.4 INDUCED DRAFT FAN MAINTENANCE

- 192 -

5.4 MAINTENANCE OF FUME DUCT AND AIR DUCT

- 199 -

5.5 AIR HEATERS AND PIPE MAINTENANCE

- 202 -

6 ESP

-

203 -

6.1 ESP TECHNICAL SPECIFICATIONS

- 203 -

6.2 STRUCTURE OF ESP

- 203 -

6.3 MAINTENANCE OF ESP

- 203 -

6.3.1 MAINTENANCE OF CATHODE WIRE AND ANODE PLATE

- 205 -

6.3.2 CATHODE, ANODE RAPPING UNIT MAINTENANCE

- 210 -

6.3.3 MAINTENANCE OF CATHODE SUSPENSION DEVICE AND LARGE/SMALL FRAME

- 214 -

6.3.4 MAINTENANCE OF OTHER AUXILIARIES OF ESP

 

- 215 -

6.3.5 ESP ASH HOPPER AND SLIDE DAMPER

- 218 -

6.4

TESTS AFTER ESP MAINTENANCE

- 219 -

6.4.1

PREREQUISITE FOR ACCEPTANCE TEST

- 219 -

7. DOUBLE SCREW ROD AIR COMPRESSOR(ZRSERIES)

- 221 -

Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

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SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

7.

1 DOUBLE SCREW ROD AIR COMPRESSOR TECHNICAL SPECIFICATIONS

- 221 -

7.

2 DOUBLE SCREW AIR COMPRESSOR STRUCTURE

- 221 -

7.

3 MAINTENANCE LEVEL FOR DOUBLE SCREW AIR COMPRESSOR

- 225 -

7.4.1

MAINTENANCE PREPARATION:

- 226 -

7.4. 2 DISMANTLING OF UNIT SYSTEM PARTS:

- 226 -

7.4.3 DISMANTLING OF MINIMUM PRESSURE VALVE, OIL CUTOFF VALVE, AIR INLET VALVE AND OIL PRESSURE

REGULATOR

- 227 -

7.4.4 CHECK, VERIFY, REPAIR, REPLACE SYSTEM PARTS

- 227 -

7.4.5 WASHAFTERCOOLER:

- 228 -

7.4.6 CHECK SENSORS

- 228 -

 

7.4.7 RECOVER

- 228 -

7.4.8 STARTUP COMMISSIONING:

- 228 -

8 OIL FREE SCREW AIR COMPRESSOR

-

229 -

8.1 TECHNICAL SPECIFICATIONS

- 229 -

8.2 OIL FREE SCREW AIR COMPRESSOR CONFIGURATION

- 229 -

8.3 MAINTENANCE AND SERVICE

- 229 -

8.4 COMMISSIONING

- 230 -

9 REFRIGERATED AIR DRYER

-

231 -

9.1

RSL TYPE REFRIGERATED AIR DRYER TECHNICAL SPECIFICATIONS

- 231 -

9.1.1 WORKING PRINCIPLE DESCRIPTION

- 231 -

9.1.2 REFER TO FIGURE 1 FOR THE WORK PROCEDURE OF THE REFRIGERATED AIR

- 231 -

9.1.3 PROCESS DESCRIPTION

- 232 -

9.2

MAINTENANCE AND SERVICE

- 233 -

9.2.1 PRINCIPLES

- 233 -

 

9.2.2 CONTENT

- 233 -

9.2.3 RSL AIR DRYER TROUBLESHOOTING

- 234 -

10 GASIFICATION BLOWER

-

238 -

10.1

TECHNICAL SPECIFICATIONS

- 238 -

10.1.1

WORKING PRINCIPLE

- 238 -

10.2

MAINTENANCE AND SERVICE OF THE BLOWER CAN BE AS PER THE TABLE

- 241 -

10.2.2

ASSEMBLING

- 243 -

10.3

MAIN PARTS AND CONSUMABLES

- 248 -

10.3.1 LIST OF MAIN PARTS

- 248 -

10.3.2 CONSUMABLES

- 249 -

11 SLAG REMOVAL SYSTEM

- 250 -

11.1

SLAG HOPPER MAINTENANCE AND SERVICE

- 250 -

11.1.1 SLAG HOPPER AND SLAG GATE STRUCTURE

- 250 -

11.1.2 SLAG HOPPER AND MAINTENANCE AND SERVICE

- 250 -

11.2

SLAG CRUSHER MAINTENANCE AND SERVICE

- 254 -

Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

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Rev. : A

SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

11.3 SLURRY PUMP MAINTENANCE AND SERVICE

11.3.1 TECHNICAL SPECIFICATIONS

11.3.2 SLURRY PUMP MAINTENANCE

11.4 DEHYDRATION GRANARY MAINTENANCE AND SERVICE

11.4.1 BRIEF INTRODUCTION

11.4.2 PROCEDURE AND QUALITY STANDARDS

11.5 MAINTENANCE OF CONCENTRATION TANK AND BUFFER TANK

11.5.1 MAINTENANCE PERIOD: AS PER THE SYSTEM OVERHAUL

11.5.2 MAINTENANCE ITEMS

11.5.3 MAINTENANCE PROCEDURE AND QUALITY

11.6 MAINTENANCE OF PUMPS IN THE SLURRY SYSTEM

11.6.1 HIGH, MEDIUM, AND LOW PRESSURE PUMPS

11.6.2 BACKWASHING PUMP

169H11.6.3 DREDGE PUMP 170H11.6.4 LIFT PUMP

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Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

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SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

1 Main Technical Specifications and Structure of Boiler ( Taking SG-995/17.3-MMX Boiler as Example)

1.1 General

W-flame boiler has a different structure from regular coal-fired boiler. It’s combustion chamber consists of lower combustion chamber and upper burn-out chamber. The depth of combustion chamber is 80%-120% greater than that of burn-out chamber. The top of the front project part form the arch, on which the pulverized coal flow and secondary air nozzles are placed (Some W-flame boiler arches are only equipped with pulverized coal flow and steam exhaust nozzles). The jeting down pulverized coal extends downward after being fired. In the lower part of combustion chamber, it meets tertiary air, then turns upward, rising along the axis of furnace chamber, thus forming the W-shape flame. The burned product rises to the burn-out chamber.

Generally, the W-flame boiler is divided into wet bottom boiler and dry bottom boiler. The aboard practice indicates the biggest problem from W-flame wet bottom boiler is the large amount of NOx emission, further, there are also problems such as high temperature erosion of water wall tube, long time of maintenance, weak capability of peak load regualtion. So in general, the wet bottom boiler is not adopted; W-flame dry bottom boiler can steadily burn anthracite and meager coal, Vdaf=6%~20%, and even the anthracite, Vdaf=4% can also be burned. So, this kind of boiler is recommended by general aboard companies. The boilers having been put into services are also such kind of boilers.

To ensure the burning of anthracit e or meager coal, the primary air rate of W-flame boiler is lower, which is 15% to 20%. For the penetrating depth is insufficient due to the own air amount and flow rate of primary air,large amount secondary air must be send from the arch. The lead jet of secondary air from the arch is utilized to ensure the better penetration depth of the primary air.

1.2 Technical Specification of the Boiler

Supplier: Shanghai Electric Group

Type: SG-995/17.3-MXX

Style: Subcritical controlled circular drum furnace, double arch W-flame single furnace, axial burning, primary middle reheated, two-stage attemperating, balancing ventilating, openair disposed, dry ash handling, all-steel structural, all suspended structural II-model boiler

Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

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1

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Rev. : A

SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL
 

Boiler Type

 

SG-995/17.3-MXX

 

Main parameters of boiler

   

superheated steam

B-MCR

t/h

995

Rated evaporation(RO)

t/h

889.1

Steam Pressure (B-MCR/RO)

MPa·g

17.29/17.13

Steam Temperature(B-MCR/RO)

 

541/541

Reheated Steam re

Steam flow(B-MCR/RO)

t/h

882.498/736.407

Inlet,outlet steam pressure(B-MCR)

MPa·g

3.53/3.34

Inlet,outlet steam pressure(RO)

MPa·g

3.14/2.98

Inlet,outlet steam temperature(B-MCR)

 

320/540

 

Inlet,outlet steam temperature(RO)

 

309/540

 

Feedwater temperature(B-MCR/RO)

 

281/273

1.3 Boiler Structure

The boiler proper is designed by Alstom, and its technical support of commisioning and performance test is also supplied by Alstom, it is made by Shanghai Boiler Works, Ltd. The style of boiler is double-arch W-flame single-furnace, primary middle reheated, forced water circular, subcritical drum boiler. Two units are equipped with one startup boiler, which acts as the startup steam source during the unit startup;

The coal type of the boiler is anthracite, which is from CAM PHA mineral area and HON GAI mineral area in Vietnam.

Combustion system: it adopting hot air for pulverized coal feeding, each boiler equipped with 16

dual-split double direction pulverized coal feeders and 32 burners. The capacity of pulverized

coal burner is 100% BMCR of designed coal type. The startup and flame stablizing of boiler

uses heavy oil, according to standard of TCVN 6239-2002. The boiler employs two-stage

ignition, i.e., the heavy oil gun is fired by the electric spark of high-energy ignitor, then the heavy

oil gun ignite the pulverized coal. Oil gun adopts steam atomization. For the project, 2×5000 ton

oil tanks, 2 oil drain pump, 2 × 100% capacity AC/DC oil feeding pump, 1 dirty oil pump and 1

sewage pump are disposed.The fuel system is disposed the oil feed pipe/oil return pipe to

burner of boiler according to the principle of single oil feed/return main pipe.

Oil burner: there are 8 heavy fuel oil HFO) burner at each folded flame corner, i.e., each boiler

equipped with 16 burners. Auxiliary steam with pressure stablized at 5.25 bar(g) allow HFO

attain at atomization state, the auxiliar steam is also used for burner clean. The heavy oil is

ignited via the high energy ignitor, each HFO burner is equipped with special flame inspector.

Date: 2008-10-20

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SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

Cooling wind is provided to burner and flame inspector via two independent special loops.

During stop, fuel burner retreated from burner nozzle about 330 mm, to prevent the affection of

boiler radiation( avoiding the burnout of oil burner). All burning capacity (LHV base value) 30%

BMCR fuel heat input value, only adopting 12 burners can attain 30% BMCR burning capacity

(two burners per folded flame corner stop operation). The regulation ration of burner is 1:5. J11

oil burner is employed.

Smoke exhaust and ash system of boiler: the smoke exhaust system adopts negative balancing ventilation style, smoke and gas come from ESP to FGD, then exhausted to atmosphere, or directly vented to atmosphere via FGD bypass. Induced/forced draft fan is axial type, forced draft fan is adjustable moving-blade one, and induced fan is adjustable static-blade one. The pulverizing system is warehouse type, smoke drying pulverizing system, adopting negative pressure ventilation. Each boiler is equipped with two single-in-single-out BBI ball miller. The primary fan (pulverized coal exhauster) use centrifugal fan. The smoke exhaust goes through the fabric filter undergoing the pulverized coal filtering, and then to the smoke exhauster, being vented to the atmosphere.

Ash handling and ash yard: dry bottom handling style is adopted. The bottom ash is discharged to ash sump via the slag crusher, hydraulic ejector. The ash collected from air preheater, ECO and electric precipitator is sent to large scale ash silo (each of the two silos has capacity of 2500 m3). Dry ash is further sent to ash slurry pond through blending of ash and water, and then conveyed to ash yard by ash slurry pump (Composite utilization of dry ash is kept at the same time).

Dust collection and desulphurization system: four-electric field electrostatic precipitator is chosen. For this phase, a 200m-height dual steel flue stack will be built. Synchronously, 100% capacity FGD is to be built, adopting wet desulphurization process, limestone-plaster forced oxidation, using gas - gas heat exchanger (GGH);

Compressed air system: this system is considered according to less lubricant, three 50% capacity compressors are equipped.

Safety valve: Spring loaded safety valves from Crosby Company of U.S.A. are used for the boiler. Detailed position: 3 pieces for boiler furnace1 piece disposed at outlet pipe of superheater, 2 pieces for inlet pipe of reheater, 2 pieces for outlet pipe of reheater, also a electromagnetic relief valve(ERV) is placed at outlet pipe of superheater, with brand of VTI, USA, supplied in whole unit by Crosby Company. The maximum evaporation is 995t/h, total discharge amount of safety valve of boiler drum is 881.796t/h, accounting for 88.62% of maximum evaporation, the discharge amount of superheater safety valve is 153.86t/h, account for 15.46% of maximum evaporation, the sum of total discharge amount of boiler drum and superheater is 1035.656t/h, being 104.09% of maximum evaporation. The maximum flow rate of reheated steam is 848.6t/h, the sum of total discharge of reheater inlet safety valve is 512.94t/h, accounting for 60.45% of maximum flow rate of reheated steam, the sum of total discharge of reheater outlet safety valve is 379.157t/h, accounting for 44.68% of maximum flow rate of reheated steamthe sum of total discharge of reheater inlet/outlet safety valve is 892.097t/h, account for 105.13% of maximum flow rate of reheated steam. The discharge rate

Date: 2008-10-20

No.:QN1-SEC-G-04-TP-009

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Rev. : A

SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES

SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 × 300 MW BOILER & AUXILIARIES MAINTENANCE MANUAL

of dynamic discharge valve is 166t/h, occupying 16.68% of total evaporation of boiler, its discharge will not be included in discharge rate of safety valve.

2 Boiler Proper

2.1 Drum

2.1.1 Specification of drum

In the drum, along the direction of length, arranged circular interlayer, eddy-current

separator, corrugated plate separator, louver moisture separator, water feeding distribution

header, continuous blowdown pipe and inlet flow equalizing plate, cross plate of downcomer.

2.1.2 Equipment inside the drum

Designation

 

Quantit

Material

Designation

Quantit

Material

 

y

y

Arc diaphragm

 

14

pcs

AY3F

Inlet equalizing pipe of

4

 
   

downcomer

Seat plate of separator

14

pcs

AY3F

Cross

plate

of

4

 
 

downcomer

Lower

support

of

56

pcs

EG25

Pipe φ48×5, L406

 

4

20

steel

separator

     

Eddy-current separator

56

pcs

 

Sampler inside the drum

1

 

Corrugated

plate

dry

72

 

Pipe φ51×4, L566

 

36

20

steel

box

   

Sluice tube plate

 

18

 

Pipe φ51×4, L

 

18

20

steel

Water

feeding

1

 

Pipe φ51×4, L

 

18

20

steel

distribution header

     

Blowdown piping

 

1

 

Stud connection

 

12

 

Sluice pipe

 

18

       

2.1.3 Drum maintenance inspection

Maintenance

Workmanship and precautions

Quality standard

item

I

Maintenance

1. Remove insulation cover of manhole at both

 

preparation

sides, remove the manhole door screws with

drum manhole special gate spanner. After

remove, the manhole screws and nuts should

be placed in special oil tank or oil disc to

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avoid loss and rust.

   

2.Open manhole door, mount draft fan to cool

 

down the inside of drum. Maintenance

person can only enter the drum after the temperature of drum decrease below 40.

3.

To prevent the tools and parts fall into the

downcomer, after take down the filter screen

of downcomer, rubber should be laid on the

bottom of drum. When carry out job inside the

drum, the maintenance person must strictly

comply with the requirement of Clause 270 of

“Safe Operation Regulation of Electric

Industry”(Thermal Machinery Section)”.

 

4.electric tools and lighting used in drum must meet the requirements of Clause 272, 273 and 274 of “Safe Operation Regulation of Electric Industry”(Thermal Machinery Section)” issued by certain Ministry.

5.

After the open of manhole door, temporary

manhole gate must be mounted. During the

maintenance, the maintenance person should

close the temporary manhole door when he/she

leave the drum.

 

II Inspection of

1.

Firstly, the chemical supervision personnel

1. The completeness of

facilities

&

inspects the fouling and rust inside drum and

 

the moisture separator,

accessories

the surfaces of inner facilities.

 

without loose, tilting

inside the drum

2.

Check

and

record

the

completeness,

and corrosion; the

and dirty clean

 

louver has no damage

 

leakproofness and security.

 

and deformation .

 

3.

Check the connection screw and fastening

 

screw of moisture separator.

 

2. No fall-out, loosing to

the connection screw

4.

Clean

the

surface

fouling

of

drum

and

 

and fastening screw of

moisture separator.

 

moisture separator.

 

Caution: Do not damage

 

the

glossy

3. Cleanness of the inner

anticorrosion film on the metal or its surface.

 

surface of drum and

 

surfaces of moisture

5.

Clear and dredge the blowdown pipe, sample

 

pipe, chemical feed pipe, connection pipe of

 

separator and

accessories.

water gauge and pressure meter.

   
 

4.

Free-flowing

in

the

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blowdown pipe, sample

pipe, chemical feed pipe

and connection pipe of

water gauge and

pressure meter.

 
 

III

remove

&

1. Before disassembly, number the moisture

1.

Moisture

separator

assembly of

 

separator according to sequence of

and

cleaning

hole

facilities in drum

left-right-front-back.

 

mounted correctly.

 

2. When dismantling, first remove the draining

2.

Cyclone separator

 

pipe and the cyclone separator barrel and

cartridge and top hat

connection screw and fasten screw of top

may be kept vertical and

hat, then take down the separator and top

smooth.

hat.

 

3.

No

loosing

of

the

3. Remove the connection screw of support

connection

screw

and

 

plate of dry box; draw out the dry box along

fixing screw.

the support plate.

   

4. After remove the connection screws and

fixed screws, count out them, and not to leave

them in the drum.

 
 

IV Inspection of

1. Polish the surface of longitude joint and

1. Polish the weld and

welding

joint

 

circular joint of inside/outside the drum and

surfaces along the

inside/outside

100-150mm area along weld with polisher.

weld, removing the

the

drum,

inner

Detailed section and length should be

fouling and rust,

wall corrosion

stated by the metal supervision personnel.

showing the original

and crack

   

metal color.

 
 

2. After clean of drum inner wall, check

 
 

erosive point and crack on the surface of

2.

After erosive point

inner wall. If common erosive points and

and crack polishing,

cracks are found, polish them with

such polished section

polisher. For serious erosive points and

should be flat and

cracks, report to higher technical

smooth, having no

department for making special technology

edges and corners.

measures.

 

V downcomer

1. According to requirements of metal

1. Edges of downcomer

pipe and other

 

supervision, polish the edges of drum

seat inside the drum

visible pipe seat

downcomer seat weld. After that, the metal

have no crack.

 

weld inspection

supervision personnel carry out flaw

2.

the

fillet

welds

of

detection on polished surfaces.

cross

plate

of

2. Clear

the

fillet

weld of

cross plate of

downcomer have no

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downcomer, and inspect the fillet welds. If

 

crack and erosion.

cracks exist, polish them until removal.

 

3. The fillet welds of

3.

Inspection of fillet welds of connection

 

connection pipe of

pipe seats of blowdown, chemical feed,

blowdown, chemical

water gauge and pressure meter. If cracks

feed, water gauge

exist, deal with them.

 

and pressure meter

 

have no cracks.

4.Grind the edges of pipe seat corners of

 
 

safety valve with polisher, and give flaw

4. The fillet welds of

inspection to fillet welds by the metal

 

safety valve pipe seat

supervision personnel.

 

have no crack.

 

VI

Weld

1. Check

the

circular

isolating

plate

and

1. The welds of circular

inspection

of

 

upper

side

plate

welds

with

light

 

isolating plate and

inner

parts

of

transmission method, if any, repair weld.

side plates have no

drum

   

cracks.

 

2. Check the tee pipe of water distribution

 
 

pipe and side heads with light transmission

2.

Welds

of

Tee of

method. If any cracks, repair weld.

 

water distribution

 

pipe and side heads

3.Clear embedded parts’ welds of manhole

have no cracks.

 

hinges. If any cracks, grind and repair weld

 

them.

3.

The fillet welds of

Note: Do not generate arc from drum.

 

manhole hinges have no cracks.

 

VII

Drum

1.

The drum levelness measurement shall

 

levelness

 

base on the horizontal central lines of side

measurement

circumference.

 
 

2. Use a rubber pipe with glass pipe plugged

 

in both ends, full water in the rubber pipe,

and put the two end glass pipe on the side

circumferential horizontal lines.

 

3. Measure and record the distance from

 

drum central line to glass pipe water level,

compare the distances of two sides. The

difference is deviation of drum levelness.

VIII Maintenance

1. Clear the junction surface of doorframe

1 The junction surface

 

of manhole door

 

and doorplate of the manhole door with

 

of frame and plate

   

should be smooth.

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butt chisel and sand paper.

 

Use special flat ruler

 

and

filler

gauge

to

2. Check the junction surface of doorframe

check

12-1

points

 

and doorplate. If cracks or flaw points

exist, grind them. For trace of blowing

along

circumference

of

the

grinded

damage, carry out bead welding after

surface,

the

error

grind, and then grind it again.

should be less than

3. Kerosene should be used for clean of the

0.1-0.2mm.

 
 

screws and nuts of the manhole door; and

2. The screws and nuts

then check the threads of such screws and

   

of manhole door have

 

nuts. The thread burr should be repaired

no burrs and breaks.

with file or on the machine tool; for those

 

have serious fault, change them.

3. Screw hardness HB

 

197.

 

4.The hardness of screw should be checked

 
 

for each over haul.

IX

1. Check the contact of derrick and drum.

1. Derrick and drum

support/suspen

 

well

contacted,

sion

frame

2. Check the appearance of suspension nut

having large contact

   

of derrick.

check

 

area.

3. Check the appearance of derrick.

2.

The suspension nuts

of derrick are even

loaded, and have no

erosion on surface.

 

3. The derrick surface

 

has no erosion.

 

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close

of

1. After the maintenance inside drum, the

1.

No foreign matter in

manhole

 

maintenance tools should be taken out, and

the drum.

 

count, reviews them.

2.

The junction surface

2.

Last inspection should be given to drum

is well contacted after

 

before close manhole.

manhole closed.

3.

Before close manhole, the high pressure

3.

The fixing screws are

 

seal gasket, and coat the door frame, door

even loaded after

plate, screws and nuts with molybdenum

manhole closed.

disulfide.

4. After close the manhole, check the contact

 

circumstance of junction surface with filler

gauge.

5. After cold state fasten of the manhole door,

 

hot fasten the door again when the

pressure increase to 0.3—O.5MPa.

2.2 Lower Drum

2.2.1 Lower drum technical specification

The circular structured lower drum, Φ914mm, will replace lower header of all evaporation

heating absorption area. It has the same function with normal low header of boiler water wall.

The lower drum is equipped with multi-hole strainer cover and orifice plate, the diameter of

strainer is 0.6mm with opening area ratio of 52%. The function of the strainer is to prevent the

foreign matter entering the water wall tube. The orifice plate is mounted in the inlet end of the

water wall tube. Each tube is equipped with orifice plate. The function of the orifice plate is to

normally distribute the feed water, ensuring the safe operation of water wall. The diameter of

orifice plate is calculated for each loop and each water wall tube according to heat load

distribution curve along the direction of furnace height and the different flow resistance under

different working condition.

2.2.2 Maintenance of lower drum

Maintenance item

Workmanship and precautions

Quality Standard

I Preparation before

1. After the open of manhole, the

 

maintenance

chemical supervision personnel enter

the drum to check the erosive points

and sample the scale.

2. Pave rubber on the nozzle of front and

rear drain pipe to prevent the falling in

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of tools.

   

II Disassembly of

1.

Number the cover of multi-hole

1.

The orifice plate is

orifice plate

strainer, remove the fixed screw of the

smooth, with correct

cover, and take down it.

 

mounting position.

Note: After remove the screws of cover,

2.

After assembly, the

take them out of the drum, and count

orifice plate should be

them.

 

secure without loose.

2. Group and number the orifice plate.

3.

The

surface

of

strainer cover should

3. Remove

the

retainer

enclosed

the

 
   

be smooth and clean.

 

orifice

plate,

take

down

the

orifice

 

plate.

4.

The

mounting

Note: After remove the screws of cover,

position of multi-hole

strainer

cover

is

take them out of the drum, and count them

correct.

And

the

to store collectively.

 

cover has

no

loose

4. After removal, the orifice plate must be

after installation.

5.

 

put into oil disc or other container to

The

change

rate

of

wash. If meet with acid cleaning, the

hole

diameter

of

orifice plates and multi-hole strainer

orifice plate should be

cover may not be removed, cleaning

less than 5%.

with the system. But, after that, spot

 

check a group of orifice plate to find

the result of acid cleaning.

 

5. After plate clean, spot check orifice

 

plate to measure the diameter of hole.

If the diameter exceeds the standard,

change the plate.

 

6. Assemble the orifice plate according

 

to the number. Do the same with

strainer cover.

 

7. After

reassembly

of

orifice

plate

 

retainer, check the looseness.

III Inside clean of

1.Clear the fouling in the inner wall of

1.The

inner

wall

of

lower drum

 

lower drum, pipe seat of water wall

 

lower

drum

is

and of downcomer with wire brush and

smooth,

free

of

compressed air.

 

fouling.

2.

Clear the fouling on the surface of

2.There is no fouling on

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mulit-hole strainer cover with wire

brush and compressed air.

the pipe seat of water

wall and downcomer.

3.The orifice plate is flat

and smooth.

4.The

strainer

smooth,

fouling.

surface

cover

free

of

is

of

2.3 Water Wall

2.3.1 Technical specification of water wall, steam-water connection pipe, water wall header.

The water wall, adopting all welding type membrane water wall, together with drum,

furnace water circling pump and lower drum etc., form several force-flow independent loop. The

water wall has two types, i.e., smooth pipe and inner thread pipe.

2.3.2 Maintenance of water wall and header

Maintenance

Workmanship and precautions

Quality Standard

item

I Preparation

1.Erect firm and stable scaldfold from bottom ash

 

of water wall

hopper to inlet elbow of wall reheater around ther

maintenance

furnace.

2.When use elevating platform in furnace, make

sure to operate according to sepecification.

Note: Do not exceed the limited weight or serve as

lifting tool when use elevating platform.

3.Certain number of lights should be put in the

furnace to ensure sufficient lighting of the

furnace. The power line to the furnace should be

overheaded.

II Coke and

1.Before coke cleaning of water wall, a wood board

1.There is no coking

ash cleaning

should be paved on the slope of bottom ash

or ash deposit on

of water wall

hopper to separate the furnace and the hopper, in

the surface

of

order to prevent strike of coke on the slope water

water wall.

wall tube.

2. No damage to the

2.Strike the coke suspending on the water wall

water wall surface.

upside down with hammer, let it break away from

the water wall.

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Note: Do not damage the water wall when stike and

 

remove the coke.

 

3.

Remove the thin coke and ash deposit attached

to the water wall with round spade along the

surface of water wall.

 

III

Visual

1.Use thickness tester to measure the water wall

1.

The reduced value

inspection of

thickness besides the burner and around the blow

of thickness of

water wall

hole of soot blower and the thickness of

worn pipe should

suspending pipe.

 

be less than 30%

 

of tube thickness.

2.

Use a slide caliper or caliper gauge to measure

 

the expanded value of pipes along the both sides

2.

The

expanded

of burner and suspended pipe at furnace outlet.

value

of

pipe

should

be

less

Note: Remove the ash deposit on the surface of

than 3.5% of tube

pipe with brush before measurement.

 

diameter.

 

3. Check the deformation, pits of water wall tube of

3.

The slope water

bottom ash hopper slope and erosion points near

wall of bottom ash

the water seal trough.

 

hopper has no

4. Check the crack of fin of water wall, if any, repair

deformation and

weld with electric welding.

 

pits, the depth of

5.With

respect to water

wall

tube at

high heat

erosive points of

 

tube should be

loaded area, also performance the high

less than 30% of

temperature erosive inspection.

 

tube thickness.

 
 

4.

The fins of water

wall

have

no

crack.

IV

Sampling

1.The location of supervision tube of water wall may

1.

The cut position of

of

be determined by the metal supervision

tube is correct.

supervision

personnel.

 

The distance that

tube

 

cut point away

2. For the cut of supervision tube, the cutting point

should avoid the rigid beam of water wall, and

from the rigid

beam and bend

also stagger with the weld of adjacent tube, the

 

distance staggerred may be more than 50 mm.

 

start point of elbow

should be more

Further, after cut, the fin of water wall should be

than 150 mm. The

cut more than 25mm along the wall to ensure the

 

welding quality.

   

cut point shoud be

more than 150 mm

3. The length of supervision tube usually is not less

away from the

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than 250 mm, the sampling tube should include

adjacent

weld

the new and old section.

seam

at

same

tube.

4.During the cutting, do not damage the tube proper

and adjacent tube. Try to use machine to perform

2.The sample tube

the cut and avoid the falling of weld slag into the

and adjacent tube

tuge when using flame cutting. Following

have no damage.

completion, seal the tube open to the top.

5. After remove the supervision tube, show the

location of supervision tube, the side facing flame

and flow direction of fluid in the tube.

V

1.Following the tube cut, use facing machine to

 

Replacement

make the divided edge of cross section. Before

of tube

butt welding, the pipe inner/outer wall should be

ground until showing proper metal color. The

length to be ground is 10-15mm in general.

2.Before the cut of new tube, visual inspection and

pipe thickness measurement should be given to

tube. For curved tube, the ellipticity of bending

section should be carry out and given ball passing

test. Additionally, aid cleaning may be

implemented before use, and purge the tube by

the aid of compressed air before butt welding.

3.Argon arc weld may be used for pipe, or with the

argon arc weld as the backing, electric weld as

the covering technology. There will leave 3 mm

gap between pipes.

Note: Do not butt weld forcely. After the tack weld,

not to strike with hammer.

4. Following the of weld, carry out flaw detection to

the tube. The fins can be restored after confirm

the qualification of weld seam. The expansion

efficient of fins should be in line with that of fin

tube. Seal welding will be adopted.

5.When replacing suspended tube, the cold-drawn

dimension of tube should be measured and

recorded after the cutting of tube to ensure the

cold-drawn value during the restore of tube.

When replacing several suspended tubes, it

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should be done one by one. Do not cut two or

more tubes at the same time.

2.4 Superheater, Reheater and Header

2.4.1 Specification and structure of superheater and reheater

2.4.1.1 Structure of superheater and reheater

According to gas flow process, the superheater system is divided into five stages,

i.e.,separation platen, rear platen, last stage, enclosure and low temperature superheater;

according to steam flow process, such system is divided into such five stages as top furnace,

low temperature superheater, separation platen, rear platen and last stage convection

superheater:

Reheaters are well distributed at high temperature gas area, they are classified into

three stages: wall reheater, platen reheater and last stage reheater. The wall reheater is low

temperature reheater, disposed at front wall on top of furnace and front side of two-side walls,

close to the water wall and cover the water wall.

2.4.1.2 Technical specification of superheater and reheater

The wall thickness of superheater tube is determined by strength, of which the material is

depended on work temperature of superheater and relied on the principle of safety and

economic.

No.

Item

Unit

 

1.

Saturated steam tube

   

Nominal outer diameter

mm

57/44.5

Longitudinal distance

mm

127.5/153

Material

   

Quantity

 

136

Outlet steam temperature

362

Pressure drop from lower drum to superheater outlet

kg/cm 2

14.1

under condition of BMCR

2.

Saturated steam header

   

Quantity

 

1

Nominal outer diameter

mm

244.5

Nominal bore diameter

mm

 

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Length

m

About 15.8

Material

 

SA106 C

3.

1 st stage superheater

     

Quantity

   

1

Gap of tranverse gas flow

 

mm

102

Gap of gas flow direction

 

mm

89

Nominal outer diameter of tube

 

mm

44.5

Heat absortion area(effective)

 

m

2

about 8150

Total circumferential heat area

 

m

2

Should

be

   

announced

Gas duct area

 

m

2

Should

be

   

announced

Material

 

SA210C

SA209T1

Platen quantity

   

149

Steam flow tube number

   

447

Outlet steam temperature

 

393

Total