Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
,
Tiruchirapalli
- 620 014
Boiler Performance & Proposals / Engineering
CONTRACT PHASE TRANSMITTAL
Cust./Plant
: JPL/O.P.JINDAL
Contract No : 1604-1607
EBPP:CPT:JPL600:64
STPP/RAIGARH
- 4 X 600 MW
Date:
contract
phase
transmittal
CPT. REV.
NO. / NO.
Cat
for
NO. OF
SHEETS
--------------[Page
revision status]---------------------------1
1 2 3 4 5 6 7 8 9 012
3 456
0 0 0 0 0 0 0 o 0 0 0 0 0 0 0 0
Page no:
Rev no:
08/09/2010
wise
~'
SIGNATURE
1. SRI N.SEKAR
2. SRI L.A.E.FERNANDEZ
3. SRI P.SADAGOPAN
MGR/COMMERCIAL/BLD.24
AGM/C&I/FB/BLD.53
MGR/ITS&S/BLD.2&4
Dt 30.03.2006
Dist.List
15.03.2006
TABLE OF CONTENTS
Sl. No.
DESCRIPTION
PAGE No.
INTRODUCTION
PERFORMANCE
STARTING UP
SHUTTING DOWN
WATER LEVEL
AIRHEATER
SOOT BLOWER
10
11
12
BLOW DOWN
10
13
TUBE FAILURES
10
14
FURNACE EXPLOSIONS
11
15
12
16
INSPECTION
13
17
LAY-UPS
14
18
14
19
16
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 1
All steam generating equipment are designed for a specific purpose. When supplied with
feed water at a specific temperature, the unit will deliver a definite quantity of steam at
the rated pressure and temperature. Operating at conditions, which exceed the design
limitations, will shorten the life of the boiler and its components.
2.
The concentration of solids entrained in the steam leaving steam drum will depend to a
great extent upon the quality of the feed water. Suitable make-up water treatment and an
adequate blow down program should be employed to control the boiler water alkalinity,
and the concentration of silica, dissolved solids and suspended solids in the boiler water.
Adequate mechanical deaeration of the feed water should be provided and steps should be
taken to control the level of metal oxides entering the boiler in the feed water. Refer to
the Water Treatment section of the manual.
3.
The quantity of fuel consumed is generally measured and recorded. The method used will
depend upon the nature of the fuel and the equipment available for measuring. A
representative fuel sample should be obtained periodically. The services of a competent
laboratory should be employed to analyze the fuel with respect to chemical constituents,
calorific value, viscosity (liquid fuels) and other physical characteristics that could have
an unfavourable influence on operation and efficiency.
4.
An analysis of the flue gases leaving the boiler is invaluable as an index of complete,
economical combustion. Combustion should be completed before the gases leave the
furnace. The presence of carbon monoxide (CO) in the flue gas indicates incomplete
combustion. The best percentage of excess air to be used to ensure complete combustion
will depend upon the nature of the fuel, design of the fuel burning equipment, as well as
other factors. The most desirable excess air for different rates of evaporation must be
established for the particular installation.
Use of an Orsat is the most reliable means of analyzing flue gases. It should be used as a
check, even when other instruments are provided to furnish this data. For determination of
the percentage CO, CO2 and O2 gas samples should be obtained at the rear pass outlet
upstream of the air heater.
5.
When the heat transfer surfaces are kept clean, the temperature of the flue gases leaving
the air heater and the draft loss through the unit will generally be constant for a given
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 2
Ensure that the boiler circulating pumps have been properly filled and vented.
2.
3.
Open the bypass valves around the other boiler circulating pumps.
4.
Establish purge flow to the pumps to ensure that leakage is from the pump motor cavity to
the pump casing.
Fill the boiler unit till the water level is close to the top of the gauge glass to prevent the water
from dropping out of sight when the first boiler circulating pump is started.
If hot water (hot relative to the boiler metal temperatures) is used to fill the boiler, be careful to
feed slowly to avoid severe temperature strains on the drums and headers.
The drum purge and bleed vent, which vents the outer drum shell, should be closed prior to
starting the first boiler circulating pump. The regular drum vents should be closed when the drum
pressure reaches 2.0 kg/cm2 (g). The back pass rear header drains should remain open until all air
is vented from the unit. The unit is usually considered free of air when the drum pressure reaches
2.0 kg/cm2 gauge.
STARTING-UP
In order to detect an incorrect firing condition (may be detected) promptly, ensure that the
instruments used to monitor operating conditions are in good working order before lighting off.
Draft readings, temperature readings, pressure readings and a reliable indication of how much
excess air is being used are a prerequisite to intelligent operation.
Prior to lighting off the unit, the drainable portions (headers, inlet, outlet and connecting links
and piping) of the superheater should be drained through lines free from back pressure and vented
at the outlet. The superheater drains should be closed in accordance with information given on
Valve Operating Diagram for this installation. To protect the superheater elements from
overheating, the superheater outlet vent (starting vent) must remain open to ensure a flow of
steam through the superheater until the unit has gone on the line and is carrying load till HP
bypass is cut in. Refer to Unit Operating Procedures for specific valve operation.
During start-ups, when there is no steam flow through the reheater, residual moisture in the
reheater element must be boiled off. This is accomplished by opening the vents on reheater
headers before the lighting off. Atmospheric drains or vents must be closed prior to raising a
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 3
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 4
Fans and boiler circulating pumps may be operated as required to achieve the desired cooling rate
and uniformity of cooling. Refer to `Unit Operating Procedures for details, such as airheater
protection and boiler circulating pump cooling water requirements.
WATER LEVEL
Before lighting a fire, the operator should check the water level in the upper drum by blowing
down the water column and gauge glass. Usually slowly cracking the drain valve on high pressure
gauges will suffice. A liberal blow down will usually clear the drain valve seats of any foreign
matter. The gauge glass should be blown down several times at low pressure while warming up a
new boiler. Routine checks of the water gauge should be made at least once per shift while a
boiler is in operation.
(Refer to Water Gauge instructions for procedures on checking level). If the action of the water in
the gauge is sluggish when the drain valve is opened or closed, investigate the cause and correct
the condition immediately. To protect the gauge glass, blow downs should be kept to a minimum,
during normal operation.
The water level should be slightly above the recommended operating level before putting a boiler
circulating pump in service. This is necessary to prevent the level from falling out of sight when
the pump is started.
During normal operation the water level in the gauge glass should be observed periodically even
though the boiler may be equipped with a reliable feed water regulator and/or remote water level
indicator.
While steaming, the boiler should be protected from rapid changes in feed water temperature .The
feed water flow to the boiler should correspond rather closely to the steaming rate and should not
be shut off completely while the boiler is being fired.
The recommended water level and operating range is indicated in the Section Steam Drum
Internals. Unless there is information to the contrary, the water level should be carried near the
center of the gauge glass. The gauge glass center line is normally set to indicate normal level
inside the drum at full pressure conditions. If the unit is operated at significantly reduced pressure,
the level indicated at the gauge glass center line will correspond to a lower than normal actual
level inside the drum, due to the difference in temperature between the water in the gauge glass
and the water inside the drum. Any adjustment of the water level should be gradual .If the water
level is too high, carryover or even priming may occur, especially if the steam demand is large
and rapidly fluctuating.
Perhaps the most serious emergency that may be encountered is low water level. As mentioned in
previous paragraphs, the water level must be watched continuously and water gauges should be
checked periodically to ensure proper operation. Protection of water level transmission lines
should be provided to avoid freezing or other damages of these lines. Do not rely solely on high
and low level alarms.
If the water level falls out of sight in the water gauge, due to failure of the feed water supply or
neglect of the operator (except in the case of momentary fluctuations that might occur with
extraordinary changes in load), appropriate action should be taken at once to extinguish the fire.
Any decision to continue to operate, even if only for a short time at a reduced rating, would have
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 5
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 6
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 7
If the steam temperature is too low, the furnace walls should be cleaned only as necessary and in
steps, using one wall blower, followed by operating for a period and then using another wall
blower at another wall. Cleaning the furnace walls at once may give extremely low steam
temperatures; however, neglecting to clean the furnace may lead to other difficulties.
The superheat steam temperature will drop suddenly and recover if the boiler is priming. The
temperature fluctuations increase in frequency and severity as the total solids or alkalinity in the
boiler water increases.
The following conditions may produce steam temperatures abnormally high for a given rate of
evaporation:
1.
2.
3.
A dirty furnace.
Too much excess air.
Lower than rated feed water temperature.
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 8
If the steam temperature is generally too high, the furnace should be cleaned thoroughly and
completely as often as necessary to keep the temperature down. As slag develops in the furnace,
the heat absorption rate of the furnace will be decreased materially and the steam temperature and
overall performance of the unit will be affected. Continuously increasing steam temperature, with
no change in steam output, indicates progressive fouling of the furnace. If slagging becomes
acute, localized ash accumulations may obstruct portions of the superheater or reheater and
produce high gas mass velocities in the free areas, with overheating possibility. The operators
should develop a suitable procedure for using the wall blowers to deslag the furnace. Soot
blowers will give best results if the ash is not sticky.
Frequent furnace inspection should be made to see that no slag accumulates around the windbox
opening, since unsatisfactory flame conditions can result. Such accumulations, if found, should
be removed promptly.
SUPERHEATER AND REHEATER
Consideration for protecting the superheater and reheater is a controlling factor in determining
how rapidly a controlled circulation unit should be brought upto pressure. The superheater
elements should be heated as evenly as possible, and the maximum temperature of the flue gases
entering the first gas touched superheater elements (the furnace exit gas temperature) should be
carefully monitored and controlled during start-ups.
The furnace exit gas temperatures are normally measured by means of a startup thermocouple
probe traversing about half the width of the furnace. The point of maximum temperature must be
determined each time the firing pattern is changed. The maximum furnace exit gas temperature
should be limited to 540 Deg. C until the HP-LP by pass is cut in and steam flow through the
reheater is established.
To ensure superheater element loops are clear of condensate, provision must be made for adequate
flow of steam through the superheater while starting up. Drain and vent valves in the outlet
headers and /or the main steam line should be opened before the unit is fired and kept open until
the unit is steaming under load (Refer Valve Operating Diagram). The startup vents may be
throttled gradually as drum pressure increases provided sufficient flow through the superheater is
ensured at all times. When the HP bypass is cut in, turbine is synchronized and carrying load, an
adequate steam flow will be ensured; the superheater start-up vents may be closed.
(Before lighting off, reheater vents should be opened. As the pressure in the boiler increases,
residual moisture in the reheater will be boiled off). Reheater drains connected to the condenser
should remain opened until the turbine generator is on the line and under light load. Vents open to
atmosphere should be closed before attempting to pull a vacuum in the condenser.
It is advisable to operate a condenser circulating pump during the early stage of firing the boiler to
prevent overheating of the condenser by hot vapor from the reheater drains.
When the unit is carrying load, the gas temperature near the superheater and reheater surfaces are
quite high. A sudden interruption of cooling steam flow could cause the superheater or reheater
tubes to overheat and subsequently fail. It is imperative that all fuel be tripped immediately when
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 9
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 10
The accumulation of unburnt fuel in the furnace due to incomplete combustion, loss of
ignition or fuel valve leakage.
The mixture of this unburnt fuel with air in explosive proportions.
The application of sufficient heat to raise the temperature of a portion of this mixture to
the ignition point.
Unburnt fuel may accumulate in the furnace in a number of ways, for instance:
1.
2.
3.
4.
Through leaky main fuel or ignition fuel inlet valves on idle fuel compartments.
If the fires are extinguished and the fuel is not shut off promptly.
If the fuel is not burning as fast as it is entering the furnace.
If difficulty is experienced in establishing ignition during startup.
During a start-up, maintain a minimum air flow of 30% of full load air flow, to ensure an
air rich furnace atmosphere and prevent accumulation of explosive mixtures.
2.
Be sure that the main fuel and ignition fuel inlet valves on idle fuel compartments are
closed tightly and do not leak. It is advisable to remove idle guns from the guide pipes, to
avoid dripping.
3.
Watch the fires so that the fuel may be shut off without delay if proper combustion is not
maintained. If the fires are lost, trip all main and ignition fuel immediately. Close all trip
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 11
5.
When a boiler has been idle, purge the furnace for 5 minutes with 30% of full load air
flow, before putting ignitors in service. Be sure that the warm up fuel firing rate is high
enough to produce a flame that is not easily extinguished.
Never attempt to light an oil or gas nozzle without the required ignition energy source.
Be sure that steam for the steam atomizing oil guns is dry and the oil is heated and
circulated to give the required viscosity at the nozzles.
Do not use heavy oil/mechanical atomization oil guns for boiling out, lighting off and
warming up. Use light oil/air atomizing or heavy oil/steam atomizing oil guns.
On coal fired units always use the required ignition energy source when placing any
pulverizer in service.
6.
7.
During outages thoroughly check out, inspect and maintain furnace safeguard supervisory
system provided.
Boiler design parameters are based on conservative average flue gas velocities and normal coal
ash percentages, to achieve minimum possibility of erosion. However, the possibility of localized
erosion cannot be entirely avoided nor can the degree or location be predicted for each
installation.
It is important that the unit be inspected for indications (See Note) of erosion, especially in areas
mentioned above, whenever the opportunity presents itself but at least during annual outages.
When coal with a high ash content is fired, a definite periodic inspection programme must be
established.
Note:
The effects of erosion can be controlled by protecting the affected areas (pad welding, installation
of removable tube shields, refractory coating for example) or by dispersing the flue gas streams
through the use of plate or wire mesh baffles (See Note).
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 12
Extreme care must be exercised when installing baffles not to create new areas of erosion
or to shift erosion from one area to another.
The method of control and/or correction depends on the degree and location of the erosion and
can only be established after thorough evaluation of the local situation and some experimentation.
The effectiveness of correction methods must be checked. In the event of extreme or unusual
erosion problems, this company or its representative should be consulted.
INSPECTION
Whenever the boiler is shutdown, and the furnace is cool enough to enter, make an external
inspection of the boiler, water walls, superheater, reheater, economiser and airheater. Clean the
firesides where necessary and examine all tubes for evidence of corrosion, erosion, swelling,
warping, blistering, burning and cracking.
Swelling of superheater tubes indicates overheating which may have been caused by bringing the
boiler up to pressure too quickly, failure to vent the superheater sufficiently while the boiler is
being brought-up to pressure, or scale on the internal surfaces due to carry over of water from the
boiler. Slight warping is not serious if steps are taken at once to determine and eliminate the
cause.
Check the condition of the furnace setting and check the casing and doors for leaks.
Periodic inspection should be made to examine the watersides of the boiler unit. When entering
the boiler for internal inspection during freezing weather, care must be taken that no water
remains trapped in piping or above valve seats. In particular, gate valves in vertical piping (such
as boiler circulating pump suction valves) should remain open during the outage to prevent
damage to the valve seats due to freezing. Some condensate will remain in non-drainable
superheater and reheater pendant loops. Some source of heat must be provided to prevent
freezing.
CAUTION
If the unit has been bottled up with a nitrogen blanket, the nitrogen must be purged before
personnel may enter the drum. Nitrogen will not support respiration. Open both drum manholes
and use an air mover to purge the drum off nitrogen.
Before entering the drum, make sure that all valves in drum connecting piping (feed water,
auxiliary steam, chemical feed, blowdown, drains, sampling, gauge glass drains and such) are
closed tightly and properly tagged so that they will not be opened inadvertently. Remove the
manhole covers and check the drum internals for tightness and cleanliness.
Check the drum for corrosion and pitting. Oxygen pitting is a common form of corrosion that can
be found in boilers, usually in the steam drum above the normal water level, but also found in
tubes and waterwall drums.
Remove a sufficient amount of handhole pipes from each boiler and water wall header for
inspection of the internal tube surfaces. Wash down the unit to remove any sludge.
Remove and check for cleanliness of orifices of the wall tubes in the waterwall drums (ring
header).
Inspect and if necessary clean external heating surface of the economiser.
See that the heating surfaces of the airheater are clean. Corrosion, if present, would appear in the
cooler portion of the heater, particularly where soot and fly ash are allowed to accumulate. Make
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 13
LAY-UPS
When the unit is shut down for stand-by and draining of the boiler is not required for maintenance
or repairs, the boiler metals must be protected against corrosion. Refer to Lay Up Procedures in
this manual
Full load operation may not be possible due to increased pressure losses from plugging.
The increased pressure losses increase the head on the ID Fan, resulting in reduced
capacity.
2.
Laning through the superheater and reheater can result in overheating elements in the
open lanes.
3.
Normal cleaning by the use of soot blowing is not possible due to the plugged passes.
This leads to acceleration in the rate of plugging.
4.
Boiler efficiency will be lost due to reduced effectiveness of coated heat transfer surface.
The need for water washing is indicated by increased pressure losses through the boiler. Other
indications are reduction in steam temperature, increase in exit gas temperature, reduction in
capacity, or, the buildup observed in a visual inspection.
Requirements for water washing are:
1.
2.
A supply of water with provisions for maintaining the desired pressure and temperature.
3.
Means for removing the wash water effluent from the boiler and its disposal.
4.
Suitable lances for washing between the elements in the superheater and reheater sections.
These can be made from sections of 1/4 (6 mm) or 3/8 (9 mm) pipe. Drill 1/8 (3 mm)
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 14
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 15
________________________________________________________________________
Bharat Heavy Electrical Limited
Page No. 16