devdeep bose dgm ( commng & testing)
TRANSCRIPT
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