devdeep bose dgm ( commng & testing)

Devdeep Bose DGM ( Commng & Testing)

• INTRODUCTION TO SUPER CRITICAL UNI -

POINTS OF DISCUSSION

SUB CRITICAL & SUPER CRITICAL BOILER

SIPAT BOILER DESIGN

SIPAT TURBINE DESIGN

DESIGN PARAMETERS

COMMISSIONING

PRE COMMISSIONING PROBLEMS

POST COMMISSIONING PROBLEM

Description unit 660 500

S/H STEAM FLOW T/HR 2225 1625

SH STEAM PR KG/CM2 256 179

SH STEAM TEMP 0C 540 540

RH STEAM FLOW T/HR 1742 1397.4

RH STEAM TEMP INLET 0C 303.7 338.5

RH STEAM TEMP OUTLET 0C 568 540

RH STEAM PRESS INLET KG/CM2 51.17 46.1

FEED WATER TEMP 0C 291.4 255.2

COMPARISION OF 660 MW Vs 500 MW BOILER

Description 660 MW 500 MW

Structural Steel Erection 7383 9200

Boiler Proper & Accessories (Pre. Parts) 7080 5300

Refractory, Insulation & Cladding 1410 2000

Power Cycle Piping 3032 2200

Soot Blowing System 54 76

Coal Firing System 3573 2000

Draft System 5275 5200

Fuel oil system 62 200

Miscellaneous System 130 280

Electrical & Instrumentation 282 380

TOTAL 28281 26836

Tonnage Comparison

Material Comparison

Description 660 MW 500 MW

Structural Steel Alloy Steel Carbon Steel

Water wall T22 Carbon Steel

SH Coil T23, T91 T11, T22

RH Coil T91,Super 304 H T22, T91,T11

LTSH T12 T11

Economizer SA106-C Carbon Steel

Welding Joints (Pressure Parts) 42,000 Nos 24,000 Nos

Structural Comparison

Slno 660 MW 500 MW Remarks

1 STRUCTURALS

a

Entire structural is bolting type- entire structure is bolted. Holes are drilled on the columns and gusset plates, and supplied with matching plates.

Structural is assembled at site with welding

Advantages (660MW) of Bolting structure:oFast in erection.oClean environmentoNo Welding network requiredoSafety at siteoPainting finish is good o( No Weld surface)

b.No Welding work involved in assembly/ Erection , except Walkway rail post welding

Assembly is carried out with Welding

Can be dismantled if required ( For Maintenance purpose)

c

Material supply is tier wise including staircases, railing, gratings etc.

Material is supplied as per the erection sequence.

Erection completion tier wise, including gratings, platforms , staircases etc.

1 Cost of SG Package 1970.73 Cr 1020.54 Cr with ESP

2 Cost of ESP 183.54Cr

3 Total cost of Boiler + ESP 2154.27 Cr 1020.54 Cr

4 Cost of Boiler per MW with ESP 1.09 Cr 1.02 Cr

5 Cost of TG for entire stage 1204.72 Cr 634.31 Cr

6 TG cost per MW 0.6Cr 0.63 Cr

COST COMPARISON

BOILER SPECIFICATION

Description unit

S/H STEAM FLOW T/HR 2225

SH STEAM PR KG/CM2 256

SH STEAM TEMP 0C 540

RH STEAM FLOW T/HR 1742

RH STEAM TEMP INLET 0C 303.7

RH STEAM TEMP OUTLET 0C 568

RH STEAM PRESS INLET KG/CM2 51.17

FEED WATER TEMP 0C 291.4

Quoted Turbine Heat Rate

100% Load 1904 Kcal / KWH

80% Load 1924 Kcal / KWH

60% Load 1973 Kcal / KWH

50% Load 2065 Kcal / KWH

Net Plant Heat Rate = NTRH

= 2207 KCal / KWHR ( at 100% TMCR)

80% TMCR = 2222 Kcal / KWHR60% TMCR = 2276 Kcal / KWHR50% TMCR = 2376 Kcal / KWHR

Plant Efficiency at 100% TMCR = 38.96% 80% TMCR = 38.7 % 60% TMCR= 37.78% 50% TMCR = 36.19%

= Boiler Efficiency

100% TMCR 86.27%

80% TMCR 86.60%

60% TMCR 86.68%

50% TMCR 86.91%

Supplier : M/s DOOSAN

Erection By : M/s L&T

When Water is heated at constant pressure above the critical pressure, its temperature will never be constant

No distinction between the Liquid and Gas, the mass density of the two phases remain same

No Stage where the water exist as two phases and require separation : No Drum

The actual location of the transition from liquid to steam in a once through super critical boiler is free to move with different condition : Sliding Pressure Operation

For changing boiler loads and pressure, the process is able to optimize the amount of liquid and gas regions for effective heat transfer.

UNDERSTANDING SUPER CRITICAL TECHNOLOGY

SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration

Steam flow :2225 T/HrSteam temp : 540 ‘cSteam Pres : 256 kg/cm2RH pre : 51.6 Kg/cm2RH Temp : 568’cFeed water Temp : 291’c

256 Kg/cm2

0

100

200

300

400

500

600 540’C 568’C

ENTROPY

TEMP 1

2

3

45

HPT

IPTLPTCONDENSER

FEED WATER

FRS

STORAGE TANK

SEPARATOR

BWRP

Spiral w

ater walls

MS LINE

HRH LINE

VERTICAL WW

ECO I/L

ECO JUNCTION

HDR

ECO HGR O/L HDR

FUR LOWER HDR

FUR ROOF I/L HDR

DIV PANELS SH PLATEN SH

FINAL RH

FINAL SH

LTRH

ECONOMISER

290°C, 302 KSC

411°C, 277Ksc

411°C, 275 Ksc

492°C, 260 Ksc

540°C, 255 Ksc

30

5°C

, 4

9 K

sc

457°C, 49 Ksc

568°C, 47 Ksc

GLPT

Boiling process in Tubular Geometries

Heat Input

Hea

t Inp

utWater

WaterWater

Steam

Steam

Partial Steam GenerationComplete or Once-through Generation

SIPAT SUPER CRITICAL BOILER

BOILER DESIGN PARAMETER

DRUM LESS BOILER : START-UP SYSTEM

TYPE OF TUBE Vertical Spiral

SPIRAL WATER WALL TUBING

Advantage Disadvantage over Vertical water wall

Vertical Tube Furnace

To provide sufficient flow per tube, constant pressure furnaces

employ vertically oriented tubes.

Tubes are appropriately sized and arranged in multiple passes in

the lower furnace where the burners are located and the heat input

is high.

By passing the flow twice through the lower furnace periphery

(two passes), the mass flow per tube can be kept high enough to

ensure sufficient cooling.

In addition, the fluid is mixed between passes to reduce the upset

fluid temperature.

Spiral Tube Furnace

The spiral design, on the other hand, utilizes fewer tubes to obtain

the desired flow per tube by wrapping them around the furnace to

create the enclosure.

This also has the benefit of passing all tubes through all heat

zones to maintain a nearly even fluid temperature at the outlet of

the lower portion of the furnace.

Because the tubes are “wrapped” around the furnace to form the

enclosure, fabrication and erection are considerably more

complicated and costly.

SPIRAL WATER WALL

ADVANTAGE

Benefits from averaging of heat absorption variation : Less tube leakages

Simplified inlet header arrangement

Use of smooth bore tubing

No individual tube orifice

Reduced Number of evaporator wall tubes & Ensures minimum water flow

Minimizes Peak Tube Metal Temperature

Minimizes Tube to Tube Metal Temperature difference

DISADVANTAGE

Complex wind-box opening

Complex water wall support system

tube leakage identification : a tough task

More the water wall pressure drop : increases Boiler Feed Pump Power

Adherence of Ash on the shelf of tube fin

BOILER OPERATING PARAMETERFD FAN 2 No’S ( AXIAL ) 11 kv / 1950 KW 228 mmwc

1732 T / Hr

PA FAN 2 No’s ( AXIAL) 11 KV / 3920 KW 884 mmwc

947 T / Hr

ID FAN 2 No’s ( AXIAL) 11 KV / 5820 KW 3020 T / Hr

TOTAL AIR 2535 T / Hr

SH OUT LET PRESSURE / TEMPERATURE / FLOW

256 Ksc / 540 C

2225 T / Hr

RH OUTLET PRESSURE/ TEMPERATURE / FLOW

46 Ksc / 568 C

1742 T / Hr

SEPARATOR OUT LET PRESSURE/ TEMPERATURE

277 Ksc / 412 C

ECONOMISER INLET 304 Ksc / 270 C

MILL OPERATION 7 / 10

COAL REQUIREMENT 471 T / Hr

SH / RH SPRAY 89 / 0.0 T / Hr

BOILER EFFICIENCY 87 %

1. High erosion potential for pulverizer and backpass tube is expected due to high ash content.

2. Combustibility Index is relatively low but combustion characteristic is good owing to high volatile content.

Parameter Unit Design

Coal Worst Coal

Best Coal

Young Hung #1,2(800MW)

Tangjin #5,6(500MW)

High Heating Value kcal/kg 3,300 3,000 3,750 6,020 6,080

Total Moisture % 12.0 15.0 11.0 10.0 10.0

Volatile Matter % 21.0 20.0 24.0 23.20 26.53

Fixed Carbon % 24.0 20.0 29.0 52.89 49.26

Proximate Analysis

Ash % 43.0 45.0 36.0 13.92 14.21

Fuel Ratio (FC/VM) - 1.14 1.00 1.21 2.28 1.86

Combustibility Index - 2,067 2,353 2,476 2,781 3,492

Carbon % 39.53 31.35 40.24 63.03 62.15

Hydrogen % 2.43 2.30 2.68 3.60 3.87

Nitrogen % 0.69 0.60 0.83 1.53 1.29

Oxygen % 6.64 5.35 8.65 7.20 7.80

Sulfur % 0.45 0.40 0.60 0.72 0.68

Ash % 43.00 45.00 36.00 13.92 14.21

Ultimate Analysis

Moisture % 12.00 15.00 11.00 10.00 10.00

Grindability HGI 50 47 52 45 48

ASTM Coal Classification - Hi–Vol. ‘C’ Bituminous

Hi–Vol. ‘C’ Bituminous

Hi–Vol. ‘C’ Bituminous

Midium Vol. Bituminous

Hi–Vol. ‘C’ Bituminous

Coal Analysis

1. Lower slagging potential is expected due to low ash fusion temp. and low basic / acid ratio.

2. Lower fouling potential is expected due to low Na2O and CaO content.

Parameter Unit Design

Coal Worst Coal

Best Coal

Young Hung #1,2(800MW)

Tangjin #5,6(500MW)

SiO2 % 61.85 62.40 61.20 57.40 57.40

Al2O3 % 27.36 27.31 27.32 29.20 29.20

Fe2O3 % 5.18 4.96 5.40 4.40 4.40

CaO % 1.47 1.42 1.52 2.70 2.70

MgO % 1.00 1.03 0.97 0.90 0.90

Na2O % 0.08 0.08 0.08 0.30 0.30

K2O % 0.63 0.32 1.22 0.70 0.70

TiO2 % 1.84 1.88 1.80 1.30 1.30

P2O5 % 0.54 0.55 0.44 - -

SO3 % 0.05 0.05 0.05 - -

Ash

Analysis

Others % - - - 3.10 3.10

Initial Deformation oC 1150 1100 1250 1200 1200

Softening oC - - -

Hemispheric oC 1400 1280 1400

Ash Fusion

Temp. (oC)

(Reducing

Atmos.) Flow oC 1400 1280 1400

Ash Content kg/Gcal 130.3 150.0 96.0 23.12 23.37

Basic / Acid B/A 0.09 0.09 0.10 1.63 1.63

Ash Analysis

Constant Pressure Control

Above 90% TMCR The MS Pressure remains constant at rated pressure

The Load is controlled by throttling the steam flow

Below 30% TMCR the MS Pressure remains constant at minimum Pressure

Sliding Pressure Control

Boiler Operate at Sliding pressure between 30% and 90% TMCR

The Steam Pressure And Flow rate is controlled by the load directly

BOILER LOAD CONDITION

+1

0

-1

-2

-3

-4

20 40 60 80 100E

ffic

ienc

y C

hang

e %

Boiler Load %

Constant P

ressure

Variable Pressure

CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC

Benefits Of Sliding Pressure Operation ( S.P.O)

Able to maintain constant first stage turbine temperature

Reducing the thermal stresses on the component : Low Maintenance & Higher Availability

No additional pressure loss between boiler and turbine.

low Boiler Pr. at low loads.

WHY NOT S.P.O. IN NATURAL/CONTROL CIRCULATION BOILERS

Circulation Problem : instabilities in circulation system due to steam formation in down comers.

Drum Level Control : water surface in drum disturbed.

Drum : (most critical thick walled component) under highest thermal stresses

LMZ (LENINGRADSKY METALLICHESKY ZAVOD)

K STANDS FOR KLAPAN LTD.,BULGARIA WHICH SUPPLIES TURBINE,NOZZLES,DIAPHRAGMS, SEALS,BLADES ETC.

1.TG DECK IS VIS SUPPORTED AND HAS 26 CONCRETE COLUMNS (T1 – T26).2.TG HALL IS CONSTITUTED OF 3 MAINS ROWS OF COLUMNS – A,B ,C ROW AND TWO BAYS – AB BAY AND BC BAY. THE WIDTH OF AB BAY IS 36m AND BC BAY IS 12m

3.CONDENSER TUBE BANKS (CW PATH) HAS AN INCLINATION OF 40.4.THERE ARE TWO MAIN EOT CRANES FOR TG HALL.EACH EOT CRANE IS HAVING A CAPACITY OF 200t FOR MAIN HOIST AND 20t FOR AUXILIARY HOIST. 35.5m IS THE MAXIMUM VERTCAL DISTANCE A HOIST CAN TRAVEL.TANDEM OPERATION OF TWO EOT CRANES ARE ALLOWED.

IP Turbine

LP Turbine

Ext.No

Source Of Extraction Destination Equipments

1 13th stage of HPT HPH-8

2 CRH HPH-7

3 3rd stage of IPT HPH-6 *

3 3rd stage of IPT TDBFP

4 6th stage of IPT DEAERATOR

5 8th stage of IPT LPH-4

6 11th stage of IPT LPH-3

7 2nd stage of LPT LPH-2

8 4th stage of LPT LPH-1

Condenser

• Design LMZ

• Design CW Flow 64000 m3/hr

• Vacuum 77 mm Hg (abs) at 33 0C

89 mm Hg (abs) at 36 0C

• No. of passes 1

• Total no. of tubes 22.225 (OD)x0.71 (t) - 29920

22.225 (OD)x1.00 (t) - 2080

• Tube material ASTM A-249 TP 304

• Rated TTD 3.40C

• DT of CW 100C

Condensate Extraction Pump

• Design flow rate 238.75 Kg/s

• Discharge pressure 32.15 Ksc

• Shut off head 395 m

• Pump speed 1480 rpm

• Power input 972.3 KW

• No. of stages 6

• Type of first stage impeller double entry

• Depth 7.43 m

MDBFP

• Pump flow 769.950 TPH• Suction temp 186.2 0C• BP Suction pr. 14.05 ata• BFP Suction pr. 21.01 ata• BFP Discharge pr. 335.78 ata• BFP Discharge temp. 187.9 0C• BP Discharge pr. 22.01 ata• Shut off head 4830 m• BFP Speed 6275 rpm• BP Speed 1490 rpm• Normal R/C flow 220 TPH• HC Rated O/P Speed 6505 rpm• Outer casing type barrel• No. of stages 7• BFP warm up flow 15 TPH

TDBFP

• Pump flow 1283.14 TPH• Suction temp 186.2 0C• BP Suction pr. 14.10 ata• BFP Suction pr. 28.24 ata• BFP Discharge pr. 335.83 ata• BFP Discharge temp. 187.8 0C• BP Discharge pr. 29.06 ata• Shut off head 4580 m• BFP Speed 4678 rpm• BP Speed 2098 rpm• Normal R/C flow 365 TPH• HC Rated O/P Speed 6505 rpm• Outer casing type barrel• No. of stages 7• BFP warm up flow 20 TPH

Drip Pump

• Design flow rate 324.509 TPH

• Discharge pressure 43 ata

• Shut off head 306.7 m

• Pump speed 1486 rpm

• Power input 310.1 KW

• No. of stages 5

• Type of first stage impeller centrifugal, single entry

• Depth 1090 mm

RATED CONDITIONS

• LOAD : 660MW• BEFORE HP STOP VALVE

• STEAM PRESSURE : 247KSC• STEAM TEMPERATURE : 5370C• STEAM FLOW : 2023.75T/HR

• AFTER HPC• STEAM PRESSURE : 48KSC• STEAM PRESSURE : 298.710C

• BEFORE IP STOP VALVE• STEAM PRESSURE : 43.2KSC• STEAM TEMPERATURE : 5650C

• STEAM FLOW TO REHEATER : 1681.12T/HR.• DESIGN CONDENSER PRESSURE : 0.105KSC (abs.)• COOLING WATER FLOW : 64000M3/HR• FINAL FEED WATER TEMP. : 286.350C• FREQUENCY RANGE : 47.5 – 51.5 Hz

STEAM TURBINE• Generator rated speed 3000 rpm• Generator manufacturer Electrosila• No. of bleedings 8• Length of the turbine 36.362 m• No. of stages

HPT 17 IPT 11x2 LPT-1 5x2 LPT-2 5x2 Total 59

• Turbine Governing system Mode of Governing Nozzle Type E/H Control fluid Firequel-L make

Supresta-USA Normal Operating Pr. 50 Ksc Capacity 600 lpm Fluid pump motor rating 200 KW Filter material Ultipor Mesh size 25 µ

Turbine Protections

Turbine protection system consists of Two Independent channels, each operating the corresponding solenoid (220V DC) to trip the Turbine in case of actuation of remote protection

Hydraulic Protection: Apart from the Electrical Trip, Turbine is equipped with the following Hydraulic Protections:

1. Local Manual Trip (1V2)2. Over speed Trip #1 at 110% of rated speed3. Over speed Trip #2 at 111% of rated speed4. Governing oil pressure < 20 Ksc

Contd..

5.Axial shift Very High (2V3) [-1.7mm, +1.2mm]

6.Turbine bearing vibration : Very High (2V10 including X & Y directions)* >11.2mm/sec (Td=2 sec)

7.Lube oil tank level very Low (2V3)* Td=3sec (Arming with two stop valves open)

8.Lub oil pressure Very Low (2V3) < 0.3 Ksc; Td =3 sec (Arming with two stop valves open)

9.Condenser pressure Very High (2V3) > - 0.7ksc (Arming with condenser press < 0.15 ksc Abs)

Contd

10.M.S. temp Very Low (2V3) < 470 deg C (arming > 512 deg C)*

11.M.S. temp Very High (2V3) > 565 deg C*

12.HRH temp Very Low (2V3) < 500deg C (arming > 535 deg C)*

13.HRH temp Very High (2V3) > 593deg C*

14.HPT outlet temperature Very High (2V4) > 420 deg C

Contd…

15.Gen seal oil level of any seal oil tank Very Low (2V3)* < 0 mm;Td=15 sec (Arming with any two stop valves open)

16.All Generator seal oil pumps OFF (3V3)* Td: 9 sec (Arming with any two stop valves open)

17.Generator Stator winding flow Very Low (2v3) < 17.3 m3/hr; Td =120 sec (Arming with any two stop valves open)

18.Generator hot gas coolers flow Very LOW (2V3)* : <180m3/hr; Td=300sec(Arming with any two stop valves open)

19.Generator cooler hot gas temp. Very High(2V4) > 85 deg (Td = 300sec

Contd

20.MFT operated: (2V3)

21.Deareator level Very High (2V3) > 3400 mm*

22.HP heater level protection operated (2V3)*

23.Generator Electrical protection operated (2V3)

25.Turbine over speed protection operated (114%)

26.Turbine Controller failure protection operated (2V3)

OF SIPAT SUPER CRITICAL UNIT

1ST UNIT SYNCHRONIZED AT : 18.02.20111ST UNIT FULL LOAD ACHIEVED AT :

2nd UNIT SYNCHRONIZED AT : 03.12.20122ND UNIT FULL LOAD ACHIEVED AT : 24.12.2012

PRE – COMMISSIONING ACTIVITIES

CHEMICAL CLEANING OF BOILER :

REQUIRED FORMaintaining steam quality at the turbine inlet.Minimizing corrosion of the metal surface of boiler.

DETERGENT FLUSHING OF PRE-BOILER SYSTEM

To remove dirt ,oil ,grease etc., from Condensate ,Feed water, Drip and Extraction steam lines of HP and LP heaters prior to putting these systems in regular service. This is to ensure flow of clean condensate and feed water to the boiler.

STEAM BLOWING OF POWER CYCLE PIPING :

The purpose of steam line blowing is to remove pipe slag, weld bead deposits and other foreign material from the main and reheat steam systems prior to turbine operation. The cleaning is accomplished by subjecting the piping systems to heating, blowing steam and cooling cycles in sufficient number and duration until clean steam is obtained.

SAFETY VALVE FLOATING

PRE – COMMISSIONING CHECKS

All commissioning procedure should be finalized.

P&I Drawings should be finalized and available with site engineer

Different systems check list should be finalized with all concerned agencies

All Field quality checks should be completed.

P&I Checks should be finalized.

Start – Up procedure should be finalized

COMMISSIONING SEQUENCE OF TG SIDE

1.Commissioning of stator water cooling system for HV testingbefore generator rotor insertion.a) Stator water pump trial run.b) Flushing of the system bypassing winding.c) Flushing of the system through the winding.

2.Commissioning of MCW,ACW and DMCW system.a) Trial run of pumps.b) Flushing of the system.

3.Detergent Flushing of pre boiler system (Feed water ,condensate ,HPH and LPH drip system)a) Cold water flushing until turbidity comes below 5NTU.b) Hot water flushing (600C) with 2 hrs circulation of each circuit.c) Raising water temperature to 600C and addition of Detergent d) (Coronil 100%)

e) Circulation through each circuit for 2 hrs.f) Hot draining of the systemg) DM water rinsing of each circuit until conductivity comes below 5µs/cm and oil content BDL.h) Passivation with ammonia and hydrogen peroxide solution at a temperature of 400C.i) Draining of the system.

4. Lube oil flushing of MDBFP lube oil system.5.Trial run of MDBFP.6.Lube oil and seal oil flushing of main TG.7.CF system flushing.8.Condenser flood test.9.Trial run of CEPs10.Commissioning of generator gas system.11.Generator ATT.12.Calibration of HPCVs and IPCVs13.Putting turbine on barring.14.Vacuum pumps trial run.

15.Commissioning of seal steam system.16.Commissioning of HP and LPBP system.17. Vacuum pulling.18.Lube oil flushing of TDBFP.19.Steam blowing of TDBFP steam line.20.Commissioning of TDBFP.

FUR DRAFT SYSTEM

SEC AIR SYSTEM

TG ON BARRING

BRP TRIAL RUN

TG LUBE OIL / GEN SEAL OIL SYSTEM

FURNACE READINESS

FUEL OIL SYSTEM READINESS

DDCMIS FSSS READINESS

MFT CHECKING

GATES, DAMPERS / VALVES

TG :

SG : (13 / 190 )

STATOR COOLING WATER

CW SYSTEM READINESS

CHEMICAL CLEANING OF BOILER

MS Line Welding Completion ( 30 Pen)

CRH Line Welding Completion ( 12 Pen)

HRH Line Welding Completion (34 Pen)

MS Line Hanger Erection Cold Setting

CRH Line hangers Cold Setting

HRH Line Hangers Cold Setting

MS Line Insulation CRH Line Insulation HRH Line Insulation

MS Line HT CRH Line HT HRH Line HT

COMPRESSED AIR SYSTEM READINESS

AUX PRDS READINESS

CONDENSER VACCUM SYSTEM

POWER CYCLE PIPING STEAM BLOWING

UNIT SYNCHRONIZTION

MDBFP Trial

CEP Trial

TG SEAL STEAM SYSTEM

TG CONTROL FLUID SYS

TG GOV SYSTEM

GEN GAS SYSTEM

Questions Please Enlighten Us

Discussion

Evaporator – heat absorption

Reduced number of evaporator wall tubes.

Ensures minimum water wall flow.

SPIRAL WALL ARRAMGEMENT AT BURNER BLOCK AREASPIRAL WALL ARRAMGEMENT AT BURNER BLOCK AREA : :

Support System for Evaporator Wall

• Spiral wall Horizontal and vertical buck stay with tension strip

• Vertical wall Horizontal buck stay