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TÜRKIYE

ELEKTRİK

KURUMU

CATALAGZ!

THERMAL ' POVVER

PLANT

UNIT

No.2,

INSTRUCTION

MANUAL

M/S

V.

TRANSELEKTRO

FERENC

MÜNNICH

UTÇA

13

'

"H"-'1394

BUDAPE5T

HUNGARY

Contract

No.:

122-46-6/0566

I. Book

I. BOOK

C0NTENT 5

1./ OPERATHîG TIAUUEL POR THE STEAM GMERATING UITIT

l.l*

Specification of the plant

1.2.

Starting of the steam generator from cold state

1.3.

Starting from marm state

1.4.

Operation

1.5.

Putting the boiler out of operation

1.6.

Drawings

2./

RA.PH /REGMERATIV AIR PREHEATER/

 

2.1.

Mounting instruötion of RAPH

2.1.1.

List of mounting designs

2.1.2.

General Information

2.1.3.

Order of mounting

2.1.4» Sketches of order mounting

2.2.

Operating and maintenance Instructions

2.2.1.

Operating instructions

2.2.2.

Maintenance instructions

2.2.3.

Operating and maintenance plans and drawings

3./

EVT - Beater ifflıeel Mili Type; s 32.60.

3.1. Operation

3.2. Maintenance

3.3. Repair

3.4. Drawings list

4./ PüLVIS shaft clutch Model W 750

4.1. Operating instruction

4.2. Instructipn Leaflet concerûing the Alignment

4.3. Supplement to the Operating instructions W0

4.4. instructions for the Disassembly and Reassembly

5./ PEEDER

-

2

-

6./ BĞlt conveyor - with scraper chain

II. BOOK

7./ OIL BIMÎERS

7.1. Instruction manual for oil burners type ENO-1500 M and

control eq;uipnıetıt MO-SOOO M

7.2. Oil bumer s type MO-150 0 M G-354-00

7.3. Mainte-nance Instructions for valves type PSZN

7.4. Instrumeut manual for flame relay 5180-0 developed by TÜKI

7.5. Hardware Bescription

7.6. The PA-8K LOKATOR

7.7. Instrument manual for the control appliance V-Y 3041

8./

SOOT

-

BLOWERS

8.1.

Water Blower: Type SK 58 E

8.1.1.

Description of the Blower

8.1.2.

Transport and Installation

8.1.3.

Start - up

8.1.4.

Operation

8.1.5.

Routine service

8.1.6.

General maintenance

8.1.7.

Sketches

8.2.

Long retractable blower Type: RKS 80 E

8.2.1.

Description of the blover

8.2.2.

Installation and start - up

8.2.3.

Operation

8.2.4.

Maintenance repair and clear avray of faults

9./ PAN

9.1.

i

d

fan

9.1.1.

Operating conditions

I

'

-

3

-

9.1.2.

Description of the fan

9.1.3.

Service instructions

9.1.4.

Mai-ntenance of the fan

JF

*

9.1.5.

Lubricatinş, iTistructioıas

9.1.6.

Causes of trubles and repalr

9.1*7.

Demounting and mountiıag of axial fan parts

9.1.8.

Spare parts list

9.1.9.

Connecting-up of the piping

9.1.10.

Conservation for Compressors and Pans

K-İCOK

9.2./ FD - fan

9.2.1. Operating conditions

9.2.2. Pan description

9.2.3. Aerodynamic prepequ.

9.2.4. Maintenance of the fan

9.2.5. Lube oil instructions

9.2.6. Causes of troubles and repair

9.2.7. Dismounting and mounting of fan parts

9.2.8. Spare parts list.

9.2.9. Connecting-up of the piping

9.2.10. Conservation measures

9.3./ KNV-63/2880 centrifugal fan

9.3.1. Data sheet

9.3.2. Installation

9.4./ VHK-160/167-960

9.4.1. Data

9.4.2. Placing

9.4.3. Guarantee

9.4.4. Storage

9.4.5. Mounting

9.4.6. Servicing

9.4.7. Handling

9.4.8. Maintenance

9.4.9. Spare parts

9.4.10. Appendix

-

4

-

9.5. •TIîK-45/14440 Bearing - coollnr fans

9.5.1.

Data Sheet

^.5.2.

Installation

n.5.3.

Guarantee

0.5.4.

Storage

9.5.5.

Assembling

9.5.6.

Putting the "^an into "'nerfition

9.5.7.

Maintenance

0.5.8.

Spare porst

9.5.9.

Enclosure to SERVİCE UmjAL

10. •.UTÎGT ELTİCTRICAL PRECİPITATOR

10.1. Descriptoin and Operption

10.1.1. General Information

10.1.2. Technical Data

10.1.3. Mode of Operation

""0.1.4.

Structural Design

Operating Instructioı s

I,0.1.5.

Instructions

10.1.6. Uaintenp.nce

10.1.7. Installatlon and Rem'val Instructions

10.1.8. Walkthrough Inspecticn of ESP

10.2. Instruction for Stor?^e and Erection

10.3. Controls for HT

- Un? t s T)010/D011

10.4. Control cabinet for ?ux. drives

10.5. RICO High voltage

Direct current equİT'Tient

10.5.1.

linit parts

10.5.2.

Punctioning

10.5.3.

Instructions for storage

10.5.4.

Instructions for Tnai-> tenance

 

10.5.5.

High vottage control unit

Type

TH-S 5

10.5.6.

H.Y - unit testing

11. MOTOR

II.1.

11.1.1. Introduction

11.1.2*

11.1.3. Technical description

Type PBDO 716 SlO

Tecljnical data

11.1.4. Stator

^

 

-

5 -

 

y

11.1.5.

Rotor

11.1.6.

Beariıags

11.1.7.

Ventilation

11.1.a.

Handliüg aüd malntenance instnıctions

11.1.9.

DravTings of doctmentation

.IV.BOOK

 

11.2.

Type: FBDO 566 S4

11.2.1.

Introduction

11.2.2.

Technical data

11.2.3.

Technical deseription

11.2.4

Stator

11.2.5.

Hotor

11.2.6.

Bearings

11.2.7.

Ventilatlon

11.2.8.

Handllng and tnalntenatıce instruction

11.2.9.

DrauTİngs of dolcumentatlon

11.3.

Type : PBDO 566 L6

11.3.1.

Introduction

11.3.2.

Technical data

11.3.3.

Technlcal description

11.3*4.

Stator

11.3.5.

Rotor

11.3.6.

Bearings

11.3.7.

Ventİlation

11.3.8.

Handling and malntenance instruction

11.3.9.

Drawlngs of dokumentations

11.4.

EVIG / Threo phases inductlon motors/

11.4.1.

Packing

11.4.2.

Voltage

11.4.3.

Moımtlng of the motors

11.4.4.

Mounting of the "bearings

11.4.5.

Shaft end

11.4.6.

Temperature rise

11.4.7.

Protection

11.4.8.

Start - delta swlch

11.4.9.

Motor with woıınd rotors

6

-

6

-

11.4.10,

Rotor started

11.4.11-

Spare parts

11.4.12.

Repair

11.4.13-

Connection to the raain and first startlng

12.

Operating Instruotions for Vertical Centrifugal Pumps

/ ALIı\7EILîîR /

13.

ATBIA - Actuators

13-1-

13»2-

13-3.

13-4.

13 - 5.

13-6.

13-7.

Special features

Practical considerations

Anma - compact

Basic ©nuipment

Sizing data

Dlmensions

Type GST 12-1600

14.

BEMAR D - Actuators

14-1-

14-2.

General

Electric Actuators

14.3.

Reduction (îearboxe3

15-

SfflPSU, Safety Relief Valve

Type : VS 99

15-1-

15-2.

15-3.

15-4-

15.5.

15-6.

Disassembly

Inspection and servicing

Assembly

Inspections after start - up

Spare parts

Drawings

16.

Solenoid Control Valves

16.1.

Deseription

16.2.

Design

16.3-

Mode of operation

16.4-

Installation

t

-

7

-

16.5. Insulation

16.6. Diassembly

16.7. Inspection and Servicing

16.8. Assembly

16.9. Piping

16.10. Spare Parts

16.11. Drawings

17•

Slag - removing

 
 

17.1. Technical Description

17.2. Siting and Mounting

17.3. Lubrication

17.4. Coramissioning

17.5. Operation and Maintenance

17.6. Conditions of Guarantee

17.7. Technical Data

18^

Hydraulics of Submerged Gate /HYDROPNEU/

 

le.l.

Descriptlotı

 

Lines and connections

 

18.3*

Puttlng iTito operation

18.4.

Maiutenance

18.5.

A.pparatus llst

19-

Slag Crusher Rolling lülll

TYpe: HPJ 80/120

 
 

19-1.

Scope of application and oporation

19*2.

Technical description

19.3.

Technical data

19*4.

Poundation and assembly instructions

19-5»

Asseıily and maintonance

19.6.

Safety instructions

19.7.

List of apare parts

20.

Installation - and Operation

instructions for Globe Valve

20.1. General

20.2. Putting Into service and operation

20.

20.4.

20.5.

-

8

-

Maintetıance

Repacking - and replacing the gland packing

Disman-tlitıg and repair

21. înstallatlon, Treatment and Operation

of Pressııre measııring Instruments.

21.1. Installlng

21.2. treatment

21.3. Operation

22. Conveyor Belt

CB 7A/B;

CB 9A/B and CBIO

22 .1.

Blaulpment manual

22.1.1.

Prellminarieg

1.2. Technical Specifications

1.3. Teohnical Descriptlon

1.4. Manufacturlng Instructlons

1.5. Transporting

1.6. Assembling

1.7. Patting Into Operation

1.8. Operation

1.9. Uaintenance

1.10.

Safety Instructions

1.11.

Techn. Dese. for Pire Protecting

1.12.

Spare Parts List

1.13.

Appendices

23. DEHOPLAST

23.1. Problems conceming the storage and conveyan^se of bulk. materials

-

9

-

23.2.

Details of lining

23.3.

Non - adhesiou and sliding

23-4.

properties Abraison

23.5.

Ezamples of lining

i

l

.r-

.ti"; :-/;'.';.-

y.

EVT Energie untJ Verfahrenstpchnik GmbH - Stuttgart

Preliminary Operatlon Manual

T"

-

-

"

-

<

for

Natura!^ Circulation Steam Gener&tors

with EVT Engineering

Stuttgart, 31.06.80,

Dept, IS-Mer/Ea

Plant: CatalagziAurkey Order No: 5,36 52o

İt

I N

-

1

.

D S X

Prefsce

1.

Gpecificatlon of the plont

1.1

•^peçificstion of the steom generotcsr

1.2

Cepacît^ data

1.3

fiâ8X. permİ33İble water and ateam temperatares

1.4

Suppl^ water and boiler water values

1.5

3afety equipment

1.51

IIP ıfeduction station

1.52

D m m safety valves

1.55

liP aafety valvee

1.54

Reheater aafety valves

1.6

Parnace air

1.7

î'irirg

1.71

Ignition firing

1.72

Coal firing

1.721

Firing dota

'

1.722

Feeder

1.723

Deslagger

1.724

31afi cruaher

1.8

Flue ges

1.9

Deashing

1.91

J5VT deelagger

1.92

Diving plates

Page

4

5

5

7

8

9

10

10

10

10

10

11

11

11

11

12

13

13

13

13

14

14

15

T-

-

2

-

2.

Adjustment data

3.

I^srting of the steam generator rtom eoid .8|;ete

3.1

-Pr^p^i^tione

3,11

Pr^paratoi7 work /general/

3.12

PFeparatîons at the water/stQ8m aide

3.13

Fîlling of the boiler

3.14

Preparatio n fet Lhe air/flue gs s side

3.15

Ignition oLl firing

"" 3.16

Coaİ

3.17

Deâlaggex

3.18

Mills

3.2

Putting into oeration

3.21

Au*iliai7 agfiregotes

3.22

Pre-ventilation

3.23

Ignition of oil-firing

3.24

Acceleration o f ihe steam generator

3.3

Putting into'operotion of milis

4.

3terting from warm state

. 4.1

Hot-starting

4.2

WanQ^starting - ••

*

t

Page

15

15

15

15

17

17

1 8

19

20

20

20

20

20

21

22

22

25

26

26

27

-

3

-

Pöge

5.

Operation

28

5.1

Operption

of the boller

^

2 8

5.2

Fii?ing '

,

29

5.3

E^utting a mili out of operation

30

5.4

Wet'dea3hing

 

31

5.5

Gafety cut-out system

31

6.

Putting thg boile^r out of operation

32

6.1

Stoppinfi for normal atandstilla

32

6.2

Stoppdng, cold-running and dischorging

33

7.

Generol principlea for boller operation

Annexes; Jtorting diagrom - cold-storting

Störting diagram - «orm-storting

2 diagraına of permisslble temperature change velocities.

I>A

-

4

-

Preface

With regard to the operation and maintenance of the plant described hereunder we suppoae that the persons entrusted with such tasks are properl^ slcîll€d«

Therefore we can forbear to explain details generslly known| the more aa an operation manual cennet reploce ali necessary'experience and knowledge as a whole,

A

In principle the legal regulationa, İn particular "Technische öfegeln für Dampfkeasel" TRD 601, /technical rules for steam generotora/ "Sicherheitstechniache Richt- linien" /technical direction for the safe operoting/ and the general lahour aafety regulationa are to be ob- aerved*

This operation manuol is written to give directives for operation under the a.m. auppoaitionp The boiler ia to be operated and mointained according to thia ınonual,

Thö practıcal advisea of e^cperteea delegated to the si- te by.different deliverers, further the detail-operation mauals edited by the sub-auppliers ere always volid and very important aa well.

-

5

-

1.

Specification of thg plsnt

^

1.1

Gpecificotion of the steam gencretor

/3ee 3oiler Circuit Diagrem No, 5

520/012-005/202/

The ateam generator is designed for nstural circu- ^

lation and simple-ateam reheoting.

ît ia a single-pass conatruction with a secnndaı^ idling pass,

The outer walİ3 of the steam generator ere formed bj' boiler tubea tight welded together, wich ere fed with water by collectors of regiater type» The whole steam generator is auspended et the top of the steel atructure and can öxpond downward without limit,

Through the economiser the feed water gets into the drum to fiil the up- and downcower tubes /furnacc

chamber/ of the system. By heating the furnoce cham- ber a weight difference occurs between the water

in the downcomer tubca and the water/a tcam mi*ture

in the heated upcoıaer tabea, wich resulta in a natural circulation, '

In the drum the water and steam are separated* Together with recharged «öter the seporated water ia fed into the boiler tubes again, while the ge- ne rot ed steam flowa through the succeaaive IIV-su-

perheaters* The suapending tubaiopârheater No*l

0

is constructed with threo bronchosı the auccesaive îlP-superheaters No. 2-4 with two branches. To compensate ineqU8İity of heat extension in the furnece chamber caused by different mili combina- tion, the individual superheoter branches are crosoedy each tiine to occupy other poaİtions in the flue gas flow.

/ıt

-

6

-

Oetween the superhe&tcrs No» 2 and ^ and 4 each branch contoins injection coolers for re-

gulation öf the steom temperature, Afte r the fi- nal superhester /No. 4/ the two branches ere u -

nited. ^rom

part of the türbine or -et atarting or at break- down8 - it ia guided through a IIP reduction stotibn to the cold rail of the reheater. The steam coming from the HP türbine or re^acti-

on station flows through the rebeotcra la, Ib

and 2 also divided into two brancheg. Ûetween

the re the ateam flow3 to tl» iIP

the

jection coolers, The reheated steam is then gui-

reheaters. Ib

ond 2 each branch inciudea in-

ded to the medium-pressure part of the türbine or - at starting or ot breakdowna - through the low-pro3sûre by-pess to the condenaer.

-

7

-

1.2 CaPBCİty deta

lîP ateam generating capecity

^ermissible pressure

Druffl pressure Live-steam temperature

Pressure at superheater outlet

Feeâw8ter temperature

Heheatcr 3teomquantity

Pressure at reheater inlet

Steam temperature at reheater inlet

Pressure at' reheater

3teem temperature at reheater outlet Air temperature after the steam air preheater

Air temperature before rotating »ir preheater

Air temperoture"after rota-

outlet

ting air preheater

Flue gas temperature

t A

480

bar

170

b ^

154,65

538

bar

136,4

250

t/h

404

bar

39,93

369

bar

3 8

538

20

40

334

158

-

8

-

^ximm D permiasible stesm teinpereturea

Superheater outlet No,t)l

 

392

Superheeter outlet No.OlI

474

Superheeter inlet No.OlII

%

442

Guperheeter outlet No.ÜIII

°C

512

Superhester inlet No.OlV

495

Superheater outlet No.OlV

°C

541

Reheeter inlet No.ZÜI

°C

4^6

Heheoter outlet

No.ZÜI

,°C

548

Reheater inlet Nö.ZÜII

491

iieheater outlet

No.ZÖII

54^

-

9

-

1.4 FeedtfBter dato

/at continuous operotlon, measured at the steam

generator inlet/

General requireme¥it:

Conductivity:

/observe authoratative values for boller water, see below/ pH-value et 25°C, with volatile alkalizer only

Oxygen /Oj/:

Total iron /Fe/:

Total'copper /Cu/:

clear and colourless

>9

i

<0,02 mg/kg

^0,02 mg/kg ;

•s0,03 mg/kg /observe authoritative values for boiler vrater, see below/ not detectable «g/kg

not detectable mval/k,

< 5 mg/kg, if poosible

<0,5 mg/kg

Total carbonic acid /CO^/ Ilardness:

KMnO^ consumption:

Oil:

3oiler woter values /at continuous operation/

Conductivity:

/at 25 C in the by-pass on the spot, samples being taken continuously/

Silide acid /3İO^/ı

pH value at 25°C:

p value

< 50

S/cm

<0,3 mgAg

9,0-10,0

<0, 1 mval/kg

(iP

-

1 0

-

1.5

SaTcty eguipment

 

1.51

IIP rcduction station

To protect the reheeter at storting and possible breokdowns of the tarbine, the IIP steam is giu- ded through two IIP re^iaction stations to the re- heater and through the LP reduction station to the condenaer.

The IIP reduction station alao aerves as sefety valve.

3y injectioa the steam temperatures are cooled

af ter the IIP

reduction

stations to the. reheater

inlet temperatures.

1.52

^rum safety valve

At broakdowna resulting on inodtniüaible presaure increasG in the evaporating part of the boilor it ia protpcted by a safety valve desifined for 50% steam capacity.

1.53

IIP aafetv yalve

 

The HP

safety valve at the final overheater outlet, designed for 50% steam capacity.

part of the boiler

is protected by a

lm3A Reheater safety valves

2 safety valves at the outlet serve for protec- tion of the reheater part.

-

11

-

1.6

Fumoc e 9İr

j-he air arvi flue gas passea ere constructed with

two passes, Two fresh-oir sxİ8İ ventilators with

impeller blede regulstion supply farns'ce oir

through the steam and the rotating flue gea air-

preheoters to the burncrs^ The tv/o rotating pre-

heoters are regenerative onea with rototing heat

storing parts. At rotation through the gos chonnel

the heîjting L'lementa extract heat from the_ flue

gos, tronsmitting it to the furnace air during

rotation through the air channel, 3y the steam

preheater installed before each fresh-air venti-

lator the furnace air can be warmed up to +20

Recirculotion of hot air enableo further heating

to +40a ^ per.nonent maxiaıum load,

1.7

Firınn

^

1.71

Innitıon fıping

a burners of abt. 30^ total heating capacity, arranged in equal prportion at both side walla.

Fuel: heavy: oil of 9600 kcal/kg /40,2 UJ/kf»/.

1*72 Coal firina /See Draving No.

36 520/0*54-001/0018/

The main fîiring sistem consists of EVT type stone

coal heatiqg with direct dust injection, '

inciuding: ;

6 coal milis of 3 32.60 type, cpmbined

recirculation ductg and chutea,, box-tj'pe

dassifier s and dust ducts from the milis

to the burners.

- 12

-

From the pit coal bunkcr the cool İ3 supplied

to the mili över distributoro of atagelessly

adjustsble speed, a coal chute ond follwa^.

In the mili it is dried by odding hot flue

goses ond then

. cold gog the fuel temperoture of obt. 130°C

ground, By odding hot^i r and

İ 3 odjusted nfter the closaifier /claasifier

temperoture/. From the mili the cool dust/gna

mixture İ3 blown through the closüifier, cool

dust ducta and burncr into the furnace cham-

ber. In the classifier the rough and fine

porticles are separated from each other, The

big parto are returned to the grinding pro-

ccss. The furaoc'e air is guided to the bur-

ners trough upper, central, lower and com-

buation air ducts; the cotnbustion air alao

oervoa för cooling the burner caaing.

1.721

Firinn da ta

Type of

fiiring:

tangentiol firing

^alculated:

100% boiler capacity

No. of milis:

29,66 kg/a Turkiah mineral carbon 6., ene of them as

reaerve,Çvr-ın'.üı i^f^s^ı.^O Max. milling capacity per mili:8,14 Vg/a

Type of clöasifier:

Tempereture after classifier:

Origin of fuel:

box-type claasifier

130 C Coal-mine, Çatalagzi

-

13

-

Güorotee fuel

Lower heating vslue:

12.435 MJA g

Ilumidity:

18%

Ash:

40%

. Volotile conponents:

1.722 Pisiribütora

Not inciuded in the delivery scope of EVT,

1*723 Desla/^r.er

 

Type:

1400x19170

Number:

1

1.724

31a/^ crugher

•t

Type:

NFJ 80/120

Mumber:

1

1.8

 

r-

For removal of flue gos two ID fans ere at dis- posal. From the boil/er outlet to the funnel the flue gases pass the âownward-leading flue gaa duct, the rotating air preheatersi and the pre- cipitatora.

At the end of the furnace chamber part of the flue gaaea is sucked off by EVT coal milli for drying

the coal and as carrying gaa., Another part of the

flue gases is sucked off of ter the electric fil-

ters b;> two fnns. liost of this cold gas quantity is used for.regulotion of the mili outlet tempe- roture. At not full lond operntion the cpld gas portion tnk^s part in Lhe reheater temperature

regulation.

'

i

304232

FI4Y V

11.

-

14

-

1.9

ı^eashin^

1.91

EVT deosher /Drawing No. 5.

520/670-002/0e/

' i'he ashes profluced in the furnsce chomber and

on the coupled after-heoting surfoces ore ex-

tinguished in the wet desiseler and transpor-

ted to the outlet by scraping blades guided

b;y t;vo endless chains.

I''or 3İow cooling of big pieces of slag ond

prevention of posaible eyplosions occuring ot

sabmerging of the slog e floating platform is

built in.

The deslucüpr is filled up to the overflow, the wnter cupply is regulated hy a thermoste- ticall^- controlled regülatör valve, to keup the WDter tempernturo ot about 60°C.

From the deslai'^^.er the aah ia thrown through

crushers to a coupled conve;yor belt trans-

porting it into the v;et aah bunker,

The discharge specd of the deslog;;er ia adjua-

table in.2 stagea.

In case 6f a repir of the deslagaer becoming

necesaary in the courae of operation the

boiler is to be sealed temporaril^ by cloaing

of the diving platea.

604293FNYVİt.

4

-

15 -

1.92 Divinr-, plotcs

•^he cliving plates ensure oirtight aesling bet-

\veen the furnace chomber and deslogi^er. They

corujiot of one front, one reer and aeveral

. right- and left-hond uide plates actıiated

hydraulically. At breakdovma of the deslafi-

ger the boiler can be sealed by closing the

diving plates, so thot the necessor^' repairs

or reploceiiient of the deslag^^cr can be exfffu-

ted.

Prior to closing the diving plates it is advi-

asbie to reluce the boiler output to minimum

coal consumption- Dcpending on the quantit;y

of ashes, this state of operation can be ınain-

tained for ::bt. 3 hours.

2. I^ckinA and stoppin;^ criteria /3ee İ^VT locking plons/

^rBWİng No» 50 5 520/021-01/'52 5.36 520/021-08/32

3,

otortig^T of the steam r.enerator from cold state

3,1

Preparationa

3,11

^reparatory work /general/

Ali inspection and man holes in the boiler and at the flue gas and air channels are to be closed. The safety valves and reduction atati- ons must be ready for operation.

The deslagr^er is to be filled with water, Ali aggregates of the block plont must be put in a state reody for operation, as the following parts of the boiler, specialîy:

-

16

-

Feedvveter pumps

FD fans

id fons

Cold gas fans

Air prehesters

Precipi tators

Mills

Dİ3tributors

Desla^y^er

31og crusher

i^lue düst deasher

Ignition firing

Soot blower

The following operation must be at disposal in

sufficient quantitie3:

Feedv/ater

occording to VGB /germon/ regula- tions or to the contrect, res- pectivel^

Pit cool

in the bunkers över distributors

Oil

for starting

Compre33ed air

at ali necessary placea

Coolini^ yyater

for ali aggregates

Flüshin;^ WBter

for deslagger

I/tnition f^aa

for ignition of oil barners

Steem

for oil preheoting and carborotion

804202F^^^•v ıı.

-

17

-

3.12 Preporotioru3 at the ?;oter anc3 steam aide

If the boller is ompt^, the boiler fittings are

odjuated reop, their odjustmont is checked be-

fore filling. Open the bleoding

volv ^ of the

• econoraiser and drunu Close outlets of econoaai-

ser and evaporator, Open outlets: 3aperheeter

1 to suıperheater IV, reheater I, reheate.r II.

Open all locking elementa to measaring ond control

devices.

Open hand-operoted shut-on valves in injection

pipes:

2 X injcction 1 :to superheater II

2

X injection 2 to superheater III

2

X injection to reheater I

Open rni'î '.le presGure tap at the feedwoter pump /for retıeater injection/.

i:^ke the emer/ıency outlet of the drum reod^ for

operation. Adjust the IIP rc^uction atatlon to

abt. 50:6.

3.13 Filling of tho boiler

By means an electric feedwater pump the boiler is

filled throuch the by-pass feedweter valve with o

water quantity of 100-150 t/h. During the filling

close the bleoding valves of the economiser, when

water appears steadil^ at that place. Filling is

finished ss soon as the lowest v/ater level is re-

ached İn the drum*

lîefillinA of the boiler

If the boiler '//as shut down in normal operation

\vlthout eaptying it, all water-Gİde bleedings

remaiR closed, Also refilling takcs place to

the lawest v;ater level in the drum.

-

18

-

Preporptions ot the oir and flue fies sitle

nefore the ID fons, FD fans and cold gas fsns are switched on /see the menufacturer's direc- tions for operation/ the dompera prnvided ot . the flue gas and air side ere adjustt^ as fûllows:

1, Inî-ernal and/or externel air suction to be ope- ned /adapted to temperature conditions/

2. Air iampers before FD fan to be opened, bchind

fan to be closed. Dampers behind the fon get

a starting impulse, when being switched on,

Air dampers before oir preheater to be put in throttie position, after air preheater to be opened.

Dampers in cold air bj-poso duct /air prehea- ter/ to be opened»

5./3econdory oir regulating dompera to be opened, secondary air and oil air valves to be put in cooling position,

u. Ilopper air regulating damper to be put in coo- ling position, hopper air valves to be opened.

7. Mili hot-air, mili cold-air and mili locking- air dampers to be closed.

8. lîot-air recirculation dampers to be closed.

9- Flue gaa dampers before air preheater to be opened.

-

19

-

10» Flue gos dampers before ID fan ond in connection cîuc t to be openerl.

11. flue g8S dempera

af ter ID fan to be

closGd. When the fan starts they get

order to "öpen".

^

12. Put dampers before cold gos fen ond in ita connection duct in "öpen" position.

13. The dompers ofter the cold gas fans get order to "öpen", when the fans a - re stârted.

Cold go3 dampers before flue gas recir-

calstion duct to be put in about "open position".

10%

3houl:l it become necesüory for any reason to operoLe only the fans installed ot one side or in other crosG combinations, the dampers are to be adjasted nccording to the air and flue gos duct reqaired for this. /Circuit

Diagram 5 . 36

The two ateom air prehtioters are put into ope- ration ahortly before starting with the FD fans according to the aupplier'a direction for operation.

5ro/034-001/001d/ .

3.1 5

Ignition oil firinR

This port of the plont is to be put into opera- tion and prepared according to the supplier'a directions for operation» The oil heatitıg is read^ for ignition aı: aoon as the locking con- ditions are met and the boller ventîlation is reolizcd.

-

2 0

-

3.16

Coal

The coal bunkera must be filled

eni the coel in the

feeders must be advanced to the output end» ^ate vole in riust duct to be closed.

 

Gate velve before mili door to be opened,

 

r-

3.17

İ)e3İa;>r.er

/3ee İpecial Directions for Operation/

 

The dislascer must be filled to the overflow. The

flushing wotQr necessgı^ for the return pulle^/s .in

the through and the choin-cleaning a^stem before the

delivery end is to be turned on.

The diving plates must be opened as to dive into

the

water of the deslagger,

3.18

Coal milis

Mills are to be carefully controlled in point of view

of readiness for operotion, occor-lin/; to their Gpeci-

al Directions for Operation.

Gpecial core ahould be taken that the cooling ^v.jter

is odjusted correctl;/ and the oil levels reach the

mid'île of the oil level gaagea.

Check working poaition.of clasaifier's dampers.

 

3.2

Putting into operation

3.21

Auyiliary ag/^regates

The Buyiliary ag^'^egates can be put into operation

simultaneously with filling the boiler.

For ali oarts of the plants the 3peciel Directiona for Operation are to be observed.

Putting into operation takes place according to the following sequence:

- 21

-

1. Jteam preheoters

2. ıtotating air preheeters

3. id fsns

4. FD fans

5. Cold-ges fana

^

f

Deslogger

The id fans, FD

fons Qnâ colrî-gas fans arc to be

starte'î in zero guide-vane blsde position. The start- ingitsel f makes the pressure-aide dampera opeıü

After this the furnace preasure is to be adjusted to

ubout - 7 mm CV/ ond the automatic si^ste'm keeping it

at thi s value İ3 to be adjaated accordingl^.

-i-'he dcsla/;,;er is to be operated \vith lov/eat poû^ible

specd, to keep the weoring at o niniaum and to

achieve fovournblc filling of the acroping bladcs

of the

The speed is changed in dependence upon the osh quantit^ produced,

3.22 Preventilation

/Gee: Work UchecluİG "Preventilation and Releaae for Ignition-/ 3efore igoition of the oil bumer s it is to be enau-

red by 3-fold air exchonge in the bciler end flue

gaa ducta .that the -furnace is free from i^nitable

fuel/air mixture8«,.For this purpoae the air dam-

open at abotıt 30/J T D

pera of the bumer s muöt be

fen capsciti'. The cold-,:;as fana are to be a'ljustcd

to thİG air quantity«

-

22

-

Time of ventilation: 10 min. After ventilotion there is reer^iness for igni- tion for 10 minutes. During this period is thc FD faîi copecity to be reiuced to the cooling . stoge, The cold gas quantity is to be reduced to the minimum,

Preventilation is to be repeatcd, when

1, the time of readiness for i^nition has expired,

2. ignition has been tried tv/ice in yain,

the

interrupted .

Chai n

o f

3ofet;y-3yste m

woald

be

aı^yhov*

3.2 3

I^nitio n of oi l firin ^

•Vhcn o 1 1 lockin g condition s o re falfilled , the o i l burners can be ignite d v/ithi n the i^nitio n sofety period . ijnition of the first oil bume r it is to be ensured that the IIP reduction station is opened to obt» ^0%, becaıise the superheaters are flovm through oircady at the initial stage of dcvelop- ment of steam generatlng*

3»24

Acceleration of the steam /jeneratör

In the first phase of the acceleration the number of oil burners resp. the fİring itself, are to be limited to a value ât wich the flae gas temperature does not exceed 500°C before the superhcater sur- faces wich are not yet flovm through. After steam has been developed and abt, 2 bar ar<= reached, tho blecders o f the economiser and drum are to be closed, When abt. ^ bar are reached^ :e have to close ali drains.

-

23 -

otill bctore i^nition the condenser shoulâ be pat ander vocuum, 30 that for the purpose of rcheoter cooling the generoted steam con be guided throuşh the IIP reduction station, reheoter and LP by-pass ^

stetion to the condehser.

As soon as a steam fTow of - 25 t/h is reached, the firing con be increased to the admissible tempgroture and presoure increose .'^radienta, /See 3tarting Diogratn and observe türbine conditions./

In the starting phase the water level will rise ;)S a resul t of- expan3İon caused by heoting, by drainage through the drum outlet valves the water is to be kept at medium to moximum lovel.

As soon as the starting conditions are givon for the

tıırbine, i t msj' be started, *Jefor e this the IIP ducts

İGodin g to th e turbine are to be vıarmed

fresh Gteam ^olo is to be opened. Aftor load accep- tonce by the turbine further acceleration takes pla- ce according to the admissible gradients of the ele- ments or according to the load schedule, respectively.

The pressure is increased to working pressure, Initially, in order to get off the dew point area at the air preheater as soon as possible, only part of

up and the

the

fumac e air is supnlied through the flue gas pre-

heater, while most of it is guided through the pre- heater bıy-pass. Only when a flue gas tempersture^f 120°C after the preheater is reached, can the air portion flowing through the preheater be increased correspondingiy, ®hen the air İnlet dempers ore en- tirely open, the preheat.er by-pass can be closed.

-

-

To kaep the flue gaa temperature'at the flııe fiaa preheater outlet över the acid dew pont,

the tempereture level is raised tiy recircula-

tion of

hot air to tho suction side ofth e FD

fan.

As 300n 03 we reoch a flae gaa temperoture af- ter the preheater of - 120°C and a minimam oil firing of - 20^, coal dust firing can be invol- ved to continue incrcosing of lood«/3ee corres- pondirig paragraph "J.V

For putting the first mili into operation, at lotest, the precipitotor is to be 3witched on.

'.Vhen connectin/^ additional milis, heating sim- me tr;y should be achieved, i.e. the aecond aill Ghoald be put into operation immedintelly after the first ene was put undrr load.

After otorting up the oil firing is not taken out, os long aa there is no stable cool combus- tion. In the atarting phaae thia is posaible under the following conditions:

- At least three milis muat have been in opera- tion for a time.

- = 50-Ca6 boiler load

- Correct air aupply with<7 % O2 values.

- >200°C air temperature-

- Peedweter preheated according to the load.

- Fıırnoce depression at norm;^l fluctvıotio^ range.

/

3,3

-

25 -

Puttipg into operation of milis /3ee t)İ3o Gpecial Directions for ^dill Operotion/

The individaal milis ore pat into operotion as

. folloo:

1, Tu m on cooling vvater

2, Öpen locking oir dempers

3, Start mili motor

-I» Depçnfiing of the outlet temperoture of the in- riivldual raill, add cold gas and hot air in or- der to reduce the increase- in temperature.

5. Open furnace air iamî er and

adjust minimum air

qaantity /abt. 30^», related to burner capacitj'/

by meana of the re/;ulatins domper.

o. Vıhcn the classifier temperature is IIO^C and the starting current of the mili motor ho3

decayed, connect the coal feeder.

7. Adjust the mili load to obt. A0% at first.

8, Oy addition of cold gas and hot air /clasaifier temperature regulotion/ keep the temperature after the mili in a working range of 130°.

It ahould be preferred to achieve temperature regulation of the mili by cold gas. An additi- onal cold air aupply to the mili is admissible only es long as no coal is fed into the sys- tem /to preyent eyceeding of the inertiza- tion limit/.

-

26

-

9» Ificrease mili load occordinfî to the oâ^ aiîssible operating requirements,

10» Aijust'fuel ond oir in correct proportion

a^ eoch burner.

^

11. odmissiblc mili temperature: 210

4.

Jtartln;; from warnı state

4,1

Hot.sifert

V/hen pfitting.tho steam generstor înto oper^tion

t

ogsin DftC'r öhort atandotills, e.g. aftcr a

breokdown of the plant, high temperotures are to bc reached oiruady with the firat steam e- misöLotı, in order to prevent thermal shocka

-

j »

in the tubes- stili bein^ hot.

This requires quick increasin;? of the firinr,

capocity to abt.

bumer a and early starting of coal İTiring.

3efore ignition the rated pr.cssare value of the

IIP reiuction atatflon is adjuated to the ectual

value, thus enabling it to open at firat firing

and to effect a steam flow»

of ter i/;nition of thr oil

At the reheater side steam flow is to be provi-

ded either to the condenaer or över the roof.

3till before İgnition refeeding is necessaıy, in

order to avoid poasible steam emission from the

eco during the standstill,

Ttfhen the tube duct and türbine temperatures ore

reached, the.türbine may be accelerated nnd can

accept load.

-

27

-

•Vorm ^tart /See Sterting Diagrom/

ûerm jtarta take ploce after standatills of oeveral hours, e.g, night standstilîâ, when boforîî reetortin/^ a minmuni pres^are of 10 bor İ3 stili given, but the steam ducts after the stenm "i^enerator have cooled fiown considerably.

3tnrtip,q procgsa:

i-iefeefîing*to drura wBter level at lovvest level.

Preventilation:

Afljust the rated value of the IIP reduction ata- tion to the actuol volue, thuo enabling it to oppn at first presüure increase.

Igni tion:

Increase the firing copncitj, keeping the ad- missible temperature grodienta- When the con- ditions for starting of the türbine ore given, the türbine ca n occept load^

-

2 8

-

^m

Operation

5.1

Operotiön o f the gteem /jeneratör

The operâtion of the oteam generator is to b^ sur- veyed continoasly by the operetine staff»

Irregulai'ties possibl^ occuring muat be recognize 1 in Lime and corresponding measures must be token, giving priority to the protection of the plant'a components rather than maintaining capacit;y operotion^

*

In general the boiler operâtion is regulated outo- meticâlly'; required lood changes are effecte^l orûj by adjusting.the rcquired capacity value. In spe- cial casee and whçn putting the plant into or out of operHtion it is advisabl® to operete individaal regulating circuits by hand.

The ateom. gene ra tor is opera ted wi th fixed preaau- rn, i.e. the lîP outlet pressure ia kcpt constant in the '.vhole operâtion lond nree. In oppoaition to this, sliriing presaure conditiona exİ3t in the reheater, corresponding to the individual load.

The system ia to be fed wi th woter of s quality as per paragraph To mainteln the boiler wa- ter quality a certain quûntity İs continuously to be elutriated from the dnım. /Observe; NEVER elutriate at the evaporation header during boiler opeırotion./

injection into the IIP end feheater it is to

3y

be enaured that the max« admisşible steam tem-

peraturea are not eyceede at a ^ time.

-

29 -

The rcquired vslues of thc corresponding reguls- ting circuits are to be adjusted occorflinslif.

To influence the reheater temperoture and iajec- ted woter quontîty we hove to regıılote^the cold- ^ s recirculation quantity. v;ith the increosing pollution of the boiler or in cose of majör chon- gflis in the fuel charocteristica readjuatments of thc rated values might bçcome necessary,

In coae of sudrlen load chanses or of breakdowns resulting in a considerable change of the ateam

5.2

f

temperoture we have to intcrförç bj hond, if ne- i

cessary.

Firin/^

The numbur of milis in operotion dopenda on the boiler losd, coüI qurîlity and we8rinö stote of the milis. At normal coal situgtion full load

is operated with 5 milis, V/ith partial loads it

is

to chooae a correspofadins mili dombination.

advisoble to lood the fumac ö equolly, i.e.

4

With loads undcr

milis we hsve to work with 10% oil supporting firing, 3upportins firing;^ as alaip applied at ali those states of operation,^ «here the combustion ^

and ©Iso w^th loşa than 3

becomes irregular.

3hould oil firing be involved, when coal operati- on is already on, the operatora have tc convince themaelvea of the unob.jectionabl^ bumin g of the coal fire directl;y before connection of oil fi- ring.

-

30

-

In cose of or^ disturbonce of the coal fire the oil burners must not be ignited.

At

loocl the ouperfluous air shall be kept at content efter the furnoce. Ir>-case of

'milis standing stili a small air qaantit^ /abt.

15^ air of the burner corner/ is order to cool the burner,

to be added in

3y recirculotion of hot air or vdth the help of the atenm prehenters the rotating preheater in- let temperoture is to be adjusted to

In case of chonged lood it io iraportartt to con- nect or 'lisconnect milis according to the chon- Sed 3tate of operotion in due tİme,

V.'hen 3 mili is connocted, odditional heat is ne- cesGorj' to v/arnı it up,

5.3 Puttlng a mili oat of oreration

m

Dischorge the feeder and distribute the load to other milis, therefore disconnuct the feeder

from automatic load regulatlon« At the aame time

reduce the

air auppl^ to the burîjer come r in

proportion to load distributioıvı Üpen the cpld- gaa and hot-air dampers to the milİ by Whe n the minimum feeder speed is reached, dia-

connect the feeder»

U \

- 31 -

Then 'iisconnect the mili immer^ iotely; the cold-

8İr floaper to the mili

se the secondary eir donpers of the burner. /Combustion eir dampcra vıithout drive remsin in ^

open position./

order to open, Clo-

Close the locking air decıpers.

Close the hot-air damper, whe n the clasoifier out-

let temperoture omounts to ^ 150°C.

.Vith milis out of operotion the cold-gas dampers are to be adjasted to ©bt. 10% open position, in order to enaure thot the ducts ere not subject to falling below the dew point. About 6 minutes after disconnection of the mili the cold-air dam- per clûses.

5.4

'.7et dcaahin;^

The wet deslog^er should in apy case be operated with a lo-.ver HPM, The hi^her RPMs should be uaed onl^ in case of maljor ash quantities*

5»5

Safety cut-out syatem

/See cut-out plana of EYT/

Drawing No.

520/021-01/32 t^

•Fire out"

"Fire oat"

"Fire out"

5.36 520/021^8/32 -

»

-

Drum W8ter level^^in.

Actaated in case of emergency stopping

In case of a breakdovn of both XD fans and/or both FD fans

«

"Fir e

''Fire

Limi t

-

32

-

out**

out"

Ai r

or

Furnsce

of

loadability :

flu e

gas

pressure

duct s

blocke d

<

min,

or

^may.

i

n

case

o f

a

breal<down

o f

the

feed-wate r

pump,

and

ID

fan s

or

rototin g

si r

preheater

the

loed

İ3

reduced

by

an

adjustabl e

rated

value

regülatö r

/e.g .

50%/ .

6.

PuttinA the steam jeneratör out of operation

6.1

3toppinn for normal atandstills

The

accordin g

to the requireınont3 of operatio n to 40^6, mointainin g

capacit y

of

the

bloc k

is to

be

reduce d

rcasonable load chongc grodient s /3/Vmin/ « I n case

of forcin g reasons,

the

înax.

load

velocit y

of

60lo/min

c

a n

be

ru n

betwee n

the

loa d

pqint

s

at

10 0

an d

Thia

copocit y

i s

to

be

mointaîlned

i n

3-mil l

opera -

tio n

unti l

the

türbin e

i s

discherge d

to zero and

separate d

from the

nctvork .

At this the steaoı ge -

nerato r passe s öve r to b^-pas a operation . Then the

firin g is stopped

of the last three miUs.ohould it become necessary

to reduce firin g under 40j& sloı^rly, oi l supportin g

fir e

by simultaneoua

disconnectio n

o f

109^,

a t

least ,

is to

h İ

involved ,

After **fire out** the wet desl&l^^r ^nd following

j-

be İ t

apeed. \Vhen the sla g quantitie^ ' discharge d from

conve^ors

a f e

to

be

operşted^vit h

iDaximum

 

the

wet

deslag^;er

becoae

small ,

the

FD and ID

fona

are

to

be

3witched

of f

and

the

boile r

i g

to

be

sea -

l

e d

i n

order

to

keep

ı t

warın,

i.e .

a t

the

flu e

gaa

and

o i r

side

the

dampers

before

the

ai r

preheaters

are

to

be

closed .

 

3(Mzaa Fr^v ıı.

-

-

3witch the prccipitator off.

The rotating preheoters continue working; they are put out of operation only at a temperture of<100°C« Stop the steam preheaters, close the fresh steam gate. The IIP reduction stotion must bÇ closed auto- maticolly after finishing re-evaporotion.

The drum voter

ia to be raised to normal level, then

the feed-wBter suppl^ to be stopped.

otoprinK. cold-running and diacharging /e.g. for rcpoir work in the boller/

Ag described undçr item 6.1, the boller ia to be ahu t do'.vn t o AC^ load. Then the load is further decreooed v;ith the help of oil firing.

At this the fresh steocı- and reheoter steam-tempe-

roturc İ3 to be rcduccd hy the. admiasible ent,

Ijct the deslofif^er run out at nörmal speed and then stop it. The FD and ID fana and air preheaters

shall continue to operote with 30% air quantit^

^^rodi-

1

until the required temperature-lconditiona of the ^

the

normal level, then

^fee d vater after "fire out" intil reaching

boiler are echieved.

M

stop the. feeâ-wBter supply.

/

.

.

Prom abt. 6 bar on the boİler the outleta.

emptied through

^

'Jîhen 1 bar is reached, the bleed«ra of the boiler

should be opened for the purpose of ventilation.

-

34 -

General principles for boller opcration

To survcy operation and to recocnize irregulerities occuring during boller operation in time, it is indispefcaoble to read and record the most impor- tsnt efficiency factora continuously/*

Ali importont occurencea v/ithin the plant, like

break-downs, reodjuotment of equipment, replace-

ment of ports, repairs, ete. are to be rtcorded

in a shift book of boiler.

Froıa the notes it must be posoible to recognize the

couse of the break-downs or the reasons of reod-

justınents and repairs perfonaed.

3cfore inspecting the plant or parts of it, it muat

be ensured thot the apaces to be inspeclod are free

from toxic or eyplooive sooes.

At inspectlon of the furnoce İt ahould be provided

for that no accidents can happen by downfalling ob-

jects,

slag or oimilar.

For lighting of the boller spaces to be inspecte'l

and for operation of electric mechinery within

the boiler low-voltage equipment /42 V/ is to

be used.

^y marking or locking /chain wi^h lock/ it İs to

be ensured that parts of the plant, wich are to

be inspected, will not be subject to dengerous

penetration of steam, water, gaa, olB:» ete.

t

from neighbouring equipment bcing under presaure

or in operation.

- 35 -

After iinspection of the plont or porta of it /air d:wcts, flue gas dacts, ete./ çare should be taken that eli objects used for inspection /lamps^ scaffolds, parta, ete./ are daly remo- ^

ved. *

*

Prior tlje operation, before locking ali (üon ho- les it .must be mafie sure that nobody remoined within the spaces,

Re/jılor maıntenonce involves thot ali mechani-

t

cal devicea and noving parts are lubricated and tecte d in respect of thei r wG3ckability .

Proper lubrication of this equipraent should be checked continuoualy by means of the control eqaipmeht provided /oil level gauges, level indicotors, ete./.

O n the basis of this note it will not be nentio- ned in the operation manual that before atorting of each mnchine or other eguipment ia to be checked in respect of aufficient labrication.

The sealing of oll stuffing boxes,^flanges, packings, etc« should be checked. For repairs not other msterial than prescribed should be used*

.w'i-

Each time before the plant is pat into operation

and during

taken that ali indidating, meaauring and regu- lating devices belonging to the plant and also the snfety and signal equlpaıent are road^r for operation at ony time.

operation, os '.vell^' çare is to be

-

36 -

Cocks, vnives ond goteg are to be oprnerl ond cloaed graduall^ end carefully.

In case. of tvvin fittings those situated at the presüure side ore opened first to lOC^, while thoGG aituoted ot-the non-pressure side ore clo- sed first.

In cose of twin fi'ttinga ot the bleedinga and

droins alv/a^s the aecond one is to be oct^otcd,

whiİ G the first

armatüre ot the boiler side re-

mains open. The ornoture st the boiler side is

to be closed onl^" in cose of a leakage second volve.

of the

tubes arc to be -^ormed up f',rndunlly and to be 'Irnined continuously ot the ir lo-.vest roint,

The proper state of the snfety valves is to be checked fîontinuousl:/. Arbitrar^ alterations of the volves, especioll^f their nnt ırolization, a - re prohibited.

Domeges are to be elirainoted as soon as possible. In cese of damages involving danger the boiler İ3 to be put out of operation immediotely,

Csre shoald be taken that the correct steam valaes are indicatcd onl^ when s^eam is trsns- mitted, i.G. when the saper heöters ere flown throagh.

-

37

-

The injection system is to bernıjclsreedy for operation in due" time.

The ateom tcmpero-iûre requiped ot the boilur end for connection of the türbine cojj be rea- ched only by loediög the boiler occording to its superheoter chsracteriatics.

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