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QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW

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BOILER & AUXILIARIES OPERATION MANUAL

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2 300 MW Anthracite Coal Fired Power Station

Boiler & Auxiliaries

Operation Manual

Date: 2008-09-15

No.:QN1-SEC-G-04-TP-003

Rev. : A

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW

SEC

BOILER & AUXILIARIES OPERATION MANUAL

Index
1 SCOPE ..................................................................................................................................................... 4 2 SPECIFIC QUOTING DOCUMENTS .................................................................................................... 4 3 BOILER TECHNIQUE SPECIFICATION.............................................................................................. 5 3.1 3.2 3.3 3.4 3.5 INTRODUCTION OF BOILER .................................................................................................................. 5 BOILER NAMEPLATE ............................................................................................................................ 7 BOILER DESIGN INFORMATION ............................................................................................................ 8 REQUIREMENT FOR QUALITY OF BOILER STEAM............................................................................... 16 BOILER AUXILIARY EQUIPMENT TECHNICAL SPECIFICATIONS ............................................................ 19

4 BOILER AND INTERLOCK PROTECTION VALUE AUXILIARY EQUIPMENT........................... 34 4.1 4.2 BOILER PROTECTING LIMIT VALUE .................................................................................................... 34 BOILER AUXILIARY INTERLOCK PROTECTION VALUE AUXILIARY EQUIPMENT. ................................... 35

5 START-UP.............................................................................................................................................. 44 5.1 5.2 5.3 5.4 5.5 5.6 BASIC REGULAR ................................................................................................................................ 44 REPAIR TEST AND ACCEPTANCE INSPECTION ...................................................................................... 44 CHECK AND PREPARATION BEFORE START-UP..................................................................................... 70 COLD START-UP SEQUENCE ................................................................................................................ 74 HOT START-UP .................................................................................................................................... 83 PARAMETER CONTROL VALUE IN THE PROCESS OF START-UP ............................................................. 87

6 MONITORING AND ADJUSTMENT IN BOILER OPERATION ...................................................... 88 6.1 6.2 6.3 THE MAIN TASK AND OBJECTIVES OF OPERATION ADJUSTMENT ......................................................... 88 MAIN PARAMETER AND LIMIT OF OPERATION CONTROL .................................................................... 88 CHECKING, MONITORING AND MAINTENANCE IN BOILER OPERATION ................................................ 91

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6.4

BOILER & AUXILIARIES OPERATION MANUAL

BOILER OPERATION MEASURE CONTROL .......................................................................................... 100

7 SHUT-DOWN OF BOILER................................................................................................................. 100 7.1 7.2 7.3 7.4 7.5 7.6


BASIC REGULAR (GENERALS ) .......................................................................................................... 100

PREPARATION BEFORE SHUT-DOWN OF BOILER ................................................................................ 101 SHUT-DOWN WITH SLIDING PARAMETER (NEED COOLING ) .............................................................. 102 NORMAL SHUT-DOWN (HOT STAND-BY ) .......................................................................................... 104 EMERGENCY SHUT-DOWN ................................................................................................................ 105 SHUT-DOWN MAINTENANCE ............................................................................................................ 105

8 BOILER AUXILIARY EQUIPMENT ..................................................................................................113 8.1 8.2 8.3 BASIC REGULAR OF AUXILIARY EQUIPMENT OPERATION.................................................................. 113 MOTOR OPERATION .......................................................................................................................... 117 START-UP, STOP AND OPERATIONAL MAINTENANCE OF AUXILIARY EQUIPMENT AND SYSTEM .......... 117

9 PERIODIC WORK, TEST AND SHIFTING OF THE BOILER AND RELEVANT AUXILIARY EQUIPMENT............................................................................................................................................. 171 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 ACCIDENTS PROCESSING OF BOILER......................................................................................... 172 BASIC PRINCIPIA OF ACCIDENTS PROCESSING ................................................................................. 172 BOILER EMERGENCY SHUTDOWN .................................................................................................... 174 SHUTDOWN APPLICATION OF BOILER .............................................................................................. 178 BOILER ABNORMAL OPERATION PARAMETER ................................................................................. 178 LOAD REJECTION OF UNIT ............................................................................................................... 183 AUXILIARY POWER SUPPLY INTERRUPTION ..................................................................................... 184 CONTROL&INSTRUMENT AND APPARATUS POWER SUPPLY INTERRUPTION .................................... 185 FIRE ACCIDENT ................................................................................................................................ 186 PROCESSING INFERIOR QUALITY OF WATER AND STEAM ................................................................ 188 BOILER HEATING SURFACE SLAGGING SERIOUSLY...................................................................... 190

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10.11 10.12 10.13 10.14 10.15 10.16 10.17 10.18 10.19 10.20 10.21 10.22 10.23 10.24 10.25 10.26 11 11.1 11.2 11.3 11.4 11.5

BOILER & AUXILIARIES OPERATION MANUAL

GAS DUCT REBURNING................................................................................................................ 191 UNIT TRIP .................................................................................................................................... 192 STEAM DRUM FULL FEEDED ........................................................................................................ 194 STEAM DRUM SHORT FEEDED ..................................................................................................... 195 PRIMING ....................................................................................................................................... 197 HIGH FURNACE PRESSURE ........................................................................................................... 197 LOW FURNACE PRESSURE............................................................................................................ 198 BOILER BURNING OUT ................................................................................................................. 199 FUEL TRIP .................................................................................................................................... 200 WATER WALL TUBES TXPLOSION ................................................................................................. 201 ECONOMIZER TUBES EXPLOSION................................................................................................. 202 SUPERHEATER TUBES EXPLOSION ............................................................................................... 203 REHEATER TUBES EXPLOSION ..................................................................................................... 204 THE BREAK OF STEAM PIPES OR FEEDWATER PIPES OUTSIDE THE BOILER ................................. 205 HIGH STEAM DRUM PRESSURE .................................................................................................... 206 AUXILIARY FAILURE .................................................................................................................... 208

APPENDIX .......................................................................................................................................... 232 THE CONTRASTIVE LIST OF THE ABSOLUTE PRESSURE AND TEMPERATURE IN SATURATED STATES .. 232 BOILER COLD START-UP CURVE ....................................................................................................... 233 BOILER HOT STAR-TUP CURVE......................................................................................................... 234 BOILER DRUME LEVEL VS LOAD CURVE ........................................................................................... 237 BOILER O2 IN FLUE GAS VS LOAD CURVE ........................................................................................ 238

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1 Scope This operating &

BOILER & AUXILIARIES OPERATION MANUAL

maintenance

manual

provides

the

principle,

methods

and

steps of the start-up, shut-down, operating & maintenance, control and adjustment of the boiler for Vietnam Quang Ninh 2300MW Project. All the staff engaged in operating equipment maintenance and management of manufacture and production technology management in Quang Ninh power plant should be familiar with all or relevant parts of the manual and execute extremely strictly. 2 Specific Quoting Documents The items included in the following Chinese standards are made of the items of this manual by citing it. When this manual was promulgated, all the standards in it are valid and will be revised .The parties using the manual should explore the possibility of the latest version of following standard which will be decided whether to apply to this standard. Besides the following standards, when the equipment manufacturer has the special requirement which meets the safety operation the No. 01 02 03 04 equipment manufacturer should standards, the special requirement from be complied with.

Standard Code DL/T 607-1996 DL/T 6111996 DL/T 6121996 DAS(1994)277

Standard Name 300MW turbine operation guidelines 300MW boiler operation guidelines Monitoring regular of power industry boiler and pressure vessel Working regulation of power safety (Thermal mechanical parts) Working regulation of power safety

05

DL408-91 (power plants and substations parts)

06 07

DL558-94 DL435-91

Investigation of production accidents in power industry Explosion-proof of furnace regular for thermal Power Plant pulverized coal-fired boiler Vapor and chemical monitoring guidelines of thermal power plant The quality of vapor of thermal power generating units and

08

DL/T 56195

09

GB/T 12145-1999

steam power equipment

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10 11 12 13 3 3.1 SD223-87 GB7596-87 GDF(2000)589

BOILER & AUXILIARIES OPERATION MANUAL Anti-corrosion guidelines of stand-thermal power plant equipment Oil quality standards in turbine in the operation of power plant 25 pieces of key requirement to prevent accidents in power production Design information and equipment information of manufacturer major

Boiler Technique Specification Introduction of Boiler This boiler is designed by Alstom who provides performance-test technique support .It is manufactured by Shanghai Boiler Works Ltd. This form of boiler is doublearched, W-flame with single furnace, then one middle reheat, control circulation and sub-critical steam drum furnace. Two units are equipped with one start-up boiler for steam source. Design coal for boiler is anthracite which is from Vietnam CAM PHA and HON GAI mining areas. Combustion system: the system adopts hot air feeding, each boiler with 16 duplex-type feeders, 32 pulverized coal burner. The capacity of pulverized coal combustions is 100% heavy the BMCR with design-coal. Start-up and the stable HPO combustion burner and adopt then oil according to TCVN 6239-2002 standards. This boiler adopts twoigniter ignites heavy-oil burner ignites pulverized coal. Fuel oil burners will be steam

stage ignition. The high-energy

atomized. This project set 25000 tons tank and 2 unloading fuel pumps, two 100% capacity AC, DC supply pump, 1 dirty oil pump and 1 sewage pump. Oil burning system arranges oil supply pipe and oil return pipe to boiler burners according to oil supply and return single piping circulation. Oil burners: Each arch nose has 8 HFO burners, namely each boiler has 16 burners. The auxiliary steam which pressure is constantly 5.25 bar (g) makes HFO atomization and also cleans the burners.HFO will be ignited by high-energy igniter. Each HFO burner will be equipped with specialized flame detector. Cooling wind will be provided through two separate specialized circuit burner and the flame detector .When oil burner is stopped, it will exit from burner quarrel by about 330 mm to avoid impact of radiation (prevent the burners from damaged). Low heat value (LHV value) is fuel heat input at 30% BMCR by adopting 12 burners to achieve the burning capacity at 30% BMCR (two

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW

SEC

BOILER & AUXILIARIES OPERATION MANUAL burners in each arch nose are stopped operation).The adjustment ratio of burner is 1:5

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using J11 burner.

BOILER & AUXILIARIES OPERATION MANUAL

Flue and air system, pulverized coal system: flue and air system adopts balance draft, the then Force flue gas will and be discharged to the to the is atmosphere passing flow axial passing the fan. FGD FDF is ESP and FGD, or directly atmosphere bypass. moving equipped

draft-fan

induced draft-fan

blade adjustable and IDF is static blade adjustable. Milling system bin and flue gas drying milling system with balance draft. Each boiler is with 2 single way BBI globe mill. Primary air fan adopts centrifugal

fan .The vent will be filtrated pulverized coal through cloth dust collector and then discharged to atmosphere through vent fan. Ash slag removal and ash yard: Adopting dry ash extraction ash at the bottom is discharged to slag pool through slag crusher and hydro ejector .The fly ash collected from AP. economizer and ESP is sent to the large ash silo(total 2 ash silo ,each has 2500 m3 volume), the dry ash is further dealt with through the ashwater mixture silo through and transported to ash pool and then transported to ash ash emulsion pump (the method for retaining and comprehensive

utilization of dry ash) Desulphurization and dust removal system: Choose 4 ESP. This project sets up one 200m-high two-steel cylindrical chimney and also sets up 100% capacity scrubber adopting Limestone - gypsum wet desulphurization process and GGH Compressed considering air system: total three 50% capacity compressors

little lubrication oil.

Safety valve: This boiler is equipped with 8 spring safety valves supplied by Crosby America ,who are located in the following places: 3 valves at the drum, 1 valve at SH outlet RH outlet piping, 2 valves at RH relief outlet valve piping, is 2 valves on at SH piping, one electromagnetic mounted is

outlet piping. The valve is VTI brand supplied by Crosby America. BMCR is 995t/h, the total discharging capacity of drum safety amounting to 88.62 percent of BMCR. The valves 881.796, discharging capacity of SH

safety valves is 153.86t/h, amounting to 15.46 percent of BMCR. The discharging capacity of SH and drum safety valves is 1035.656t /h, amounting to 104.09% percent of BMCR. Max RH steam flow is 848.6t/h. The discharging capacity of safety valves at RH inlet is 512.94t/h, amounting to 60.45 percent of Max RH steam flow. The discharging capacity of safety valves at RH outlet is 379.157t/h, amounting to 44.68 percent of Max RH steam flow, The aggregate of discharge capacity at RH outlet and

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW

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inlet flow.

is

892.097t/h,

BOILER & AUXILIARIES OPERATION MANUAL amounting to 105.13 percent of the Max RH

steam

The

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BOILER & AUXILIARIES OPERATION MANUAL

discharging capacity of electromagnetic Relief Valve is 166t/h, amounting to 16.68% percent of BMCR, It is not included in Safety Valve capacity whatsoever. 3.2 Boiler Nameplate Unit SG-995/17.5-M728 SBWL 728-1-8069 Double-arched, Boiler form furnace, drum t/h t/h M Pag t/h MPag MPag 995 889.1 541541 17.2917.13 882.498/736.407 320/540 309/540 3.53/3.34 3.14/2.98 281/273 then W-flame a with single reheat,

Type of boiler Manufacturer Fabrication no.

middle

control circulation and sub-critical steam Boiler maximum rating(B MCR) Continues rating(RO) Rated temp. of main steam(B-MCRRO) Rated pressure of main steam B-MCR RO) Reheater steam flow(B-MCRRO) Temp of reheater inletoutlet(B-MCR) Temp of reheater inletoutlet(RO) Pressure of reheater inletoutlet(B-MCR) Pressure of reheater inletoutlet(RO) Temp of feed water (B-MCRRO) Date of starting erection Date of starting manufacture continues

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3.3 3.3.1 No. 1 2 Primary system 3

BOILER & AUXILIARIES OPERATION MANUAL

Boiler Design Information Water Bulk of Boiler Pressure Parts System Pressure Drum Water wall Superheater economizer and header and other connecting pipe Reheater Secondary system Header and connecting pipe m3 151 Units m
3

Date 40 82

Total

m3

273

4 5 3.3.2

m3 m3

48 24 72

Boiler Safety Valve Setting Pressure and Discharge Blow Set pressure Specificat down Different Openi ng MPa 20.50 20.60 20.70 18.70 4.50 4.60 4.10 Blo w dow n MPa 19.8 9 19.7 8 19.6 7 18.1 4 4.37 4.46 3.98 ial pressur e% 3 4 5 3 3 3 3 291.697 293.924 296.175 153.860 253.574 259.366 187.347 369 369 369 557 313 313 554 Dischargi ng capacity t/h Desi gn temp

N o.

Location

Type of valve

ion (inch)

1 2 3 4 5 6 7

DRUM DRUM DRUM Reaheate r outlet Reaheate r outlet Reaheate r outlet Reaheate r outlet

HE-96W HE-96W HE-96W HCI-98W HCI-46W HCI-46W HCI-48W

3 M2 6 3 M2 6 3 M2 6 3 L2 6 6 RR10 6 RR10 6 RR10

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8 Reaheate r outlet Superhea 9 ter outlet(ER V) 3.3.3 HCI-48W

BOILER & AUXILIARIES OPERATION MANUAL 6 RR10 4.20 4.07 3 191.810 554

E0L121N7BWR A5P1

2..54

18.50

18.1 3

166

557

Thermal Performance Calculation for Boiler Operation Coal combustion(loads) Items Unit BMCR RO 300 995 995 822.5 849.4 kg/cm g 190.4 176.3 169 37.6 33.7 362 541 538 323 538 kg/cm g
2 2

75% RO 225 639.4 639.4 543.0 555.0 156 149 145.5 24.7 22.1 347 539 538 301 538

60% RO 210 518.9 518.9 443.8 443.8 127.5 121.9 119.1 20.0 18.0 333 539 538 304 538

Minmum loads *60% RO

1. Total output of Generator 2. Steam flow (a) (b) (c) (d) (a) (b) (c) (d) Reheater outlet High-pressure turbin inlet High-pressure turbin

MW kg/H

882.7 882.7 735.3 756.5 186.5 174.7 169 33.6 30.1 360 540 538 312 538

Exhaust Mid-pressure turbin inlet Drum Superheater outlet High-pressure turbin inlet High-pressure turbin 3. Steam pressure

Exhaust (e) Mid-pressure turbin inlet 4. Steam temp. (a) (b) (c) (d) Drum Superheater outlet High-pressure turbin inlet High-pressure turbin

Exhaust (e) Mid-pressure turbin inlet 5. Feedwater pressure (a) BFP outlet

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(b) outlet (c) (d) (a) (b) Economizer inlet Economizer outlet High-pressure heaters

BOILER & AUXILIARIES OPERATION MANUAL

193.9 193.4 281 299 % flue

189.4 189.0

158.7 158.5

129.9 129.8

6. Temp. of feedwater Feedwater pump outlet Economizer inlet loss in the (high dry

273 291

254 275

243 267

(c) Economizer outlet 7. Heat heating l (a) gas ) Heat

4.19 1.13 2.36

3.88 1.12 2.34

(L ') (b) Moisture in fuel (L2') (c) The water generated hydrogen in in the from the (d) (e)

combustion air((L4')

The moisture

0.11 3.00

0.12 3.00

Un-burned carbon ((L5') formation of

(f) The carbon

id ((L ') (g) Heat loss due to radiation ((L ) (h) Other((L8) (i) ((L9) Total(L) (j) (k) (l) Ambient air temperature Relative Humidity Atmospheric pressure % kg/cm2 % kg/H kcal/kg 4815 24 80 1.0332 Manufacturing allowance

0.20 0.25 0.50 11.75 24 80 1.033 88.25 129500 4815

0.26 0.25 0.50 11.48 24 80 1.0332 88.52 99100 4815 4815 4815 24 80 1.033 1.0332

8. Total heat efficiency 9. Fuel consumption (coal) 10. (a) Heat LHV of coal

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(b) HHV of coal (total heat release) (a) (b) (c) 12. (a) (b) Per Effective volume Per Flat area Per effective Air temp. Steam heater inlet Steam heater outlet preheter preheter inlet inlet protruding 11. Furnace heat absorption

BOILER & AUXILIARIES OPERATION MANUAL 4980 4980 4980 4980 4980

x 103 kcal/m3H x 106 kcal/m2H x 103 kcal/m2H

86.9 2.9 163.1

78.5 2.6 147.4

59.3 1.95 111.2

49.9 1.65 93.7

radiation surface

29 29 31 29 356 333 580 110 1015 825 670 400 131 124

29 29 31 29 352 333 580 110 990 800 650 392 127 121 TBA 77

29 29 31 29 324 311 580 110 910 730 610 358 118 111 TBA 72

29 29 31 29 308 297 580 110 860 700 580 340 109 102 TBA 69 TBA

(c) Air primary i (d) (e) air (f) Air (g) (h) 13. (a) (b) (d) (e) Air

secondary air Air preheter outlet primary preheter outlet

secondary air Mill entrance Mill export Gas Temperature Furnace outlet Superheater inlet Air preheter inlet Air preheter outlet

(c) Superheater outlet

(Un-corrected) (Corrected) 14. Dew-point preheter of air

76 80

tl t 15. Temp of cold end metal of AP.

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16. Flue gas volume (a) (b) Economizer outlet air preheater outlet

BOILER & AUXILIARIES OPERATION MANUAL 103 kg/H 1332 1422 10 kg/H M/s 103 kg/H % Vol 24 25 34.4 % Vol 3.8 4.0 5.1 % Vol 14.4 14.3 13.4 x 106 kcal/H 264.7 225.0 116.5 28.5 634.3 TBA 0.0 of x10
3 3

1205 1291 1101 9.8 37.8

936 1020 864 7.2 28.7

827 910 765 6.2 24.1

17. Combustion air volume 18. Maximum speed of flue gas flow in convection section 19. Ash content of economizer outlet 20. Excess air (a) Furnace outlet (b) (c) (d) 21. (b) (c) (d) 22. (b) (c) (d) Economizer outlet Air preheater outlet ESP outlet O2 Economizer outlet Air preheater outlet ESP outlet CO2 Economizer outlet Air preheater outlet ESP outlet

1216 11.2 41.7

24 25 34.9

28 29.5 42

35 37 52

(a) Furnace outlet

3.8 4.0 5.1

4.3 4.5 5.9

5.2 5.4 6.8

(a) Furnace outlet

14.4 14.3 13.3

14.0 13.8 12.7

13.3 13.1 11.9

23. Heat absorption (a) (b) Furnace Superheater

249.2 195.2 106.1 24.6 575.1 TBA 0.0

202.4 139.9 77.8 19.3 439.4 TBA 0.0

172 116.8 64.3 17.1 370.2 TBA 0.0

(c) Reheater (d) Economizer Total (e) 24. Air preheater The heat intensity (f) Steam air heater heating surface

kcal/m2H

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(a) (b) Furnace Superheater

BOILER & AUXILIARIES OPERATION MANUAL TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA

(c) Reheater (d) Economizer (e) 3.3.4 No. I Heat value High heat value Low heat value II 1 2 3 4 5 6 7 8 III 1 2 3 4 5 6 7 IV 1 2 Analysis Total Moisture(as received) Free moisture Inherent Moisture Air preheater Characteristics of Fuel(coal)

Symbol HHV LHV War Ws Win Wad Cfar Var Ad Aar

Unit Kcal/kg Kcal/kg % % % % % % % %

Range 4680-5300 4490-5157 5.55-12.0 4.81-9.88 0.78-2.35 0.80-2.41 49.54-63.15 5.82-8.61 28.0-37.36 25.48-34.0

Date 4980 4790 9.00 7.63 1.48 1.39 53.68 6.83 33.5 30.49 100.00

Moisture in the air dried sample Fixed carbon (as received) Volatile matter(as received) Ash content(air dried basis) Ash content(as received) Total Element analysis C(ADB) H(ADB) O(ADB) N(ADB) S(ADB) A(ADB) M(ADB) Total Physical characteristics Hardness, grindability index Pulverized coal particle size (0-15 mm) +10mm -

Car Har Oar Nar Saror Aar War

% % % % % % %

46.83-63.75 2.56-2.97 1.66-2.68 0.73-0.86 0.27-0.66 25.48-34.0 5.55-12.0

54.62 2.62 2.09 0.77 0.41 30.49 9.00 100

45-70 6.16-17.5

47 100 10.53

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5-10mm 2.5-5mm 1.25-2.5mm 0.63-1.25mm 0.315-0.63mm -0.315mm 3 4 3.3.5 No. Density static angle

BOILER & AUXILIARIES OPERATION MANUAL % % % % % % 9.89-18.3 15.60-21.71 8.73-13.76 12.36-18.13 6.80-14.45 11.47-31.47 0.92-1.10 33-39 14.89 10.02 20.77 1.00 37 14.22 18.62

Characteristics of Burning(ash) Components Ash components Symbol Unit Range Design date

1 2 3 4 5 6 7 8 9 10 11 12 13

SiO2 Al2O3 Fe2O3 V2O5 TiO2 CaO MgO K2O Na2O P2O5 SO3 MnO Other Total Ash physical characteristic

% % % % % % % % % % % % %

57.60-64.10 23.3-28.64 4.26-6.16 0.018-0.028 0.50-0.91 0.30-0.77 0.67-1.42 3.35-4.70 0.15-0.55 0.19-0.30 0.251-0.481 0.006-0.050 0.00

62.83 24.76 5.41 0.026 0.68 0.44 1.11 3.64 0.48 0.24 0.341 0.043 0.00 100.00

1 2

Ash density FYI Solubility of ash Initial temperature Hemispherical temp. Fluid temp. softening deformation R

g/cm3 cm

0.224 - 0.370 301x10 - 603x10


2 2

0.291 525x102

1 2 3

T1 T2 T3

C C C

1210 - 1280 1430 - 1600


0

1250 1570 1530 - 1600

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3.3.6 3.3.6.1

BOILER & AUXILIARIES OPERATION MANUAL

Characteristics of Fuel(heavy-oil) Characteristics of heavy-oil Date No.1 No.2A =< 0.991 =<180 No.2B =< 0.991 =<180 No.3 =< 0.991 =<380 TCVN 6594:200 (ASTMD1298) ASTM D445 TCVN67O1:200O (ASTM TCVN3753:1995 ASTM Test method

Characteristics

Density at 15 mt/m3 Viscosity at 50 cSt Sulphur weight Pour point Ash content % Water volume Purity, by weight Flash point HHV, kcal/kg LHV, kj/kg 3.3.6.2 content, by content, by

=< 0.965 =<87

=<2.0% =<2.0% =<+12 =<+24

=<3.0% =<+24 =<0.15 =<1% =< 0.15% 66 >= 10,000

=<3.5% =<+24 =<0.35 =<1% =< 0.15% 66 >=10,O00

=<0.15 =<0.15 =<1% =< 66 >= =<1% =< 0.15% 66

D97 TCVN2690:1995/ASTM D482 TCVN2692:1995/ASTM D95 ASTM D 473 TCVN 66O8: 20O0/ ASTM ASTM D480 D382S/ASTM D240/ ASTM

>= 10,000 10 000 40,800(usual)

The corresponding value of temp. of fuel burner entrance and viscosity of heavy oil (for detail information refer to viscosity - temperature curve) Item HFO No.1 2.5 E 95 0.917 HFO No.2A & 2B 2.5 E 110 0.934 HFO No.3 2.5E 130 0.922

viscosity of fuel required in the entrance of burner Required Matching temp. Required Matching density 3.3.6.3 J11 oil burner design parameter HFO flow of each burner HFO Atomization Steam pressure of

pressure of steam flow of

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SEC

BOILER & AUXILIARIES OPERATION MANUAL each burner each burner l/h bar(g) 20 14 2 kg/h 110 115 165 each burner bar(g) 5.25 5.25 5.25

Maximum 30% BMCR, running 12 burners Standard values 30% BMCR, running 16 burners Minimum 3.3.6.4

1935 1450 390

Requirement for oil and steam parameters in burners operation Fuel oil parameter 2.5E (make of the the Burner pressure 5.25 bar(g) corresponding Steam parameter(dry steam as required)

Viscosity at the burners

adjustment temp, at

Estimated Temp. 30% input, flow about 200 Max flow 2.6 t/h, Peak flow is 3.9 and are t/h (atomization cleaning t d continuous

Burner pressure

2 ~ 20 bar (g) Maximum BMCR heat

Flow

namely 21280 kg/h. The constant flow in return line is 10% of

3.4 3.4.1

Requirement for Quality of Boiler Steam Requirement for Date of Quality of Boiler Steam in Normal Operation Item Unit Normal range

1. Feed water Conductivity (after cationic resin exchanger) at 25C Expected values : pH obtained by ammonia injection Total hardness detectable by : i. e. not mg/kg (O2) mg/kg (N2H4) S/cm (microSiemens/cm) < 0. 30. 2 9. 29. 4 Nil 0. 01 > 0. 0100. 020

l i t Dissolved oxygen at degasser outlet


Hydroxide content at economizer inlet

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Item Total iron (Fe), Total copper (Cu) Silica content, 2, Boiler water Conductivity (at 25) pH (at 25 )
Phosphate content Free caustic

BOILER & AUXILIARIES OPERATION MANUAL Unit mg/kg mg/kg mg/kg (SiO2) Normal range < 0. 010 < 0. 003 < 0. 020

S/cm

< 20 9. 29. 5

mg/kg (PO43-)

23 Nil

Silica content, recommended 3.4.2 Alert date for abnormal quality of boiler steam Item pH value
Condensate

mg/kg (SiO2)

0. 0100. 300

Steam sample

Status In the regular scope


More than or equal to More than or equal to More than or equal t

Date 9. 1 to 9. 5 20 ppb 0. 5 S/cm 10 ppb 9. 1 to 9. 5 0. 5 S/cm 10 ppb 10 to 20 ppb 50 S/cm 9. 0 to 10. 0 100 ppb 1ppm -

dissolved oxygen
Cation conductivity

Feedwater at outlet Feedwater at

Degasser

dissolved oxygen pH value


Cation conductivity

In the regular scope


More than

economizer inlet

Dissolved oxygen Hydrazine Conductivity pH value

Less than In the regular scope More than In the regular scope More than More than More than
More to than or

Boiler

Silicic acid F Na

Saturated steam

Cation conductivity

equa 0. 5 S/cm

Na Silicic acid
Cation conductivity

More than M th More than to M th or

20 ppb 50 ppb
equa 0. 5 S/cm

Superheated steam

Na

20 ppb

Date: 2008-09-15

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Steam sample

BOILER & AUXILIARIES OPERATION MANUAL Item Silicic acid Status


More than

Date 50 ppb

Date: 2008-09-15

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3.5 3.5.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Use Quantity High-pressure bypass

BOILER & AUXILIARIES OPERATION MANUAL

Boiler auxiliary equipment technical specifications

Basic date

Parameters High-pressure bypass valve Equipped with 2 units

Fluid characteristics Type of fluid Maximum control flow(max CV) Min differential pressure at max CV Minimum inlet pressure at max CV Max temp. at max CV Minimum control flow(min. CV) Max differential pressure at min CV Max inlet pressure at Min CV. Min temp. at Min CV. Quick-opening set pressure Slow opening set pressure Characteristics and specifications of executive body Differential pressure after the valve is shut off Type of executive body (electric, pneumatic and hydraulic) Fault location indicator 205 bar hydraulic open steam 750 t/h (75%BMCR) 130 bar 179. 3 bar 543 8 t/h 205 bar 205 bar 420 182. 8 bar 179. 3 bar

Solenoid operated control valve (SOV) yes or it h b d f Manual control Limit switch Pressure switch for air pressure difference Location transmitter Gas source pressure reducer with instrument Characteristics i k t t yes 3& 20 sec(from 0to100) close no yes no

Stroke Period (fast& control)

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28 29 30 3.5.2 Design pressure Design temp.

BOILER & AUXILIARIES OPERATION MANUAL 205 bar is effective 543+5 acc. to ANSI rank V

Tightness rank(selon / B16-104) Air preheater Item Unit

Design date A. P( trisector, rotating the heating surface ) 2-29VI(T)-86SMRC

Form Type Rotor diameter Rotor height Height of heating surface Quality Manufacturer Motor Type Power Voltage Rated Current Rotating speed Reducer Type Reducing rate of speed Axis rotating speed(main t ) Axis rotating speed(axial t ) Rated Torque output Support bearing Guild bearing r/min r/min N. m kw V A r/min mm mm mm set

10318 2185 Hot section 880,cold 2 ti 305 1000, middle layer of hot section

SBWL
Main Motor

Auxiliary Motor Y160L-8B3(Double-axis) 7. 5 380 720

Y180M-4B3 18. 5 380 1470

SGW100D 128. 3 11. 46 5. 61 12300

Thrust spherical roller bearing Type: 90394/750 Double-out centripetal roller bearing Type: 3153172 Guidance bearing dilute-Oil station OCS-D2A Support bearing dilute-Oil station OCS-D2A

Oil circulation system Oil station Type

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Item Type of Motor Motor power Motor speed Type of oil pump Flow Rated pressure Working temp. of Cooler Temp of cooling water Consumption cooling of

BOILER & AUXILIARIES OPERATION MANUAL Unit Y802-4B3 kw r/min m /h MPa m3/h MPa
3

Design date

0. 75(2 set) 1390 3GR254 tri-screw pump 0. 8 1. 0 6070 30 0. 8 0. 2 SPL25C-2 net GLC1-0. 8 Tubular

t Pressure of cooling water Type of oil filter Type of oil cooler 3.5.3 Induced draft fan Item Form Type Manufacturer Quality Rotation direction Motor Power 3.5.4 Forced draft fan Item Form Type Manufacturer

Unit Axial

Design date

Remarks adjustable static-blade

G158/273 Shanghai Blower works Ltd. set 2


Anti-clockwise

At the direction of air flow

Kw

1500

Unit

Design date Axial(hydraulic, adjustable moving-blade) FAF20. 4-10-1 Shanghai Blower works Ltd.

Date: 2008-09-15

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Quality Air fan total pressure Speed Shaft output Efficiency

BOILER & AUXILIARIES OPERATION MANUAL set Pa r/min kw 2 5267(T. B) 3660(BMCR) 1470 T. B:621,BMCR:405 84.08(BMCR condition:86. 50) T. B:650,BMCR:418 operating

operating 83.21(BMCR condition:86. 72)

Range of moving-blade Rotation direction Rotation power Rotation speed 3.5.5 Primary air fan Item Form Quality Type Manufacturer Speed Outlet total pressure Inlet temperature Power Direction 3.5.6 Mill fan

degrees 45 Anti-clockwise(at the direction of end of Motor shaft ) kw r/min 1250 1482

Unit

Design date Single-suction centrifugal

set

2 1788AB/940 Shanghai Blower Works Ltd.

r/min Pa kw

1480 TB:14850 Pa BMCR:11000 Pa TB:39 BMCR:24 400 Inlet:90o outlet:0o(from Motor side )

Type: M25452 Type: Centrifugal: Media of mill fan: air

Date: 2008-09-15

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Item Standard Flow Inlet Temp. Inlet Gross Pressure Outlet static Pressure Total Pressure of Air fan Selection point efficiency Compression factor Axial power Rotation direction Rotation power Rotation speed Motor voltage Manufacturer 3.5.7 Milling Item Manufacturer
Mill cylinder type Mill cylinder effective diameter Mill cylinder effective length

BOILER & AUXILIARIES OPERATION MANUAL Unit Nm3/h Pa Pa Pa TB operating condition 151650 120 -8500 -700 7800 83. 1 0. 9735 BMCR operating condition 144430 110 -8000 -1200 6800 76. 8 0. 9767

correction

kw r/min kw r/min kv

622. 5 980 710 980 6. 6

543. 8

China ChengDu Electrical power machinery factory

Unit

Design date

Remarks

Shanghai Heavy machinery Works Co. Ltd.

BBI4796 mm mm 4650 9740 Ball mill with drying and purging by hot air

Milling method

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Item Main Motor Manufacturer Type Power Voltage Speed Electric
Single-phase voltage

BOILER & AUXILIARIES OPERATION MANUAL Unit Design date Remarks

Shanghai Motor Works YTM900-6 kW V r/min heater V 3500 6600 986 230 Power 1200x2 W(used when shut-down)

Main Motor lubrication dilute-oil station (XYZ-20)


Nominal pressure Nominal flow

MPa L/min

0. 5 20 450 46 turbine oil L-TSA

Primary Volume

Lubrication

Lubrication Speciation Cooling water volume Power Voltage Speed Main Reducer Type Speed rate Lubrication Type i m3/h kW V r/min

2. 5 1. 5 400 1400

ML2PSF150 9. 275 Reducer with compulsory lubricating of

independent dilute-oil station

Date: 2008-09-15

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Item Power Voltage Primary Volume Lubrication Speciation Cooling water volume Lubrication

BOILER & AUXILIARIES OPERATION MANUAL Unit kW V L 11 400 1500 ISO VG320 m3/h 8 Design date Remarks

Low speed driving set [plant reducer(An auxiliary motor)] Type Speed rate Motor Type Motor Power Motor Speed Motor Voltage Revolving speed of disk Primary volume Lubrication Speciation lubrication kW r/min V r/min L i NMCD560-125 125 YEJ280S-6(B35) 45 970 400 0. 105 180 Mid-extreme pressure industry gear oil N220(GB5903-86)

Main bearing HP and LP lubrication dilute-oil station Type Lubrication Speciation Cooling water volume Cooling water volume Electric heater m3/h L GDR-60/10/170 2800 ISO VG460 18 Total 6 (400VAC/3kw x 6)

Date: 2008-09-15

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Item LP pump(1 set)
Nominal pressure Nominal flow

BOILER & AUXILIARIES OPERATION MANUAL Unit Design date Remarks

L/min MPa

170 1

LP Pump Motor(1 set) Power Voltage Speed


Injecting HP oil pump (1 set) Nominal pressure Nominal flow

Kw V r/min

7. 5 400 1440

L/min MPa

4X15 20

Injecting HP oil pump motor(1 set)

Power Voltage Speed


Electric wire heater

Kw V r/min

30 400 1470

VAC/kW 230/

HP lubrication pump(1set)
Nominal Pressure Nominal Flow

L/min MPa

2X5 10

HP lubrication pump motor(1set)


Nominal Pressure

Kw V r/min

3 400 1440

Nominal Flow Speed

Date: 2008-09-15

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Item

BOILER & AUXILIARIES OPERATION MANUAL Unit Design date Remarks

The girth gear grease circuit lubricating equipment Type Operation Pressure Max Pressure
Max volume of oil supply Required capacity gas supply

GSPZ-Z-8 MPa MPa g/min 0. 4~0. 6 0. 8 1500 0. 6MPa

m3/min 0. 42 MPa 20 8 NLG100-0

Working oil pressure Quantity Lubrication Speciation Gear sealing air equipment Air fan type Flow Pressure Power Voltage Speed Spring coupling equipment Primary grease volume
Grease speciation

CQ3-J m3/h pa kw V r/min 800 590 0. 37 400 2900

kg

about 4 NLGI 02
Lithium Grease

lubricants

Gear coupling equipment Primary grease volume kg About 13

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Item
Grease speciation

BOILER & AUXILIARIES OPERATION MANUAL Unit Design date E. P. Lithium Grease lubricants Remarks

Small gear equipment rolling bearing


Grease speciation

SKF ALFALUB LGEP 2

3.5.8

Cold feeder Item Specification MSD100 YVP160L-6 ZSY250-80 30110 Tonshour Pulverized Coal feeder Item Unit Design date Remarks Manufacturer
China's Hubei YiDu Electrical and Machinery Engineering Co., Ltd.

Main body Motor Reducer Output 3.5.9

China Xi An Motor Works


China's JiangYin, JiangSu gear box Works

Manufacturer Type Output 3.5.10 t/h Pulverized Coal Feeder Item Manufacturer Type Transmission distance Motor Power m KW Unit

China ShenYang Power Plant Engineering Ltd. SGF13 313

Design date

Remarks

China ShenYang Power Machinery Works

LSG500 32. 2 7. 5 2

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3.5.11 classifier Item Manufacturer Speciation 3.5.12

BOILER & AUXILIARIES OPERATION MANUAL

Unit

Design date

Remarks

Chian Wuxi Liangxing power equipment Ltd. 6800mm

Thin pulverized coal separator Item Unit Design date Remarks

Manufacturer Speciation 3.5.13 Vent fan Item Manufacturer Type Form Direction of air intake Direction of air outtake Impeller diameter Rotor critical rotation speed Inlet flow volume Air fan total pressure Inlet temperature Air fantotal pressure effciency Air fan axial power Motor effciency Unit

China WuXi Joint Venture Power Equipment Co., Ltd.

3500mm

Design date
China's Shenyang Blower Factory

Remarks

SFY15F-C5A Single inhalation double support centrifugal 90 left rotation(right rotation) 45 left rotation(right rotation ) mm 1500 r/min 1930 m3/s 28. 36 KPa 5. 7 % 120 84 Blade outlet

kW 200 kW 250

Date: 2008-09-15

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Motor voltage 3.5.14

BOILER & AUXILIARIES OPERATION MANUAL kv 6. 6

Boiler water circulation pump Item Unit Design date LP head with no seal LUVc2502-410/1 England company Heyward Tyler HAYWARD TYLER Single inhalation Remarks

Form Type Manufacturer

Medium

water

double support centrifugal Quantity Design pressure Hydraulic test pressure Absorbed pressure Medium density Design temperature Max differential pressure of pump shell and boiler water Pump flow Efficiency Absorbed efficiency Pump inlet and outlet differential pressure Motor Form Three-phase squirrel-cage set bar bar bar Sg m3/h kw 3 210 315 198 0. 554 369 lower than 56 Higher than 56 trip 2 operation meet BMCR

2182 83 222. 7

Single Cold/hot Hot:130. 0 Lower than 0. 11 alarm

MPa

about 0. 3(31. 1mH2O ) Lower than 0. 055 trip

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BOILER & AUXILIARIES OPERATION MANUAL induction

Type Rated power Rated voltage Rated speed Rotation speed Rated current Start-up current Motor efficiency Power factor Input power Total efficiency of pump kw kw KV r/min A A

LUV55/4FQ20-605 200 6 1450 27. 5 135 88. 0/87. 0 0. 805/0. 72 252. 8/140. 5 73/72. 2 cold/hot cold/hot cold/hot cold/hot

Water cooler of HP filling water and cleaning water HP side design pressure HP side hydraulic test MPa MPa MPa test MPa 21 31. 5

pressure LP side design pressure LP side hydraulic

1 1. 5

pressure Design temperature Motor heat exchanger HP side design pressure LP side design pressure LP side required pressure HP side design temperature

180

MPa MPa MPa

22 3 0. 65 343

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LP side inlet temperature LP side outlet temperature HP side motor circulation

BOILER & AUXILIARIES OPERATION MANUAL m3/h 38 44 11 max max

water volume HP side water temp. LP side required flow Heat exchanging efficiency Required flow forLP motor circulation

m3/h kJ/s m3/h

3249

normal operation

8. 5 34. 2 2

Lower than 6. 5alarm Cold,2 pump operation Lower than 1. 5alarm

cooling water hot panel hot panel outlet

allowable highest temperature LP cooling water hot

50

panel required pressure At flow 2 m3/h, hot

MPa

0. 2

panel pressure drop 3.5.15

KPa

0. 050. 08

Flame scanner cooling air fan Item Unit SBWL VC 710 N/2 m3/h Pa 1153 9480 Design date Remarks

Manufacturer Type Air flow Total pressure 3.5.16

Intermittent and continuous blowdown flash tank Item Unit Design date China Jinan pressure vessel plant Remarks

Manufacturer

Date: 2008-09-15

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Continuous blowdown flash tank Form Type Volume Design pressure Design temperature

BOILER & AUXILIARIES OPERATION MANUAL

Vertical LP-3. 5 m3 MPa 3. 5 1. 5 360

Intermittent blowdown flash tank Form Type Volume Design pressure Design temperature 3.5.17 Steam air preheater Item Manufacturer Primary air A. P Type Volume Design pressure Design temperature Secondary air A. P Type Volume m3 NFZ3. 2-1-2. 690FBZ 607. 5 m3 MPa NFZ3. 2-1-2. 645FBZ 185 1. 6 360 Unit Design date China Hankou power equipment plant Remarks m3 MPa Horizontal DP-20 20 1. 0 250

Date: 2008-09-15

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Design pressure Design temperature Steam drain box Type Volume air preheater

BOILER & AUXILIARIES OPERATION MANUAL MPa 1. 6 360

NSL-16-0. 5 m3 0. 5

4 4.1

Boiler and interlock protection value auxiliary equipment. Boiler protecting Limit Value Units LL L N H HH Drum Remarks water level

Name

under the center Drum water level 100Load:0 mm -425 -240 50Load -115 +100 +200 line of drum 175mm; L, H: alarm; HH/LL B il L, H: alarm, Pa -2500 -2000 -100 +1000 +4000 LL/HH: Boiler MFT N:HPO isolating valve allowable L: alarm Burning oil pressure Mpa 0. 5 1 2. 5 LL: Burning oil trip H:HPO pressure high alarm Burning oil pressure Mpa 1. 85 1. 9 N:HPO leaking MFT

Furnace pressure

test pressure proper

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Name Units LL

BOILER & AUXILIARIES OPERATION MANUAL L N H HH H: Remarks HPO leaking

test pressure low N:HPO allowable Burning oil temperature 90 95 100 135 L:HPO temperature alarm LL/H:HPO trip L: low pressure alarm Atomization steam pressure Mpa 0. 4 0. 5 0. 9 LL: low pressure low temperature

Burning oil trip H: high pressure

alarm L: low Atomization steam temperature 180 230 H: high temperature alarm 4.2 Boiler auxiliary interlock protection value auxiliary equipment. Name 1. preheater N: open allowable; Bearing temperature <70 70 85 H: alarm profit Air Air Units LL L N H HH Remarks alarm temperature

Preheater

open;

HH: Air Preheater trip 1 Rotation speed L: alarm, delay 10Sjum r/min 0. 5 0. 8 1 to Motor, then after 3 s open M t stand-by

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BOILER & AUXILIARIES OPERATION MANUAL LL: air preheater trip

2 Inlet flue gas temperature 3 Temp. of primary and d 4 Soot blowing Steam temp. 5 Soot blowing steam 6 2 ID Fan Lubrication flow Lubrication pressure L/min 3 0. 4 0. 6 4 Mpa 1. 04 1. 2 i 130 378 478 150 419

L: after lower than L allow stop Air Preheater

H: fire alarm

If L: higher than L allow soot blowing

L:

soot

blower blowing

allow soot

Working pressure

>3

ID

Fan

open

allow;<3alarm L: alarm; LL:

Mpa

0. 12

alarm, delay 30S trip LL: stand-by pump

Hydraulic oil pressure

Mpa

0. 86

2. 5

automatic; L:ID Fan open allow

Oil filter differential pressure Oil position of oil bank Bearing blanking ID Fan open, mm 150 alarm 6070 90 110 H: alarm; Mpa 0. 35 H: alarm

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temperature Temp. of Oil in Oil Bank Oil cooler outlet temperature Surge Motor bearing temperature Stator coil temperature 3FD Fan Bearing temperature Motor bearing temperature Motor coil temperature Vibration Lubrication pressure FD fan lubrication flow L/MIN mm/s Kpa

BOILER & AUXILIARIES OPERATION MANUAL HH: ID Fan trip L: open heater 30 30-40 40 H: close heater

45

45,alarm

+100 on site

delay Fan trips H:

15S ID

85

95

alarm,

prohibit

open; HH: trip H: alarm, prohibit

90

130

135

open; HH : trip

80

90

90

100

130 8

140 11 L: alarm;

Mpa

0. 35 LL: alarm, trip >3FD Fan open

allow;<3alarm

Date: 2008-09-15

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FD fan hydraulic oil pressure FD fan differential pressure FD fan oil location of oil tank FD fan temp. of oil in oil tank FD Fan oil cooler outlet temperature FD fan KPa surge 4 Primary air fan Bearing temperature Motor bearing temperature Motor coil temperature Vibration Outlet air pressure mm Mpa Mpa

BOILER & AUXILIARIES OPERATION MANUAL L: stand-by pump open 0. 86 2. 5 automatic H:FD Fan open allow

0. 35

H: alarm

150

L: alarm

L: open electric heater 30 30-40 40 H: close electric heater

45

45alarm

On site

delay 15S and FD Fan trips

80

90

90

100

mm/s Pa 2400 3000

130 8

140 11 L: alarm, LL:

Pulverized coal

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BOILER & AUXILIARIES OPERATION MANUAL trip, N: adjustment

5Pulverized coal exhauster Bearing temperature Motor bearing temperature Motor Coil temperature Vibration 6 Vent air fan Vent fan bearing temperature Vent fan motor bearing temperature Vent fan motor Coil temperature Vibration Vent temperature High temp. for produce pulverized Bag type filter 150 300 700 800 L, H: alarm mm/s 8 11 L, H: alarm; 90 110 120 130 HH: Stop Vent fan 130 140 90 100 80 90 80 90

90

100

mm/s

130 8

140 11

Date: 2008-09-15

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temperature 7Mill Mill Lubrication pump outlet main pipe pressure HP oil pressure Mpa 0. 02 Mpa

BOILER & AUXILIARIES OPERATION MANUAL

1. 035

H: Open safety valve at lube oil pump outlet

1. 823 Mill open Jacking oil pressure Mpa 1. 5 allowable ; HH: Open Safety valve at jacking oil pump outlet Bearing rotation oil pressure N: Mill open allowable; Bearing temperature 45 <85 65 70 H: alarm HH: Mill trips Mill small gear Bearing temperature Temperature of reduction gearbox Motor bearing temperature <85 85 90 HH: Mill trips <77 77 88 H: alarm N: Mill open allowable Mpa 3

N: Mill open allowable H: alarm HH: Mill trip H: alarm

<80

80

90 HH: Mill trips

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Motor coil temperature

BOILER & AUXILIARIES OPERATION MANUAL H: alarm <120 130 140 HH: Mill trips LL: L: heater; b t l l allow Lubrication put N:

Lubrication temp

opening 24 27 32 46 49 pump; electric h MPa 0. 15 0. 25 t

stop electric heater; H: Lubrication filter differential pressure Lubrication flow Reducer oil supply flow Cooling water flow Temperature of air Mill inlet Primary air pressure Classifier outlet primary air temp. Differential pressure of non-drive Inlet and classifier Kpa 3. 5 4. 5 100 150 175 H: delay 3min Mill trips N: feeder H: 15M ti open coal Kpa 3 11 mill 250 inlet primary L/min 30 L: alarm

L: alarm;

L/min

60 L: Mill open

m3/h

15

allowable H: Mill open

allowable L: Mill open

allowable H: Mill trips L: Mill open allowable;

allowable; alarm, delay and Mill

Date: 2008-09-15

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outlet primary air Differential pressure of drive Inlet and classifier outlet primary air Mill Lubrication station strainer differential pressure 8 Boiler water circulation pump pump inlet outlet differential pressure Mpa 0. 10 Kpa Kpa

BOILER & AUXILIARIES OPERATION MANUAL

N: open coal 3. 5 4. 5 feeder allow;H: alarm, delay 15M Mill trips

H: Require changing 207 242 the strainer; HH: go bypass

L: 0. 14

Low

differential

pressure alarm LL: Low differential pressure trip H: high temperature

Motor room temperature

alarm 55 60 HH: high temperature trip

9Air compressor Compressed air main pipe pressure Air Mpa 0. 7 0. 8 Mpa 0. 4 0. 55 0. 75 L/LL: open alarm, stand-by shunt Air

compressor L: load, unload

Date: 2008-09-15

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compressor vent pressure Air compressor cooling water outlet temperature 10Soot blower Soot blowing steam supply pressure Drain temperature Steam air preheater Water level of drain tank mm 200 Mpa 3. 0

BOILER & AUXILIARIES OPERATION MANUAL

50

3. 5

LL: alarm

280

H: close drain valve and allow soot blowing

300

550

800

900

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5 5.1 5.1.1 Start-up Basic Regular

BOILER & AUXILIARIES OPERATION MANUAL

Before the start-up of the new erected or overhauled boiler, the trial operation, test and

equipment acceptance of main equipment and auxiliary equipment should be finished. Before start-up of the boiler having minor repairs, the trial operation and test and equipment acceptance of the repaired equipment should be finished. 5.1.2 After major or minor repairs, the shift supervisor should have the final report about

improved items of equipment and instruments after finishing system change. 5.1.3 5.1.4 5.1.4.1 Choose the right method of start-up If the following arbitrary conditions occur, the start-up boiler should be prohibited: If the repair work of the system or equipment affecting the boiler start-up is not finished or work sheet is not canceled, inspection test and trial operation is not acceptable. 5.1.4.2 5.1.4.3 Interlock, protection and trip test are not performed. DCS system is not in service affecting the operation and monitoring of the units.

5.1.4.4 Thermal control main instrument. For e.g., main steam temperature, main steam pressure, reheat steam temperature, reheat steam pressure, drum water level, furnace pressure, feed water flow and steam flow cant be put in service. 5.1.4.5 5.1.4.6 5.1.4.7 5.1.4.8 Quality of boiler water cant reach the requirement. FFCS cant be put in service. Thermal control signal system cant be put in service. The safety valve system for main boiler auxiliary system (e.g. Safety valve, ERV valve, drum emergency drain valve, burning oil Electromagnetic valve) are not in service. 5.2 5.2.1 Repair test and acceptance inspection Requirement of acceptance inspection refers to acceptance inspection procedures in

instructions of boiler professional overhaul 5.2.2 Acceptance inspection after repair should be executed acc. to scattered trial operation

acceptance inspection and system trial operation acceptance inspection and whole start-up acceptance inspection. 5.2.3 All acceptance inspections of thermal control interlock test are confirmed by static test

method.

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All auxiliary scattered trial operation acceptance inspection is through acceptance

inspection of motor empty operation and the method with auxiliary equipment operation. 5.2.5 5.2.5.1 Classification of repair test First type of test: A. B. Hydraulic test of boiler body. Furnace cold air dynamic field test.

C. Procedure control test for soot blower and blowdown. D. FSSS, CCS cold position simulation test. E. F. G. 5.2.5.2 Safety valve setting test. Each rotation machine Single logic test. Air leaking test of boiler body.

Second type of test: A. Interlock test of Boiler rotation machine (including milling system). B. Accidents button Test of Boiler rotation machine. C. Single protection trip test of Boiler rotation machine.

5.2.5.3

Third type of test: A. B. Main valve, duct damper single test. Each intermittent work, intermittent test.

5.2.5.4

Test requirement: A. B. All tests should be done after overhaul. Before starting the units, minor repair, sudden inspection and the second and third type of test should be done. If necessary, the first type of test is also required. C. Make the associated test when the equipment is abnormal. D. HP motor is usually done the static test E. The responsible department should write a detailed testing procedure. They shall report it to higher authorities for approval and the test result with signature the

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relevant departments authorized is also required. F. Make the detailed record for the test. Any issues should be reported to the relevant depart and dealt with till acceptable. G. Each intermittent work and intermittent switching test is required acc. to the relevant requirement. 5.2.6 5.2.6.1 Boiler Hydraulic test The over-pressure test should be performed if any of the following situation occurs(Working pressure test first): 1 After major repairs or replacement of the heating surface (replacement of water wall tubes is more than 50%, replacement of any components of superheater, reheater, economizer and major repairs of drum). 2 Resume operation after shut-down for more than 1 year. 3 Boiler pressure is seriously more than 1.25 times of working pressure. 4 Large deformation of heating surface occurs after serious shortage of water. 5 Acc. to the operation status, the reliability of safety equipment is suspected. 6 After major and minor repair or repair of local heating surface of boiler, working pressure test should be done. 5.2.6.2 Boiler Hydraulic test pressure value is as following: Primary system Working pressure(MPa) Overpressure test(MPa) 5.2.6.3 Boiler Hydraulic test scope : 20. 5 30. 75(1. 5 times) Secondary system 4. 5 6. 75(1. 5 times)

1 Primary system includes all the pipes, heating surface and header from non-return flap at feedwater pump outlet to HT superheater outlet (i.e. including feedwater pipe, economizer, drum, water wall, LT superheater, HT superheater, connecting pipes and header). 2 Secondary system includes all the pipes, heating surface and header from reheater inlet to HT reheater outlet (i.e. including LT reheater, HT reheater connecting pipes and header).

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3 At working pressure, the following valve should be check secondary damper firstly and then primary damper(Acc. to the test procedure): A. B. Lower furnace drum drain valve. Drum Air damper.

C. Economizer outlet pipe Air damper D. Superheater Air damper. E. F. Reheater Air damper. Superheater drain valve.

G. Reheater drain valve. H. Thermal control instrument pipe valve (If there is not any secondary damper only do pressure test for primary damper). 4 At working pressure, pressure test will be only done for primary damper of the following pipe valves: A. B. Soot blowing steam primary damper. Primary attemperator drain primary damper.

C. Secondary attemperator drain primary damper. D. Reheater attemperating water primary damper. E. F. Chemical sample primary damper. Intermittent blowdown primary damper.

G. Blowdown primary damper. 5 For firstly. blowdown system at the furnace bottom, close motorized valve

Open completely

the former manual valve to do pressure test. If the test is

acceptable, close manual valve to do pressure test. 6 Working pressure test with remote and local water level instruments, i.e. close the remote water drain valve level instrument drain valve and local water level instrument and completely open other damper, test water level instrument drain

valve; then close water level instrument and try water side and steam side primary damper.

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7 At working pressure, perform pressure test with drum safety valve, check seal conditions but the valve stem should be jammed by the feed screw to prevent trip. Other superheater and reheater safety valve should be jammed and isolated. 8 Open economizer re-circulation damper when it is fed water. if it is finished close the damper. 9 Perform instrument pump the overpressure or and Boiler test, jam withdraw safety remote valve. and Boiler local water level

and isolate

each

water

circulation

motor

is thoroughly isolated. Boiler water circulation pump

plugging plate for overpressure test should be installed. 5.2.6.4 Conditions for Boiler Hydraulic test : steam be check, pipe valve in pressure test, valve, after heating surface valve, repair control work, valve

1 All

should should 2 After should

be acceptable;

Motorized

pneumatic

finished adjustment. And acceptance inspection is acceptable. installation and reset of steam system pressure instrument

be finished. Primary system pressure test is confirmed by drum local pressure

instrument on roof. Secondary system pressure test is confirmed reheater inlet local pressure. Pressure instrument accuracy is 0.5. The span should meet the test requirements(span shall be 1.5 to 2.0 times of overpressure test pressure). 3 Each system Suspenders, springs and hangers have been adjusted and forced smoothly. 4 Each valve, Setscrew, Suspenders (Hanger) shouldnt be fixed too tightly before hydraulic test. 5 Expansion indicator correction is finished, and direction is correct. 6 Boiler platform, stairs path is Unobstructed, remove all impeding scaffolding 7 Drum wall temperature measurement points is corrected and can be put in service. 8 The scaffoldings of each checking parts are safe and firm with adequate light. 9 Feedwater pump trial operation is acceptable. 10 Pressure test provisional pipes are installed and checked acceptable. 11 HP bypass quick open condition is compulsive. 12 Producing water by Chemical water system is in service. Chemical feed system and

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primary Water system used is

BOILER & AUXILIARIES OPERATION MANUAL

chemical is prepared. Water quality and chemical is checked acceptable. Water used by about Test 550t water (about 2 water times is of water water 180t with Volume 200 ). by secondary water. system about adopting ppm

dematerialized

is dematerialized

ammonia+ hydrazine treatment and PH value is higher than 10. 5. 13 Emergency pressure drop method must be prepared. Intermittent blowdown valve and motorized and pipes drain valve at lower furnace drum are well stand-by are unobstructed to do quick pressure drop if overpressure.

14 Set up local pressure instrument of drum and reheater and make control room with well communication. 15 When hydraulic test, circumstance temperature is usually higher than 5,otherwise make the anti-freeze measures. Water temp. from 30 to 70 is suitable (not lower than 20). 16 At working pressure hydraulic test shall be chaired by repair

(installation)

tech. responsible staff. Overpressure test shall be chaired Chief

Engineer and designated person in charge. 17 All test staff should follow a clear division of labor, subject to a unified command and insist on jobs. 5.2.6.5 Introduction of hydraulic test method: Open motorized feedwater pump and fill the water through economizer from main feedwater system. One side of superheater secondary attemperator water or main feedwater bypass pipes raise pressure, but these two methods cant be performed at the same time. Only one can be selected. Reheating system feeds water to Reheating system through attemperating water pipes. Close main feedwater pipes valve and then do pressure test. Test should be performed in order of high to low, i.e. Hydraulic test of steam system, then hydraulic test of reheater system. If for 5.2.6.6 all tests are finished, do pressure drop and drain. Do pressure test

some secondary damper and primary damper.

Hydraulic test steps

1 Open all air damper of Drum, Superheater and reheater system 2 Close all drain valve of Superheater and reheater system.

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3 Besides drain primary damper of intermittent blowdown, continuous blowdown, cold reheater, close all drain primary damper and secondary damper. 4 Close boiler main steam valve and main steam bypass valve, close primary drain valve, secondary drain valve in front of main steam damper. 5 Before hydraulic test, 3 boiler water circulation pumps should be fed water to exhaust steam acc. to the manual, (Notice: Hydrazine can only be fed to deaerator, not to condenser). After filling water and exhausting air, open outlet nonreturn flap of 3 boiler water circulation pump. 6 Acc. to normal filling procedure fill the boiler to the visible drum water level. Stop filling through feedwater pipe and change to filing through superheater water spray secondary attemperator till air dampers of drum and superheater is continuously overflowing the water. Close air dampers of superheater and drum and stop filling. 7 Forbid filling the boiler through feedwater control system and superheater water spray attemperating at the same time. 8 Check HP bypass damper at closed condition and quick open condition is been compulsory. 9 Check reheater system pressure zero. 10 Completely some side open motorized pump recirculation damper and valve of

of secondary superheater attemperator water and motorized isolation

damper. Micro-open motorized control valve. Make use of the open position of the motorized control valve and feedwater pump rotation speed to control pressure rising speed 0. 3Mpa/min. 11 Before filling, after filling water is full and when working pressure is reached, the record of indicators of expansion system shall be checked. 12 If whole pressure rising reaches 12Mpa, 10M Pa and 75 of working pressure, suspend system. if it is pressure rising and do primary check for Primary normal, continue raising pressure. if working pressure is

approached, decrease pressure rising s peed 0. 2Mpa/min to prevent overpressure. 13 If 5min valves. primary system drop pressure reaches of 20. 5Mpa, stop pressure the rising, of

monitor

local pressure pressure

instrument

drum,

record

status

and comprehensively check each heating surface and pipe

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14 Acc. to the scope of pressure test, switch the primary valve and secondary valve of primary system. Raise pressure again to 20. 5 Mpa, record the status of 5 min pressure drop and check each first valve etc. 15 If overpressure test is required, after above check result is normal, confirm boiler water circulation pump motor and boiler water are isolated and boiler water circulation pump plugging plate for overpressure test is installed. Drum water level instrument trips. After the staffs withdraw the scene, with pressure rising speed 0.

1Mpa/min raise the pressure to 30. 75Mpa .Keep 1020min and then open final superheater air valve at roof or cold superheater drain valve to do the pressure drop. Pay attention to pressure drop speed 0. 1Mpa/min. After pressure is dropped to 20. 5Mpa, close pressure drop air valve or drain valve, record the status of 20 min pressure drop, and comprehensively check. 16 If pressure test is acceptable or check abnormal, open superheater drain valve, drop the pressure to zero and pay attention to controlling pressure drop speed0. 30. 5Mpa/min. 17 When hydraulic test of primary system is finished, do hydraulic test of reheater system. 18 Use reheater attemperating water pipe to fill the reheater, after water

overflows at reheater outlet air damper, close all reheater system air dampers, open the first reheater exhaust steam valve and stop filling water. 19 Control feedwater pump rotation speed. Through reheater attemperating water control valve with 0.3Mpa/min pressure rising speed and raise to the 1

pressure MPa. Comprehensively check reheater system.

20 If the check result is normal, raise pressure to 4. 5Mpa, stop pressure rising, isolate reheating system, monitor local provisional pressure instrument 5min, record the status of pressure drop and comprehensively check reheating system. 21 Acc. to scope of pressure test, switch the primary valve or secondary valve of primary system, do pressure rising again to 4. 5 Mpa and record the status of 5 min pressure drop. 22 If the overpressure test is required, after above check result is normal and the staffs

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BOILER & AUXILIARIES OPERATION MANUAL withdraw the scene. With pressure rising speed 0. 1Mpa/min raise the pressure to 6, 75Mpa. Isolate reheating system, keep 1020min and observe changes in pressure.

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23 Micro-open final reheater air valve at the roof to drop pressure, monitor provisional pressure instrument and pay attention to pressure drop speed 0.1Mpa/min when pressure reaches working pressure in the overpressure test. When pressure drop to 4. 5Mpa, close pressure drop air valve, record the status of 5 min pressure drop and comprehensively check 24 When reheating system pressure test is acceptable, open final reheater air valve at roof or reheater drain valve to drop the pressure to zero, monitor provisional pressure instrument and pay attention to pressure Drop speed 0. 3~0. 5Mpa/min. 25 When pressure test of reheating system is acceptable, drop pressure to zero and open superheater and reheater drain valve to drain. For e.g., if Boiler needs draining, open lower furnace drum blowdown valve to comprehensively drain for drum and water wall. 5.2.6.7 The key position for hydraulic test check:

1 Whether the valve of each system after repair is leaking. 2 Whether joint of safety valve is leaking. 3 Whether each heating surface, especially the position having repair work

and the position requiring strict check is leaking and deformation. 4 Whether each expansion indicator, pipes hanger has abnormal expansion. 5.2.6.8 Hydraulic test acceptable standard(Hydraulic test meet the following requirements, i.e. acceptable ): 1 There are no leaking traces of water on pressure parts, metal wall and welding seam. 2 At primary system working pressure, when stop raising pressure., pressure drop in 5min is <0. 5Mpa. At secondary system working pressure, when stop raising pressure, pressure drop in 5min is 0. 25MPa. 3 No obvious deformation of pressure parts. 5.2.6.9 Boiler hydraulic test attentions :

1 When boiler is fully filled water, before pressure rising, jam drum and superheater safety valve; When doing hydraulic test for secondary system, jam reheater safety valve; when do overpressure test, jam each safety valve. 2 If reheating system has provisional pipes, the pipes should be purged before installation,

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each welding seam should be check acceptable and welded by acceptable welder. 3 Feedwater pump reach the top pressure, completely open recirculation valve and strictly monitor operation conditions to ensure feedwater pump operation safe. 4 Each drain valve of main steam valve outlet drain, cold reheater and hot reheater should be opened. Immediately check whether there is any water is drained to prevent cylinder from water. 5 Each drain valve at main feed water equipment side should be checked whether the valve is strict leaking and pay attention to the water entering into HP heater at pressure rising. 6 When raising pressure, monitor attemperating water flow. If flow is big and pressure rise is slow, system leaking may be serious. Check the cause intermediately. 7 Boiler filling shall be performed acc. to filling requirement. 8 Monitor drum wall temp.>20 in the test and differential temp.50. When drum is checked, heating surface wall temp. should be 49. 9 After test, open drain valve and air damper firstly to drain. If drain is finished, dismantle plugging plate valve. Because there is no drain pipe in front of the plugging plate valve, most of the water cant be drained. When dismantle plugging plate valve, firstly ease the plugging plate, let the water leak slowly form plugging plate valve to prevent steam pipes from full water and then open drain valve of steam pipes to prevent cylinder from water. 10 When do the hydraulic test, specified staff should monitor pressure instrument. Drum local Emergency and remote pressure pipes instrument shall should be be often checked. valves pressure drop valves unobstructed. The

should be operated by specified person to prevent overpressure. 11 When do the pressure test, stop all welding work on boiler body, prohibit opening valve and striking on the pressure parts arbitrarily. 12 Scaffoldings of each checking parts are complete. The path is unobstructed and full of light. 13 Specified strictly person should be responsible for pressure rising to

prevent overpressure acc. to local pressure. When pressure reach10% of test

pressure, correct local pressure instrument and control pressure instrument. When the differential pressure is large, contact with the relevant person to deal with it.

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14 When do hydraulic test, the relevant person should follow a clear division of labor, subject to a unified command and set a clear and reliable communications. 15 Only test staff can be permitted in to the scene. 5.2.7 5.2.7.1 Boiler safety valve check Conditions and requirement for safety valve check.

1 After major repair of boiler and repair or replacement of the valve, the hot check must be performed for safety valve to maintain the reliability. 2 Safety valve set value is performed as following: Design Blow down Opening reseating Differential MPa pressure% MPa 20. 50 20. 60 20. 70 18. 70 4. 50 4. 60 4. 10 4. 20 19. 89 19. 78 19. 67 18. 14 4. 37 4. 46 3. 98 4. 07 3 4 5 3 3 3 3 3 Discharging capacity t/h temp

Setting pressure No. Location Type of valve Specification (inch)

1 2 3 4 5 6 7 8

DRUM DRUM DRUM Reheater outlet Reheater outlet Reheater outlet Reheater outlet Reheater outlet Superheate r outlet(ERV) 3

HE-96W HE-96W HE-96W HCI-98W HCI-46W HCI-46W HCI-48W HCI-48W E0L121N7BWR A5P1

3 M2 6 3 M2 6 3 M2 6 3 L2 6 6 RR10 6 RR10 6 RR10 6 RR10

291. 697 293. 924 296. 175 153. 860 253. 574 259. 366 187. 347 191. 810

369 369 369 557 313 313 554 554

2..54

18. 50

18. 13

166

557

Before igniting the boiler, the safety measures to prevent the turbine from the steam must be done.

4 The leader from tech. dept. and safety dept. should be on site when checking the valve.

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It is conducted by chief engineer, chaired by repair staff in charge and operators participate in it. When test, the relevant person should follow a clear division of labor, subject to a unified command to prevent overpressure. 5 Set a convenient, clear, reliable communication. 6 Strictly close boiler main steam valve, turbine main steam valve, IP main steam valve and HP drain valve non-return flap etc. Open turbine main steam drain valve, cold reheater drain valve and hot reheater steam drain valve. 7 Turbine turning shall be put in service before the unit gets any load. 8 Drum water level high signal is compulsory (Drum water level protection releases ). 9 HP bypass quick open condition is compulsory. 10 When check safety valve, pressure indicator of local pressure instrument and before operating control panel of drum, superheater, reheater and turbine main reheater steam must be corrected. The local data and the date on the control panel shall be same. When of local to there are errors between the data on pressure instrument paid pressure instrument and control room CRT, local pressure correcting local and before operating the panel. Specified

instrument should be followed. In the process of pressure rise and checking, attention person monitor the pressure and contact relevant staff. 11 Checking safety valve shall be performed when boiler is started only or the load of

unit is only 10%20% ECR load. 12 Pressure rise of boiler shall be performed acc. to pressure rising curve. In the process of pressure rise, strictly monitor tube temperature of heating surface in the allowable value. 13 When check, monitoring and adjustment for the burning and water level shall be strengthened to prevent full water, inadequate water and overpressure. 14 When safety valve is being checked, if the valve is opened, the staff shouldnt approach safety valve. 15 When accidents occur, stop checking and acc. to relevant accidents

treatment requirement perform treatment. 16 When check, strengthen the contact and strictly finish each work acc. to each division of labor.

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17 Check for safety valve is performed in the order of high action pressure to low. Unchecked safety valve should be isolated. 18 When check safety valve, firstly check by the opening aid checking equipment. If it is acceptable, actual opening check can be performed. 19 When check ERV valve, actual opening check after control return circuit check is acceptable. 5.2.7.2 Drum and superheater safety valve check :

1 Trip water level protection. 2 Open HP bypass and put HP bypass in automatic service to ensure cooling the reheater system. Open steam exhaust valve at reheater outlet. 3 Control boiler combustion rate, put 4 to 8 oil burners in service. 4 When main steam pressure reach 10bar,stop pressure rising, inform the repair staff of hot fixing screws and comprehensively checking welding, valve, man hole and hot expansion conditions of pressure parts. If check is finished, after repair staff Informing of raising pressure, continue raising pressure. 5 When turbine condenser vacuum reach 300mbar, put LP bypass in service. 6 When and pressure stability reaches 75 85 of safety valve test pressure

is maintained, repair staff check safety valve by hydraulic check

implement, record opening pressure and reseating pressure till it is checked acceptable. 7 If informed of continuing pressure rise, put bypass control valve in manual control. Manual control the position of indicator of HP bypass (mustnt close),slowly raise pressure to safety valve design opening value and then

keep it. Repair person shall adjust it. 8 After safety opening safety valve, major open HP bypass manually and let

valve reseating.

9 Record opening pressure and reseating pressure of safety valve. 10 If the action of safety valve is incorrect and adjustment is required, repair staff shall requires pressure drop or drop pressure to 7585%of rated pressure. And then adjust the safety valve acc. to manufacturer requirement.

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11 If adjustment is required for more than 3 times, the adjustment should be performed after safety valve is cooled. In cooling period, the staff can check other safety valves, but need locking the cooled safety valve. 12 When check safety valve, if safety valve has no action, keep pressure stable. 13 Raise pressure to safety valve opening pressure, pop safety valve. When safety valve

has action, record the data of opening and reseating pressure. 14 Using the same method to check each safety valve of drum and each safety valve, ERV valve of superheater in the order of high open pressure into low. 15 If safety valve check is finished, all safety valve lock shall be dismantled and the safety

valve should be in service. 5.2.7.3 Reheater safety valve check:

1 If safety valve of drum and superheater check is finished, resume water level, control the combustion and control boiler pressure drop speed. If pressure drops to 68MPa, use HP, LP bypass or units load to control the setting pressure of safety valves of reheating steam to reheater inlet. Stabilize the combustion and maintain stable pressure. Repair staff should check reheater safety valve. 2 Adjust opening and reseating pressure of safety valve to 7585%of test pressure. Other operation and record refer to drum and superheater safety valve. 3 Using same method, check each reheater inlet safety valve and outlet safety valve in the order of high opening pressure to low. 4 If safety valve check is finished, all safety valve lock shall be dismantled, put safety valve in service. 5.2.7.4 If safety valve check is finished, acc. to the shift supervisors order shut-down the boiler or raise temperature and pressure to start up the boiler. 5.2.7.5 If safety valve check is finished, inform thermal control staff of releasing signal of compulsory. 5.2.7.6 1 Attention for safety valve check: When check safety valve, HP bypass cant be closed completely to prevent reheater burning. Also LP bypass cant be closed completely; otherwise reheater outlet steam exhaust valve should be opened.

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2 In order to decrease safety valve center safety valve,

Pressure Drop should be performed to let safety valve reseating. 3 When Prevent 4 check safety full valve, fluctuation of drum water level is large.

or inadequate water accidents lead by false water level.

When safety valve takes action, it may lead differential pressure and current fluctuation of boiler water circulation pump. One boiler water circulation pump can be closed acc. to the situation (pay attention to it and fill the water in time).

5 Each Superheater metal temperature shall be controlled in allowable scope. When main steam flow 150T/H, profit using attemperating water. When air steam flow150T/H, if attemperating water is required, control the speed not too fast. Control attemperating water in min. scope to prevent temperature from sudden drop and too much stress to damage the equipment. 6 Checking jobs. Subject 5.2.8 5.2.8.1 to and a monitoring instrument implement staff and follow a clear to division of

Prepare necessary

repair

implement

prevent

noise.

unified command and insist on jobs.

Main valve and flue gas damper test Test attention:

1 All motorized valve, Electromagnetic valve, control valve, pneumatic valve and flue gas damper should be done the reliability test before start-up of boiler. 2 Before test, confirm that there will be not any corresponding movement of the medium and any repair work etc . Safety of equipment, pipes and duct, and personal security cant be affected. 3 Before test, do the manual test to confirm machinery part normal. 4 5.2.8.2 1 Specified staff is responsible for monitoring. Acceptable standard for test. When doing local manual operation, opening and closing operation is flexible, accurate and reliable. 2 Opening and closing operation is flexible and limit switch action is accurate when doing local electric operation.

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3 When DCS operator does the test, opening and closing operation is flexible and limit switch action is accurate. The data on the instrument indicator is consistent with local actual location. 4 For motorized intercept valve which can be interrupted do the interruption test. 5.2.8.3 5.2.8.3.1 Test method and steps: Motorized valve check :

1 Confirm that test valve dont affect operation system. After repair work, contact with thermal control staff and repair staff should be on site. 2 Valve power has been in service .Signal and indicator is correct. 3 Confirm valve at close position showing the corresponding CRT screen. 4 Put valve manual control at a suitable position of indicator. (keep travel

from the closing direction or opening direction) 5 Motorized test switch is correct. If the valve has stop button, test stop function in service. Limit switch contact and automatic/manual switch also should be tested in service. 6 Close motorized valve completely and keep remaining travel manually. Thermal control staff determines break contact for closing direction. Correct local instrument and CRT screen in the same indicator, and in closed position. 7 Open motorized valve completely. With same method adjust completely

opening remaining travel. Thermal control staff determines breaking signal at opening direction. Correct local instrument and CRT screen in the same indicator, and in opened position. 8 Record completely opening period and completely closing period of motorized valve, travel and remaining travel at opening direction and closing direction. 9 Electric completely open and completely close valve once. Check mechanical dial of position of indicator, light, signal right. Opening and closing is flexible. Motor shall automatic trip at the set point, otherwise readjust it again. 10 11 If test is finished, put valve in position before test. Motorized valve check attention: A When travel limit switch has faults or valve limit body dont cooperate with travel

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BOILER & AUXILIARIES OPERATION MANUAL limit switch well, pay attention to preventing travel limit switch from out of control to damage motor and valve. If necessary replace it.

B For non-rising stem valve or rising stem valve whose valve stem is difficult to see, in the adjustment before travel limit switch is set, dont depend on motor moment protection action or method of hearing motor surplus air sound to confirm valve completely opened, completely closed position. Must manually perform adjustment. C Confirming direction principle of valve remaining travel :At closing

after completely closing valve manual open about 0. 51 circle(HP open about 90%

valve low value, LP valve high value ) or acc. to actual conditions confirm that of full travel at opening direction and max open position of indicator is 95% of full travel. D In valve switch test opening and closing button cant be put at the same time or the to switch cant be turned from opening(closing)direction directly closing (opening) direction to prevent damaging Motor.

E If the valve is moment limit valve, never manually operate it after test. F For motorized valve with local, remote control perform full travel test for local and remote control switch once and the result shall be normal. G Motorized valve with interlock will be performed interlock test to make it normal after check is finished. 5.2.8.3.2 Control valve test :

1 Confirm that test valve dont affect operation system. After repair work, contact with Thermal control staff and repair staff. 2 Gas source and valve power is sent. Confirm that air pressure direction is normal and opening and closing direction are right. 3 When perform local test, put control valve manual/automatic switch handle in manual position. With rotation hand wheel open and close the full travel of control valve. The actual conditions must be consistent with travel indicator in check process. Change the handle to automatic position. 4 Show the corresponding CRT screen. Manually operate corresponding switch of control valve to separately intermittent and continuous open and close full travel

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test once. Check signal, mechanical dial of position Indicator is consistent with the actual data and control is flexible. 5 Cutting off air test: Cut off air source of control valve, check AO valve automatic closed after cutting off air source. Check AC valve automatic opened after cutting off air source. In air cut-off test, prevent system operation from affecting. 5.2.8.3.3 Damper test :

1 Before test, carefully check equipment. If repair work is finished, keep the site clean. 2 Confirm that test valve dont affect operation system. After repair work, contact with thermal control staff and repair staff should be on site. 3 Send relevant air valve, then power of damper, air source, and put relevant air pressure instrument instrument, in service. negative pressure instrument, temperature

4 Signal and mechanical dial of position Indicator are normal. Each damper rotation is good and transmission equipment is also good. 5 Each piece of auxiliary equipment of the system has opening condition. 6 Operate corresponding CRT screen, manually response damper dial and of

separately perform intermittent and continuous opening travel once. Check signal position indicator and direction consistent with the direction correct.

and closing full

mechanical

7 There is not any leaking and other abnormal phenomenon in operating pneumatic equipment with flexible action and right direction. 5.2.8.3.4 Air fan moving-blade test :

1 Before test, carefully check equipment. If repair work is finished, keep the site clean. 2 Before test put corresponding hydraulic control oil system in service, control oil pressure normal and then send control power. 3 Rod and pin of executive body are not loose, bended and exfoliated. 4 Local and main control switch control the moving blade. The direction is right and

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the action is flexible. When the position of indicator on the CRT screen is from 0~100%, local position should be consistent with it. 5 Record period and angle of opening and closing full travel in the test. 6 In the process of test, when abnormal conditions occur, stop test, check for the cause and solve it and then test again till it is acceptable. 5.2.9 5.2.9.1 Opening, closing and accident button test for auxiliary equipment : Test condition and requirement :

1 After auxiliary motorized equipment and control circuit is repaired, must perform test for auxiliary equipment switch and accident button. 2 Acc. to repair work requirement, learn the detail in equipment repair content, abnormal situation, that repair work test requirement and scope. Check and confirm of mechanical and motorized parts on site is all finished, work-

sheet is recovered and the test condition is had. Then resume relevant system. 3 If empty trial operate the motor, confirm that motor wiring and earthling cables are complete, backrest wheel disengages and oil quality of bearing Lubrication position is normal. After check it normal, contact to send the power. In trial rotation pay attention to the correctness of rotation direction of motor. 4 Before trial operation of auxiliary equipment, when motor power is cut off, rotor is without collision and blocking, oil position oil quality is normal, cooling water valve, seal water valve is opened, outlet and Inlet instruments of primary damper are opened, pump is filling water to exhaust air is finished, Inlet valve of centrifugal pump is confirm ed opened, outlet valve of volume pump is confirmed opened, inlet and outlet valve of axial pump is confirmed opened. After all the conditions are normal ,do the test. 5 Auxiliary equipment which can be operated on CRT screen and local operation board should be operated separately. 5.2.9.2 Test method :

1 Contact with electric staff to put 6KV rotation machine switch into test position. Before test position. check the correctness of electric, thermal control instrument, sound and light signal. Confirm operation button and interlock switch is at stopped

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and coal feeder has no remaining coal. 3 Switch on each rotation machine acc. to normal procedure (A. P, ID

fan, FD fan, primary air fan, seal air fan, mi and coal feeder) once. Each rotation machine status color should be changed from green to red. 4 In the order of the contrary of above sequence on the CRT screen gradually stop each rotation machine. Each rotation machine status color should be changed from red to green. 5 Gradually switch on air preheater, ID fan, FD fan, Primary air fan, and mill and coal feeder. In the contrary sequence locally put accident button of each rotation machine. On color switch. 5.2.9.3 Auxiliary equipment protection test : become the CRT screen corresponding rotation machine status yellow, accident speaker sound alarms. If test is finished reset each

1 Test condition and requirement : A. After units are major repaired or minor repaired and auxiliary electric equipment and control circuit are repaired, must perform auxiliary equipment protection test. B. Auxiliary equipment protection test must be performed after auxiliary equipment starting and stopping test and accident button test is acceptable and meet relevant requirement for starting auxiliary equipment and accident button. C. In the test, 6kV can be only operation power. If switch is at test position, 380V auxiliary equipment is sent as dynamic power. 2 Test method : A. Stand-by auxiliary equipment shunt opening test : a) Acc. to normal opening operation, open one piece of auxiliary equipment and check stand-by auxiliary equipment having opening condition. b) c) Put auxiliary equipment interlock switch in service. Turn on accident button to let operation auxiliary equipment trip and send sound and light alarm signal and stand-by auxiliary equipment is automatic opened. d) By Using the same method separately test other auxiliary equipment. If test is finished, resume auxiliary equipment to the original.

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B.

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Low oil pressure shunt opening protection test for auxiliary equipment oil pump : a) Acc. and to normal opening operation, open one piece of oil pump

auxiliary equipment and check stand-by auxiliary equipment having opening

condition. b) Put oil pressure protection in service. Thermal control staff make low oil pressure signal. When oil pressure is lower than primarily value, stand-by oil pump will be automatic secondary value, started. when oil pressure is lower than auxiliary equipment trip and oil pressure data is recorded. If

it doesnt match the set value, thermal control staff adjust it to match c) By using same method separately test other auxiliary equipment. If test is finished, resume auxiliary equipment to original condition. C. Low water (oil, Air)pressure shunt opening protection test : a) Acc. to normal operation, open auxiliary equipment and check stand-by auxiliary equipment having opening condition. b) When do the low water (oil, Air) pressure protection, Thermal control staff made low water (oil, Air)pressure signal. When water (oil, Air)pressure is lower than set value, stand-by and water auxiliary equipment should be automatic opened (oil, Air)pressure data is recorded. If it doesnt match the set value,

thermal control staff adjusts it to match. c) By using same method separately test other auxiliary equipment. If test is finished, resume auxiliary equipment to original condition. D. High temperature protection test for auxiliary equipment bearing a) b) Acc. to normal opening operation, open one piece of auxiliary equipment. Put temperature protection in service. Thermal control staff made high temperature signal. signal value, should auxiliary be When temperature is high is primarily higher value, alarm sent. When temperature than secondary

equipment

trips. Record oil temperature data. If it doesnt

match the set value, thermal control staff adjusts it to match. c) By using same method separately test other auxiliary equipment. If test is finished, resume auxiliary equipment to original condition. E. Water level of protection test

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a) b)

BOILER & AUXILIARIES OPERATION MANUAL

Acc. to normal opening operation, open auxiliary equipment. Put water level protection in service. Thermal control staff makes water level low analog signal. When water level drops to some value, alarm signal should be sent. If water level is lower than second value, auxiliary equipment trips. Record water level. If it doesnt match the set value, thermal control staff adjusts it to match.

c)

By using same method separately test other auxiliary equipment. If test is finished, resume auxiliary equipment to original condition.

F.

Air preheater oil circulation test a) Thermal control staff make guild bearing oil high temp, analog signal, guild bearing oil pump should be automatically open and then make guild bearing oil low temp. analog signal, guild bearing oil pump should be automatically stopped, record oil temp. data, if it doesnt match the set value, Thermal control staff adjust it to match. b) Sing same method to support bearing test.

5.2.9.4 5.2.9.4.1

Auxiliary equipment power test : Test condition and requirement :

1 If auxiliary equipment is repaired, trial operation must be performed. If trial operation is good and acceptance inspection is acceptable, it can be put in service or stand-by. 2 Relevant system is confirmed trip or adopts reliable safety measures. 3 Power test of auxiliary equipment should be performed after auxiliary

equipment opening and closing test, accident button test and auxiliary equipment protection test are acceptable and should meet relevant condition and requirement in auxiliary equipment protection test. 4 Relevant protection around opening auxiliary equipment should be put in service. 5 Operation and dynamic power of auxiliary equipment should be sent. 6 Before trial operation of FD fan and primary air fan, ID fan should be opened to prevent furnace from producing positive pressure. 7 Continuous operation period after repair of air preheater, primary air fan, seal air fan, ID Fan, FD fan is 24hour. Empty time of mill should not be more than 10min. Operation period of other rotation machine should be not less than 30min.

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8 When trial operation, relevant mechanical, electric repair staff should be on site. 9 Before trial operation comprehensively check auxiliary equipment. 5.2.9.4.2 Test method and steps:

1 Open Each piece of auxiliary equipment at boiler side in the order of Air preheater, ID fan, Primary air fan, seal air fan, mill and coal feeder. 2 If equipment in trial operation is abnormal, immediately stop checking the cause and solve it and then trial operation can be performed again. 5.2.9.4.3 Test acceptance inspection standard :

1 Rotation direction is correct. 2 No abnormal sound, friction and percussive sounds. 3 Bearing temperature and vibration meet in the scope equipment regular value. 4 Equipment system has leaking phenomenon. 5 Equipment output reach nameplate output and motor current shouldnt be more than rated current. 5.2.10 Boiler rotation mechanical interlock test

5.2.10.1 Interlock action specification: 1 When main motors of 2 air preheaters are stopped, shunt open air preheater auxiliary motor, 2 ID Fans trip and boiler MFT trips. 2 When 2 ID Fans are stopped, 2 FD Fan, 2 primary air fans, seal air fan and milling plant system are shunt tripping. 3 When 2 FD Fans is stopped, 1 ID Fan is shunt tripping, Boiler MFT trips. 4 When 1 Primary air fan is stopped, milling plant system is shunt tripping. 5 When 1 ID Fan is stopped, corresponding side FD Fan is shunt tripping. 6 When 1 FD Fan is stopped, corresponding side ID Fan is shunt tripping. If only one ID and FD Fan is in service, ID Fan cant be shunt tripping. 7 Mill is stopped, corresponding mill is shunt tripping, hot air valve is automatically closed and cold air valve is automatically opened.

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5.2.10.2 interlock test method :

BOILER & AUXILIARIES OPERATION MANUAL

1 Put boiler flue gas system master interlock, air fan interlock and each pulverizing system interlock, air preheater main and auxiliary motor interlock in service 2 Continuously switch on each air preheater main motor, ID fan, FD fan, primary air fan, seal air fan, mill and coal feeder. 3 Close 1 Air preheater and its auxiliary Motor should be shunt and the other rotation machines are normal. switch off 2 Air preheaters, MFT should be performed. Primary air fan and pulverizing system shall shunt trip. Trip rotation machine CRT screen status color becomes yellow. Accidents speaker alarms, alarm window lights and reset each trip switch. 4 Continuously switch on each rotation machine switch. Stop 1 ID fan,

corresponding side FD Fan shunt trip and the other rotation machine is normal. Switch off 2 ID Fan, MFT should be performed. FD Fan and the following each rotation machine should shunt trip. Each trip rotation machine status color on CRT screen become yellow, accidents speaker alarms, alarm window lights and reset trip switch. 5 Continuously switch on 2 ID Fan and the following each rotation machine. Switch off 1 FD fan, its corresponding side ID Fan shunt trips, the other rotation machine is normal. Switch off 2 FD Fan, MFT should be performed, one side ID Fan, 2 Primary air fan, each rotation machine of pulverizing system shunt trip. Tip rotation machine status on CRT screen becomes yellow. Accidents speaker alarms, alarm window lights and reset each trip switch. 6 Continuously switch on 2 ID Fan and the following each rotation machine switch. Switch off 1 Primary air fan, the other rotation machine is normal. Switch off 2 Primary air fans, MFT should be performed. Each rotation machine of pulverizing system shunt trips. Trip rotation machine status on CRT screen becomes yellow. Accidents speaker alarms, alarm window lights and reset trip switch. 5.2.10.3 Requirement and preparation for rotation mechanical test: 1 Rotation machine with major repair should be performed interlock test and should be not less than 2 hour trial operation. Before trial operation, confirm rotation machine and electric equipment and relevant system has no repair work. 2 Shut valve of 6KV rotation machine, accident button and interlock test will only be static test. Before test contact with thermal control staff, electric staff sends relevant

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operation on test position. power and

BOILER & AUXILIARIES OPERATION MANUAL instrument control power and dynamic switch is put

3 When in trial operation contact with electric staff send dynamic power. 5.2.11 Boiler MFT test

5.2.11.1 Boiler MFT test, thermal machine and electric support test should be chaired by thermal control staff. 5.2.11.2 MFT test items are listed as follows: If meet any following condition, MFT trips. 1 Control system power cant be put in service or air pressure for control is not correct (3 get 2 pressure), delay 3s and then trips. 2 No ID fan is in service. 3 No FD fan is in service. 4 No air preheater is in service. 5 Total air flow is lower than the lowest( delay 2s and then trips). 6 If water temperature is high and steam exhaust doesnt exist for more than 6s or water temperature is not high, furnace gas-temperature probe exits or furnace temperature is high (delay 6s). 7 No steam exhaust condition (delay 6s and then trips ) 8 Drum water level is too low (delay 2s then trips) 9 Boiler water higher than 112%MCR. 10 No circulation pump is in service, delay 2s and then trips. 11 Furnace pressure is high or low. 12 Flame scanner cooling air pressure is too low (delay 600s and then trips) 13 Furnace surge is reset, or all flame scanners fail. If they fail, delay 15s, finally burners flame scanners fail. 14 Superheating steam pressure is too high (pressure switch), delay 6s and then trips. level is too high (delay 60s), and Steam flow is

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15 ESP Inlet flue gas temperature is too high, delay 2s and then trips. 16 In load-dump, after delaying T1, steam flow is still higher than x1% of initial flow before load-dump and only 1 circulation pump is in service. 17 In load-dump , after delaying ts(T1 + T2) , steam flow is still higher than x2% of initial flow before load-dump and only 1 circulation pump is in service. 18 Any accident button is put. 19 In load-dump, at least 1 coal feeder control circuit is at manual position and steam flow is higher than y%. Notice: above x1, x2, y value is per the data on site or is confirmed by thermal control logical value.

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5.2.12 Drum water level test

BOILER & AUXILIARIES OPERATION MANUAL

5.2.12.1 When Drum water level is higher than first value (+100mm) ,send alarm signal. 5.2.12.2 When Drum water level is raised to protecting value (+200), trigger MFT. 5.2.12.3 When Drum water level is lower than the first value (-240mm) ,send alarm signal. 5.2.12.4 When Drum water level is as low as the protecting value (-425), trigger MFT. 5.3 5.3.1 5.3.1.1 Check and preparation before start-up Mechanical check before start-up Before start-up of boiler, must confirm that installation and repair work has been finished, acceptance inspection is acceptable and all repair work is finished. 5.3.1.2 Each platform, stairs, unobstructed path, railings is firm and integrity, ground is clean, full of light and fire prevention is complete. 5.3.1.3 No one works in check furnace and duct. Confirm that there is not any implement left, scaffolding is dismantled., heating surface is cleaned, and refractory belt is complete and not exfoliated. Switches observation hole and checking hole are flexible and closed strictly after checking. 5.3.1.4 Insulation of each system (pipes, vessel etc.) is well, hanger is complete, and instrument is complete and not leaking. Each erosion-proof valve is complete and obstacle is unobstructed. 5.3.1.5 Air valve, damper and valve are complete. Marks are complete and switch is right and flexible, direction is clear, remote control equipments is firm. 5.3.1.6 Each expansion indicator is complete with right location and pilot graduate is clear and correct. Pointer is without jam and record defaults. 5.3.1.7 Burners have good heat insulation. Duct and blast box has no dash, oil and debris to obstruct expansion of blast box. 5.3.1.8 Burning oil system and steam to purge, oil burners, igniter and control system are complete and can be put in service. 5.3.1.9 The ash handling equipment is available for service, soot blower transmission is flexible, the location is showed correctly, and at exit position. 5.3.1.10 Furnace gas-temperature probe retracts flexibly and is put in service. Furnace flame monitor and cooling system is complete.

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5.3.1.11 Local water level is clear and in service, opening and closing steam valve is flexible and not leaking. It is full of light and camera system is complete and can be put in service. 5.3.1.12 Safety valve and ERV are complete, steam exhaust is unobstructed and fixed. 5.3.1.13 Inform dash, chemical, combustion operation staff of comprehensively checking each system, preparing for start-up and having the start-up condition. 5.3.1.14 Check for each auxiliary equipment, rotation machinery and auxiliary equipment is acceptable. Mechanical parts is with no jam, Lubrication quality is acceptable and oil is full. Cooling water, seal water and etc. are normal. 5.3.1.15 Check each valve, air valve is in open position. 5.3.1.16 Raw coal and pulverized coal bunkers are filled and available. 5.3.1.17 HFO is available. The associated heat tracing and pretreatment system have been checked and are available for service. 5.3.1.18 The ESP is available and ready for service. The rapping and the insulator heating systems are in service. Low temperature or low level alarms are cleared. 5.3.2 5.3.2.1 5.3.2.2 Thermal control and electric check before start-up: In center-control room, there is full of light and accident lighting is reliable. Each instrument is sent the power, operation switch and change-over switch, Light of indicator are complete. 5.3.2.3 Open all transmission and sample valve for signal pipe of measuring instrument and close blow down valve. 5.3.2.4 Alarm equipment, protection panel, control panel and each monitor instrument, record instrument and printer are normal and put in service. 5.3.2.5 DCS station is normal. The data on CRT screen and instrument is consistent with equipment actual status. 5.3.2.6 Check all safety interlock equipment in service. Confirm interlock protection for CCS, FSSS, PLC, DAS etc. correct. 5.3.2.7 5.3.3 5.3.3.1 Each piece of auxiliary equipment Motor has good insulation. Test and prepare before stat-up : All the main test before start-up of boiler: 1. Opening, closing position test for valve and damper

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2. Static opening, interlock logical test. 3. 4. 5. 6. 7. 8. 5.3.3.2 5.3.3.3

BOILER & AUXILIARIES OPERATION MANUAL closing, change-over and accidents button test and

Gang test for auxiliary equipment. Gang test for auxiliary equipment lubrication pump. Air preheater drive equipment test. Boiler interlock protection test i.e. MFT condition test. Turbine, boiler and generator big interlock logical protection test. Other test acc. to repair conditions.

Confirm that each valve, air valve, damper meet the requirement. Each auxiliary equipment power and operation power are sent. Each instrument get power and control power.

5.3.3.4 5.3.3.5

Put industry water system in service, check operation normal. Open air compressor system, check system operation normal, and keep compressed air pressure above 0. 65Mpa.

5.3.3.6

Contact with neighbor unit or start up boiler to supply auxiliary steam header with air, and keep pressure about 0. 525Mpa.

5.3.3.7

Check and put oil circulation of burning oil system in service. Put purging steam in service to heat the pipe and drain to clean.

5.3.3.8 5.3.3.9

Put water seal at boiler bottom and fully fill water. According to oil temp conditions, put electric heater in service. If oil temperature is consistent with the regular, open oil equipment of each mill and air peheater, FD fan oil station. Acc. to temp. of Oil in Oil tank, put cooling air fan of ID fan in service.

5.3.3.10 At the 12th hour before igniting the boiler, put ESP ash box heating automatic. At 2nd hour before igniting the boiler put ESP rapping in service 5.3.4 5.3.4.1 Initial firing precautions: To insure a maximum safety margin during start-up, an air flow of at least 30% of full load air must be maintained in order to produce the following conditions: 1 An air-rich furnace atmosphere

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2 To avoid the possibility of accumulation or stagnation of explosive mixtures in the event of poor or delayed ignition after fuel is introduced to the Furnace. 5.3.4.2 As the boiler load is increased, the operators shall check that the air flow is increased to maintain the design operating excess air. A periodical verification should be made. Refer to the curve Design excess air versus boiler load at the end of this section. 5.3.4.3 Never attempt to light a burner without its associated igniter or without atomizing /scavenging medium available. 5.3.4.4 If combustion hasnt started within 15 seconds after the fuel is fed to burner nozzle the fuel should be cut off and a furnace purge during 5mn should be performed again. 5.3.4.5 During start-up, the boiler firing is done preferably with the oil burners located at the center of the arch. The required firing rate shall be adjusted to operate without exceeding the maximum allowable furnace exit gas temperature of 550 C. 5.3.4.6 As an addition, in order to maintain the Furnace exit gas temperature below 550,the necessary fire rates to obtain the required pressure rise gradient are approximately the following(airflow% refers to the airflow MCR): 1 6 % of the BMCR firing rate with an airflow of about 30% during the first stage of the pressure rise. 2 When increased 5.3.4.7 the pressure rise slows down, the firing rate can be

by approximately 12 % of the BMCR with airflow of about 40%.

When the boiler is being warmed up, the saturated steam temperature rise gradient must be limited to 100 C/hour during the first hour and to 110C/hour during the second hour. Note: It is recommended to follow the shower rate of temp. increases during the initial start-up of a new unit or after repair works in Furnace This will allow sufficient time for drying the refractory, checking the expansion movements and to allow the operators to become familiar with the characteristics of the steam generator and its auxiliaries.

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5.3.4.8

BOILER & AUXILIARIES OPERATION MANUAL

The boiler limits shall not be exceeded. Consult the start-up curves and diagrams given at the end of this section.

5.3.5 5.3.5.1

Superheater and reheater protection during cold start-up : This is especially important when there is no demand for steam such as when starting up and shutting down. During the periods when there is no steam flow through the turbine, an adequate steam path shall be ensured.

5.3.5.2

During start-up, the superheater is protected by the steam flow passing through the HP bypass and the reheater is protected by the steam flow passing through the start-up vent or through the LP by-pass. It is considered that the minimum steam flow required for a proper protection is 10% of BMCR (approx. 100t/h).

5.3.5.3

During the first phase of the boiler start-up, the generated steam flow is insufficient to cool down and protect the superheater and reheater elements from high flue gas temperature. Therefore, particular care must be taken not to overheat the exchangers.

5.3.5.4

In order to protect the superheater and reheater until a sufficient and continuous steam, the firing rate must be controlled to keep the maximum Furnace exit gas temperature from exceeding 550

5.3.5.5

When the steam flow is established above the minimum required (steam flow approx 100t/h), the thermocouple probe may be retracted and the firing rate increased. However, care must be taken to ensure that the totality of the steam flow crosses the reheater, i. e., that there is not any auxiliary steam from cold reheater pipes.

5.3.5.6

When steam is taken from cold reheat to feed the auxiliary steam header, never take more than 20% of the steam flow through HP by-pass during start-up phases.

5.4

Cold start-up sequence If the period after shut-down is more than 40 hour or remnant drum pressure is lower than 20

bars, it is called cold shut-down. At Design condition estimated period of cold start-up to full load is 6. 5hour. 5.4.1 5.4.1.1 Boiler filling If checking work before igniting the boiler is finished, after getting boiler of filling water, Boiler can be filled and the requirement for boiler filling is as following : 1 Confirm all valves of steam system in right position. 2 Clean the system before filling the boiler. Water quality should be assayed

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acceptable. temp. Try

BOILER & AUXILIARIES OPERATION MANUAL Water temperature is decided acc. to drum wall

decreasing differential temp. If it is large, the speed of filling shall be slow to prevent drum, header and etc. from producing too big hot stress. 3 3 boiler water circulation pumps are filled water. Air exhaust is finished. Motor cooling water system are put in service and the cooling water is adequate. 4 Economizer recirculation valve has been opened. 5 Open feedwater bypass motorized valve. 6 Locally open 3 boiler water circulation pump outlet valve. 7 Boiler filling period should be controlled in: Sumerhour, Winter 4 hour. 5.4.1.2 Condensate of boiler filling or dematerialized water quality should meet requirement : dematerialized water colorless 0umol 1000ug/kg 200ug/kg hardness Conductivity SiO2 pH 0mmol/L 0. 5us/cm 20ug/L 9

Condensate water Form hardness Fe Cu

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5.4.1.3

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Temperature of filled water is higher than 20 and approach drum wall temp as possible as it can. The differential temperature of water temperature and drum wall temperature shall not be over about 28.In the process of filling, the differential temperature of drum upper and lower wall temp cant be higher than 40.

5.4.1.4

Acc. to requirement of filled water temperature required by drum wall temp, open condensate water pump or steam booster pump (or motorized pump) through feedwater bypass to fill boiler till economizer air damper overflow water and then close valve economizer air damper.

5.4.1.5

Open feedwater bypass valve and adjust water pump rotation speed to fill the water smoothly. Control filling water speed. If water temp approaches drum wall temp, add the speed suitably. But Drum wall differential temp. cant be over set value.

5.4.1.6

When water level rise to lowest water level on the drum local water level instrument, turn down feedwater control valve, control filling speed to let water level rise to high water level slowly. If perform superheater hydraulic test, continue filling till each air damper of superheater continuous overflow water and then close each air damper.

5.4.1.7

If filling is finished, close each water intake valve, stop water pump, and monitor drum water level should be kept constant, otherwise it is required that checking for the cause and reporting to the shift supervisor.

5.4.1.8

When filling boiler, 3 boiler water circulation pump Motor room continues keeping filling water till boiler water circulation pump finishes air exhaust, boiler is ignited and pressure rise to 2. 07MPa and then stop filling water.

5.4.2 5.4.2.1

Boiler cold igniting pressure rising Start 2 boiler circulating pumps, and readjust drum level to approach the low level if necessary. Select the third pump in hot stand by.

5.4.2.2

Open the air and gas path, that means: 1 Start both air heaters 2 In the sequence open the breaking damper at burning air outlet.

3 Put the flame scanner cooling air system and the fuel-oil burner sealing air system service. 4 Start one I. D fan and put the furnace pressure in automatic. CAUTION: The ID fans are able of developing excessive drafts that may damage

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part of the air/gas circuits. Care shall be taken to establish and maintain an open air/gas path through the unit prior to starting an ID fan. Ensure that: Air dampers to HFO burners are in open position; The balancing dampers of secondary air compartments are not closed; The shut off damper and the control valves of at least one FD

fan are opened. 5 Start one F. D fan. 6 Take care, during starting the first FD fan to maintain opened the shut-off damper and control valves of the other FD fan. 7 Increase the secondary air flow at the minimum required, i. e. 30% of full load airflow. 8 Successively start the second ID fan and the second FD fan. 9 Put in automatic control all the fans and combustion airflow command. 10 Put in automatic control the air dampers on secondary and tertiary air circuits FCA/B PCV 11A, 11B, 11C, 21A, 21B, 21C, 14, 15, 24, Check the following recommended positions FCA/B PCV 11C and 21C are opened 100% FCA/B PCV 11B and 21B are opened 20% FCA/B PCV 11A and 21A are closed FCA/B PCV 14, 15, 24 and 25 are closed

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5.4.2.3

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Start the steam air preheaters (if auxiliary steam is available) and verify that the temperature set point is in automatic.

5.4.2.4 5.4.2.5 5.4.2.6 5.4.2.7 5.4.2.8 5.4.2.9

Start both primary air fans and put PA pressure control in automatic control. Put in service the retractable probe. Open the reheater start-up vent FRS UV 01. Open the economizer re-circulating valve FSR UV 002. Open the rear pass and ITS drain valves FSR UV 003 and 005. Verify that the cold reheat drain valve FRS UV 002 is in automatic

5.4.2.10 With airflow of 30 % of nominal flow, perform a Furnace purge during 5 minutes. Soot blowing allowable condition : 1) Whole security of the units is established. I.e. control system power is in service, air pressure of instrument is normal. 2) 3) 4) 5) 6) 7) 8) 9) At least one ID fan is in service. At least one FD Fan is in service. Close all oil burners. Pulverized coal feeder is in service. All ESP system is shut down. All flame scanners dont scan flame. Close burning oil main closure valve. Close all pulverized coal burners, i.e. primary air damper is closed.

10) Burning improving air valve of burners is at purge position (open specified air valve, close other valve ). 11) Total air flow (primary air and secondary air) is from 25% to 40% BMCR flow. Furnace purge is correct, and then ignite burning oil burners. In furnace purge time if any condition cant be reached, purge will be stopped; 5 min timer must be reset.

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BOILER & AUXILIARIES OPERATION MANUAL In furnace purge time, finish burning oil circuit leaking test. If leaking test is not

finished or leaking test is abnormal , need reset furnace purge end storage. Check the cause for failure, re-perform a furnace purge. 5.4.2.11 Check the boiler safeties setting conditions. 5.4.2.12 Open the boiler isolating valve and the HP by pass. Place the HP by-pass in auto with the HP pressure set point at 60 bars. This will position the HP by pass at a constant opening (minimum start-up opening, around 20%). 5.4.2.13 Start one after the other, 2 oil burners at the centre of the arch (FBI+FBN or FBH+FBF), and check locally the correct operation of the burners and the quality of the combustion. Furnace igniting allowable condition: 1 Boiler purge is finished and Purge end storage is set up. 2 Control system power can be put in service and air pressure for control is correct. 3 At least one ID Fan is in service. 4 At least one FD Fan is in service. 5 At least one air preheater is in service. 6 Total air flow is higher than min value. 7 Boiler drum water level is not at high position. 8 Drum water level is correct, i.e. above too low water level. 9 At least one circulation pump is in service, i.e. pump works (Motor contactor auxiliary switch) and relevant differential pressure is higher than min value. 10 Furnace pressure is correct, i.e. between the highest and lowest (pressure switch 3 get 2). 11 Flame scanner cooling air equipment is in service, i.e. cooling air is higher than min value. 12 Superheater outlet steam pressure is not too high (3 get 2). 13 ESP Inlet Flue gas temperature is not too high.

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14 Accidents button is not put. 15 If water temp is high and steam exhaust exists or if water temp is not high, Furnace gas-temperature probe is in service and furnace temperature is not high. Notice: required condition for steam exhaust: Open HP cylinder steam intake valve (Open emergency closure valve and close turbine control valve) and open boiler outlet closure valve (close limit switch). HP bypass in not close : LP bypass valve is not closed. IP steam intake valve is opened (close limit switch) and HP control valve is not closed. Open reheater outlet air draft valve (no closure, limit switch is switched on, no action). If all conditions are met, boiler total safety storage can be automatically set up, and then the burners can be put in service. Oil supply to oil burners allowable condition: 1 2 3 4 5 6 Oil pressure is normal. Meet conditions for furnace igniting allowable or any burners is ignited. No MFT condition. No OFT condition. Oil burners secondary air damper is at igniting position. Oil a burner steam purge valve and oil valve is closed, oil burner and igniting burner exit, oil burner power is normal.

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5.4.2.14 If necessary adjust the firing rate. During pressure rise control the firing rate to keep the maximum furnace exit gas temperature below 550 C. The rising rate of saturated steam temperature is about 100 C/hour during the first hour and to 110C/hour during the second hour. The pressure rise of the boiler meets relevant requirement. (see start-up curve). 5.4.2.15 When the drum pressure increases above 2 bar, close the ITS and motorized drain valve of the rear pass. 5.4.2.16 As the water in the boiler is warmed up and expands, the level in the drum will increase. If it is required, open the intermittent blow down valve at the circulating pumps outlet to decrease and maintain normal water level in the drum. 5.4.2.17 Increase the firing rate. Start more oil burners if it is required. Continue surveying the furnace exit temperature (<550C) and the gradient of the saturated steam temperature (<110 C/hour). 5.4.2.18 Put feed water control valves in automatic as soon as possible. At this stage, the drum level is controlled by the start-up valve FSR-LCV-52D. 5.4.2.19 Close the economizer re-circulation valve, as soon as a permanent feed water flow above 100t/h is established. 5.4.2.20 When the steam flow rate is above 100 t/h, stop the retractable probe. 5.4.2.21 When vacuum is established in the condenser, put in service the LP bypass with and set the reheater pressure set point to 8 bar. Close the reheater start-up vent when the LP by-pass starts opening. 5.4.2.22 Check that spray water valves are in automatic and that temperature set points are in accordance with turbine rolling requirements. 5.4.2.23 As soon as the reheated steam conditions are within the required value, start turbine rolling 5.4.2.24 When HP pressure reaches 60 bar, the HP by-pass switches from minimum opening position to automatic pressure control mode. The by pass opens to control the HP pressure at 60 bar. 5.4.2.25 The Boiler pressure control is in automatic, manually continue increasing the firing rate by adjusting oil pressure and/or adding burners to obtain a steam flow of 200 t/h. For information, at this stage 10 to 12 oil burners are expected to be in service. 5.4.2.26 Start the electrostatic precipitator.

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5.4.2.27 When steam flow is >200 t/h, prepare to put pulverized coal burners in service if the coal silo has pulverized coal. One rotary coal feeder can be started when the permissive conditions are met. 5.4.2.28 Continue monitoring superheating/reheating steam conditions and prepare for turbo and generator synchronization. 5.4.2.29 When feed water flow is above 200 t/h open feed regulating valve and differential pressure is lower than 5 bar . The main feed valve LCV52 takes over drum level control. 5.4.3 5.4.3.1 Rolling of the turbine and synchronization When the boiler load is around 20% (steam flow 200 t/h), the HP steam pressure is 60 bar, the LP pressure 8 bar. As soon as HP/LP steam temperature conditions are satisfactory, the turbine can be rolled up. 5.4.3.2 During speeding up of the turbine, the boiler is maintained at constant steam flow 200 t/h. Maintain steam temperature at 400 C on HP side and at 390 C on IP side. 5.4.3.3 When the turbo-generator warm-up is completed and permissive conditions are met steam is introduced to the turbine. 5.4.3.4 The HP by-pass is closed gradually to let the turbine HP cylinder take over the superheated steam flow. 5.4.3.5 The LP by-pass closes gradually to let the turbine IP and LP cylinders take over the reheating steam flow to the turbine and generator are synchronization. 5.4.4 5.4.4.1 5.4.4.2 Load rise The maximum boiler load that can be achieved with oil burners can reach 30% at most When steam flow is higher than 200t/h, start one rotary coal feeder and after stabilization start a second one on the opposite side of the Arch nose. The associated oil burners should be in service to ensure ignition of the pulverized coal. 5.4.4.3

diving of the flames

Adjust the secondary air distribution in the arch compartments, in order to obtain diving of the flames (the control stations of dampers FCA/B PCV 11A/B/C and 21A/B/C are operational as soon as a rotary feeder is in service)

5.4.4.4 5.4.4.5

When steam flow is higher than 250t/h start the milling plant if require. Start more coal burners according to load and pressure rise. The total coal demand can be put in automatic and the firing rate can be then controlled by the boiler load demand set point.

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5.4.4.6

BOILER & AUXILIARIES OPERATION MANUAL

When the HP by-pass is closed, raise the pressure gradually by controlling the firing rate. The saturated steam temperature gradient shall remain below the Design limits (see start-up curve).

5.4.4.7

Keep the fuel-oil burners in service as long as required and until the expected numbers of coal burners are operating. Furthermore, it is recommended to keep in service 4 oil burners after reaching full load to obtain a stabilized temperature on the refractory.

5.4.4.8

Transfer the turbine control and the boiler load demand to automatic. Under this mode the unit is in the coordinated mode selected by the operator (boiler or turbine following). Normally the boiler following mode is used: the opening of the turbine valves controls the load and the firing rate controls the steam pressure.

5.4.4.9

Put the steam temperature control in automatic. Verify that correct set points have been reached.

5.4.4.10 Check the total airflow which has to be sufficient at all times for the actual firing rate. 5.4.4.11 When the target load is reached, verify that boiler-operating conditions are in conformance with design data. Refer to expected values and to the sliding pressure and excess air curves. 5.5 Hot start-up Hot status boiler is classified as the following types: Moderate: Shut-down for 10 to 40 hour, boiler pressure is from 2. 0 to 6. 5 MPa. hot: shut-down for 1 to 10 hour, boiler pressure is from 6. 5 to 14. 0 Mpa. Extremely hot: shut-down for less than 1 hour, boiler pressure is higher than 14. 0 Mpa. 5.5.1 5.5.1.1 5.5.1.2 Check and preparation before hot start-up: Control air source, power is reliable, and control air source pressure normal. Fire scanner and fire-proof system is normal, Air preheater fire extinction equipment is reliable. 5.5.1.3 Put water seal at boiler bottom in service. Filling water, each piece of equipment of ash handling system is at stand-by status. 5.5.1.4 5.5.1.5 Burning oil system and atomization steam system is normal. The following equipment operation is normal, If it is stopped, open it again : 1 2 Air Preheater.

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2 AC flame scanner cooling air fan, DC air fan are at interlock. 3 2 boiler water circulation pump, and stand-by pump is at interlock. 5.5.1.6 The following auxiliary equipment is at stand-by status 1 A, BID Fan 2 A, BFD Fan 3 A, BPrimary air fan 4 A, Bpulverizing system 5 All pulverized coal feeder and oil burner 6 A, BSteam air preheater 7 A, B ESP 5.5.1.7 5.5.1.8 5.5.1.9 All soot blowing burners position are correct and at exit position. A, B Furnace outlet flue gas temperature probe has been put in service. A, B Furnace flame TV has been put in service.

5.5.1.10 Steam system check is finished and its valve position meets the requirement before igniting the boiler: 1 Close all air damper of superheater and drum. 2 Open economizer recirculation valve. 3 Open atmospheric relief valve at reheater outlet. 4 Automatic drain valve at cold reheater main pipe is reliable. 5 Each manual valve of attemperating water system is opened, each motorized valve, control valve are closed. 6 Main steam valve and bypass valve are closed

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5.5.1.11 Close the left drain valve of superheater. 5.5.1.12 Check that drum local or TV water level instrument has been put in service and drum water level is normal. 5.5.1.13 Each valve position of soot blowing system is right. 5.5.2 5.5.2.1 5.5.2.2 Boiler hot start-up steps Open opening vent valve FRS UV 001 of the reheater. Make sure that there is no drain opened in reheat pipe and automatic drain valve FRS UV 002 is available and ready for service. 5.5.2.3 Open during a sufficient time (see table) the automatic drain valves on superheater: 1 Drain valve of steam walls of rear pass FSR UV 003. 2 Drain valve of LTS inlet FSR UV 005. 3 Drain valve of superheater outlet steam pipe FSR UV 004. 4 The drains have to be opened before firing the boiler during a time long enough to eliminate all the water out off the superheater. The time is function of the duration of the shut down and the pressure in boiler. Follow the indications here below Residual drum pressure (bar) duration of opening (mn) before firing: - FSR UV 003 - FSR UV 004 - FSR UV 005 2 2 2 5 5 5 10 10 10 65 60 60 150 80 50 10

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5.5.2.4

BOILER & AUXILIARIES OPERATION MANUAL

Open drains and conditioning devices of the main steam lines according to the instructions of the turbine manufacturer.

5.5.2.5 5.5.2.6 5.5.2.7 5.5.2.8 5.5.2.9

Start, one side after the other, the ID and FD fans. Start the steam air preheaters. Start one after the other both PA fans and put PA pressure control in automatic. Adjust the airflow to 30 % of nominal flow and perform Furnace purge during 5 minutes. Open the HP by-pass gradually by adjusting pressure set point below the actual remaining pressure.

5.5.2.10 Start 2 diagonals of oil burners as soon as possible. 5.5.2.11 According to turbine conditions, maintain or raise boiler pressure by adjusting HP by-pass set point and increasing firing rate. 5.5.2.12 Close the economizer recirculation valve, as soon as a permanent feed water flow is established and put in automatic the drum level control. 5.5.2.13 When the vacuum is established in the condenser, put in service the LP by-pass and close the reheater start-up vent. 5.5.2.14 Steam flow and steam temperatures will rise rapidly in relation with the firing rate. 5.5.2.15 Open main steam line warm-up lines and boiler stop valve according to turbine manufacturer. When turbine start-up conditions are reached, start rolling the turbine. 5.5.2.16 Start the Electrostatic precipitator. 5.5.2.17 After synchronization, raise the load by putting in service additional burners. Check proper airflow. 5.5.2.18 Control firing rate to obtain the load acc. to raise startup curve gradient (110C/hour). 5.5.2.19 Put the steam temperature and load controls in automatic. 5.5.2.20 Check that firing conditions are stable. Check that pressure and temperature set points are reached. 5.5.3 5.5.3.1 Boiler star-up attentions : Metal wall initial temperature and other relevant parameter of turbine HP and MP cylinder and boiler status decide the start-up status of the unit. 5.5.3.2 In strict accordance with start-up curve of each status, raise temperature and pressure.

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5.5.3.3 5.5.3.4

BOILER & AUXILIARIES OPERATION MANUAL

When raise the pressure, pay attention to the changes of steam and water quality. When oil is burning, close monitor the changes of temperature of air preheater outlet flue gas.

5.5.3.5

In the process of start-up, pay attention to burning conditions, especially oil burning. When each oil burner is put in service, out of service and normal operation, strengthen the check for oil burner. If oil burner has oil leaking, bad atomization, when oil is leaking, immediately take measures to solve. When oil burner is stopped, close burning oil input manual valve, if the defects cant be solved, prohibit opening marks should be put on it.

5.5.3.6 5.5.3.7 5.5.3.8

Check the reliable operation of flame scanner equipment at any time. Check economizer protection, i.e. the using condition of economizer recirculation valve. Check protection for superheater and reheater and cant allow operation of steam with no path. Pay attention to monitoring metal wall temp. in the allowable scope.

5.5.3.9

For the oil with primary start-up or with major repair, confirm boiler hot expansion of each parts, especially the low hot expansion. Record each data of boiler expansion indicator for reference of start-up.

5.6 5.6.1

Parameter control value In the process of start-up Parameter which should be controlled in boiler cold start-up
Time(min )

Parameter

Units 0 60 6 144 60 255 60 400 390 200 15 synchronization 390 167 541 539 995 300 full load

Main steam pressure Main steam temperature Reheat steam temperature Main steam flow unit load specification

bar t/h MW

0 0 0 boiler igniting

260 400 240 390 0 0 200 0 turbine impulse starting

5.6.2

Parameter which should be controlled in boiler hot start-up


Units Time(min )

Parameter

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0 20 78 50 100 60 100 480 460 300 15 synchronization 110 167 541 539 995 300 full load

Main steam pressure Main steam temperature Reheat steam temperature Main steam flow Unit load specification

bar t/h MW

0 0 0 Boiler igniting

400 480 380 460 120 300 0 0 turbine impulse starting

6 6.1

Monitoring and adjustment in boiler operation The main task and objectives of operation adjustment Keep evaporative capacity of boiler is in the rated value and meet the requirement of unit

6.1.1

load. 6.1.2 6.1.3 6.1.4 6.1.5 Maintain normal and stable steam pressure, steam temperature and drum water level. Maintain water and steam quality acceptable. Keep good combustion, raise boiler efficiency and keep the furnace clean. Ensure that boiler and subsidiary equipment should be opened, stopped safely and

operated economically and safely. 6.2 6.2.1 Main Parameter and limit of operation control Different load operation control main Parameter value: Coal burning(load ) Item Units BMCR 1. Generator total RO 75% RO 225 60% RO 210 Min load

*60% RO

output power 2. Steam flow (a) Superheat steam

MW kg/H 995

300

882. 7

639. 4

518. 9

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(b) Reheat steam

BOILER & AUXILIARIES OPERATION MANUAL 849. 4 kg/cm2g 190. 4 176. 3 33. 7 541 538 kg/cm2g 193. 9 281 kg/H preheater 29 356 333 110 670 400 124 650 392 121 610 358 111 580 340 102 29 352 333 110 29 324 311 110 29 308 297 110 273 129500 254 99100 243 189. 4 158. 7 129. 9 540 538 539 538 539 538 186. 5 174. 7 30. 1 156 149 22. 1 127. 5 121. 9 18. 0 756. 5 555. 0 443. 8

3. Steam pressure (a) (b) Drum Superheat steam

(c) Reheat steam 4. Steam temperature (a) (b) Superheat steam Reheat steam

5. Feedwater pressure (a) Economizer Inlet

6. Feedwater temperature (a) Economizer Inlet

7.Fuel consumption (coal) 8. Air temperature (a) Inlet (b) (c) A. P outlet Primary air A. P outlet Steam air

Secondary air (d) Mill outlet

9. Flue gas temperature (a) (b) (c) Superheater outlet A. P Inlet A. P outlet

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10. (a) (b) 6.2.2

BOILER & AUXILIARIES OPERATION MANUAL

O2 content in Flue gas % Vol Economizer outlet A. P outlet 4. 0 5. 1 4. 0 5. 1 4. 5 5. 9 5. 4 6. 8

Limited value of boiler operation main Parameter control : Units bar mm Setting value 1755 5415 5385 range 2 2 2

Parameter Name Superheat steam pressure Superheat steam temperature Reheat steam temperature Drum water level

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6.3 6.3.1 6.3.1.1

BOILER & AUXILIARIES OPERATION MANUAL

Checking, monitoring and maintenance in boiler operation Checking in boiler operation : Intermittently check each operation parameter and equipment operation conditions in DCS screen in boiler normal operation. If there are abnormal parameters or abnormal conditions of equipment, immediately analyze and take corresponding control measures.

6.3.1.2

Intermittently check equipment operation conditions in boiler normal operation. If there is abnormal vibration, abnormal sound or coal leaking, pulverized coal leaking, air leaking, steam leaking or oil leaking etc. in equipment operation, immediately take isolation measures.

6.3.1.3

Often analyze each operation parameter, comparative analysis of each data of indicator of equipment on site and each parameter from DCS. If there is any doubt or big errors, the cause must be checked carefully and solved.

6.3.2 6.3.2.1

Combustion control of boiler: In boiler operation immediately control coal quality condition fed to the furnace and per coal quality condition, adjusts mill outlet temperature and differential pressure between inlet and outlet.

6.3.2.2

In operation close monitor change of air flow and oxygen content of flue gas. At any time air flow should be more than lower than 30% BMCR operating condition, keep Flue gas oxygen content in suitable scope.

6.3.2.3 6.3.2.4

Often check burning condition in the furnace and observe fire condition pulverized coal . When furnace burning is not stable, immediately put oil burner in service for stable burning. When Boiler load is lower than 60% BMCR, input oil for stable burning.

6.3.2.5

When raise load, crease air flow and then crease fuel. When drop load, decrease fuel and then decrease air flow

6.3.2.6

Intermittently check total air flow for boiler burning, adjust to keep appropriate rate of air /coal to reach good burning operating condition.

6.3.2.7

Acc. to coal quality and burning condition, adjust the position of air valve of air adjustment and axial blade, keep reasonable pressure drop of burners and alternate secondary air rotating speed to confirm degree of disturbance of mixture of air and pulverized coal.

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6.3.2.8

BOILER & AUXILIARIES OPERATION MANUAL

Acc. to boiler combustion system each parameter and steam temperature change trend immediately adjust the position of indicator of secondary air dampers at front, rear arch A, B, C row, and minor adjust the position of indicator of each upper and lower tertiary air valve of front and rear wall to change the length of W flame.

6.3.2.9

Good burning operating condition is that fuel air mixtures is burning in furnace lower parts, i.e., the mixtures stay longer in the furnace with full of flame which is golden yellow. If oil is burning, flame is white and light. And dont impact water wall and plate superheater. Ignition point of fuel cant be approached which can cause burners burned and damaged by around coking easily. And incompletely burned fuel content in ash and fly ash is low.

6.3.2.10 Turn up external secondary Air damper. Flame ignition point of pulverized coal becomes remote; Otherwise, turn down external secondary Air damper, ignition point of fuel become near. Add external secondary air flow and carbon content in the fly ash is obviously decreased but maintain burning safety at the same time. The final setting value for the position of indicator of external secondary air shall be a little smaller than critical position of indicator. 6.3.2.11 Internal secondary air damper should be decreased to make flame closer and make critical position of indicator of external secondary air become large and make burners air flows direction to external secondary air to make it economical. 6.3.2.12 If burning flame is instable, check primary air flow. Big air flow and thick pulverized coal will cause flame instability. Otherwise, too low primary air flow may cause pulverized coal uneven distributed in burner tips to lead burning disturbance. 6.3.2.13 In normal operation, keep furnace negative pressure -100Pa. 6.3.2.14 Furnace outlet oxygen content is decided by different fuel characteristic and load. When oxygen content is at manual position, control it acc. to oxygen content control setting value. If oxygen content control is automatic, through automatic or manual method change oxygen content setting value to perform automatic control. When oxygen content in flue gas is at automatic measure, acc. to the range in the following table to perform adjustment. Boiler load (T/H) Flue gas oxygen content 400 6. 8 500 5. 5 600 4. 7 700 4. 35 800 4. 15 900 3. 95 995 3. 95

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6.3.2.15 When oil burner is in service, burning oil fire condition should be monitored by flame scanner. If there is not any oil burner, the corresponding pulverized coal feeder cant be put in service. 6.3.2.16 The best operation measure of pulverized coal feeder is that same burning tip is on two arches to maintain the burning stability. In big load, try to put all pulverized coal feeder in service and rotation speed should be controlled under 10rpm and cant be more than 11rpm to prevent pulverized coal feeding pipe of rear wall blockage. When control rotation speed pulverized coal feeder, the rate of increase or decrease should not be large to reduce the interference of burning. 6.3.2.17 In operation, try to make rate of air /coal(PA/PC) meet the following requirement Boiler load (%) PA/PC(air /coal) rate BMCR 1. 03 100%ECR 75ECR 0. 98 0. 98 50%ECR 1. 17 40%ECR 1. 13

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6.3.2.18 When do combustion adjustment or increase load of the boiler, besides keep steam temperature and steam pressure normal, keep water wall outlet operating conditions temperature in normal scope. After burners are put in service, immediately check whether fire condition is good and immediately adjust air flow to prevent smoke emission form the chimney. 6.3.2.19 In boiler normal operation, often check air leaking conditions of the body and duct. Check seal of each section good, each valve and hole are closed strictly and ash handling equipment seal good. 6.3.2.20 In boiler normal operation, operation conditions of burners and heating surface should be checked. Strengthen analysis and comparison. If there is phenomenon of slag building, clogging and fire extinction, immediately adopt adjustment measures. 6.3.3 6.3.3.1 Steam pressure control: When unit are in the operation with turbine and boiler coordinating measure, through inner control circuit, compare actual measured value of main steam pressure setting value and actual measured value of boiler outlet main steam pressure to change boiler load in order to let boiler combustion obtain adjustment and finally reach the objective of controlling steam pressure to meet requirement of unit load. 6.3.3.2 In the period of starting-up the unit, minimum start-up pressure is controlled by HP bypass at 60bar and unit is operated at setting pressure operation measure. 6.3.3.3 In the process of increasing unit load, gradually close HP bypass till it is completely closed. HP bypass is changed to operation with variety gradient control measure. Unit control measure is changed to sliding pressure operation. 6.3.3.4 Put boiler main load requirement and oxygen content control into automatic. The unit gradually increase load through increasing steam pressure setting value. 6.3.3.5 When the following condition occurs, HP bypass shall be quick opened to control boiler outlet pressure: 1) 2) 3) Turbine trips. Operate with auxiliary power. Main steam pressure is over 18. 5MPa.

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6.3.3.6

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Main steam pressure normal adjustment is controlled in0. 2 MPa and not more than 0. 5Mpa. If main steam pressure18MPa, it is regarded as Main steam high pressure.

6.3.4 6.3.4.1

Steam temperature control In boiler normal operation, main steam temperature is controlled at 5415, two side differential temperature is lower than 10 and at the same time operation medium temperature in each section and wall temperature doesnt exceed regular.

6.3.4.2

Main steam temperature is controlled mainly by water spray attemperator. Superheater primarily attemperator will perform rough adjustment for steam temperature and its water spray volume is decided temperature before using attemperator. Keep wall temperature of mid-temperature superheater from exceed the allowable value. By using secondary attemperator of superheater performs micro-adjust to main steam temperature to keep instability of boiler outlet steam temperature, high sensitivity of controlling steam temperature by secondary water spray attemperator, and small delay. Through changing flame center position, main steam temperature can be auxiliary controlled.

6.3.4.3

Control of reheater steam temperature is mainly performed through combining attemperating water and burning adjustment, i.e. through changing the position of indicator of upper and lower third air control damper of front and rear arch to change flame center position to reach the objective of decreasing or increasing reheat steam temperature. Adopt water spray attemperating to control reheat steam temperature.

6.3.4.4

Use and attention for attemperating water : 1) Superheater, reheater water spray attemperating control can be used at main steam flow150T/H. Superheater primary water sprays attemperating is used to control wall temp. of mid-temperature main steam superheater, prevent over limited water not be and auxiliary spray more control temperature. Secondary

primary attemperating is the final adjustment for the main steam than 10 , Strictly control that attemperator outlet steam

temperature. Differential temperature of two side of superheater should

temperature must be higher than saturated temperature 15 at its operation pressure. 2) When control attemperating water and keep steam temperature,

adjustment of attemperating water cant be quick increase or quick decrease for the operation has a certain lag. 3) When control attemperating water, pay attention to differential pressure relation

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between drum pressure and feedwater main pipe pressure. When feedwater pressure is changed, attemperating water control valve should be correspondingly adjusted. Usually keeping feedwater pipe pressure higher than drum pressure 20 bar is better. 6.3.4.5 When the following condition occurs, especially pay attention to monitoring steam temperature to prevent overheating and sharp drop of steam temperature. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) Increase or decrease load Start or stop burners Start or stop Feedwater pump Start or stop air fan (single side air fan trip or resume) Start or stop pulverizing system Start or stop high temperature heater Instable steam pressure Coal quality is changed. Ash deposit, slag building on heating surface Bad burning condition or changes of flame length Pulverized coal is unbalanced. Pulverized coal fineness is changed Soot blowing occurs. Large fluctuation of drum water level Boiler blowdown When oxygen content in furnace is being changed.

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6.3.4.6

BOILER & AUXILIARIES OPERATION MANUAL

In normal operation, each water spray attemperator shall be put in automatic service. Pay attention to water spray automatic control in normal service. In changing operating conditions, strengthen monitoring steam temperature to prevent over temperature. For e.g. automatic control cant follow the changes of steam temperature. Switch to manual measure to adjust.

6.3.5 6.3.5.1

Drum water level control Strictly monitor drum water level. Control variety rule of drum water level and feedwater pump characteristic. Be familiar with equipment system and performance. In operation keeping stable normal water level is the chiefly task to maintain boiler safety and economical operation.

6.3.5.2

The change of water level shows the balance relation between boiler load and Feedwater. When start the boiler and main pipe pressure of feedwater pump50 bar, open feedwater pump outlet motorized valve. At this time put feedwater pump rotation speed into automatic. On the control console send the opening order to feedwater control isolation valve to automatically trigger the following procedure: For e.g. if feedwater low flow control valve FCV52D is closed (ZSL52), open its isolation motorized valve UV20A, UV20B (ZSH20A ZSH20B), put FCV52D into automatic operation. For e.g. If feedwater main flow control valve FCV52 is closed (ZSL52), when Boiler main steam flow 380T/H and send main flow control isolation valve UV19 opening order. Open FSRUV19 (ZSH19) and feedwater control is switched from bypass control automatic to main flow control valve FCV52. In boiler normal operation, through FCV52 control drum water level. When load drop to flow286T/H or feedwater control valve front and rear differential pressure (PT90-PT85=PPS90) 60bar, feedwater control is switched from feedwater control automatic to bypass control valve FCV52D. Drum water level is controlled through feedwater control valve and feedwater pump rotation speed. When only through feedwater pump rotation speed controlling Drum water level, it will cause the fluctuation of attemperating water pressure which makes steam temperature difficult to control. Therefore, this measure cant be adopted. When feedwater has to be controlled through feedwater pump rotation speed, the staff should be more careful and pay attention to change of attemperating water volume to prevent fluctuation of steam temperature.

6.3.5.3

Work scope of drum normal water level is -290mm-175mm. When its water level drop s to -240mm or rises to +100mm, low or high drum water level alarm is sent. When its water level drops to -425mm, rise to +200mm, MFT trips.

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6.3.5.4

BOILER & AUXILIARIES OPERATION MANUAL

In normal operation, put feedwater flow control into automatic, drum water level is set automatic feedwater pump rotation speed and feedwater control valve is put at automatic measure. And monitor drum water level in the following scope. Boiler load () Drum water level(mm) 50 -290 60 -265 70 -245 800 -220 90 -200 100 -175

6.3.5.5

When boiler operating conditions is changed, e.g. When load, steam pressure, feedwater pressure are changed, change of feedwater pump operation measure and change of burning operating condition occur and boiler blowdown etc., strictly monitor change of water level. If the fluctuation of water level is large, immediately switch water level control to manual control to prevent the accidents caused by full water, inadequate water. If emergency occurs, use continuous blowdown and intermittent blowdown valve to cooperate with control.

6.3.5.6

When attemperating water flow is increased and water spray attemperating control valve opening position is 70%, feedwater pump rotation speed should be automatic increased and feedwater control valve should be automatic closed about 10%. (but not completely closed). Keep feedwater main pipe pressure constant to avoid large fluctuation of drum water level.

6.3.5.7

When drum water level automatic control jumps to manual measure, strengthen monitoring and control of drum water level, feedwater flow and feedwater pressure.

6.3.5.8

If the following condition occurs, strengthen monitor and adjustment of water level : 1) 2) 3) 4) The large fluctuation of feedwater pressure and feedwater flow. When safety valve is opening or reseating and boiler blowdown. When load is changed and HT heater exit operation. When opening or closing feedwater pump, impulse starting, synchronization and etc in the start-up or shut-down of boiler. 5) 6) When feedwater pump and control equipment fault occurs. When switch over control valve control and feedwater pump rotation speed control or steam pump and motorized pump. 7) When pressure parts leaking occurs.

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8)

BOILER & AUXILIARIES OPERATION MANUAL

When open or close turbine control valve, bypass valve, superheater and main steam pipe drain valve.

9) 6.3.5.9

When burning is instable or perform fire extinction treatment.

Any data on drum remote water level indicator is abnormal, immediately contact with thermal control staff to deal with If it cant be resumed, and relieve water level protection.

6.3.6 6.3.6.1

Boiler blowdown To keep steam, water quality and heating surface internal clean, must perform boiler blowdown. Classify boiler blowdown to continuous blowdown and intermittent blowdown.

6.3.6.2

Continuous blowdown is controlled blowdown volume acc. to the result of chemical analysis and boiler water quality parameter and through adjusting position of indicator of continuous blowdown valve FSRUV17.

6.3.6.3

Intermittent blowdown is performed acc. to the result of chemical analysis and after receiving the notice from chemical shift supervisor, through intermittent blowdown valve FSRUV02 or 2 mins blowdown at morning shift every day. Intermittent blowdown shall be performed at low load

6.3.6.4

Intermittent blowdown operation 1 Check closure valve FSRHV034 at Open condition, micro-open

intermittent blowdown valve FSRUV02 to heat pipe. 2 After heating pipe, fully open intermittent blowdown valve FSRUV02, after 2min, close this valve. 3 In the process of intermittent blowdown, pay attention to the change of drum water level and operation conditions of boiler water circulation pump to prevent water circulation from damaged. 4 If blowdown is finished, blowdown valve FSRUV02 should be checked closed strictly. 6.3.6.5 If the following condition occurs, stop intermittent blowdown operation : 1) 2) 3) When drum water level is not normal, feedwater control is no good. Blowdown system fault or strong vibration of pipe. Boiler accidents occurs.

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6.3.6.6

BOILER & AUXILIARIES OPERATION MANUAL

Prohibit long period blowdown and blowdown valve leaking. In operation to prohibit boiler blowdown by boiler water circulation pump inlet header drain valve.

6.4 6.4.1

Boiler operation measure control Totally there are 5 types of units operation measures: manual, Boiler following mode,

turbine following mode and coordinate control and electricity network control. 6.4.2 Manual measure: it is the most basic measure, boiler main controller and turbine main

controller operation measure is at manual measure, i.e. Boiler side, turbine side is manually kept parameter by operation staff and change unit load or keep stable operation acc. to requirement. 6.4.3 Boiler following mode: Turbine controls load, Boiler controls inlet pressure. At this time,

turbine main controller is at manual measure, or remote control of DEH system not put in service. At this measure, turbine controls load, and boiler main controller in automatic measure operation, automatic closed loop control inlet pressure. 6.4.4 Turbine following mode: Boiler controls load, Turbine controls inlet pressure. At this time,

boiler main controller is at manual measure, but turbine main controller is in automatic measure operation. Through changing position of indicator of control valve to stable inlet pressure, at this measured DEH systems put in service. 6.4.5 Coordinate control measure: at this measure, boiler main controller and turbine main

controller is in automatic measure operation. 6.4.6 Electricity network control: at this measure, unit coordinate control is put in service, and

electricity network load dispatch system put in automatic following. Electricity network send Generator unit load order, Generator unit automatic follows load order and boiler and turbine make corresponding automatic control to meet requirement of electricity network load order. 7 7.1 7.1.1 Shut-down of Boiler basic regular (generals ) Boiler normal shut-down must strictly be accordance with shut-down curve control relevant

parameter. 7.1.2 In boiler abnormal shut-down must prevent shut-down in the process of accidents or

enlargement accidents. 7.1.3 7.1.4 Before shut-down of boiler do corresponding check and preparation. After shut-down of boiler, if emergent repair is needed, accelerate boiler cooling i.e.

compulsory cooling and adopt the following operation:

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7.1.4.1

BOILER & AUXILIARIES OPERATION MANUAL

Keep Drum high water level+300+500mm, and strengthen changing water, deaerator water temp. is decided by boiler cooling condition.

7.1.4.2

After shut-down for 6 hour, Boiler is sealed. After shut-down for 618hour, Boiler naturally air draft.

7.1.4.3

At 18 hour after shut-down, open 1 ID, FD Fan, keep about 30BMCR air flow Boiler to compulsory air draft.

7.1.4.4

Strictly control Pressure Drop speed, total temperature drop and pressure Drop In the process of drum upper, lower wall differential temperature40.

7.1.4.5

Strictly monitor boiler water circulation pump operation conditions, when Drum pressure 15bar, close 1 boiler water circulation pump. If boiler water circulation pump has vaporization Phenomenon, immediately stop boiler water circulation pump operation.

7.1.4.6 7.1.5

When boiler water temperature70, close boiler water circulation pump, Boiler drain. After shut-down, in order to prevent heating surface from internal erosion, per different

conditions, perform corresponding shut-down maintenance work. 7.1.6 When boiler pressure doesnt drop to 0 and Motor power isnt cut off, giving up monitoring

boiler unit and auxiliary equipment can be allowed. 7.1.7 In the process of shut-down strictly control Pressure Drop speed, seriously operation, and

strictly monitor differential temperature of drum upper, lower wall is less than 40. 7.2 7.2.1 Preparation before shut-down of boiler The shut-down of Boiler unit must obtain the superior order, and the measure, reason and

period of shut-down and then prepare for the shut-down, and inform chemical, burning operation, desulphurization staff on duty and Thermal control staff of shut-down period. 7.2.2 Before shut-down, inform each staff on duty to comprehensively check system managed

by himself to record all detailed defects condition to solve all the defects after shut-down. 7.2.3 If the period for shut-down is more than 3 days, grind all the coal in the bunker grinding.

Pulverized coal in pulverized coal bunker need be burned out. If the period for shut-down is in 3 days, the position of pulverized coal shall be less than 5 meter. 7.2.4 Comprehensively check Burning oil and Atomization steam system has been put in

stand-by. Atomization steam pressure is normal; each oil burner is reliable which can be put in service at any time. 7.2.5 Decrease load before shut-down, soot blow boiler body and air preheater.

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7.2.6 7.3 7.3.1

BOILER & AUXILIARIES OPERATION MANUAL

Comprehensively check HP bypass system, confirm Hydraulic plant operation normal. Shut-down with sliding parameter (need cooling ) Shut-down adopts sliding parameter shut-down; gradually reduce the boiler combustion

with turbine decreasing load to keep steam pressure, temperature and flow suitable for the requirement for turbine sliding parameter decreasing load. 7.3.2 When decrease fuel, decrease corresponding air flow. Strictly prohibit total air flow

30%MCR till the unit are shut-up. 7.3.3 When pulverizing system thoroughly pumped, stop pulverizing system and keeps

lubrication system of tube mill long operation. 7.3.4 7.3.5 Close moisture absorption valve at pulverized coal bunker. At 75% of boiler load (Steam flow 750t/h) stop PC burners as required and keep the

associated fuel oil burner in service, continue decreasing load and monitor furnace temperature. 7.3.6 Switch from global flame detection mode to individual scanning mode occurs when the

boiler load is below 70% BMCR (618t/h). Stop PC burners as required and keep the associated fuel oil burner in service (at least until the PC pipes have been purged).And from then on the measure is mixture of oil and pulverized coal. Put A. P soot blower, keep continuous soot blowing pattern. 7.3.7 With drop of unit load, slowly decrease main steam pressure setting value, monitor

superheat steam temperature and Reheat steam temperature drop rate should be 1/min., In the process of whole pressure drop, Drum upper and lower wall differential temperature should be lower than 40. 7.3.8 7.3.9 When automatic control is not good, switch to manual adjustment. Gradually close pulverized coal feeder. Firstly close pulverized coal downcoming gate of

pulverized coal feeder .When pulverized coal is empty, close pulverized coal feeder. 7.3.10 When Boiler Main steam flow286T/Hour feedwater control valve front and rear differential

pressure60bar, feedwater control is switched form feedwater automatic control to bypass control. 7.3.11 When Main steam flow250T/H, all pulverized coal feeder is stopped unconditional.

Inform of stopping ash handling, keep cathode and anode rapping in operation and ash handling equipment in operation.

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7.3.12

BOILER & AUXILIARIES OPERATION MANUAL

When Main steam flow150T, stop using attemperating water . When water spray

motorized valve and control valve cant be closed tightly, stop each water spray manual valve, and make operation record. 7.3.13 When the load is 75MW, switch to auxiliary power. When load is 50MW, switch valve of

turbine, quick decrease load to 0. Generator reverse Power trip, perform shunt tripping of turbine. Shut-down the boiler and close all burners. Purge all PC pipes correctly. Close burning oil safety valve and each oil burner input oil manual valve and burning oil control plant inlet oil manual main valve. Confirm all fuel is cut off. 7.3.14 To prevent Atomization steam from entering into furnace in the period of shut-down of

boiler, close atomization steam main valve. 7.3.15 After boiler trips, close the superheater stop valve FSR UV 004 and the HP by-pass.

Open rear pass drain FSR UV 003, 005. Open the drains and blow down devices of the main steam piping and main turbine piping, according to the instructions of the turbine manufacturer. 7.3.16 Do not reduce airflow below 30 % of full load airflow. keep total air flow 30%MCR, after

performing furnace purge for 10 mins, gradually stop Primary air fan, FD Fan, ID Fan, confirm each air fan Inlet and outlet damper closed. 7.3.17 7.3.18 Trip A, B side Steam air preheater Contact with chemical staff on duty, stop chemical feed pump, and close chemical feed

valve, continuous blowdown valve and ach sampling valve. 7.3.19 Keep 2 Air Preheaters operation, 1 flame scanner cooling air fan in operation, 1 oil burner

cooling air fan operation. 7.3.20 Keep 2 boiler water circulation pump in operation, When drum pressure15bar, per the

conditions stop 1 boiler water circulation pump operation. Keep drum high water level +100mm. Open Economizer recirculation valve. 7.3.21 Control boiler cooling rotation and keep the differential temperature measured by any two

thermal couple is less than 50 C. 7.3.22 7.3.23 When Drum pressure3bar, Open each Air damper of superheater and reheater. To prevent economizer, air preheater and etc. from secondary burning which damages

equipment. After shut-down boiler, monitor gas temperature of each section. When air preheater inlet gas temperature 120, stop A, B air preheater operation, stop flame scanner air fan and oil burner cooling air fan operation.

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7.3.24

BOILER & AUXILIARIES OPERATION MANUAL

When boiler water temperature70, stop boiler water circulation pump. Close outlet

non-return flap and heating pump manual valve, power of 3 boiler water circulation pump should be cut off. Open Drum left, right side interlayer of air damper. 7.3.25 When boiler water temp.70 and boiler water circulation pump is stopped, if boiler must

be drained, comprehensively check the steam and water system. 7.4 7.4.1 7.4.2 Normal shut-down (hot stand-by ) When shut-down, try to keep main steam pressure and Main steam temperature. Speed of pressure drop when load is dropped is much lower than cooling speed of normal

shut-down. 7.4.3 7.4.4 Put soot blowing equipment in service for A.P. When the turbine is off load, the boiler should continue to be fired in order to increase the

pressure above 140 bar before bottling (Per the conditions of hot stand-by equipment). 7.4.5 After boiler fire-off, close main steam valve and HP bypass valve, close all air valve

damper to bottle-up. 7.4.6 Operation of shutting-down each valve of steam, water system for hot stand-by is as

following: 7.4.7 7.4.7.1 7.4.7.2 7.4.8 Open Reheater outlet steam exhaust valve, FSRUV001. Open cold Reheater main pipe drain valve FRSUV002. Keep all drain valve and Air damper of drum, Superheater and Reheater closed. Keep total air flow 30%MCR, after performing furnace purge for 10 mins, stop Primary air

fan, ID Fan, FD Fan. 7.4.9 7.4.10 7.4.11 Steam air preheater trip. Keep Drum high water level+100mm, completely close Feedwater motorized valve. If hot stand-by period, keep 2 Air Preheater, 1 flame scanner cooling air fan, 1 oil burner

cooling air fan, 2 boiler water circulation pump operation. 7.4.12 7.4.13 Keep lubrication system of tube mill long operation. After shut-down for 20 hour, open the following drain valve to drain 1 hour for superheater

system. Keep Air damper of Drum and superheater closed. 7.4.13.1 Open front wall enclosure drain valve FSR UV003 7.4.14 Open rear wall enclosure drain valve FSR UV005

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7.4.14.1 Open Main steam valve front drain valve FSR UV006 7.5 7.5.1 Emergency shut-down Emergency shut-down is quick shut-down to prevent from serious accidents or enlarging

accidents needed when serious faults of boiler or other main equipment occur. 7.5.2 Emergency adopts the MFT order which will cut off immediately all the fuels to the boiler

furnace (coal and fuel oil). 7.5.3 The sequent operation follows the operation after the boiler fire-off in hot stand-by

shut-down terms 7.6 7.6.1 7.6.1.1 Shut-down maintenance Maintenance in short shut-down of boiler (shut-down 3~4 days) : Maintenance in short shut-down of boiler (shut-down 3~4 days), for hot stand-by, Boiler can be started arbitrarily. 7.6.1.2 7.6.2 7.6.2.1 Treatment after shut-down refer to Boiler normal shut-down (hot stand-by). Maintenance in medium-period shut-down of boiler (shut-down 3~4 weeks) : After Boiler fire-off, immediately sub-control closing boiler main steam valve FSRUV04A, FSRUV04B. When shaft seal of turbine don't use steam, immediately close HP bypass. 7.6.2.2 Open reheater outlet steam exhaust valve FRSUV001, High temp. Reheater inlet, outlet Air damper: FRSHV006, HV007, HV014, HV008, HV009, and cold reheater main pipe drain valve FRSUV002. 7.6.2.3 Open Superheater drain valve: Open front wall enclosure drain valve FSRHV019, UV003. Open rear wall enclosure drain valve FSRHV020, UV005.Open main steam valve front drain valve FSRHV068, UV005. 7.6.2.4 7.6.2.5 Close continuous blowdown valve, each sampling valve, chemical feeding valve When Drum pressure3bar, open superheater air damper, When Air damper doest overflow steam, immediately close Air damper, drain is finished, close Each drain valve, and completely isolate hot seam pipe and of the atmosphere. 7.6.2.6 When reheater drain is finished, close reheater outlet atmospheric relief valve. Each Air damper of high temperature reheater inlet and outlet, and cold reheater main pipe drain valve completely isolate reheater steam pipe and the atmosphere.

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7.6.2.7

BOILER & AUXILIARIES OPERATION MANUAL

When boiler water temperature drops below 180 and drum water level is at about -290mm, inform chemical staff of adding N2H4 and NH3, keep boiler water circulation pump operation to keep N2H4200ppm, PH10. 5. in boiler water and keep drum water level+100mm.

7.6.2.8 7.6.2.9

When boiler water N2H450ppm, immediately add N2H4. When boiler water temperature120, boiler water circulation pump can be stopped.

7.6.2.10 Superheater system filling N process: 1 When 1bar, Superheater drain is finished, Boiler pressure drops to

open superheater filling N valve FSRHV031, and HV029, Open drum inner

layer filling N valve FSRHV007, and HV005. Notice, must fill N in the boiler cooling process. In the process of filling N keep Nitrogen pressure in the scope of 0. 1~0. 3bar to prevent air entering in to furnace. 2 When boiler water circulation pump is stopped, Open drum inter layer filling N valve :FSRHV045 and HV044to fill N to the furnace, and keep Nitrogen pressure 0. 10. 3bar. 7.6.2.11 Filling N Process of reheater system: 1 Check before reheater system filling N 2 In the cooling process of Boiler 3 Close HP bypass valve 4 Each valve of reheater water spray attemperating system closed tightly 5 LP bypass valve close 6 Close turbine HP cylinder steam steam exhaust and non-return high flap, air Medium pump

pressure cylinder

intake

valve,

#section

valve and isolation primary damper on pipe. 7 After cold Reheater main pipe drain is finished, close drain valve.

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW

Date: 2008-09-15

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BOILER & AUXILIARIES OPERATION MANUAL

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BOILER & AUXILIARIES OPERATION MANUAL

7.6.2.12 After reheater air exhaust is finished, close reheater outlet atmospheric relief valve and air damper at high temperature reheater inlet and outlet. 7.6.2.13 Open reheater filling N valve FRSHV012 and HV006, HV014 to fill reheater system N, keep Nitrogen pressure 0. 1~0. 3 bar, to prevent air entering in to reheater system. 7.6.3 7.6.3.1 Maintenance for boiler long shut-down(shut-down 4weeks~3 months):(wet) Maintenance pricinple: 1 Under normal conditions, after shut-down of boiler perform wet

maintenance for superheater system. Only the major or minor repair and repair on pressure parts occur, dry maintenance (hot boiler drain) shall be performed. 2 When unit are shut-down for more than 2 weeks, change from feedwater pressure maintenance ammonia or dry maintenance (hot boiler drain) to -hydrazine maintenance for superheater.

3 Reheater adopts filling N maintenance. 7.6.3.2 Maintenance method key points: Drain the ammonia remaining left water in Boiler. Fill the boiler superheater with

-hydrazine solution maintenance liquid. Prevent Air from entering. Perform filling N maintenance for reheater. 7.6.3.3 Superheater system maintenance operation method : 1 At cold status of boiler, open air damper, drain valve and water discharge valve of steam, water system. Drain the remaining water in feedwater system, water wall and superheater. When the remaining water in feedwater system, water wall and superheater is drained,(about 2hour ),close all drain manual or motorized valve and water discharge valve and intermittent blowdown manual valve and continuous blowdown manual valve (Open when perform chemical sampling) 2 Chemical staff maintenance makes the maintenance solution

maintenance chemicals box, When water level of feedwater box is highest after level which can be seen (2800mm). Open pump feed feedwater with chemical (chemical feed is switched to feedwater box) 3 After receiving the notice that chemical staff finishes feeding chemicals, open feedwater pump to circulation feed water 30 min, mix the chemicals and liquid.

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Date: 2008-09-15

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BOILER & AUXILIARIES OPERATION MANUAL

4 Chemical make the sampling analysis of feedwater that the concentration of maintenance liquid:N2H4200mg/l,PH 10~10. 5. 5 Open condensate water pump to fill water to boiler water circulation pump motor. 6 When filling water for boiler water circulation pump motor is

finished, open feedwater pump, make use of feedwater bypass to fill boiler to +100mm, run 3 boiler water circulation pump for 3 times, put #2boiler water circulation pump in service. At this time, stop filling water for boiler water circulation pump and stop filling Boiler. 7 Make system is finished. 8 Inform of chemical boiler water sampling analysis, water quality standard is: PH 10~10. 5, N2H4 50~200mg/l. 9 In high the period of maintenance, open when 1 Drum water level drop to use to of superheater secondary attemperator water

fill superheater acceptable maintenance solution, system top

pressure, When Drum pressure reach 0. 3Mpa, close all air damper, boiler filling

water level+500mm,

feedwater

pump.

Through

superheater

secondary attemperator fill water to boiler, top pressure. When

drum pressure reach 1 bar, stop fill water to boiler. 10 When maintenance solution in feedwater box is not enough, inform chemical

staff of making chemical, feed chemicals feed and water feedwater box. 7.6.3.4 Perform filling N maintenance of reheater system, Nitrogen pressure is kept at 0. 3~0. 5 bar and method is as following: 1 Check before reheater system filling N : a Boiler has been cooled. b HP, LP bypass has been closed. c Motorized B valve, control valve and manual valve of reheater A,

side attemperating water have been closed. turbine HP cylinder vent non-return flap and bypass

d Close

motorized valve ,mid pressure cylinder steam intake valve ,high temperature heater #7 section steam pump motorized valve and drain manual valve (AHP HV087), motorized motorized valve at cold valve at cold reheater to deaerator and

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW

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Date: 2008-09-15

BOILER & AUXILIARIES OPERATION MANUAL

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BOILER & AUXILIARIES OPERATION MANUAL reheater to auxiliary steam header,

e Open cold, hot reheater main pipe drain motorized valve (for steam exhaust). f Atmospheric relief valve at reheater outlet is closed.

g Each Nitrogen bottle at Nitrogen station is full filled with nitrogen. h Safety valve at Nitrogen station air supply main pipe has been

checked acceptable. 2 Filling N operation : a Micro-open air supply valve at each Nitrogen bottle of Nitrogen station. When the pressure before opening pressure governor valve at air supply main pipe reach 120bar~150bar, stop opening Nitrogen bottle. b Manually control pressure governor valve at Nitrogen station. Keep Nitrogen pressure after opening pressure governor valve at 5 bar. Fill Nitrogen pressure governor station with Nitrogen to exhaust air. c Close front ,rear manual valve pressure governor valve at pressure governor station. d Manually open pressure governor station bypass manual valve

and make valve outlet Nitrogen pressure 2 bar and reheater system filled N to exhaust air. e After 60min, manual close pressure governor station bypass manual valve. Reheater system filling N to exhaust air is finished. f Manually close bypass manual valve of pressure regulation station and close drain motorized valve of cold reheater and hot reheater main pipe. Purge reheater system and exhausting air is finished. g Open reheater system filling N valve FRS HV012, FRS HV006, FRS HV014. h Open front ,rear manual valve pressure governor valve at pressure governor station, manually clockwise control pressure governor valve to make pressure after opening pressure governor valve 0. 3 bar0. 5bar. i Reheater system filling N is finished. Record Nitrogen pressure of Nitrogen station and Nitrogen pressure governor station

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW

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7.6.3.5

BOILER & AUXILIARIES OPERATION MANUAL

Monitoring in the period of maintenance: 1 Each shift record boiler drum pressure, reheater Nitrogen pressure twice. 2 Every Monday separately open each boiler water circulation pump

once and each time is 30min. If circulation is finished, inform chemical staff of sampling and analyze concentration of maintenance solution. 3 In the period of maintenance, boiler water, open feedwater box sampling valve, and keep flow of 50~200ml/h. 7.6.4 Boiler heating with pressure drain maintenance method:( suitable for mid, long period

shut-down ) 7.6.4.1 When in the mid or long period of boiler shut-up boiler or after shut-up, pressure parts need long repair time and cant be performed wet measure. And when perform filling N maintenance, boiler can adopt heating boiler with pressure and drain. When Boiler water is drained out, make use of boiler remaining heat to dry instrument of pressure parts in boiler to reach the objective of maintenance. 7.6.4.2 Operation steps After boiler shut-down, when drum pressure is 10bar: 1 Stop boiler water circulation pump, inform electric staff cut off power. 2 Close boiler water circulation pump outlet valve and boiler water circulation pump is at isolation condition. 3 Open HP side air exhaust damper of boiler water circulation pump cooler. 4 Boiler drains. Each valve position in the system is listed in the following table : No. Valve Name Valve No FSR HV032 1 Economizer drain valve FSR HV033 FSR HV081 2 Continuous blowdown valve HV082 UV17 3 Drain valve at boiler water circulation FSR HV012 open close close close open Status open

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BOILER & AUXILIARIES OPERATION MANUAL pump Inlet header Water wall circumferential FSR HV060 FSR HV049 HV080 HV062 FSR HV071 HV084 FSR HV034 open open open open open open open

header drain valve

Intermittent blowdown valve FSR UV002 FSR HV068

Main steam valve inlet drain valve FSR UV06

5 If drain is finished, close all drain valve in above table. 6 When Drum pressure reach 3bar, open the following Each valve : 1 2 Economizer outlet air exhaust valve Drum inner-layer air damper Drum interlayer air damper 3 Drum interlayer air damper 4 5 Top outlet header air damper Low temp. superheater outlet FSR SV40 HV047 FSR HV063 HV064 FSR HV021 HV022 open open open FSR HV074 HV073 HV075 open

FSR HV005 HV006 HV008 HV009 open FSRHV044 HV046 open

air damper

Mid temp. superheatier outlet header FSRHV054 HV055 HV056 air damper High temp. superheater outlet header air damper High temp. reheater Inlet air damper FSR HV029 HV030 FSRHV014 HV006 HV007

open

7 8 9

open open open

Reheater outlet steam exhaust valve FSRHV013 UV001

7 When Boiler drain is finished for 2hour, Open each drain valve of steam side: No. Valve Name Valve No Status

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1 2 3

BOILER & AUXILIARIES OPERATION MANUAL Drain valve at roof Inlet header Front wall enclosure drain valve Rear wall enclosure drain valve Drain valve from low temp. temp. FSRHV023 HV024 HV035 FSRHV050 HV059 FSRHV019 UV003 FSRHV020 UV005 open open open open

superheater superheater

tomedium

5 6 a)

Main steam valve front drain valve

FSRHV068 UV006

open open

Low temp. reheater Inlet drain valve FSRHV015 UV002

When above air damper and drain valve is opened for 2hour, close all air damper and drain valve.

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7.6.5 7.6.5.1

BOILER & AUXILIARIES OPERATION MANUAL

Points for attention of Boiler maintenance: In the period of boiler maintenance, chemical staff shall assay boiler water quality acc. to regular, when N2H4 concentration 50ppm, it should be added to original content.

7.6.5.2

Before boiler is added hydrazine and ammonia (i.e. N2H4 and NH3), only keep 1 boiler water circulation pump in operation, other outlet of 2 boiler water circulation pump shall be closed.

7.6.5.3 7.6.5.4

Before boiler is filled N after cooling. After filling N maintenance, if entering in to drum to work is needed, perform air draft and then can enter into it.

7.6.5.5

Boiler adopts maintenance of adding Na3PO4. 12H2O(Na3P04)solution, before open boiler, must perform drain and rinsing work. Its drain method is as same as shut-down drain method.

8 8.1

Boiler auxiliary equipment Basic regular of auxiliary equipment operation Check before auxiliary equipment is put in service: Check work-sheet is finished, no staff works on the equipment. Full of light on site, clean ground, no debris obstructing operation. Equipment Appearance is in its integrity with heat good insulation. Each hole valve is strictly closed, connection with the system completely. Instrument is complete and direction is right.

8.1.1 8.1.1.1 8.1.1.2 8.1.1.3

8.1.1.4

Bearing Lubrication position is normal, oil quality is acceptable, and Lubrication system at good stand-by status. Grease is added per the regular.

8.1.1.5 8.1.1.6

Cooling water unobstructed, water flow is adequate and don't overflow. The Anchor Bolt is complete and firm. Motor wiring and earthling cable is good. Insulation is acceptable.

8.1.1.7 8.1.1.8

Shields are complete and integrated. The data on DCS of each air valve is consistent with the actual and transmission machine is complete.

8.1.1.9

Control circuit power, interlock, thermal control staff protection test is acceptable and is in service, automatic equipment is put in service or has the start condition.

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8.1.2 8.1.2.1

BOILER & AUXILIARIES OPERATION MANUAL

Auxiliary equipment open principle: Normal open 6KV equipment and 380V equipment. Specified staff stands at the position of accidents button to monitor it on site. If any problem is found, immediately put accident button stop operation.

8.1.2.2

The equipments with the same trunk cant be operated at the same time before opening 2,6 KV equipment inform the electric operation staff. Without permission, it cant be opened.

8.1.2.3

In normal condition, squirrel-cage Motor at cold status can be allowed opened twice. Each interval will not be lower than 5min. At hot status can be allowed opened only once. Only when there is accident treatment and opening time is not more than 23 mins, motor can be opened once more. Otherwise, it can be opened after 30min (iron core temperature is hot status when it is above 50, below 50 it is cold status).

8.1.2.4 8.1.2.5

Strictly prohibit opening with load. When open auxiliary equipment pay attention to its the executing condition of opening procedure, current returning time, current indicator and other Parameter of equipment. Pay attention to the display on monitor CRT equipment status is correct.

8.1.2.6

After open equipment local check equipment in good operation, without any abnormal sound, vibration,, friction and percussive sounds.

8.1.3 8.1.3.1 8.1.3.2

General rule for

Auxiliary equipment operation maintenance:

Cooling water is adequate and lubricating system is normal. Equipment operation is stable without any abnormal noise and abnormal friction and impact sound. Each parts and inlet or outlet pipes are complete and not loose, non-swing and etc.

8.1.3.3

Operation of Each valve, air valve and primary dampers flexible, action is normal and position direction is correct.

8.1.3.4

Each thermodynamic, electric instrument for measure and display is normal. Thermodynamic, electric protection and relevant automatic control is put in service and is normal.

8.1.3.5

Control the following parameters according to manufacturers requirement. If there is no requirement, control according to the following requirement: 1 Rolling bearing temperature80,sliding bearing temperature65.

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2 The shell temp. of gear gearbox 60. 3 Opening Motor shell temperature65,enclosed motor shell humidity 80. 4 Rolling equipment axial shaft displacement is 2~4mm. Sliding equipment axial shaft displacement is 0. 5mm: 5 Vibration value: Rotation speed(r/min) Vibration value(mm) 3000 1500 1000 750

0. 05

0. 085

0. 10

0. 12

6 When any of the following conditions occurs, emergently stop auxiliary equipment operation : a Bearing temperature abnormal rises or exceeds the regular. b When strong vibration on the equipment or axial shaft displacement or the danger which may damage equipment occurs. c Motor or cable smokes and fires. d The obvious sound of metal friction in the inner of equipment can be clearly heard. e Other faults which endangers safety of person and equipment. 8.1.4 8.1.4.1 General rules for rotation equipment fault and treatment When any of the following conditions occurs, emergently stop operation of rotation equipment : 1 Equipment has strong vibration. 2 The obvious sound of metal friction in the inner of equipment can be clearly heard. 3 Motor or cable smokes and fires. 4 Bearing smokes and fires or sliding bearing temperature exceeds 80, rolling bearing temperature exceeds 100. 5 Equipment leaking endangers safety of person and equipment.

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8.1.4.2 fault pump (air fan ):

BOILER & AUXILIARIES OPERATION MANUAL

When any of the following conditions occurs, firstly open stand-by pump (air fan ),stop

1 Gland heats, smokes or with overflowing water, oil leaking, and adjustment is not efficient. 2 Sliding bearing temperature reaches 65,rolling bearing temperature reaches 80 and with rising trend. 3 Motor shell temperature rises to 70,and continues rising. 4 Motor Current exceeds rating value. 5 Motor cable is serious overheating. The insulation exude a smell of burning 8.1.4.3 Treatment for operation pump (air fan) trip: 1 Confirm operation pump (air fan) trip and stand-by pump (air fan ) shunt good. Reset gang pump (air fan )switch. If stand-by pump (air fan )is not gang ,manual open it. 2 Cut off trip pump (air fan )operation switch. 3 check each section of gang pump (air fan ) normal, check the reason for trip of trip pump (air fan )and solve it for stand-by. 4 If opening stand-by pump (air fan )dont take effect, immediately check for the cause. For the 380V motor ,start trip pump (air fan )again once more . Confirm 6KV power equipment should be checked no obvious fault ,it can be switched on again.

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8.1.4.4

BOILER & AUXILIARIES OPERATION MANUAL

For important plant service auxiliary equipment, besides the faults which endangers safety of person and equipment must be immediately stopped. Usually open the stand-by auxiliary equipment and then stop fault auxiliary equipment.

8.2 8.2.1

Motor operation Motor can be operated at the temperature of rated cooling air according to the specified

data on manufacturers name plate. 8.2.2 The highest monitoring temperature of motor coil and iron core shall not be exceeded

in any case according to manufacturers regulation. If manufacturer has no regulation, the highest temperature of the motor coil and iron core cant exceed 105 and the rise of temperature cant exceeds 65. 8.2.3 Motor can be operated in the scope of 95%~110% of rated voltage, and its rated output is

constant(5. 76. 6 KV, 360420V). In the period of rated output operation the unbalanced value of voltage between phases cant exceeds 5. In the period of operation at unbalanced voltage pay attention to over-hot and vibration of the motor. 8.2.4 In normal operation , motor current shall not exceed 5 of rated value. If it exceeds

5 to 10 , in 15 min shift supervisor cant decrease the current to rated current. If it is caused by the accidents of main motor, the above rule neednt to be followed. 8.2.5 Temperature of motor bearing is controlled according to the following standard (If the

manufacturer has its own requirement, perform according to manufacturers regulation): 8.2.5.1 8.2.5.2 8.2.6 Sliding bearing :cant exceeds 80(Temperature rises by 40). Rolling bearing :cant exceeds 100(Temperature rises by 60). Daily check work, maintenance for motor and the detailed requirement of opening and

stopping operation refer to specific terms in electric operation manual. 8.3 8.3.1 8.3.1.1 Start-up, stop and operational maintenance of auxiliary equipment and system High voltage bypass Check-up before the start-up of high voltage bypass.

1) Make sure that every pipeline is perfectly connected with facilities, valves complete, and test and adjustment fully completed and that movement is flexible and reliable as well. 2) Make normal sure that the functioning of the hydraulic pressure station is

without leakage.

3) Thermal meter and controlling system should be put into use

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4) Open the hand-operated valve of attemperating water HV002. 8.3.1.2 1) 2) 3) Start-up of high voltage bypass Make sure that the hydraulic pressure station is normally functioning. Put into use the high voltage bypass on DCS. Turn on the pressure-reducing valve controller of the high voltage bypass to 20% by hand. 4) Set main steam pressure and steam pressure lower limit (the stream pressure is set at 60 bar). 5) Set steam temperature of the high voltage bypass outlet at 320, press the automatic button on the attemperating water regulating valve controller of high voltage bypass. 6) Send out the start-up order, the red indicator light at the HSN001 operation station will soon be brightened. 7) Operate automatic on the pressure-reducing valve of the high voltage bypass, the high voltage bypass thus enters into operation with a minimum opening of 40% and the minimum opening indicator light is on. 8) When the steam pressure of the boiler outlet is below the minimum fixed value (60bar) on starting up, set the regulating valve of the high voltage at start-up opening fixed value (40%). 9) When steam pressure reaches the minimum start-up pressure (60 bar), the minimum opening indicator light is off, while the minimum pressure indicator light is on, ensuring the high voltage bypass is controlled in a state of minimum pressure. 10) Maintain the minimum pressure of start-up when the pressure-reducing valve of the high voltage bypass gradually opens as the burning is intensified. 11) When the the high-pressure cylinder switch signal has been sent out,

minimum pressure indicator light is off, while slip pressure indicator is on,

bringing the system into an operational state. 12) Close the high voltage valve as turbine valve gradually opens to maintain the fixed pressure values, and during this process, the PI controller will set the changing gradients at the fixed value of 4 bar/min.

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13)

BOILER & AUXILIARIES OPERATION MANUAL

As the turbine load increases, the high voltage valve will be narrowed till it is fully closed when the slip pressure indicator light is off while the normal functioning indicator light is on

14)

After that, the high voltage pressure-reducing valve will automatically regulate rate of pressure rise of the boiler.

8.3.1.3 1) Items Steam

Functional maintenance and parameter High voltage bypass parameters Unit temperature of Data 540+5

the high voltage bypass inlet Pressure of the high voltage bypass inlet Pressure of the high voltage bypass outlet Steam temperature of

bar

184

bar

44

the high voltage bypass outlet Flow of high voltage bypass Pressure of

T/H bar of

337+5(>360alarming) 760 210

attemperating water Temperature attemperating water The start-up controlling time of the high voltage bypass Swift-opening time of

257

12

the high voltage bypass Opening attemperating valve time of

water stop

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Full-opening attemperating regulating valve 2) time of water S

BOILER & AUXILIARIES OPERATION MANUAL

Conditions for swift opening of pressure reducing valve of the system a) Reach safety P (adjust safety valve to influence load) b) Reach Pmax safety (adjust safety valve) c) When turbine is running (high voltage main body of turbine opens), auxiliary power operates, or else steam turbine will trip, forecasting the full close down of high voltage main body. d) Operator can open it by hand (press any button), and under any circumstances, it can be swifted from the manual-controlled model to the automatic model when the high voltage valve is opened. It is also suitable for desuperheat-regulating ductwork.

8.3.1.4 1)

Operation of high voltage bypass in the stoppage process of the unit When the set pauses in the phase of slide pressure, lower the main steam pressure setting and ensure high voltage maintains set pressure for regulating.

2)

When the set enters into the phase of fixing pressure to reduce load, as the regulating valve of the steam machine gradually narrows, the pressure-reducing valve is opened, maintaining the fixed pressure.

3)

Hydraulic pressure station keeps on operating after the boiler stops working to ensure that the pressure-reducing valve remains in a closed state.

8.3.1.5 1)

Faults and countermeasures of high voltage bypass Causes: a) Failure of hydraulic pressure station b) Failure of 380V power supply and tripping of hydraulic pressure oil pump c) Failure of 48V DC power

2)

State

Automatic closing and locking of FCV58, UV59 and TCV59 3) Countermeasures

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Find out the causes and have faults removed immediately 8.3.2 8.3.2.1 1) Air preheater Check-up before the start-up of air preheater Make sure that there are no people working and no foreign bodies in the air preheaterhas no, and that man holes are fully closed when the maintenance of work ticket is finished, and that the surrounding of the air preheater has no sundries. 2) Make sure that the smoke and air flues are well connected and that the executive mechanism of sealing device is in a high position. 3) 4) Make sure that executive mechanisms UV03 and UV04 have sent off electricity. Make sure that the speed reducer has been injected with qualified oil, and that hydraulic couplers has also been oiled without leakage. 5) Make sure that soot-blower is placed in the outlet and that the soot-blowing and steam pipelines are connected. 6) Make sure that smoke, air pressure, and temperature and fire-measuring devices and local control switch as well, are in good condition. 7) Fire protection and check-up of cleaning system: a) Make sure that pipes are fully connected and equipment complete. b) Close fire protection and fire-extinguishing nozzle manual valveHV001 and HV007, close fire-fighting water-cleaning manual inlet valveHV002 and cleaner manual valve as well. c) Open fire protection hose leak-hunting valveHV003, HV005 to ensure they have no water, and prove that HV001, HV007, HV002 and HV004 are sealed. d) Close washing water preparation station hand-operated valveHV008 8) 9) 10) Make sure that position detector and revolution detector have be switched on. Make sure that main motor, low-speed motor and oil pump motor have been switched on Make sure that smoke and gas inlet baffle UV01D, UV01C, heat primary air outlet baffle UV01B and servo motor heat secondary air outlet baffle UV01A have sent off electricity and is in the closed state.

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11)

BOILER & AUXILIARIES OPERATION MANUAL

Put in bearing oil system and cooling water a) Open force-bearing bearing oil-receiving valveHV022 and oil removing valveHV024. b) Open the cooling water-receiving valveHV020 and removing-valveHV021 of the oil cooler to make sure that the cooling water flows smoothly. c) Open the cooling water the guiding bearing oil cooler. receiving-valveHV010 and removing-valveHV011 of

12)

Check-up of oil system and duplex strainer a) Make sure that the filter is complete and that duplex three-way valve HV012 (HV023) is normally placed and is flexible in switch, and that differential pressure gauge indication is correct. b) Use single control on the DCS to launch bearing lubricating oil pump, check the pressure difference of duplex filter. c) Examine the oil system to make sure has no there is no oil leakage and see to it that the safety valve of pipe is in the re-seating state without leakage. d) Stop the oil pump when the check-up is done

13)

Locally try low-speed motor and examine the following items in initial start-up after the maintenance a) Make sure that the moving direction of air preheater is right b) It should be free of blockage and noises, and is flexible in turning c) Make sure that speed reducer sounds normally and hydraulic couplers have no oil leakage. d) If something abnormal is detected in the trial, the trial can not be resumed until errors have been removed

8.3.2.2 1)

Operation of air preheater Start-up of sub group level a) Make sure that the check-up before start-up is done b) Operate the manipulation (HSN001) on the DCS to issue start-up order

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c)

BOILER & AUXILIARIES OPERATION MANUAL

Low-speed motor should be tripped if it is in the process of operating, and when it stops validating, main motor will start working with green light off and red light on.

d) Force-bearing and guiding bearing oil pump enter into linkage back-up uses e) Smoke and gas inlet baffle and heat secondary air outlet baffle automatically open f) Heat primary air baffle (UV01B) remains closed until corresponding primary blower starts g) When the air preheater is operating at a low speed, the low speed motor will automatically stop when the subgroup starts, and main motor also starts, which, if 20mins after start-up, still can not reach normal speed will automatically stop, while low speed motor automatically restart. h) Should the above problems are met (1.2.4), resume the subgroup. If it also does not work, resume until errors have all been removed. 2) Single control start-up a) Confirmation of check-up before start-up b) Use the single control start-up order on the DCS and make sure air preheater starts operating c) 3) Locally open smoke and gas inlet baffle and heat secondary air baffle

Local start-up a) Start-up check-up confirmation b) Set the remote or local button to be local c) Press the start-up button locally, make sure that air preheater starts slowly and operates normally d) Open the smoke and gas inlet baffle and heat secondary air outlet baffle when necessary.

4)

Maintenance and surveillance of air preheater in operation a) Put air preheating sealing devices into operation after boiler gets ignited, (when driven by the main motor), and operate HSN005 by using single control.

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BOILER & AUXILIARIES OPERATION MANUAL

b) The right place of sector board is decided by function generator based on load. c) Position fixed value is invariable when load is low (below 40%), it becomes variable when the load is between 40% and 100%, and position limit (above and below) can solely be adjusted by 4 fanning strips. d) Prevent the device from being clamped as there is an order of automatic receding every 24 hours. e) Operator can issue receding order either by operating HSN005 on the DCS, or by pressing button local. f) Regularly check up the air preheater to guarantee that it has no noises in operation and its gearing is normal. g) Make sure that the force-bearing and guiding bearing system is normal without leakage and that the temperature of oil is at a normal level. h) Make sure the smooth circulating of cooling water and normal

temperature i)

of backwater.

After the air preheater has been charged (at a normal or lower speed), when the temperature of bearing increases to over 60, oil pump will automatically start up, and 50 it automatically stop when the temperature return to (FRA/B,

TSH15,TSH25). Still, check the air duct to guarantee that it is without air leakage when the oil temperature of guiding bearing increases, if the problem exists, notify repair workers to work on it in time. j) Report to chief and shift chief-operator immediately should there be serious leakage of bearing lubricating oil and cooling water in operation. k) In operation, rationalize burning to avoid a second time burning, strictly supervise the temperature regularly of air preheater for smoke example, and the gas job of in and out, and should do soot-blowing, soot-blowing

be reinforced as the pressure difference between air preheating smoke in and out increase. l) During operation, strictly supervise the air preheater outlet and inlet and primary and secondary air temperature. If any abnormal is detected, take measures immediately. m) Normal functioning

n) Air preheater soot-blowing

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o) Use the flame measure the temperature difference between air temperature of air preheater outlet and that of heat-up component outlet. When it exceeds 50, the controlling room should give off warning signal. 8.3.2.3 1) Halt of air preheater Do not halt the operation of air preheater until the smoke temperature in outlet is at a degree of more than 175 after stopping burning. 2) Stop operation, give subgroup stop order(HSN001) through DCS. a) Main motor ceases to run b) Force-bearing and guiding bearing oil pump automatically stops. c) Heat secondary air outlet baffle automatically closes

d) Smoke and gas inlet baffle automatically close e) If heat alternative stops burning, yet air preheater keeps on functioning, normal check-up maintenance should be done f) If there be repair work after the burning of boiler, cut off main motor and low-speed motor power 8.3.3 8.3.3.1 1) 2) 3) 4) 5) 6) 7) 8.3.3.2 1) Induced fan Check-up before the start-up of induced fan Check the basic principles and rules for basic check-ups Adjustable baffle can give electricity and normally switch Inlet and outlet baffles can give electricity and completely open and close as well Motor has delivered power Local button is sound Every circuit measuring and protective devices are checked out and put into use Requirements for start-up of themal regulator are met Start-up of induced fan Conditions for start-up

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a) b) c) d) e) f) g)

BOILER & AUXILIARIES OPERATION MANUAL

Air preheater on the corresponding side is operating. Vibration of air fan is slight. At least inlet and outlet baffles of one force fan are openned. Corresponding inlet vane is closed. Corresponding outlet truncated baffle is closed. Every oil gun air baffle is opened. Open A, B and C secondary air regulating baffle and tertiary air regulating baffle as well.

2)

Sequential control start-up a) Using DCS, send out induced fan subgroup control start-up order, with the green light off and red light on. b) After conditions for start-up are met, confirm and complete requirements asked of induced and force fan and inlet and outlet baffles as well. c) Outlet baffle automatically opens 30 seconds later, and inlet adjustable baffle is automatic. d) When the induced fan on the other side is not running, its outlet baffle automatically closes. e) When the induced fan on the other side has began functioning, start

the second induced fan, when the motor is started , it will automatically open the outlet baffle, the inlet adjustable baffle of these two induced fans should be adjusted correspondingly, and automatic should be put in. 3) Start-up by hand a) b) c) Set manual on inlet adjustable baffle Make sure that requirements for start-up are met Using DCS, send out induced fan single control start-up order and make sure that the induced fan starts normally. d) Open outlet baffle

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e) f)

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Set inlet adjustable baffle to be automatic. When the induced fan on the other side is not operating, close its inlet and outlet baffle.

g)

If the induced fan on the other side has began operating, open the outlet baffle by hand when the motor is started, and put in automatic when the opening of these two inlet adjustable baffles are adjusted consistently.

8.3.3.3 1) 2) 3) 4)

Maintenance and surveillance Regularly check the induced fan Make sure that bearing oil level is at a normal level and is good in quality. Make sure that transmission gear is complete and functions normally. Examine the temperatures of induced fan bearing, motor and bearing, vibration should be normal and be in line with BTG operational inspection value.

5) 6)

Vibration of the air fan should be less than 120m When bearing temperature reach 90, warning signal should be given off, and when it reaches over 105, operation should be stopped.

7)

When motor bearing temperature reaches 90, a warning signal should be given off, and when it reaches over 105, operation should be stopped.

8)

When of coil temperature reach 100, a warning signal should be given off, and when it reaches more than 120, operation should be stopped.

9) 8.3.3.4 1)

Current of motor should be less than rated current Out-of-operation of induced fan Sequential control stops a) b) c) d) Outlet baffle is automatic Force fan on the corresponding side has stopped running Use DCS to issue stop order This induced fan stops operating with red light off and green light on. The current is zero

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e)

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When the induced fan on the other side is running, outlet adjustable baffle and inlet baffle of the former fan automatically close.

f) g)

Stop of the last induced fan: Corresponding force fan and primary fan have stopped operating, and the inlet and outlet baffles of a force fan automatically start.

h) i) j) 2)

Use sequential control to stop the last induced fan Outlet baffle of the two induced fan close 15mins after it automatically opens Set the inlet adjustable baffle to be manual, and make it zero.

Manual operation suspension a) b) c) d) e) f) Stop the corresponding force fan Set the inlet adjustable baffle of the suspended fan to be manual. Gradually narrow the inlet adjustable baffle and take care to keep the draft of hearth. Manually execute the stop order and wait for the stop of the induced fan. Close outlet and inlet baffles. When stopping the last induced fan, open the outlet and inlet baffles of these two induced fan, and appropriately open the inlet adjustable baffle according to the draft of hearth, and what is more, close all baffles 15mins after draught.

8.3.4 8.3.4.1 1) 2) 3) 8.3.4.2 1) 2)

8.3.4 Force fan Conditions for start-up Corresponding air preheater is running Corresponding induced fan is running Its inlet and outlet baffles should be closed Sequential control start-up Make sure that the inlet baffle of the induced fan is set automatic Make sure that the cooling air balanced baffle in the force fan which waits for start-up is closed.

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3) 4)

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Open the outlet and inlet baffles of another force fan. After issuing the start order for waiting force fan on the DCS, confirm and complete all conditions for start-up.

5) 6)

The force fan then slowly starts, with green light off and red light on. 30 seconds later, inlet baffle will automatically open, manually open inlet adjustable baffle to 10% (the inlet adjustable baffle can be directly set automatic).

7) 8) 9)

Cooling air balanced baffle automatically opens. When another force fan is not running, its outlet baffle automatically closes. If the force fan on the other side is already running, outlet and cooling air balanced baffles will automatically open 30 seconds after the second force fan low-speed motor gets started. Manually adjust the opening of the two force fan inlet adjustable baffles and make them consistent. The opening degree is decided by total load demand multiply 30%, and the inlet adjustable baffle of the force fan can be set automatic.

8.3.4.3 1) 2) 3) 4) 5) 6) 7) 8) 9) 10)

Manual start-up Set inlet manual adjustable baffle of the start-waiting force fan to be manual. Open the inlet and outlet baffles of another force fan on the other side. Close cooling air balanced baffle on the waiting side that wait for opening. Operate single control start order. Force fan now starts slowly. Open the outlet baffle 30 seconds later. Open the side cooling fan balanced baffle. If the force fan on the other side is not running, make sure that its inlet baffle is closed. Gradually open the inlet adjustable baffle, and set automatic. If the force fan on the other side is running, start the second force fan, and 30mins later, manually open the outlet baffle and cooling balanced baffle, also, adjust the inlet baffle of the two force fans to be consistent and set automatic.

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8.3.4.4 1)

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Maintenance and surveillance When the force fan is running at a high speed, its current should be less than the rated current.

2) 3) 4) 5) 6) 7) 8.3.4.5 1) 2) 3) 4) 5) 6)

When the hearth blows, the amount of air should be between 25%MCR and 40%MCR. Amount of air/that of burning should be more than 9kg/kg Vibrating should be less than 120m Temperature of bearing should be more than 90 (warning) Temperature of motor bearing should be more than 90(warning) Temperature of coil should be more than 100(warning) Operation suspension of force fan Set the inlet adjustable baffle to be automatic Using DCS, issue the stop order. When the force fan stops running, green light turns on while red light goes out. Automatically close the inlet and outlet baffle if the force fan on the other side is running. Automatically close cooling balanced baffle. Outlet baffle will automatically open after the two force fans have stopped operating, and it will automatically switched to manual. close 15mins later when inlet adjustable baffle is

Single control operation suspension of force fan 1) 2) 3) 4) 5) Manually narrow the inlet adjustable baffle until it reaches zero By solely executing the stop order, stop the running of force fan. If another force fan is running, make sure that the outlet baffle of the former one is closed. Close the suspended side cooling balanced baffle. After these two force fans stop operating through the single control order, using DCS, manually open their inlet baffles and have them closed 15mins later.

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8.3.5 8.3.5.1 1) 2) 3) 4) Primary air fan Conditions for start-up

BOILER & AUXILIARIES OPERATION MANUAL

Air preheater on the corresponding side should be in operation Induced fan on the corresponding side should be in operation. Inlet and outlet baffles of start-waiting primary air fan should be closed. Heat primary air valve of the air preheater outlet on the corresponding side should be closed.

5) 8.3.5.2 1)

Vibrating of air fan on the start-waiting side should be slight Start up of subgroup control After making sure that conditions for start-up are met, using DCS, issue the subgroup control order.

2) 3)

Primary air fan starts running with green light off and red light on. 1min after the primary air fan starts, its outlet baffle will automatically open, so will heat primary air valve of the air preheater.

4)

Gradually open inlet adjustable baffle and set primary air pressure and inlet baffle to be automatic.

5)

After the second primary air fan starts operating, using hand, adjust the opening of 2 inlet adjustable baffle to be consistent and set them to be automatic.

8.3.5.3 1) 2) 3) 4) 5)

Start-up of single control Make sure that conditions for start-up are met Set the inlet adjustable baffle to be automatic Through single control, execute the start order This primary air fan then starts operating, with red light on and green light off. 1min later, open the inlet baffle plate by hand

Gradually open inlet adjustable baffle plate and set it to be automatic.

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8.3.5.4 1)

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Maintenance and surveillance Normal level of primary air pressure should be at 38mbar, when it drops to 30mbar or less, sound the alarm

2)

Give 10 seconds for coal pulverizer to trip when the primary air pressure reaches 24mbar or less

3) 4) 5) 6) 7) 8.3.5.5 1)

Current of air fan should be less than 59A Vibration of air fan should be less than 80m When the temperature of bearing reach 85, a warning sign should be given off When temperature of motor bearing reach 90, a warning sign should be given off When temperature of coil reaches 100, a warning sign should be given off Out-of-operation of primary air fan Subgroup control suspended operation a) b) c) d) Issue primary air fan subgroup control stop order through DCS Make sure that the air fan stops operating Inlet adjustable baffle automatically turn to zero Outlet baffle automatically close and heat primary air will automatically shut down baffle

2)

Single control operation suspension a) b) c) d) e) Gradually close the inlet adjustable baffle by hand until it reaches zero Execute stop order Make sure that the air fan stops operating Close the inlet baffle by hand Make sure heat primary air baffle automatically close

8.3.6 8.3.6.1 1)

Pulverizing system Check-up before start-up Start and check rotating machine (refer to basic requirements)

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2)

BOILER & AUXILIARIES OPERATION MANUAL

Make sure that pipelines of the system are air proof, free of power leakage and power accumulation and that they have no fire threat

3) 4) 5)

Make sure that blast-proof valve of the system is complete Make sure that all air lock HV005,012,022 are flexible in movement and strictly closed Make sure that all thermal signal of control panel and control device are sound and useable

6) 7) 8)

Safety interlock security test is up to standard Fire-fighting equipment is complete Check the lubricating oil system a) Oil level of oil tank is normal, when it reach over 450 litre, its height should be 2/3 that of the original. b) Temperature of oil tank is at a normal degree c) Quality of oil should be fine

d) Oil quality of reducer should be fine and oil level should be at 1/2 height of the original e) Strainer of main oil system and reducer oil system should be clean and flexible in swift f) Connection of system piping should be sound and free of oil and water leakage

g) All valves are rightly placed. 8.3.6.2 1) Operate all coolers Operate low pressure oil pipe oil cooler: a) Open cooling water outlet and water inlet valve of cooler, close the bypass valve b) Make sure there is a cooling water flow (20m3 /h). c) Put in main reducer cooler water outlet of oil cooler and front and rear doors of

d) Open cooling

temperature-controlling valve (bypass valves closed), and open water inlet valve

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e) Make sure that there is a flow of cooling water 2) Put into use the main motor cooler of ball mill a) Open cooling water outlet valve of water cooler and water inlet valve, cooling water outlet valve of main motor bearing and water inlet valve as well. b) Make sure that the cooling water flow is right 8.3.6.3 1) Check-up of powder-manufacturing equipment Ensure that coal feeder has no sundries, scraper chain is complete,

pulverized coal discharging pipes are smooth, all inspection holes are closed, and coal level of raw coal bunker is sufficient. 2) Gear wheel seal cover of ball mill should be sealed and seal fan 008ZV is reliable and acts as back up. 3) Air drive guide baffles of cyclone separator UV10, UV20 can rightly operate and are reliable in action. 4) Exterior of feeder is complete, interior strict without accumulated powder and mechanical parts test normally. 5) The that 6) 7) inspection of of pulverized coal discharging machine is the same as

the pulverized coal conveyer.

Pulverized coal bunker is closed tightly, pulverized coal level measuring device is correct. All valves of the system should be in the following positions: a) Motor-operated main valves for adding steel ball are closed. b) Motor-operated sub-valves for adding steel ball are closed. c) Pulverized coal discharging plugboard and hot smoke hand-operated valve of the coal feeder are open and the air-operated valve is closed. d) Air cooling valves are closed. e) Hot air regulating valve is closed. f) Hot smoke bypass valve of ball mill is in a state of opening of commissioning.

g) Air-operated guide baffle of cyclone separator is directed to the pulverized coal

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bunker.

BOILER & AUXILIARIES OPERATION MANUAL

h) Air-operated plugboard UV06 between pulverized coal conveyer and pulverized coal bunker is closed. i) j) k) Pulverized coal-discharging valve of bunker is closed Outlet of cyclone separator is closed Inlet valve of coal pulverizer exhauster is closed, recycled air valve in the outlet is in the state of opening of commissioning, air fan bearing cooling outlet is closed and inlet thereof opened. l) m) Exhaust air fan inlet regulating baffle is closed and outlet valve is closed. Exhaust air pipe cooling air valves are opened

n) Moisture-absorbing pipe valves of coal bunker are opened, and moisture-absorbing pipe communicating valves are opened as well. o) Controlling power and utility power of various rotating machines are reliable. 8.3.6.4 1) Operation of coal pulverizing system Get lubricating oil system started a) Controlling Power and utility power are prepared, and lubricating oil system is in normal condition. b) Group control start-up (on DCS): execute group control order, lubricating oil system group control procedures automatically go on 1) Main speed reducer oil pump is got started. 2) When oil temperature of main oil tank is not more than 35, low pressure oil pump will start operating. 3) When oil temperature reaches 10 or more, low pressure oil pump get started 4) When oil temperature reaches 35 or more, top tiles and jacking oil pump get started c) Single control start-up 1) Get it started in sequence on DCS.

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2) Start-up conditions, procedure and group control start-up. d) Local surveillance of lubricating oil system start-up: Speed-reducing oil pump starts normally, and the oil flow is not less than 60 litre every second. Low pressure oil bump starts normally, and oil pipelines have no vibration and leakage. Bush oil-pumping pressure gauge should be more than 0.2bar, oil-pumping flow (meter) more than 30 litre per second, and jacking oil pump inlet oil pressure (meter) 1.6bar or so. Jacking oil pump starts normally, oil outlet pipelines have no leakage and top bad oil pressure is somewhere between 25bar and 50bar. Jacking oil pump starts normally, oil outlet pipeline have no leakage, and jacking pressure is somewhere between 35bar and 60bar 2) Setting value of lubricating oil system and their relations

Main oil tank: a) When oil level is low (less than 450 litre), low pressure oil pump will trip, so will high pressure oil pump and coal pulverizer chain b) When oil temperature is less than 10, low pressure oil pump will trip c) When oil temperature is less than 35, jacking (oil) pump will trip

d) When oil temperature is less than 35, electric heater will automatically put into action When oil temperature reaches more than 40, electric heater will automatically stop. Low pressure oil pump exporting oil temperature is 8bar, when it reaches 12bar or more, safety valve should be in place Oil temperature after cooler is 45, temperature control valve will automatically regulate When pressure difference of filter reaches 1.5bar or more, a warning signal should be given off

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When temperature of low pressure pipelines reach 60 or more, coal pulverizer will trip When bush oil flow of coal pulverizer is less than 30L per second, the sub-coal pulverizer will trip. When the oil pressure of oil pump inlet of top pad and jacking is 1.6 bar, the constant pressure valve will automatically adjust; when the oil pressure is equal to or more than 1.8 bar, the safety valve will trip while PSL111 coal mill trips and the oil pumps of top pad and jacking trip when the oil pressure is 0.2 bar. When oil pressure of jacking pump reaches 60bar or more, safety valve trips. When oil pressure of jacking pump reaches 110bar or more, safety valve trips. When oil temperature of jacking pump is too low, say 15bar, jacking oil pump will trip (coal pulverizer trips) When oil temperature of jacking is too low, say 30bar, jacking oil pump and coal pulverizer will trip When oil temperature of speed reducer reaches 65 or more, a warning signal should be given off 1) 2) Pressure difference of filter is too high, the alarm is given. Oil flow is too low, say 60 litre per min, oil pump of speed reducer and coal pulverizer will trip Big gear fueling injection equipment: big gear fueling injection air atomizing pressure is less than PSL201, 4bar, send off warning signal Stop the operation of lubricating oil system in case of the following situations Lubricating oil system needs repair Lubricating oil system lose great amount of oil and stop operating because of accidents 3) Subgroup control start-up of coal pulverizing system

Requirements for start-up a) b) Remote and local button of its transmission should be set at remote Lubricating oil system functions normally

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c) d)

BOILER & AUXILIARIES OPERATION MANUAL

Its transmission has no vibration and high alarm When temperature of bush coal mill is less than 70, it is at a normal level, as is motor bearing when its temperature is less than 90.

e)

Boiler safety protection device should be set MFT resetting, and control and drive power of all equipment belonging to the coal pulverizing system should be reliable

f) g)

Flow of steam should be more than 270T/H. Inlet adjustable baffles of both air-lack air fan and coal pulverizer exhauster should be fully closed.

h) i) j) k)

Temperature of coal pulverizer inlet should be less than 128. Gigger braking device loose. At least one of adding steel motor -driven main valve and sub valve should be closed. Thermal signal should be correct, and noise-measuring device of coal pulverizer should be put into use

l) m)

Revolution local controlling tank switch of coal feeder should be set on Star-up preparation on the DCS

Exhaust air quantity should be set between 30000 Nm3 /h and 40000Nm3 /h Temperature of coal pulverizer outlet should be set at 115 Inlet adjustable baffles of air-lack air fan, hot air and cool air should be set automatic, rev of coal supply should be set zero and automatic Start-waiting coal pulverizing system will be repositioned Start the exhaust air circuit (on DCS) a) Execute subgroup control order 1) Start the exhaust air fan 2) Cooling air baffle of exhaust air fan inlet will be closed while its outlet baffle will be opened 30 seconds after it gets started b) Inlet adjustable baffle be set automatic, fixed value of exhaust air quantity should be set

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Start mill-exhausting circuit

BOILER & AUXILIARIES OPERATION MANUAL

Execute subgroup control start-up order 1) Mill exhauster gets started 2) Inlet baffle UV02 will open 30 seconds after mill exhauster gets started Start hot smoke circuit Execute subgroup control HSN007 start-up order 1) Get hot smoke air-drive truncated baffle UV05 started 2) Inlet adjustable baffle of exhaust air fan automatically open, adjust the fixed value of exhaust air quantity 3) Adjustable baffle of hot air and cool air automatically adjust, temperature of controlling coal pulverizer outlet gradually increase until it reaches its fixed value 4) Draft of coal pulverizer outlet and mill exhauster inlet then gradually increase Start the coal pulverizer Execute the sub group start-up order when temperature of coal pulverizer inlet reaches more than 90 1) Start auxiliary motor, have ball mill slowly operate, and 2mins later, unplug the auxiliary motor and plug the main motor 2) Get big gear seal fan started 3) Put big gear oil blooming system into use If seal fan does not operate, coal pulverizer (main motor) will trip To restart coal pulverizer, use single control seal fan(on the DCS) when it is normal Start coal feeder Execute subgroup control start-up order 1) Local controlling tank is electrified 5 seconds after it gets started 2) Speed-controlling device of coal feeder will be put into a automatical control state 5 seconds after coal feeder and controlling tank are electrified.

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BOILER & AUXILIARIES OPERATION MANUAL

3) After the coal pulverizing system gets started, see to it that temperature of coal pulverizer inlet slowly increase until it reaches its fixed value, and that the adjustable baffles of hot air and cool air are in the automatic position, and that noise-measuring indicator of coal pulverizer chang from high to low until it reaches normal value 4) Group control of coal pulverizing system Conditions for start-up Start preparation on the DCS: Start-waiting coal pulverizing system reseats. Exhaust air flow control reture circuit, temperature-controlling circuit and speedcontrolling A/H order of coal feeder are all automatic. Sub group start-up conditions are met. Group control start-up Execute HSN001 group control start-up order. 1) Get exhaust air fan circuit started through automatic sequencing. 2) Get mill exhauster started through automatic sequencing. 3) Start hot smoke circuit through automatic sequencing. 4) Inlet baffle of exhaust air fan automatically adjust exhaust air flow. 5) Adjustable pulverizer a) b) c) baffles of hot air and cool air automatically adjust coal

inlet temperature until it reaches 90.

If gigger motor is operating, it will trip. Coal pulverizer automatically starts through automatic sequencing. Coal feeder automatically starts through automatic sequencing, rev control circuit of coal feeder will automatically adjust coal supply quantity.

6) Maintenance and parameter during operation Adjustment of coal pulverizing system in operation a) Objectives of adjustment

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BOILER & AUXILIARIES OPERATION MANUAL

1) Make sure that the fineness degree of coal powder is up to standard and is fine in evenness degree to avoid incomplete burning loss 2) Guarantee lower the best output of coal pulverizing system, and try to

power consumption of milling

3) When boiler functions safely and economically, guarantee coal powder supply and sufficient coal level to suit the change of load, and ensure that there is enough buffering time when coal pulverizing system fails b) Adjustment and instruction in operation 1) Coal feeding speed adjustment Coal feeding speed adjustment automatically proceeds according to the signal of noise-measuring device, and it works in the manner of automatic. In face of the problem of manually adjusting coal feeding amount, when slowing down or quickening speed, ensure that the coal feeding is slow and consistent, starting or closing the coal feeder to adjust coal feeding is banned 2) Adjustment of exhaust air amount Inlet adjustable baffle of exhaust air fan should be automatic Flow amount of exhaust air can be changed through exhaust air amount enactment, and when humidity of raw coal is high, increase exhaust air amount properly 3) Adjustment of coal pulverizer inlet temperature Adjustable baffles of hot air and cool air should be automatic, the opening of hot air adjustable baffle appropriate, and cool air adjustable baffle closed. With coal pulverizer outlet temperature enactment, hot air and adjustable baffles should be automatically pulverizer outlet temperature. Restriction loop is used to avoid temperature rise at coal pulverizer entrance, the temperature of coal pulverizer inlet should always be higher than secondary air temperature (minimum temperature difference T=20) If outlet temperature drops normal falls by too much (about10 revolution lower), slide coal feeding until it cool air

adjusted, aimed at adjusting coal

revolution slowly reaches

connecting

system

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temperature value

BOILER & AUXILIARIES OPERATION MANUAL

4) Noise control of coal pulverizer If coal pulverizer noise drops too much to avoid the blocking of coal pulverizer, coal feeder revolution is automatically shifted to 20% that of its rated revolution 5) Hot smoke bypass valve HV002 of coal pulverizer Manual baffle HV002 can control coal powder circulation amount from raw powder separator to coal pulverizer (when it is closed, the baffle increases the coal powder circulation amount, and it can only be adjusted once in the test) 6) Mill exhauster recirculating valve HV003 In debugging, fix its opening which should not be changed in operation Mill exhauster air current carries the powder from coal pulverizer

through

raw powder separator into cyclone separator, and to avoid the

accumulation of coal powder in the pipelines, the speed of gas in the pipes should be as much as that of the fixed minimum value 7) Adjustable baffle of raw powder separator Its function is to adjust the effect of raw powder separator to ensure the fineness of coal powder is up to standard, and in debugging, fix its opening level which is generally not adjusted in operation When its opening enlarges, draught of the system and coal pulverizer will increase and coal powder become thick When the fineness of coal powder passes 200 in normal operation, objective should be between 92% and 95%. c) Operational parameters of coal pulverizing system

Temperature monitoring 1) Normal value of coal pulverizer inlet hot smoke air temperature is somewhere between 350 and 700, when it reaches upper limit of 800 and lower limit of 300, a warning signal should be given off. 2) Normal value of coal pulverizer inlet temperature is 115, when it reaches 120 or is

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less than 90, a warning signal should be given off, when it reaches 130, exhaust air and mill exhauster will trip, so will interlocked coal pulverizing system Air pressure monitoring 1) Normal value of coal pulverizer outlet draft should be somewhere between 20mbar and 30mbar 2) Inlet draft of mill exhauster should be equal to 70mbar of less Exhaust air amount should be 40000Nm3/h or less Powder level of coal bunker should be maintained a level higher than 8 meters, when it is 3 meters high or less, a warning signal will sound and pulverized coal feeder will trip. When it is 11 meters high or more, sound the alarm, and when powder level reaches 12.5 meters, stop the coal pulverizing system or remove powder to another coal bunker on the other side Electric current value of rotating machine 1) Value of exhaust air fan should be less than that of rated electric current 2) Rated electric current value of mill exhauster should be less than that of rated current 3) Rated electric current value of coal pulverizer should be less than that of rated electric current Inspection and maintenance of coal pulverizing system in operation Inspectors status of should regularly check all equipment, checking the functional

all equipment, collating local instrument and control room numerical value, and

immediately reporting and acting to deal with problems when something abnormal happens. Operational parameters of all auxiliary organs should be controlled within the following scope 1) Coal pulverizer Normal temperature value of bush should be at 45 or so and less than 70. Main motor bearing temperature should be less than 90 Coil temperature of motor should be less than 100 Cooling water flow of main motor cooler should be at a normal level Cooling water flow of main motor bearing should be at a normal level

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2) Mill exhauster

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Bearing temperature should be at a degree lower than 90 Bearing temperature of motor should be at a degree less than 90 Coil temperature of motor should be at a degree less than 100 Bearing vibration should be less than 80m, when it passes 80m, air fan will trip Cooling water amount of motor should be normal 3) Exhaust air fan Bearing temperature should be at a degree less than 90 Bearing temperature of motor should be at a degree less than 90 Coil temperature of motor should be at a degree less than 100 Bearing vibration should be less than 80m, when it passes 80m, air fan will trip Cooling water amount of motor should be normal 4) Lubricating oil system Oil temperature of main oil tank should be somewhere between 35 and 40 Oil level of main oil tank should be 1/2~2/3 of its original height (based on on-site oil level gauge) Bush oil-receiving flow amount of coal pulverizer should be more than 30 litre per second Pressure difference of oil filter should be less than 1.5bar normally, when it reaches 1.5bar or more (PDSH102), rearrange the oil filter and notify workers for maintenance and clean the oil filter that has been blocked. Top pad oil temperature should be somewhere between 25bar and 50bar (normally it is 30bar or so) Jacking oil temperature should be somewhere between 35bar and 60bar (normally it is 40bar or so) Oil system has no vibration and oil leakage 5) Oil system of speed reducer

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Oil system should be free of oil leakage Oil flow should be more than 60 litre every minute When pressure difference of filter is too great, change the filter and notify repair workers for maintenance and clean the one that has been blocked Cooling water flow indictor of cooler should be placed in the protection zone 6) Big gearwheel grease-blooming system Oil in the oil barrel should be sufficient, if oil shortage problem is found, notify oil inspectors to refuel in time Motor-driven pump and oil blooming should be normal When electromagnetic valve rear pressure reaches 4bar (PSL201), sound the alarm. 8.3.6.5 Suspended operation of coal pulverizing system

1) Subgroup control stops (on DCS) a) Set the speed-controlling device of coal feeder to manual status to bring the speed down to zero b) Operate the subgroup control stop order and stop coal feeder c) After the coal feeder stops, make sure that coal in the coal pulverizer have all been removed and its outlet draft diminish, and when outlet temperature passes 120, operate pulverizer motors order), the can and subgroup be 30 control stop order.30 motor the fan gets local seconds started or after coal stops operating, stopped minutes assistant later, seal (assistant emergency

by operating

will automatically stop (it can

also be realized by operating the single control stop order on the DCS). d) Operate the subgroup control stop order, make sure that hot smoke air drive baffle and inlet adjustable baffle of exhaust air fan, and hot air and cool air adjustable baffle plate automatically close e) Operate the subgroup control stop order, mill exhauster will stop and its inlet baffle plate will automatically close f) Operate the subgroup control stop order, exhaust air fan will stop operating, and its inlet and outlet adjustable baffles will automatically close, whereas cooling air baffle

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in the exhaust air vent will automatically start 2) Group control stop (on the DCS) a) Carry out the group control stop order and stop proceeding the procedures. b) Coal feeder stops operating, and the opening speed-controlling device drops to zero c) 15 minutes after coal feeder stops operating, its subgroup control circuits also cease successively 8.3.6.6 Emergency automatic stopping and tripping of the pulverizing system

1) The pulverizing system trips when one of the following conditions is met a) Emergency stop command is operated b) Boiler MFT action is done. c) A ball mill trips when the pulverizing system is treated with group control.

d) If one of the above conditions occurs, the following steps should be operated at the same time e) The coal feeder trips automatically f) The main motor of coal mill trips automatically and the helper motor starts up after 30 seconds. g) The hot smoke air circuit trips automatically h) The pulverized coal exhaust circuit trips automatically i) The exhaust gas circuit trips automatically

2) The tripping of each subgroup control circuit The exhaust gas circuit trips when one of the following conditions is met a) Action of the boiler MFT is done b) The outlet temperature of the coal mill is equal to or higher than 130 degrees c) Steam flow<270T/H with 3 minutes delay

d) Vibration of exhaust gas fan 80m with 10seconds delay

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electricity. f)

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e) After the start-up command is given two seconds, the exhaust gas fan motor has no

The group control commands or subgroup control commands are done

The pulverized coal exhaust circuit trips when one of the following conditions is met a) When the start-up command is given 90 seconds, the entrance truncated baffle is not open b) The outlet temperature of the coal mill is equal to or higher than130 degree c) Action of the boiler MFT is done

d) The pulverized coal exhauster vibrates too sharply with 10seconds delay e) After the start-up command is given 2 seconds, the pulverized coal exhauster motor is not switched on. The group control commands or subgroup commands are done The hot smoke wind circuit trips when one of the following conditions is met a) The exhaust gas fan motor is powered off b) The pulverized coal exhauster motor is powered off c) The pulverized coal exhauster entrance baffle is not opened completely

d) The lubricant circuit of the coal mill is not put into operation e) After the start-up command is given 30 seconds, the hot smoke baffle is not open f) One tripping command is given from the group control or subgroup control

The coal mill trips when one of the following conditions is met a) The lubricant circuit of coal mill is not put into operation b) Any top bearing oil pressure is equal to or less than 30bar (top watt pressure 15bar) c) Any top watt oil blooming flow <30litre/minute with 5 seconds delay

d) The oil temperature in the oil tank is equal to or higher than 60 degree, or less than 35 degrees. e) The lubricant circuit of the coal mill is not put into operation.

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f)

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The lubricant circuit of the coal mill is not put into operation.

g) The alarm issues when cooling water flow is low. h) The temperature of top watt is equal to or higher than 70 degree. i) j) k) The locking pole of turning gear leaves the position. Both of the two steel tubes with electric valves are not closed After the main motor is started up 2 seconds, the centrifugal intermittent device of the turning l) m) gear is in a closed position

After the main motor is started up 2 seconds, the seal fan is not started up Switch to the operation of the turning gear is required

n) The time of the oil blooming systems fault is more than one hour o) The hot smoke air baffle is not open p) Action of the boiler MFT is done. q) The entrance fuel pressure of the high pressure fuel pumps is equal to or less than 0.2 bar r) s) One group control command or subgroup command is done After the main motor of coal mill is powered off 30 seconds, the auxiliary motor is started up The coal feeder trips when one of the following conditions is met a) Action of the boiler MFT is done b) The pulverized coal level of pulverized coal bunker is too high (LSHH06A/06B) c) The main motor of coal mill is powered off

d) The baffle of hot smoke air is not open. e) After the coal feeder is started up 25 seconds, the speed of revolution is too slow f) After the coal feeder is started up 2 minutes, the coal is not supplied and with 30 seconds

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g) One stop command from the group control command or subgroup command is done 8.3.7 8.3.7.1 The turning gear of the ball mill Regulations about operation of the turning gear

1) When the pulverizing system is stopped while the rotating equipment has no fault 2) When adopting mechanical supervision to the coal mill 3) Before starting up the coal mill after being stopped a long time, the lubricant system must be adjusted in the state of turning gear 4) When the main motor is started up, the turning gear motor should be run for 2 min in low speed. 8.3.7.2 The start-up conditions of turning gear:

1) The lubricant circuit of coal mill is put into operation 2) Speed reducer lubricant circuit is in operation 3) The temperature of bearing of the coal mil is normal 4) The main electromotor of coal mill is powered off 5) The braking device of turning gear is in the loose position 8.3.7.3 The start-up of turning gear

1) Start up on the spot a) When the pulverizing system is stopped, but its rotation machine is normal, the persons on duty should start up the turning gear until the main motor starts up b) Press the on-the-spot startup button to start up the turning gear when mechanical inspection is needed, or operation of coal mill at slow speed is needed for adjusting the lubricant system c) When the start-up command is given, electromagnetism gear and auxiliary motor is electrified at the same time 8.3.7.4 The tripping conditions of turning gear

1) The lubricant circuit of coal mill is not put into operation 2) The lubricant circuit of speed reducer is not put into operation

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3) The temperature of bush of coal mill is equal to or higher than 70 degree 4) The trouble time of fuel sprinkling system lasts more than one hour.t 5) After the turning gear is started up 2 seconds, the seal fan fails to start up 6) The locking pole of turning gear is not in loose position 7) One stop command is given 8.3.8 8.3.8.1 The pulverized coal conveyer The inspection before start-up

1) The inspection of the mechanical section should be normal 2) The pulverized coal conveyer should not be blocked by pulverized coal 3) Accumulated pulverixed coal, light source should not be found and the lighting should be sufficient. 4) The gas source of the guide baffle should be normal. 8.3.8.2 The pulverized coal pouring operation of the pulverized coal conveyer(AB)

1) Open the pulverized conveyer then lead it to the pneumatic flashboard of B pulverized bunker, and the pneumatic flashboard should be closed when it arrives at A pulverized bunker. 2) Open the communication valves of the moisture absorption pipe 3) Operate the startup button of the pulverized conveyer from A to B on the spot 4) Make sure that the operation of the pulverized coal conveyer is normal, the direction is normal, the motor and the transmission device is normal 5) Lead the lowering pulverized coal guide baffle of A side of the cyclone separator to the pulverized coal conveyer 6) Make sure that the operation of the pulverized coal conveyer is normal, and make sure the pulverized coal has been conveyed from A to B 7) The changes of the position of pulverized coal in A, B bunker should be monitored. 8.3.8.3 The normal maintenance of pouring pulverized coal (AB)

1) Inspect the operation of the pulverized conveyer periodically

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2) The signals of the pulverized coal conveyer and the guide baffle of the cyclone separator should be normal when being monitored by a CRT. 3) When B pulverizing system operates and pulverized coal is poured from A to B, the level of pulverized coal in B bunker rises rapidly, the changes of the level of pulverized coal should be should be paid.attention to. 8.3.8.4 The abnormality treatment of pulverized coal pouring:

1) When pulverized coal is poured and the pulverized coal conveyer trips, the guide baffle of A cyclone separator is should be made sure to be led to the pulverized coal bunker automatically 2) When the pulverized coal conveyer operates and has sprinkling pulverized coal, it should be inspected that whether the hand-operated valve of the moisture absorption pipe is opened. 3) When the chains of the pulverized coal conveyer are broken, the guide A

baffle of stop the pulverized coal conveyer 8.3.8.5 Stop pouring pulverized coal

cyclone separator should be led to the pulverized coal bunker at once, and

1) Lead the guide baffle of A cyclone separator to the pulverized coal bunker on the spot, and make sure the position of the pulverized bunker is right 2) Stop the pulverized conveyer when it has no pulverized coal 3) Shut off the pulverized coal conveyer, and lead it to the pneumatic flashboard of B pulverized coal bunker 8.3.9 8.3.9.1 The operation of adding steel balls into coal mill The steel balls should be added during the operation when the current of coal mill is equal to or less than 190A,. 8.3.9.2 The operation method of adding steel balls

1) Prepare the steel balls that to be added. 2) The quantity of the added steel balls is 1 ton/ times, and the current of ball mill is rose by about 1A 3) Operate the button of preparation of adding steel balls on the spot, the general electric

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cavity

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valve for adding steel balls are opened, and then the steel balls are filled into the locking

4) Operate the button of adding steel balls on the spot, then the general electric valve of adding steel balls are closed, the electric sub-valve are opened, and the steel balls are added into the coal mill 5) 3 minutes later, the electric sub-valve for adding steel balls are closed automatically 8.3.9.3 Attention

1) When both the general electric valve and sub-valve for adding steel balls have no signals, the coal mill will trip. 2) After adding the steel balls, make sure that the next operation of adding steel balls should be done only after the electric sub-valve is closed 8.3.10 The pulverized coal burner

8.3.10.1 The inspection and preparation before start-up 1) Open the pulverized coal feeding flashboard of the pulverixed coal feeder, and the hand-operated valve of the primary air pipe is in the position for adjusting the opening degree. 2) Various parts of the pulverized coal feeder, the speed governor and the motor should be checked whether they are all normal. 3) The primary air pipe should not be leaked, and the platform of the coal feeder has no accumulated pulverized coal and combustible substance. 4) Make sure that the controlled gas source of the primary air pneumatic valve is normal, and the hand-operated valve of the controlled gas source is opened. 5) The sampling valve of the primary air pressure meter is opened. 6) The switch of the local speed governor is in ON position 8.3.10.2 The startup conditions: 1) The general protection of boiler is put into operation, and MFT is reset. 2) The corresponding oil gun torch is put into operation 3) The steam flow is equal to or higher than 250T/H

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4) The level of the pulverized coal in pulverized coal bunker is higher than 5m 5) The hot primary air pressure is not too low. 8.3.10.3 The start-up of subgroup control (on DCS) 1) Regulate the to-be-started-up speed governor of coal feeder to zero (SC50A/50B) 2) Operate start-up command for the subgroup control of the front wall coal feeder or back wall coal feeder 3) The corresponding primary air pneumatic baffle is opened. 4) After the primary air baffle is opened for 10 seconds, the coal feeder is started up 5) After the coal feeder is started up for 5 seconds, the corresponding secondary air baffle is opened. 6) All the baffles of the A. B, C bellows are placed in the manual state, then the speed control of coal feeder is put into operation 7) The lowest rotating speed is 3rpm, the corresponding pulverized coals quantity is 4T/H. The automatic control of the fuel increase and switch is operated according to the needs of load increase, and it should be confirmed that the pulverized coal burns well 8.3.10.4 The single control of start-up (on DCS) 1) Make sure the start-up conditions are ready. 2) The speed of the to-be-started-up coal feeder is regulated to zero 3) The start-up command of the single control of the corresponding primary air pneumatic baffle is operated and the valve should be confirmed opened. 4) The start-up command of single control of coal feeder is operated, and then the coal feeder is started up. 5) After the speed controller of the coal feeder is put into operation for 5 seconds, the corresponding secondary air baffle is opened. 6) After the coal feeder starts up normally, the rotation speed should be increased manually, and it should be made sure that the pulverized coal burns well

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8.3.10.5 The running and operation of the pulverized coal jet burner 1) The rotating speed of single coal feeder is set in automation (on DCS) When the number of the coal feeder operation is increased to 8, and the rotating speeds are all 5rpm, the rotating speed of the single coal feeder can be put into automation in turn, and SC50A/50B is regulated by the general rotation speed. The operation is as follows: a) The opening degree of the general speed governor of the coal feeder is regulated to 40% (on DCS or the spare tray) b) The speed governor of the single coal feeder is used to regulate its rotation speed in order to adapt to the signal need of the general speed governor, and the regulation of the rotating speed of the coal feeder is set to automation c) As the methods described above, other coal feeders are set to automation in order.

2) The general speed governor of the coal feeder is set to automation When the quantity of the coal feeder and its rotating speed is adequate, and the volume of the pulverized coal reaches about 50%, the general speed governor can be set to automation in order to balance the air volume / fuel volume ratio automatically, the operation is as follows: a) The demand regulator of the general load should be placed in manual state, and its opening degree should be 45% b) The entrance regulation baffle of the induced draft fan and forced draft fans has been put into automation c) The smoke oxygen content should be normal, and its regulator should be put into automation d) The general rotating speed of the coal mill should be set to automation (FEO HIC 050) e) At this time, the general load needs, the rotating speed and the air flow of the coal feeder should be correspondingly increased or decreased. 3) The start-up order of the pulverized coal jet burner a) In principle, the start-up order should be operated from the middle of the arch to its

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both sides, put into

BOILER & AUXILIARIES OPERATION MANUAL (FEF, FED) (FEG, FEC) (FEH,FEB) and should be

operation correspondingly for the front and back archs. b) When the second auxiliary ejector is put into operation, put FEE (FEI, FEA) to the coal feeder c) The operative rate of the pulverized coal jet burner should be consistent with the startup burning rate curves 4) Operation maintenance and supervision a) Supervision in the control platform The primary air pressure should be equal to or higher than 36mbar The rotating speed change of the coal feeder should be balanced, the rotating speed should not fluctuate substantially when automation is set, otherwise the speed should be switched to manual control and the rotating speed of the coal feeder should be controlled equal to or less than 10rpm in order to prevent the pulverized coal from blocking of the pulverized coal pipe. b) Local maintenance Various parts of the coal feeder, speed governor and motor should be inspected and confirmed in normal condition. The coal feeder has no abnormal sounds The operation of the pulverized coal feeding pipe of the coal feeder is smooth, and the temperature is normal The pulverized coal feeding pipe and the primary air pipe has no leakage of pulverized coal and air leakage The local place has no blocking pulverized coal and self-ignition phenomenon 8.3.10.6 The stop of the pulverized coal jet burner When the boiler stops, the pulverized coal feeding flashboard should be switched off before the coal feeder stops 1) The subgroup command stops (on DCS) a) The stop command of the subgroup control is stopped.

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b) When the coal feeder stops, the speed governor will automatically return to zero c) After the coal feeder is stopped for 20 seconds, the corresponding

secondary air baffle is switched off. (If the oil gun torch keeps operating, the secondary air baffle near the oil gun torch should be opened) d) The primary air pneumatic baffle is closed 2) Stop of the single control a) The rotating speed of the to-be-stopped coal feeder is reduced to zero b) The stop command of single control is operated and the coal feeder is stopped. c) After the coal feeder is stopped for 20 seconds, the corresponding

secondary air baffle is closed. (the baffle keeps open when the oil gun torch is operating) (FEA UV13, FEI UV24 single control is closed) d) The single control demand is operated and the primary air baffle is switched off 3) The coal feeders stops for accident The coal feeder trips when one of the following conditions is met a) Action of the boiler MFT is done b) The operation conditions of the coal burner defined by the flame scanning system are not fulfilled. c) When steam flow is less than 440T/H, the corresponding oil gun torch has no flame monitoring d) When steam flow is less than 270T/H e) The (3m) f) related pulverized coals level in the bunker is too low

(FMA/B LSLL06A/06B)

The primary air pressure is too low (FSA PSLL03) with 5 seconds delay (<24mbar)

g) The corresponding primary air baffle has not been opened h) The coal feeder fails to be switched on 30seconds after the start-up command is given. i) The corresponding secondary air baffle fails to be not opened 2min after the start-up

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command is given.

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Note: Because of MFT action, if the oil gun torch is controlled in the distance, the baffle of the secondary air should be opened, FEA UV14, FEI UV24 should be closed after 60 seconds 8.3.11 Fire detector cooling fan

8.3.11.1 Inspection before start-up 1) The air duct is complete and the system connection is good 2) The strainer at the entrance of the fan is in good condition without blocking 3) The mechanical part and the motor is normal through inspection and the transmission belt is complete without looseness 4) The motor offers electricity normally. 5) The outlet hand-operated valves of two fans are open 6) Each cooling oil gun fan torch and the hand-operated valve of flame scanning

of pulverized coal ejector should be opened

7) The measuring points of air pressure are complete, and the local indication gauges are correct. 8.3.11.2 The start-up of the fan 1) The start-up of the subgroup control a) Switch off interlocking (the light is bright) b) Operate # 1 fan and choose the command (the light is bright) c) Operate the start-up command of subgroup control

d) Make sure AC fan is operated, the green light is put out, the red light is bright, and the outlet air pressure is normal e) The interlocking in put into operation, then the light is put out 2) The start-up of single control (on DCS) a) Switch off interlocking (the light is bright) b) Operate the start-up command of single control of # 1 fan, then #1 fan is started up

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c) After the option command of HSU001 #1 fan is operated, the ON command of subgroup control should be operated. d) Switch on the interlocking (the light is put out) 8.3.11.3 The linkage and periodic test for direct current fan 1) The linkage of direct current fan a) Switch on the interlocking (the light is put out) b) # 1 fan is tripped, and #2 fan linked c) When the outlet pressure of cooling air fan is less than 85mbar, and after the alarm issues with s 5 seconds delay, #2 direct current of cooling fan starts up automatically d) Make switch operate alternatively and automatically Note: the switch of the flame scanning cooling fan should be operated only after some safety measures have been adopted in order to prevent the action of the boiler MFT 2) The periodic test of direct current fan (two fans can operate simultaneously at any time) a) The 220VDC electrical source is inspected and confirmed normal b) Operate start-up command of single control of #2 fan on DCS, then #2 fan starts up c) The operation of #2 fan is checked and confirmed normally running.

d) The start-up command of single control of #2 fan is operated, then #2 fan stops e) Make sure that the flame scanning cooling air pressure should be higher than 85mbar, and the interlocking is normal (the light is put out) 8.3.11.4 Operation of maintenance and supervision 1) The operation of the fan should be periodically checked, and it should be made sure that the fan has no friction noise and its bearings temperature and vibration and its motors temperature are normal 2) The entrance strainer of the fan should have not blocking phenomenon, otherwise, it should be cleaned in time 3) The driven belt has not slippery, loose, and falling phenomenon, the local air pressure should be normal, the air duct and the connected system has not air leakage

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4) The outlet air pressure of the fan should be higher than 85mbar 5) When the outlet air pressure is lower than 85mbar (PSL02), the alarm will be emitted, and after 5 seconds delay, the direct current fan is linked 6) When the outlet air pressure is lower than 70mbar (PSLL03) with 10 seconds delays, the boiler has MFT action 8.3.11.5 Stop of the flame scanning cooling fan After the boiler is stopped for 24 hours, the operation of the flame scanning cooling fan can be stopped 1) The subgroup control is stopped (on DCS) a) Operate stop command of HSN001 subgroup control and group control, then the red light is put out, the green light is bright b) Make sure the fan is stopped 2) The single control is stopped (on DCS) a) Operate HSU002, and switch off interlocking (the light is bright) b) Operate stop command of single control, then the red light is put out, the green light is bright c) 8.3.12 8.3.12.1 Make sure the fan stops

Oil gun torch cooling fan Startup Check

1) Ensure the air duct is complete, and system connection is in good condition 2) Check whether the mechanical part and the motor are normal or not, and ensure the driving belt is complete and not loose. 3) Ensure motor energization 4) Ensure the hand-operated valves of the outlets of the two fans are open 5) Ensure all cooling dampers of the oil gun torch are open and the HV*5 hand-operated valve of the burning torch cooling air is open. 6) Ensure the air pressure measuring point is complete, and the local indicator is correct

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8.3.12.2 Fan startup 1) Sub control startup

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a) Switch-off interlock (lights on) b) Select fans to be started (lights on) c) Operate sub control startup order

d) Confirm the selected fan is started, the green light is off, the red light is on, and the outlet air pressure is normal e) Interlock is put into service (lights off) 2) Single control startup (on DCS) a) Switch off interlock (lights on) b) Operate single control startup order, and the fan is started c) Select operation fan (lights on)

d) Operate sub control ON order, the green light is off, and the red light is on. e) Interlock is put into service (lights off) 8.3.12.3 Fan in reserve and transfer The fan transfer should be locally supervised, and should be started before being stopped. 1) Sub control transfer (on DCS) a) Check interlock is in service (lights off) b) Select fan to be started (lights on) and fan to be shutdown (lights off) and the selection difference light is on. c) Operate sub control startup order, and the difference light is off when the fan to be started is started and the fan to be shutdown is shut down. d) Locally checks and ensures the operation fan is normal and the air pressure is more than 85mbar 2) Single control transfer (on DCS) a) Single-control starts the fan to be started

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b) Single-control shut down the fan to be shut down c) Operation selects the started fan (lights on) and shuts down the fan (lights off)

d) Locally check and ensure the operation of the started fan is normal and the air pressure is more than 85mbar e) Ensure the sub control is at a condition of ON, the green light is off and the red light is on. f) Check interlock is in service (lights off)

3) Linkage of standby fan a) Interlock is put into service (lights off) b) Standby fan starts when the operation fan trips. c) Standby fan starts in five seconds after the pressure of cooling air outlet lowers to 85mbar and an alarm is given. d) Automatic transfer happens alternatively 8.3.12.4 Operation maintenance and supervising repair fan operation, and ensure no grating, bearing

1) Periodically temperature

and vibration are normal, and motor temperature is normal.

2) Ensure the driving belt has no skidding, looseness and shedding, the local air pressure is normal, and the air duct and connection system have no air leakage. 3) Outlet air pressure should be more than 85mbar 4) When the fault fan is in maintenance, interlock thereof should be unlocked, the power of the motor of the fan should be cut, and the outlet valve should be closed. 8.3.12.5 Oil gun torch cooling fan shutting down

1) Shut down the oil gun torch cooling fan after boiler is stopped for 24 hours. 2) Sub control stopped (on DCS) a) Operate HSN001 shutting down order, the red light is off, and the green light is on. b) Confirm that the fan is shut down.

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3) Single control shutting down (on DCS) a) Operate HSU002 to unlock the interlock (lights on); b) Operate single control shutting down order, and ensure that the red light is off, and the green light is on; c) 8.3.13 8.3.13.1 Confirm that the fan is shut down.

Steam air heater Check before startup of the steam air heater

1) Ensure that the valves of the steam air heater and auxiliary device piping are well connected. 2) Ensure the motor-operated valve has been energized, and air supply availability is controlled. 3) Ensure the condensate system has been put into operation. 4) Ensure the auxiliary steam and the steam extraction is normal. 5) Ensure all measuring instrument is complete and correct. 6) Ensure the following instrument sampling isolating valves are open. a) Steam inlet pressure hand-operated valve b) Condensed water tank pressure gauge hand-operated valve c) Condensed water tank water level high switch hand-operated valve.

d) Condensed water tank water level low switch hand operated valve. e) Condensed water tank water level gauge water inlet valve. f) Condensed water tank water level regulating signal transmitter signal valve.

7) Open the steam piping upper air valve 8) Shut down the steam control valve; shut down the side valve and open the front and real hand-operated valve. 9) Open the steam air heater desuperheater water hand-operated valve; desuperheater water control valve auto on.

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10)

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Open the steam air heater steam intake valve.

11) Open the steam air heater outlet valve. 12) Open the hand-operated valve of condensed water outlet and inlet of the secondary steam air heater. 13) Open the hand-operated valve of the condensed water blowdown flash tank, manually shut down the control valve. 14) Open the water drain valve of the condensed water tank, and close the valve after remained water is drained. 15) Confirm that the hand-operated valve of the condensed water tank to #2 low water injection and drain tank, and manually close the control valve. 8.3.13.2 Put steam air heater into operation Natural ventilation is adopted before the boiler ignition, the steam air heater is put into operation, and the outlet air temperature is more than 90 degrees Celsius; in the normal operation of the boiler, the average temperature of the gas is maintained between 100 to 105 degrees Celsius, and the air temperature of the outlet is automatically controlled; the steam air heater is stopped when the heater is high loaded. 1) Select mode at the auxiliary steam position of DCS. 2) Pass out the steam air heater sub control startup order at DCS, to confirm that: 3) The fifth extraction motor-operated valve is closed; 4) The auxiliary steam motor-operated valve is open; 5) The drain water motor-operated valve is open; 6) The stem control valve is manually and gradually opened; 7) The drainage valve is closed when the steam bursts out; 8) Condensed water tank water level gauge is checked and the water level is normal; 9) The water level control valve of the condensed water tank is auto on; 10) 11) When turbine operation condition is permitted, the turbine can be set as auto on; The steam desuperheater water control valve is set as auto on.

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The operation of the steam source being switched over to five section steam extraction should be carried out when the operation condition of the turbine is permitted, and the specific operation is as follows: 1) Select mode at the five section steam extraction position of DCS; 2) Pass out the steam air heater sub control startup order to confirm that the the steam supply motor-operated valve is open, the check valve is open and the drain water motor-operated valve is closed. 8.3.13.3 Operating maintenance and parameter 1) The inlet steam temperature of the steam air heater should be between 130 degrees Celsius be higher than degrees Celsius. 2) Drain water tank outlet water temperature of the steam air heater should be 40 degrees Celsius. 3) Condensed water tank water level. Water level is low Water level is high alarm alarm 300mm 800mm to 200 degrees Celsius and the temperature should (at corresponding pressure) the saturation temperature by ten

4) Inlet steam pressure Pressure is low Pressure is high alarm alarm 2bar 14bar

5) Secondary air temperature of air pre-heater inlet (according to the load) 6) Air and to 110 gas average temperature should be between 100 degrees Celsius

degrees Celsius. 7) Flue gas temperature should be 150 degrees Celsius. 8) Condensed water tank water level governing a) The water level control valve should be controlled by the water level control circuit at auto position, thus maintaining the condensed water tank water level constantly. b) In normal operation, drain water in condensed water tank drains into drain tank of low-pressure heater.

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c) When the water level of drain tank of low-pressure heater is extremely high and alarm is given, the steam supply motor-operated valve will be automatically closed, and the drain water motor-operated valve will be automatically opened, and the condensed water gutter static expansion. d) The water level of the condensed water tank should plus 500mmor plus 600mm. e) When the the water level auto control of the condensed water fails,

steam supply/drain water regulating valve can be switched to manual operation.

8.3.13.4 Steam air heater shutting down 1) Pass out the sub control shutting down order at DCS to confirm that: a) The motor-operated valve is automatically closed when auxiliary steam supplies steam; b) When the five section steam extraction supplies steam, The steam extraction motor-operated valve UV01B and the check valve UV01C are automatically closed; The drain water motor-operated valve UV01D is automatically opened; And the steam control valve TCV75A and the desuperheater water control valve (TCV75B) are automatically closed. 2) Automatic shutting down of steam air heater Steam air heater tripping conditions: a) Pass out steam air heater sub control shutting down order at DCS; b) The turbine trips when the five section steam extraction supplies steam. The fifth extraction motor-operated valve and the check valve should be closed. 8.3.14 Boiler water recycle pump

8.3.14.1 Check before boiler water pump startup 1) The connection of the pump, the motor and the system should be in a good condition; 2) Check whether all valves of the boiler water pump are closed or not; 3) Check whether all instruments and the alarm system are in a good condition or not.

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8.3.14.2 Put cooler into service

BOILER & AUXILIARIES OPERATION MANUAL

1) Ensure the closure cooling water system has been put into operation; 2) Ensure the water drain valve of the cooler inlet is opened, and is closed after the sewage is drained; 3) Ensure the air valve of the cooler outlet is closed; 4) Ensure the inlet valve of the cooler is opened; 5) Ensure the outlet valve of the cooler is completely opened; 6) Ensure the outlet valve of the cooler is opened largely, and confirm that the flow if the cooling water is larger than 27m3 /h. 8.3.14.3 Motor water injection piping washing 1) Ensure the condensed water pump is in operation, the water temperature is less that 40 degrees Celsius, the water quality is qualified and no hydrazine is added in; 2) Check whether the water injection dual valve is closed or not; 3) Check whether the water injection valve and the acicular valve are closed or not; 4) Check whether the water injection tube is dismantle d or not; 5) ensure the water injection main valve is opened; 6) Ensure the water drain valve of the water injection main tube and the water drain valve of the strainer are closed after the clean water is continuously discharged; 7) 7) Ensure the water injection valve and the acicular valve are ajar, and

the water injection valve is closed after the clean water is discharged from water injection tube. 8.3.14.4 Water injection of the boiler water pump 1) The water injection of the boiler water pump should be carried out the boiler is filled with water; 2) Check whether the check valve of the boiler water pump outlet and the bypass valve of which are closed or not; 3) Ensure the high pressure side drainage valve of the cooler; 4) Ensure the pump inlet and outlet differential manometer is in a good condition and open

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the isolation valve of the pump; 5) Ensure the water injection valve and the dual valve is opened; 6) Ensure the acicular valve controls the water injection flow to be less than or equal to 2.5L/min; 7) Check whether the high pressure side drainage valve of the cooler

continuously discharges the water and the water is clean or not, and ensure the air outlet valve is closed; 8) Ensure the acicular valve is turned down and the water injection is maintained; 9) When the boiler water pump is spot-turned, the dual valve, water injection valve and the acicular valve are closed. 8.3.14.5 Boiler water pump spot turn 1) After the water injection is completed, the insulation resistance against earth of the motor conductor indicated in the 1KV megameter should be more than five megohms; 2) The boiler should be filled to a water level which is 100mm more than drum water level; 3) Ensure the check valve of the boiler water pump outlet is locally opened; 4) Ensure the boiler water pump is stopped after having been started for five seconds, and 20 minutes later, the boiler is started for five seconds and then is stopped, to drain the air in the motor chamber. 5) The boiler water pump should be put into operation and the water injection should be stopped after the boiler water pump having been spot turned for three times and no abnormity having been found. 8.3.14.6 Boiler water pump startup conditions 1) The power supply of the motor is energized; 2) The control power supply is energized; 3) The motor is stopped for more than 20 minutes; 4) The cooling water flow of the motor is more than 27m3 /h; 5) The water temperature inside the motor is less than 55 degrees Celsius;

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6) The outlet valve of the pump is unlocked; 7) The temperature difference of the boiler water and the pump (TDSH10) is less than 56 degrees Celsius; 8) The drum water level is more than 600mm; 9) The boiler water pump is spot-turned 8.3.14.7 Boiler water pump startup 1) The drum water level should be higher than +100mm before the first boiler water pump is started; 2) The local/remote switch of the pump should be positioned remotely; 3) Single control: the boiler water pump can be singly started on DCS when the startup conditions are met; Confirm the pump to be started; Select the pump on DCS and start the pump; 4) Group control startup; Check whether the group control exits or not on DCS, (the green light is on); Select the started pump on DCS ( the red light is on); Start the pump with group control (the group control red light is on) and check whether the pump is started or not; 5) Notes after startup; Check whether the differential pressure of the outlet and inlet, current and the motor water temperature of the operating pump are normal or not; The interlock can be put into operation only after the standby pump is stopped for 20 minutes; The pump should be stopped immediately if the motor temperature rises quickly and no downtrend appears. 8.3.14.8 Boiler water pump hot reserve The standby pump startup conditions comprise that:

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body is heated;

BOILER & AUXILIARIES OPERATION MANUAL

1) The bypass valve HV*14 HV*15 of the check valve of the outlet is opened, and the pump

2) The upper interlock of the DCS has been put into operation. 8.3.14.9 Boiler water pump transfer 1) Group control transfer (on DCS); a) Select the standby pump (lights on), and select the pump to be stopped (lights off); b) Integrate the group control startup, and check whether the standby pump is started or not and whether the pump to be stopped is stopped or not c) The interlock automatically quits, and is put into operation again 20 minutes later.

2) Single transfer a) Singly start the standby pump; b) Ensure that the pump is normally started; c) Stop the pump to be sopped;

d) Ensure that the pump is stopped and the current is reduced to zero, and 20 minutes later the interlock switch is put into operation. 3) Automatic transfer The group control is closed, the interlock is put into the standby pump, and the startup conditions are complete; the standby pump would automatically be started if any of the operating pump trips; the interlock quits, and can be put into operation again after 20 minutes. 8.3.14.10 The operation and maintenance of the boiler water pump

1) The normal temperature of the motor chamber should be 45 degrees Celsius, and an alarm will be given at 60 degrees Celsius, and the pump will give an extreme alarm and trips at 65 degrees Celsius. 2) The normal value of the differential pressure of the boiler water pump is more than 1.4 bar, and the differential pressure value when two pumps are in operation is 1.4 bar and a boiler MFT action would be carried out when the differential pressure is less than or equal to 1bar.

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3) The temperature between the boiler water and the pump shell should be less than 50 degrees Celsius, and a high temperature difference alarm will be given at 56 degrees Celsius. 4) The normal cooling water flow of the cooler is more than 27m3 /h, and when the cooling water flow is less than or equal to m3 /h, a low cooling water flow alarm will be gave, and 20 seconds later the pump will trip. 5) The load of the boiler is less than or equal to 60 percent MCR when only one boil water pump is in operation; 6) When the temperature of the standby pump motor chamber rises to approximately 55 degrees Celsius, the standby pump should be started and put into use, and should be stopped after the temperature is reduced. 7) The attendant should check the leakage of the boiler water pump high pressure side; when chief leakage is found, the attendant should report to the attendant, and countermeasures should be taken immediately to prevent the

motor from burning loss. 8.3.14.11 Boiler water pump shutting down

1) Ensure the water temperature of the downcomer of the drum is 90 degrees Celsius, the inner layer air valve of the drum is opened, and when the water temperature of the downcomer of the drum is less than 70 degrees Celsius, two boiler water pumps should be shut down; 2) The cooling water flow should be maintained when the pump is stopped; 3) Boiler water pump that are stopped for a long period should be periodically checked whether the motor are filled with water; ensure that the boiler water pump operates for at least 10 minutes every two months, and should be started and operated for 10 minutes every 15 days at the period of pressure maintenance. 4) Shutting down operation of the pump a) Group control shutting down; Select the group control shutting down order on DCS; Check whether all operating pump are stopped or not and whether the current is reduced to zero or not; The outlet check valve should be closed.

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b) Singly shutting down Quit the boiler water pump interlock on DCS; Select the pump to be stopped and stop it with single control; Ensure that the pump is stopped, and the current is reduced to zero. 8.3.14.12 1) Boiler water pump operation in boiler acid cleaning

All boiler water pumps should be injected with water before acid cleaning and water filling.

2) Only one boiler water pump should be in operation in acid cleaning, and the other two pumps are isolated. 3) All cooler of the boiler water pump should be put into operation, and the cooling water quantity should be more than 27m3 /h. 4) The water injection pressure should be kept higher than pressure of the drum by 6bar in acid cleaning. 5) Continuous water injection should be carried out to the operation pump in acid cleaning 6) inject the water according to the operation; ensure that the injected water is drained completely, and the water injection quantity should be maintained more than or equal to 4.5L/min; the temperature of injection water should be less than 45 degrees Celsius. 7) Before adding the liquor to the boiler, the pump should be started and in operation. 8) Continuous water injection should be carried out to the isolated pumps. 9) The outlet check valve and bypass valve should be closed. 10) High pressure side drainage valve of the cooler should be closed. 11) Inject the water according to the operation; maintain the water injection quantity by more than or equal to 4.5L/min after the air is completely drained; water injection should be carried out continuously, and the water injection pressure should be higher than the drum pressure by 6bar. 9 NO. Periodic work, test and shifting of the boiler and relevant auxiliary equipment Projects Type Period Remarks

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1 2 Oil gun torch Forced draft fan

BOILER & AUXILIARIES OPERATION MANUAL Periodic test Periodic shift Once a week Every half month

lubricant station oil pump Induced draft fan Periodic shift Every half month

bearing cooling fan Flame fan (DC) Standby check cooling Periodic test Once a week

5 6

coal

pulverizer

Periodic test

Once a week

lubricant station oil pump Boiler blowdown Boiler proper soot blowing Periodic work Periodic work Once a day Once a day Part different periods stations by tiem and

8 9

Air preheater soot blowing Local water level

Periodic work Periodic work

Every eight hours Once a week

gauge washing electromagnetic relief valve blowdown operational record Devices inspection Accidents processing of boiler Basic Principia of Accidents Processing patrol and Periodic work Every two hours parameter Periodic work Once a hour Periodic test Once a month

10

11

12

10 10.1

10.1.1 When the unit accidents occur, the operator on duty should quickly identify the cause of the accidents to restrict further development of accidents and prevent the expansion of accidents. When the accidents are confirmed to have direct threat on personal safety and equipment, the risks of personal safety and equipment should be decisively eliminated. At the same time attention should be paid to continued operation of non-fault equipment as far as possible so as to meet the

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need of system load.

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10.1.2 The operator on duty should seek to ensure power supply of electricity system of the power plant. 10.1.3 In order to accomplish the above tasks, the operator on duty must stick to his post and focus his mind to ensure the normal operation of equipment, eliminate all abnormal situations and correctly and fast implement orders given by superior officers. 10.1.4 When the unit has malfunction, the operator on duty generally should work according to the following steps to eliminate failures. 10.1.5 Rapidly eliminate the risks on personal safety and equipment and the equipment with malfunction should be immediately out of synchronization (or stopped) when necessary. 10.1.6 Correct analysis and judgement should be done to indentify the nature, location and scope of accidents and then proceed to treatment according to instrument indication, alarming signals of CRT and alarm window and external Faults of the unit. At the same time attention should be paid to continued operation of non-fault equipment. 10.1.7 Situation of each stage in failure removal should be reported to the shift supervisor as fast as possible so as to timely take countermeasures to prevent the failure expansion. 10.1.8 If the failure is caused by failure of the system or other equipment, corresponding measures should be taken to maintain the unit to operate with a certain parameters so as to make it possible to quickly recover normal operation of the entire set of unit. 10.1.9 According to the unit operating characteristics, accidents caused in any part of the unit will have a direct impact on the safe operation of the entire unit. Therefore, all posts should exchange situations during malfunction occurance and closely coordinate with each other to rapidly treat with the failure under the unified command of the shift supervisor and the chief supervisor. 10.1.10 The chief supervisor should be administered by the shift supervisor during failure removal, and should rapidly participate in failure elimination and firstly report to the shift supervisor as much as possible when the malfunction occurs. At the same time, the chief supervisor should report the taken of the measures to the shift supervisor and comply with all correct commands shift supervisor. During accident treatment, the shift supervisor is entitled to call on

10.1.11 all

concerned personnel in the power to be on-site to assist to deal with the failure and

meanwhile, all relevant leaders must quickly hurry to the spot to help deal with the failure and give necessary instructions

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special circumstances.) 10.1.12 should Careful analysis,

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to operators (all these instructions should be issued by the shift supervisor in general expect for

correct will

judgement, not be

decisive manipulation eliminated, but

and

rapid

action and

be necessary during failure treatment. In addition, impatience and panic should be failure becomes expansive The operator should repeat the received order when in treatment of

avoided, otherwise the difficult to handle.

malfunctions and make it clear until get the order understood, and promptly make reports to those who give the orders after having fulfilled the orders. 10.1.13 The operator must promptly report to the chief supervisor the unfamiliar malfunctions so as to jointly study the causes and deal with the failure. When no specified malfunctions is included in the manual, the operator should analyze and judge the causes with his own knowledge, initiatively take countermeasures and report the failure condition to the superiors at all levels. 10.1.14 The operator on duty is not allowed to leave his post freely during the time when the unit malfunctions occurs until resuming to the normal condition. When the failure occurs at the shifting time, the shift should be deferred and the shift person should continue to work with the assistance of the relieve person to jointly deal with failure. The shift can only be done until failure is removed and commond is received from the shift supervior. 10.1.15 Forbidden and eliminate the case that people who do not involve in the failure removal stay at the place where failure occurs. 10.1.16 After the acccidents have been disposed, personnel at all posts should truthfully record in detail disposal the on unit failure situation, occurance time, place and the process of the registering book for shift respectively, and analyze the failure treatment on

the meeting after shift so as to sum up experience and draw a lesson. 10.1.17 The shift supervisor and chief supervisor are not allowed to leave the control room at the same time when the system failure occurs. 10.2 Boiler Emergency Shutdown

10.2.1 If any one of the following conditions is met, the MFT starts and the boiler automatically stops: 10.2.1.1 The power failure of control system or abnormality of pressure for controlling air is delayed for three seconds. 10.2.1.2 No induced draft fan is running

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10.2.1.3 No forced draft fan is running 10.2.1.4 No air heater is running 10.2.1.5 Total air flow is below the minimum value (two secondsdelay in action) 10.2.1.6 Water temperature is too high (from TE 052I) with no exhaust sustained for above six seconds or the water temperature is not high (from TE 052I) but the furnace temperature is abnormal or too high (above six secondsdelay) 10.2.1.7 Steam discharge is undone (six seconds delay in action) 10.2.1.8 Drum level is too low (two seconds delay) 10.2.1.9 Drum level is too high (60 seconds delay) and 12% higher than the MCR flow. 10.2.1.10 Non-biler water circulating pump is in operation and the tripping action is delayed two seconds. 10.2.1.11 Furnace pressure is too low or too high 10.2.1.12 Air cooling pressure of the flame detector is too low (600 seconds delay) 10.2.1.13 Flame detector breaks down; the last burner is delayed 15 seconds after the purge and storage are re-set or the entire detector breaks down. 10.2.1.14 Superheated steam pressure is too high (pressure switch) with six seconds delay in action. 10.2.1.15 The air temperature of electric precipitation entrance is too high with this action delayed two seconds. 10.2.1.16 The steam flow after the reflux starts is still greater than x1% before the reflux and only one circulating pump is in operation after T1. 10.2.1.17 The steam flow when the reflux starts is still greater than x1% before the reflux and only one circulating pump is in operation after t seconds (T1 + T2). 10.2.1.18 Only one emergency stop button is used. 10.2.1.19 When the reflux starts, control loop of at least one raw coal feeder is in a manual state. 10.2.2 The following processing procedures should be automatically done after the MFT action, otherwise human intervention should be adopted:

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10.2.2.1 Cut off all fuel;

BOILER & AUXILIARIES OPERATION MANUAL

10.2.2.2 Pulverizer coal feeder and oil gun torch fully stop; 10.2.2.3 Fuel oil inlet solenoid valve is closed; 10.2.2.4 Pulverizing system fully stop; 10.2.2.5 Frontwall balance wind baffle plate and backwall balance wind baffle plate: A is 100%, B is 20% and C is 0%. 10.2.2.6 Turbine trips and generator runs out of synchronization; 10.2.2.7 High voltage bypass and low voltage bypass starts up automatically. 10.2.3 Manual processing methods after MFT action 10.2.3.1 Confirm that the boiler main stop valve FSRUV04A automatically closes, or the manual control should be employed to close the boiler main stop valve. 10.2.3.2 Confirm that the high voltage bypass rapidly starts up and automatically resumes to a certain opening so as to maintain the pressure of 15 bar of the reheater. If the the high voltage bypass does not start up, manual control should be applied to the hight voltage bypass so as to make it start. The high voltage bypass is then returned to a proper opening after 15 seconds and put in automatic control after the pressure of the reheater is set at 15 bar. 10.2.3.3 Attention should be paid to the drum water level. If the water level is too high, continuous relief valve and stable relief valve can coordinate for water level regulation. 10.2.3.4 Attention should be paid to that the operation of the boiler water pump should be normal and immediately suspended when there are abnormalities such as the shock, pressure difference, etc. 10.2.3.5 Confirm that after the secondary air baffle plates are locked for one minute, all secondary air baffle plates of the oil fuel burner should be in an opened state and the total air volume should be maintained at 30% MCR; and the purge procedure (for 5 minutes) of the boiler framework is then done. 10.2.3.6 If the reason of MFT action can not be identified or eliminated at the moment, the decision of stopping the primary air fan, forced draft fan and induced draft fan should be promptly made and the inlet baffle plates and the outlet baffle plates should be closed so as to maintain the boiler in a standly heat state.

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10.2.3.7 Keep the air preheater, flame scanning cooling fan and cooling fan of oil gun torch running. 10.2.3.8 If the failure can be eliminated in a short time, the shift supervior after having received the order of starting up the units should started up the units as soon as possible according to the boiler stoppage duration and corresponding conditions so as to meet the demand of system load. 10.2.3.9 If the reason of MFT action is caused by the the primary air fan, forced draft fan or induced draft fan, the boiler framework should be thoroughly purged before re-ignition; all the primary air pipelines should be purged for 20 minutes before the pulverized coal is supplied. 10.2.4 Emergency boiler shutdown 10.2.4.1 Any one of the following situations occurs, the emergency boiler shutdown button should be immediately pressed for boiler shutdown. a) When in low-load operation, the combustion instability occurs and the boiler framework pressure substantially fluctuates around 5mbar and the steam flow rapidly declines. b) The safety valve has failure to operate even when boiler pressure exceeds the working value of safety valve; meanwhile, the high voltage bypass valve and the low voltage bypass valve and the non-atmospheric relief valve of reheater are unable to start up automatically or manually. c) When blast of the main feed water piping, main steam piping, water wall, economizer, superheater and reheater occurs and endangers adjacent pipings. d) e) When all the boiler water level gauges are damaged and unable to monitor water level. When the boiler is overfed with water with the water level higher than +25 mm and MFT has failure to operate. f) When the boiler is short of water with the water level lower than -600 mm and MFT has failure to operate. g) When the combustibles reburn in the gas dust so that the flue gas temperature rises to above 200 in an abnormal state. h) When the the first and secondary spray attemperators all have failure and

steam temperature has drastic change and can not be controlled.

10.2.4.2 Treatment methods of emergency boiler shutdown are the same as that of automatic

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boiler shutdown. 10.3

BOILER & AUXILIARIES OPERATION MANUAL

Shutdown Application of Boiler If one of the following cases is met, one should ask for approval of the factory

director in charge and do the boiler shutdown in a normal manner after having received the order from the shift supervisor: 10.3.1 When pressure retaining parts which have leakage are still able to operate. 10.3.2 When the heating surface of boiler has been scorched and normal operation can not be maintained even some measures have been taken to deal with it. 10.3.3 When the quality of feed water or steam of the boiler has seriously worsened and normal operation can not be maintained even efforts have been made for adjustment and treatment. 10.3.4 When the metal wall temperature of the heat absorption area has extremely exceeds the allowable value and normal operation can not be resumed even great efforts have been made for treatment. 10.3.5 When the enclosed cooling water source of cooler of the boiler water pump motor is interrupted and the alternative water source can not be resumed immediately. 10.3.6 When the high voltage bypass after tripping can not be closed. 10.3.7 When the safety valve has defects, failure to operate or can not be reseated. 10.3.8 When main motors of two air preheaters have failure and can not be resumed in a short time. 10.3.9 When the gas dust has serious deposition of ash and is unable to maintain normal operation after much effort. 10.3.10 When chief supervisory meter has failure and is unable to maintain normal operation and can not be resumed in a short time. 10.3.11 can 10.4 10.4.1 not When the two electric precipitators have failure and normal operation

be maintained after much effort.

Boiler Abnormal Operation Parameter High temperature of main steam

10.4.1.1 Faults

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a) b)

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Alarm is given due to high temperature of main steam (> 560); If the heat absorption surface has leakage or explosion, steam temperature of various sections before the breaking point drops and temperature of various working substances after the breaking point increases.

10.4.1.2 Causes a) b) The high pressure heater is out of operation and feed water temperature drops. attemperating water system has failure th t attemperating water flow reduces abnormally. The or automatic malfunction the

c) d) e) f) g) h) i) j)

Decrease of feed water pressure causes attemperating water flow reduction. Gas duct in the rear part reburns. Coal quality or combustion operating condition change. The flame center of boiler framework moves upwards. The heating surface has leakage and blast. Air flow is too much. Coal pulverizing system starts up. The boiler framework is scorched.

10.4.1.3 Countermeasures a) When have water supply system and spray attemperating water system

failure automatically, manual adjustment should be immediately adopted. The

systems are then put into operation after the steam temperature becomes stable. b) When in soot blowing of boiler framework, the openings of the upper tertiary air baffle plate and the lower tertiary air baffle plate should be regulated for adjustment flame center. The openings of secondary air baffle plates of three rows of A, B and C should be regulated when neccessary. c) Adjust the air flow and maintain the best excess air coefficient. (That is, to maintain the best oxygen content value). d) Increase the drum attemperating water flow and pay attention to relation between

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pressure and the main feed water piping pressure. e) The high or steam temperature is caused by leakage or blast of heating

surface,

the reburning of combustibles in gas duct and should be dealt with

according to the relevant provisions. f) If the temperature of main steam keeps increasing after the above treatment measures have been taken, the turbine should be adjust together with the boiler according to relevant provisions. But the temperature of main steam should not

exceed the limit and the unit load can not drop too much. g) When the temperature of main steam stop valve in front of the turbine reaches 566, the turbine trip should be done. 10.4.2 Low temperature of main steam

10.4.2.1 Faults a) b) Alarm is given due to low temperature of main steam (< 560); Steam temperature of various sections drops and the steam piping has impact in severe case. 10.4.2.2 Causes a) The that b) The water c) d) attemperating water system has failure or automatic malfunction so

the attemperating water flow increases abnormally. feed water pressure increases abruptly so that the attemperating

flow increases.

Coal pulverizing system is out of operation. Fouling of heating surface area.

10.4.2.3 Countermeasures a) When the automatic adjustment is abnormal, manual adjustment should be immediately adopted so as to resume the normal operation. b) Reduce valve in the attemperating has water volume; and close then motor-operated close valve if the stop

governor valve case

serious

leakage

hand-operated

of emergency.

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c) d) e)

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Soot blowing should be done to the superheater. Timely regulate the air volume and lift the flame center. If the temperature of main steam keeps decreasing after the above treatment measures have been taken, treatment should then be done according to the turbine manual (when the steam temperature drops to 510, the load of turbine should be properly reduced); turbine trip should be done when the temperature of main steam drops to 450.

10.4.3

High temperature of reheated steam

10.4.3.1 Faults a) b) c) Alarm is given due to high temperature of reheated steam (< 560); Temperature at various points in the reheating system increases. If the heating surface has leakage or explosion, temperature at various points before the breaking breaking 10.4.3.2 Causes a) The attemperating water system of reheater has automatic malfunction so that the attemperating water flow reduces; b) c) d) e) f) Air flow is too much; The flame center moves upwards; The heating surface of water wall is not clean; Fuel or fuel operating condition has changed; The coal pulverizing system starts up. point drops and temperature at various points after the point increases.

10.4.3.3 Countermeasures a) When the attemperating system of reheater has failure automatically, manual adjustment should be immediately adopted so as to ensure the reheated steam is in a normal condition. b) If the air volume is too much, the air volume should be properly reduced and the combustion should be adjusted.

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c)

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Strengthen soot blowing of the heating surface of water wall and reduce temperture of main steam when necessary.

d)

If the leakage and explosion of heating surface of the reheater causes the reheated steam should be temperature to increase, measures of temperature reduction taken immediatedly and treatment should be done according to

corrsesponding provisions as well. e) The openings of the upper tertiary air baffle plate and the lower tertiary air baffle plate should be regulated so as to lower the flame center. The openings of secondary air baffle plates of three rows of A, B and C should be regulated when neccessary. f) If the temperature of reheated main steam keeps increasing after the above measures of temperature reduction have been taken, the turbine should be adjusted together with the boiler according to relevant provisions. g) When the temperature of reheated main steam increases to 566, the turbine trip should be done. 10.4.4 Low temperature of reheated steam

10.4.4.1 Faults a) b) c) Alarm is given due to low temperature of reheated steam (< 520); Temperature at various points in the reheater system decreases. If the heating surface has leakage or explosion, temperature at various points before the breaking breaking 10.4.4.2 Causes a) The that b) c) d) e) attemperating water adjustment of reheater has malfunctions so point drops and temperature at various points after the point increases.

the attemperating water flow of the reheater increases;

The flame kernel moves downwards; The unit load is too low; Fuel or fuel operating condition has changed; The main steam stop valve of intermediate-pressure cylinder or high-pressure exhaust check valve has failure on a single side so that the steam flow deviation between the left

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side and the right side is caused. f) g) h) Safety valve of reheater outlet operates or the outlet section has leakage or explosion. The coal pulverizing system shuts down. Fouling of heating surface area of reheater..

10.4.4.3 Countermeasures a) When the automatic adjustment of attemperating water of reheater is abnormal, manual adjustment should be immediately adopted so as to resume the normal operation. The motor-operated valve should be closed when necessary and the hand-operated valve should then be closed if the leak volume is too much. b) c) If the air volume is too much, the air volume should be properly increased. Regulate the openings of secondary air baffle plates of three rows of A, B and C and the openings of the upper tertiary air baffle plate and the lower tertiary air baffle plate; lift the position of flame center. d) e) Strengthen soot blowing of the heating surface of the reheater. The turbine load should be reduced according to provisions when the reheated steam temperature continues to decrease to 510. f) When the temperature of reheated steam continues to decrease to 450, the turbine trip should be done. 10.5 Load Rejection of Unit Under one of the following cases, the boiler will automatically reduce load. 10.5.1 If one set of induced draft fan trips, the load reduces to 50% MCR. 10.5.2 If one set of forced draft fan trips, the load reduces to 50% MCR. 10.5.3 If one set of primary fan trips, the load reduces to 50% MCR. 10.5.4 If one set of air preheater trips, the load reduces to 50% MCR. 10.5.5 If one set of boiler water pump trips and the standby water pump can not be interlocked, the load reduces to 60% MCR. 10.5.6 If one set of feedwater pump trips and the standby pump can not be interlocked, the load

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reduces to 60% MCR.

BOILER & AUXILIARIES OPERATION MANUAL

10.5.7 If the turbine trips, the boiler load reduces to 70% MCR. 10.5.8 If operating with auxiliary power, the boiler load reduces to 70% MCR. 10.6 Auxiliary Power Supply Interruption

10.6.1 Faults 10.6.1.1 Turbine trips and the boiler MFT action is done. 10.6.1.2 All running machines trip. 10.6.1.3 Each motor-operated valve stays at the place before power interruption. 10.6.1.4 Pressure of main steam, steam temperature and flow all decrease. 10.6.2 Countermeasures 10.6.2.1 Ensure that DC fan of the flame scanner is in operation and DC motor of air preheater starts up. 10.6.2.2 Ensure that the TV water level gauge and flame TV of boiler framework are in operation. 10.6.2.3 Check and ensure that emergency drain three-way valve FV003 of boiler water pump should automatically open and outlet valve of boiler water pump should be closed by hand when the temperature of motor chamber of boiler water pump keeps on a rise. 10.6.2.4 The seal fan should starts up after the diesel-engine generator operates. 10.6.2.5 If the boiler is treated with soot blowing when auxiliary power interrupts, immediate maintenance should be done and the soot blowing gun should be withdrawn. 10.6.2.6 The following steps should be done after the power supply is restored. a) b) Make up water for the drum to the level of -100mm. Start up the boiler water pump after the closed cooling water system resumes normal operation. c) d) Start up the main motor of air preheater. Start up the AC cooling fan of flame scanner and stop the DC cooling fan and then conduct the interlocking.

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e) f)

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Start up the cooling fan of oil gun torch and conduct the interlocking. Check valves and ensure valve that vaious are motor-operated at the valves and regulating open the

of attemperating

water

closing

position;

recirculation g)

of economizer.

Start up the lubricating oil system of coal mill.

10.6.2.7 Confirm emergency water tanks and supply water to following equipment when the closed cooling water system interrupts. a) b) c) 10.7 Supply low-pressure cooling water to boiler water pump. Supply cooling water to bearings of auxiliary equipment. Supply cooling water to various oil coolers. Control&Instrument and Apparatus Power Supply Interruption

10.7.1 Faults 10.7.1.1 General power of thermal regulator and instrument lose. 10.7.1.2 After the general power loss alarm signal of thermal regulator and instrument is given, the power indicator of instrument turns off and the alarm is warning. 10.7.1.3 Survey meters and digital instruments have failure to display. Transmitter of automatic control device loses power; the indicator turns off; relevant meters indicate zero and automatic device has failure. 10.7.1.4 The secondary instrument instruction disorders on CRT graphic display. 10.7.1.5 protection Automatic protection the limit device has power device) failure has and the failure limit and

has malfunction;

regulator

(regulating

power

automatically shuts down when in automatic operation. 10.7.1.6 Remote control of equipment on CRT graphic display has failure and the water level can not be controlled. 10.7.1.7 The rotating speed of coal feeder indicates zero. 10.7.1.8 Unit operation is instable or even has fire-off and tripping. 10.7.2 Causes

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10.7.2.1 Electrical system or power bus has failure. 10.7.2.2 Switch or knife switch has failure and standby power fails to do automatic operation. 10.7.2.3 UPS power loses. 10.7.3 Countermeasures 10.7.3.1 If boiler has not fired off and the unit has not tripped when the thermal regulator and instruments lose power, various control equipment and systems should be switched to manual control and stably operate in the original operating condition. Strengthen the supervision and inspection of instruments on the spot and ensure the unit stable load as much as possible. If operation of corresponding valves and baffles is required, the manual operation can only be done after the contact work inside and outside the control room is well done. 10.7.3.2 Ensure the boiler framework stable combustion, supervise the primary meters, strengthen contact and emphasize on operation analysis referring to other relevant parameters without blind operation. Send personnel to monitor all water levels and make sure that the water levels are controlled in a normal range and strictly prevent accidents of overfeeding or short supply of boiler and water impact of turbine. 10.7.3.3 Inform relevant personnel for thermal regulation and quickly restore control power of instruments. 10.7.3.4 unit down due to failure. 10.7.3.5 If the protection is caused by loss of power of instruments or total power loss of boiler, turbine thermal regulator and instruments has met the conditions of emergency shutdown, treatment should be done according to emergency shutdown. 10.7.3.6 If the boiler has fire-off, treatment should be done according to provisions for fire-off. 10.7.3.7 Make reports to group chief and shift supervisor after the unit shuts down; reignite and start up the unit in thermal condition according to instructions of the shift supervisor after the thermal regulator and instrument are done with energization. 10.8 Fire Accident If the instrument power fails to timely be restored which threatens the

safety operation, report should be made to the shift supervisor and the instruments shall shut

10.8.1 Countermeasures for fire catching of the oil system. 10.8.1.1 If fire catching is found in the oil system, dry fire extinguisher or foam fire extinguisher

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should be instantly adopted for fire-fighting and report should be made to the shift supervisor to promptly notify the firefighters to extinguish fire. 10.8.1.2 If the fire has not yet threatened the unit operation, measures should be taken to prevent fire spread and put it out as soon as possible. 10.8.1.3 Move away combustibles around the fire spot and cut off power supply of electrical equipment on the spot. 10.8.1.4 Strengthen the operation supervision and prepare for shut-down. 10.8.1.5 Attention should be paid to that the fire shall not spread around the spot and wetted fire-retardant materials should be covered around the equipment when necessary (pay attention to the rotating parts of the unit). Report should be instantly made to the shift supervisor for shutdown when the fire threatens the unit safety. 10.8.1.6 If the fire threatens the safety of main oil tank, emergency shutdown should be done; start up the emergency oil relieve valve (ensuring the lubricating oil supply is not interrupted before the turbine stops) when the rotating speed of turbine decreases. 10.8.2 Fire catching of pulverized coal pipeline 10.8.2.1 Causes a) The primary air pipeline is worn and has pulverized coal leakage to the extent of heat insulation and has spontaneous combustion and fire-catching. b) The pulverized coal pipeline is blocked and is not cleared up in time.

10.8.2.2 Countermeasures a) Stop the corresponding coal pulverizing system and shut-off valve of coal mill outlet in accordance with specific conditions and extinguish fire with foam or fire-fighting water. b) When coal fire catching occurs due to incomplete block off of pulverized

pipeline, personnel for locomotive maintenance should be contacted for

purging of primary air pipeline and corresponding treatment. 10.8.3 Notice items of fire extinguishing 10.8.3.1 If clothes which are not immersed in kerosene, diesel, petrol and other oils and wooden materials catch fire, foam fire extinguisher, water and sand should be employed for fire fighting.

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10.8.3.2 If oil tanks or oil in other containers catches fire, oil should be discharged from the emergency oil relieve valve and foam fire extinguisher or wetted raincloth could be used for fire fighting. 10.8.3.3 If the energized equipment catches fire, fire fighting should be done after the electricity is cut off; sand and foam fire extinguisher should not be used for fire fighting when the motor catches fire. 10.8.3.4 If found fuming, the motor should be promptly stopped running and the shift supervisor and chief supervisor should be informed of the situation. 10.8.3.5 Power Observe relevant provisions of Specification for Fire Protection of Electric

Installation during fire fighting. 10.9 Processing Inferior Quality of Water and Steam

10.9.1 Processing value of abnormal water quality of condensate

Items

Standard value With mixed

Processing value Stage I 030~0.40 Stage II 0.40~0.65 Stage III >0.65

Electric conductivity (S/cm)

bed Without mixed bed With mixed

0.30

0.20

0.20~0.35

0.35~0.60

>0.60

Hardness (mol/l)

bed Without mixed bed

2.0

>2.0

>5.0

>20.0

>2.0

Note: emergency shutdown should be done when sodium content in condensate is more than 400g/l. 10. 9.2 Processing value of abnormal water quality of boiler feedwater Items Standard Processing value

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BOILER & AUXILIARIES OPERATION MANUAL value Stage I 030~0.40 >7 <8.8 or Stage I 0.40~0.65 >20 Stage I >0.65 -

Electric conductivity (S/cm) Dissolved oxygen (g/l)

0.30 7

pH(25)

8.8~9.3 >9.3

10.9.3 Processing value of abnormal water quality of boiler water Standard value 9~10 of chloridion and Processing value Stage I 9~8.5 sodium, electric Stage I 8.5~8.0 conductivity and Stage I <8.0 alkalinity should

Items

pH(25) Note: also contents

be measured.

Definition of above processing values of three stages: Processing value of Stage I: the possibility that corrosion, scaling and salt deposition are caused by impurities may be existed and the standard value should be resumed within 72 hours. Processing value of Stage II: the possibility that corrosion, scaling and salt deposition are caused by impurities is surely existed and the standard value should be resumed within 24 hours. Processing value of Stage III: the corrosion, scaling and salt deposition are forming in a fast way and the boiler should be shut down within four hours. During each stage of abnormal processing, if the standard value fails to be resumed within the required time, processing method of a higher level should be employed and one of the methods to restore the standard value of water quality is to operate under lower pressure. 10.9.4 Principles of processing for abnormal water steam quality of unit 10.9.4.1 Promptly inspect whether the sampling is representative or not, whether

the testing equipment is in normal condition and whether the test results are correct when the water steam quality degrades. Comprehensively analyze the change of water and steam quality in the system and make reports to the chief engineer for the situation after correct confirmation and judgement and take measures to ensure that the standard value of the water steam quality is surely resumed within the allowable time.

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10.9.4.2 When each items of water steam quality reach the processing value of Stage I and the possibility that corrosion, scaling and salt deposition are caused by impurities may be existed and the standard value should be resumed within 72 hours. 10.9.4.3 When each items of water steam quality reach the processing value of Stage II and the possibility that corrosion, scaling and salt deposition are caused by impurities is surely existed and the standard value should be resumed within 24 hours. 10.9.4.4 When each items of water steam quality reach the processing value of Stage III and the corrosion, scaling and salt deposition are forming in a fast way and the boiler should be shut down within four hours if the water quality is still in bad condition. 10.9.4.5 One of the methods to restore the standard value of boiler water quality is to operate under lower pressure. 10.9.4.6 During each stage of abnormal processing, if the standard value fails to be resumed within the required time, processing method of a higher level should be employed. 10.10 Boiler Heating Surface Slagging Seriously

10.10.1 Faults 10.10.1.1 When the water wall is scorched, the temperature of main steam and reheated steam will have an abnormal increase. 10.10.1.2 When the heating surfaces of the superheater and the reheater are scorched, the temperature of main steam and reheated steam will have an abnormal decrease. 10.10.1.3 The flue gas temperature has an abnormal increase. 10.10.1.4 When the coke slag is shedding, much change will occurs in the boiler framework pressure, which will impact the stability of combustion. 10.10.2 Causes 10.10.2.1 Low ash melting point in coal combustion; 10.10.2.2 Deflection of flame center during combustion; 10.10.2.3 Overload operation of the boiler for a long time. 10.10.3 Countermeasures 10.10.3.1 Adjust the combustion operating condition and properly lower the flame center in order

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not to cause deflection of the flame center; 10.10.3.2 Decrease the flue gas temperature deviation of boiler framework outlet and lower the temperature of boiler framework outlet; 10.10.3.3 Properly strengthen the soot blowing; 10.10.3.4 Select coal with relatively high ash melting point and conduct according to specific combustion measures of corresponding coal type when the coal type alternation is unavailable; 10.10.3.5 Properly reduce the boiler operation load and strengthen the disturbance in the boiler; 10.10.3.6 Strengthen the monitoring for coking performance in the boiler. 10.11 Gas Duct Reburning

10.11.1 Faults 10.11.1.1 Flue gas pressure has a sharp increase in the gas dust; 10.11.1.2 Negative pressure in the gas dust decreases; 10.11.1.3 Flue gas exhausts in the clearance of valves and holes of the gas dust; 10.11.1.4 Fire alarm is given when the recombustion occurs in the air preheater. 10.11.2 Causes 10.11.2.1 Due to long-term application of coarse pulverized coal or improper ratio of air/coal, the incompletely-burned pulverized coal deposits in the gas duct. 10.11.2.2 Improper operation and adjustment or long-term upward moving of the flame center causes the incompletely-burned pulverized coal to enter the gas duct. 10.11.2.3 Feed pulverized coal in advance during the start-up. 10.11.2.4 Long-term operation under low load, relatively low temperature of boiler framework or the relatively small excess air coefficient worsen the combustion and cause a great deal of combustibles to burn in the gas dust. 10.11.2.5 No purging is done to the boiler framework according to provisions after boiler shutdown. 10.11.3 Countermeasures 10.11.3.1 Adjust combustion when the abnormal increase of temperature is found in the gas duct and instantly conduct the soot blowing with soot blowing gun in the duct.

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10.11.3.2 Make reports to the shift supervisor and do the emergency boiler shutdown if abnormal increase of temperature in the gas duct or flue gas still occurs after some measures have been taken. 10.11.3.3 The primary air fan, forced draft fan and induced draft fan should be instantly stopped after boiler shutdown and all the air valves and baffle plates should be closed for enclosement. 10.11.3.4 The following measures should be taken when the fire catching of preheater occurs: a) b) c) d) e) f) Ask instructions from the shift supervisor and conduct the emergency boiler shutdown. Stop all the primary air fans, forced draft fans, induced draft fans and steam air heaters. Close the air baffle plate and flue gas baffle plates of the air preheater. Open the inspection hole of the lower ash hopper of the air preheater. Instantly put the fire-fighting water device of air preheater into operation for fire fighting. Inspect the water discharge condition of ash hopper of air preheater and timely smoothen the air hopper so as to prevent the ash hopper collapse. g) The fire-fighting water supply can only be stopped after the fire completely extinguishes and the flue gas temperature decreases to a normal value. h) Water washing should be done to the air preheater if the ash deposition is serious and the air preheater should be dried with the steam air heater after water washing. 10.11.3.5 Slowly and carefully open the inspection hole for inspection and start up the induced draft fan only after no fire sources is ensured. 10.11.3.6 Ignition and start-up can only be done after the equipment is checked and ensured no abnormality and the instruction from the shift supervisor is received. 10.12 Unit Trip

10.12.1 Faults 10.12.1.1 Main steam pressure is rapidly increased, high and low pressure bypass valves are automatically and swiftly open. 10.12.1.2 Main steam flow is swiftly dropped, high and low pressure bypass valves return 15 seconds after opening. 10.12.1.3 Reheat steam pressure is rapidly increased and reheater exhaust valve is automatically

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opened.

BOILER & AUXILIARIES OPERATION MANUAL

10.12.1.4 Water level of drum is low before it gets high. 10.12.1.5 Main steam temperature and reheat steam temperature tend to be high before it drops low. 10.12.1.6 is After turbine trips, if low pressure bypass functions abnormally or

adjusted inappropriately, safety valve of reheater or of drum will start operating.

10.12.1.7 When main steam flow is under 420T/H with oil gun still unused, all coal feeders will trip and boiler MFT will start operating. 10.12.1.8 When low pressure bypass fails and closes down, reheater exhaust valve remains closed, boiler MFT will starts operating. 10.12.2 Countermeasures 10.12.2.1 Boiler load is automatically dropped to 70%MCR, or make it happen by hand. 10.12.2.2 High and low pressure bypass valves should be swiftly opened or have it opened by hand. 10.12.2.3 Make sure that exhaust valve of reheater is automatically opened, or open it by hand. 10.12.2.4 Before the oil gun is put into use, stabilize the load above 420T/H to avoid boiler MFT operation. 10.12.2.5 When the number of oil gun put into use exceeds 4 according to rules, gradually stop the pulverized coal feeder that has not yet been provided with oil guns and lower oil load to avoid closing low pressure bypass because of low vacuum in turbine. 10.12.2.6 Properly lower main steam pressure fixed value. 10.12.2.7 When main steam pressure drops, place high pressure bypass under

automatic or manual position to avoid the tripping of boiler because of the closure of high pressure bypass valve. 10.12.2.8 not Attention should be paid to drum water level, when water feeding can

work automatically, switch to manual regulation.

10.12.2.9 Maintain the superheat steam temperature and reheat steam temperature at above 500 DEG C, attention should be paid to desuperheater water to make sure that it is normal; if not,

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control it manually. 10.12.2.10 should 10.13 If tripping of

BOILER & AUXILIARIES OPERATION MANUAL

turbine

can

not

be

swiftly

restored,

boiler

combustion

be maintained and MFT operation be avoided. Steam Drum Full Feeded

10.13.1 Faults 10.13.1.1 When water level height reaches +25mm, alarm should be sounded, but if 10 seconds later, water level remains at the same level, operate MFT. 10.13.1.2 Water level of TV water level gauge and local water level gauge is too high to be seen. 10.13.1.3 Feedwater flow is abnormally greater than main steam flow. 10.13.1.4 Steam gas temperature is rapidly dropped, main throttle valve flange emits white vapor, when it is serious, water hammer will take place as a result. 10.13.1.5 Superheat steam gas conductivity is high. 10.13.2 Causes 10.13.2.1 Feedwater automatic regulation fails to work; 10.13.2.2 water Errors caused by falseness of water level indication or relaxing of

level surveillance;

10.13.2.3 Boiler load is low and feedwater regulating valve leaks too much; 10.13.2.4 Load or steam pressure fluctuation is too great; 10.13.2.5 Sudden opening of high pressure bypass or operating of drum safety valve; 10.13.2.6 All furnace water pumps trip; 10.13.2.7 When water level is in the form of default, its setting value is too high; 10.13.3 Countermeasures 10.13.3.1 When water level reach -75mm and high water level signal has been sent out, feedwater regulating should should be immediately if necessary, switched stable to relief manual valve status and and feedwater relief flow valve be diminished, continuous

should be coordinately regulated until drum water level returns to normal. 10.13.3.2 When feedwater regulating valve leaks too much, load should be increased properly, if

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necessary to maintain normal water level. 10.13.3.3 When water regulation and meter indication are inaccurate, thermal engineering experts should be immediately sent for. 10.13.3.4 During operation, surveillance of drum water level and checking of local water level gauge should be reinforced, and mistakes should be avoided. 10.13.3.5 Desuperheater water should be disconnected according to steam temperature, and drainage in superheater and main steam valve should be started. 10.13.3.6 After MFT is operated, address problems according to methods following the operation of MFT. 10.13.3.7 After the above measures have been taken, if drum water level still rises to pass +25mm, while MFT is still out of operation, the following emergency measures should be taken: a) b) Press emergency shut down button; Stop feed (water) pump and make sure that the recirculating valve of coal economizer has been opened; c) d) e) f) g) Make sure that main steam valve is closed; Open all drains of superheater system and main steam drain of turbine as well; Make sure that all desuperheater water valves have been closed; Water discharging should be reinforced until drum water level is seeable; When overflow has been ruled out and drum water level have returned to normal, boiler will not be restarted until shift supervisor have agreed to do so; 10.14 Steam Drum Short Feeded

10.14.1 Faults 10.14.1.1 Water levels shown in TV and local water level gauges are too low to be seen. 10.14.1.2 Drum water level keeps dropping after alarm is sounded when it drops to -415mm, and when it drops to -600mm, if 10 seconds after the drumwater level record low alarm have sounded, it remains at the same level, MFT should be operated. 10.14.1.3 Feedwater flow is abnormally less than steam flow (the other way round is true of coal economizer and water cooled wall leakage).

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shakes. 10.14.2 Causes

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10.14.1.4 When water shortage is serious, pressure difference of furnace water pump is low and it

10.14.2.1 Feed water control malfunction and feed (water) pump failure result in the decrease of water allowance or water main pressure becoming too low. 10.14.2.2 Falseness of water level indication results in operation that is wrong. 10.14.2.3 Feed water line leaks too much. 10.14.2.4 contact Leakage and mis-operation of blow down valve or pollution discharge

is inappropriate.

10.14.2.5 Cracking of water wall tube or economizer tube. 10.14.2.6 Load fluctuation is too great. 10.14.2.7 Opening indication of feedwater-regulating valve fall short of actual opening. 10.14.2.8 Feedwater electrically operated valve mis-close or feedwater regulating valve panel falls off. 10.14.3 Countermeasures 10.14.3.1 When water level is (-415mm) with furnace water pump operating normally and alarm is sounded, feedwater regulation should be immediately switched to manual status, and more water should be pumped into boiler to return drum water level to a normal level. 10.14.3.2 All drainage operation should be stopped. 10.14.3.3 Attention should be paid to changes of main steam temperature in the process of water inflow. 10.14.3.4 When the above measures have been taken, water level keep dropping to -600mm at which MFT begins to operate in 10 seconds, if not, the following measures should be taken. a) b) Press emergency shut down button Stop the operation of furnace water pump, feed boiler with water when drum water level is lower than visible water level. If regulating valve panel falls off, furnace water pump should be immediately stopped, boiler be fully closed, electric unit be notified to stop furnace water pump power supply, and at the same time, furnace water pump should be

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closed off and attention paid to drum wall temperature changes. c) Reasons for water shortage should be identified and it should be properly solved, boiler can not be restarted until orders to do so have been authorized by shift supervisor. d) Water inflow time and speed of water-empty boiler should be decided by director in charge who will issue the order. 10.15 Priming

10.15.1 Faults 10.15.1.1Drumwater level drastically fluctuates and water level inside water level gauge is unclear; 10.15.1.2 Feedwater self regulation is unsound; 10.15.1.3 Main steam temperature is dropped and steam conductivity is increased, when it is serious, water slug will take place inside the main steam pipes. 10.15.2 Causes 10.15.2. Quality of feedwater or boiler water is unqualified; 10.15.2.2 Boiler load drastically drops or steam pressure drastically drops; 10.15.2.3 Oil entering into the steam system. 10.15.3 Countermeasures 10.15.3.1 Report to shift supervisor, decrease and stabilize boiler load; 10.15.3.2 Open continuous relief valve, intensify stable relief valve, and lower the drum water level to -50mm; 10.15.3.4 Chemist should be notified to stop adding drugs and increase boiler water laboratory test. 10.16 High Furnace Pressure

10.16.1 Faults 10.16.1.1 Furnace pressure high I value alarm sounds; 10.16.1.2 Indication of furnace draft meter skews positively; 10.16.1.3 Fume is emitted from leaking zone of furnace;

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10.16.1.4 When furnace pressure high II value alarm sounds, MFT will take place. 10.16.2 Causes 10.16.2.1 Force fan can not track and check in time after single induced fan fails and trips; 10.16.2.2Automatic device of furnace draft fails; 10.16.2.3 Suction guide and outlet damper of induced fan or smoke damper of gas dust are mis-closed; 10.16.2.4 Combustion operation conditions deteriorate; 10.16.2.5 Pressure-bearing members inside furnace have been seriously burst. 10.16.3 Countermeasures 10.16.3.1 Guide vane of induced fan should be switched to manual status and its opening should be regulated to maintain the furnace negative pressure at a normal level; 10.16.3.2 Baffle plate that has been mis-closed should be restored to its original state in time; 10.16.3.3 When furnace pressure is high and MFT starts, problem should be addressed according to relevant rules followed by the resolution of the operation of MFT. 10.17 Low Furnace Pressure

10.17.1 Faults 10.17.1.1 Furnace pressure low alarm sounds; 10.17.1.2 Indication of furnace pressure meter is increased in the direction of minus value; 10.17.1.3 When furnace pressure low II value alarm window sound the alarm, MFT will take place. 10.17.2 Causes 10.17.2.1 Induced fan can not track and check in time when single force fan fails and trips; 10.17.2.2 Furnace draft self regulation fails to work; 10.17.2.3 Inlet movable vane and outlet damper of force fan and air duct baffle plates are mis-closed; 10.17.2.4 Assisted wind regulating baffle plate fails or is mis-closed;

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10.17.2.5 Boiler combustion working condition deteriorates or boiler fire goes out. 10.17.3 Countermeasures: 10.17.3.1 Flushing should be burned steadily by adding oil; 10.17.3.2 Regulate the opening of induced fan suction guide; maintain the furnace draft at a normal level; 10.17.3.3 When draft self regulation fails, manual regulating should be switched on; 10.17.3.4 Return baffle that has been mis-closed to its original state; 10.17.3.5 When furnace pressure low II value alarm window sounds the alarm, operate MFT according to MFT relevant rules. 10.18 Boiler Burning Out

10.18.1 Faults 10.18.1.1 Furnace pressure suddenly drops on a large scope, and primary and secondary wind pressures drop simultaneously; 10.18.1.2 Furnace losing flames alarm sounds; 10.18.1.3 Flame detector shows no sigh of flame; 10.18.1.4 Flame check of burner at all levels all disappears; 10.18.1.5 MFT operates; 10.18.1.6 Steam temperature, steam pressure and main steam flow rapidly drop; 10.18.1.7 Water level goes down before it goes up. 10.18.2 Causes: 10.18.2.1 Failure and tripping of force fan, induced fan and primary fan, etc. or operation of boiler tripping protection; 10.18.2.2 When load is low, mixture ratio of wind and coal is seriously maladjusted; 10.18.2.3 When load is low, coal quality become worse and coal powder become thick, resulting in the deterioration of burning working condition; 10.18.2.4 Oil is not put in to stabilize burning when the combustion is unstable;

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10.18.2.5 Operational manner of burner is inappropriate; 10.18.2.6 When load is low, flame is blown out by furnace soot-blowing and water wall tube blast or furnace draft is too great; 10.18.2.7 Water wall does not soot-blow, resulting in the falling of coke on a large acreage; 10.18.2.8 Oil system fails or oil-receiving electromagnetic valve is mis-closed when oil is burning; 10.18.2.9 House supply interrupts or MFT mis-operate. 10.18.3 Countermeasures: 10.18.3.1 Problems should be addressed according to relevant rules followed by the resolution of the operation of MFT; 10.18.3.2 After causes are identified and removed, start induced and force fan with over 30% that of air volume blowing furnace for 5 minutes, after that, reignite the furnace; 10.18.3.3 After fire is extinguished, the lifting of fire-extinguishing protection is banned and igniting by deflagration is adopted. 10.19 Fuel Trip

10.19.1 Faults 10.19.1.1 Send out signal alarm to prompt total loss of fuels. 10.19.1.2 MFT happens to the boil. 10.19.1.3 All pulverizing systems trip and fuel oil supply is stopped. 10.19.1.4 No flame is shown in flame scanner of the furnace. 10.19.2 Causes 10.19.2.1 Coal in all coal silos is run out of. 10.19.2.2 All pulverizing systems trip. 10.19.2.3 Trouble happens to oil system during combustion or oil intake electromagnetic valve is closed by mistake. 10.19.3 Countermeasures 10.19.3.1 Eliminate the trouble according to MFT troubleshooting.

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10.19.3.2 Find out the reason and recover operation as soon as possible. 10.20 Water Wall Tubes Txplosion

10.20.1 Faults 10.20.1.1 Steam pressure is down and water level in drum is dropped. 10.20.1.2 Negative pressure in furnace is reduced or turns to positive pressure. 10.20.1.3 The opening of baffle plates at the entrance to the induced draft fan is abnormally increased. 10.20.1.4 Smoke comes out from the part where the sealing is not good in the furnace. 10.20.1.5 Steam ejection sound or explosion is heard from the furnace. 10.20.1.6 Water supply is abnormally larger than the steam flow. 10.20.1.7 The combustion is not stable and even may go out. 10.20.1.8 The flue temperature is dropped. 10.20.2 Causes 10.20.2.1 Poor quality of furnace water, which causes serious scale formation in pipelines. 10.20.2.2 The entrance orifice of water wall is blocked, which causes bad water circulation. 10.20.2.3 Serious coking in water wall, which causes uneven heat exposure. 10.20.2.4 Flame deflection, which causes uneven heat exposure in local water wall. 10.20.2.5 Water wall is damaged by large dropping lump coke. 10.20.2.6 Bad welding of water walls. 10.20.2.7 Serious sulfur corrosion. 10.20.3 Countermeasures 10.20.3.1 If there is leakage happening to water wall but the water in the drum can be kept at a normal level, short run operation in proper reduced load is permissible, but the chief attendant should inform a factory director and ask for arrangement of boiler shut down which should be done according to regular shut down procedures. 10.20.3.2 If the water wall is seriously damaged and the water in steam drum is not kept at a

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normal level, the following measurements should be conducted. 10.20.3.3 Press emergency shut down to stop the furnace quickly. 10.20.3.4 After the boiler is shut down, the induced draft fan should be kept

running and the furnace kept at a negative pressure. Stop the induced draft fan and change the ventilation into natural ventilation when it is considered to be proper and keep the furnace at a negative pressure to emit flue and steam inside. 10.20.3.5 Continue supplying water to the furnace to maintain the water level of the drum; close static-row and link-row motor-operated valve and hand-operated valve. 10.20.3.6 If the leakage of the water wall is extremely serious, and the water level in the drum can not be kept after the furnace is stopped, the furnace water pump and feed water pump should be stopped as well as recirculation valve of economizer. 10.20.3.7 deposited deposit. 10.21 Economizer Tubes Explosion The in economizer should be received enough care and ashes

the economizer and the ash hopper of the air preheater should be

cleared up timely to prevent accidents of ash hopper and flue duct collapse caused by ash

10.21.1 Faults 10.21.1.1 Water level in drum is dropped. 10.21.1.2 Water supply is abnormally larger than the steam flow. 10.21.1.3 Abnormal noise is heard at economizer part. 10.21.1.4 Ash hopper at the lower part of economizer is blocked by wet ash or ash water is leaked from the ash hopper. 10.21.1.5 Flue temperature at the water leakage side is dropped. 10.21.1.6 There exists great difference of flue temperature at A side and B side of the entrance of the air preheater. 10.21.1.7 The opening of baffle plates at the entrance to the induced draft fan is increased. 10.21.2 Causes 10.21.2.1 Poor quality of feed water, which causes serious scale formation in pipelines and to burn tube.

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10.21.2.2 It is worn by flying ash.

BOILER & AUXILIARIES OPERATION MANUAL

10.21.2.3 The recirculation valve of economizer is not operated according to provisions in boiler starting or shutdown. 10.21.2.4 The tube is blocked when installation or maintenance. 10.21.2.5 Poor quality of tube or welding. 10.21.3 Countermeasures 10.21.3.1 Increase water supply to keep the water level in the drum. 10.21.3.2 Operate it at a lower load and pressure and ask for factory director to decide the boiler shut down time. 10.21.3.3 If the water level is not kept at a normal level after water supply increasing, stop the boiler immediately with the approval of the chief attendant. 10.21.3.4 Try to keep the water level in drum as possible after the boiler shut down and close continuous drainage valve and regular drainage valve, hand-operated valve and recirculation valve of economizer. 10.21.3.5 deposited deposit. 10.22 Superheater Tubes Explosion The in economizer should be received enough care and ashes

the economizer and the ash hopper of the air preheater should be

cleared up timely to prevent accidents of ash hopper and flue duct collapse caused by ash

10.22.1 Faults 10.22.1.1 Main steam pressure is dropped. 10.22.1.2 Water supply is abnormally larger than the steam flow. 10.22.1.3 flue tube. 10.22.1.4 Abnormal noise is heard at the leakage of superheater. 10.22.1.5 Flue temperature at the leakage side is dropped. 10.22.1.6 If roof tube, wall enclosure tube or low over leakage cause high over and medium over steam temperature rising, and if the medium over and high over leak, the main steam temperature rises. duct The negative pressure in the furnace turns positive and pressure in

is increased; steam is ejected from the part where the sealing is not good in the flue

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10.22.1.7 Large steam temperature difference between the two sides. 10.22.1.8 The opening of baffle plates at the entrance to the induced draft fan is abnormally increased. 10.22.2 Causes 10.22.2.1 Steam quality is deteriorated in the long run and scale formation in the tube causes over heat on the tube wall. 10.22.2.2 Over heat or coking happens frequently in superheater. 10.22.2.3 It is seriously worn by flying ash. 10.22.2.4 Recombustion happens to some section of superheater. 10.22.2.5 Ash gun is wrongly installed or trouble comes up during operation and the gun is broken. 10.22.2.6 The tube is not qualified or the welding quality is poor. 10.22.3 Countermeasures 10.22.3.1 When the over heater tube leaks, reduce load and pressure for operation and ask for factory director to arrange to shut down the boiler. 10.22.3.2 If the superheater tube is seriously damaged, it should prevent the worsening of any accident. 10.22.3.3 After the boiler is shut down, the induced draft fan should be kept

running and the furnace kept at a negative pressure. Stop the induced draft fan and change the ventilation into natural ventilation when it is considered to be proper and keep the furnace at a negative pressure to emit flue and steam inside. 10.22.3.4 deposited deposit. 10.23 Reheater Tubes Explosion The in economizer should be received enough care and ashes

the economizer and the ash hopper of the air preheater should be

cleared up timely to prevent accidents of ash hopper and flue duct collapse caused by ash

10.23.1 Faults 10.23.1.1 The pressure at the outlet of reheater is dropped. 10.23.1.2 Main steam flow is increased.

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10.23.1.3 Abnormal noise is heard nearby the reheater and when explosion, the negative pressure in the furnace turns to positive and even steam or flue is ejected from the part where the sealing is not good in the furnace or flue duct in serious case. 10.23.1.4 The opening of baffle plates at the entrance to the induced draft fan is abnormally increased. 10.23.1.5 The steam temperature difference at the two sides of the reheater is large and the temperature at the trouble side rises. 10.23.2 Causes 10.23.2.1 The steam quality is poor, which causes scale formation inside or maintenance of the furnace after shutdown is done improperly, which corrodes the reheater tube. 10.23.2.3 It is worn by flying ash. 10.23.2.4 Poor quality of tube or welding. 10.23.2.5 The furnace temperature is not controlled strictly during operation and steam supplying protection to the reheater is not sufficient during starting and shutdown. 10.23.3 Countermeasures 10.23.3.1 If the reheater tube is not seriously damaged, operate it in a lower load and ask for the factory director to arrange boiler shut down. 10.23.3.2 If the reheater tube is seriously damaged, do emergency shutdown after consent of the chief attendant. 10.23.3.3 After the boiler is shut down, the induced draft fan should be kept

running and the furnace kept at a negative pressure. Stop the induced draft fan and change the ventilation into natural ventilation when it is considered to be proper and keep the furnace at a negative pressure to emit flue and steam inside. 10.24 The Break of Steam Pipes or Feedwater Pipes Outside the Boiler

10.24.1 Faults 10.24.1.1 Humility, water seepage or water leakage or steam leakage in damaged part. And even leakage noise is heard. 10.24.1.2 Loud noise is heard when the pipe is explodes and steam and water are ejected and supports and hangers may be damaged.

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10.24.1.3 Steam or feed water pressure and the flow change are abnormal. 10.24.2 Causes 10.24.2.1 Poor material quality and unqualified fabrication, installation and welding, which affect free expansion. 10.24.2.2 Local wall Long run operation under over pressure and over heat conditions.

of wearable parts (such as parts near elbow and porous plate) get thin, which lower

metal strength. 10.24.2.3 Pipe heating and water drainage are not sufficient during boiler ignition process, which causes serious water impact. 10.24.2.4 Unqualified feed water quality, which causes pipe wall corrosion. 10.24.2.5 Dramatic changes of media flow, temperature and pressure happen during operation, which causes fatigue and damage to the duct. 10.24.3 Countermeasures 10.24.3.1 If the pipe is not severely damaged and is capable of supporting the normal operation and will not worsen the troubles: 1) Adjust various parameters of the boiler, properly reduces the load to keep the normal operation and report to chief attendant and apply for boiler shutdown. 2) Provide security measurement around the damaged part and prevent steam or water from hurting personnel. 3) Pay close attention to the damaged parts and precast any accident that may happen. 10.24.3.2 Immediately stop the boiler in any emergency case that the severely damaged pipe or trouble may cause accident. 10.24.3.3 Separate the damaged pipe section from the system as soon as possible after the boiler shut down. 10.25 High Steam Drum Pressure

10.25.1 Faults 10.25.1.1 High pressure indicated in the pressure gauge of the drum. 10.25.1.2 High pressure indicated in superheat steam pressure gauge. Alarm window is lighted and alarm is sounded.

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10.25.1.3 When the superheat steam pressure is up to 18.5MPa, the high pressure bypass valve and the low pressure bypass valve of the turbine are automatically opened (not been provided yet). 10.25.1..4 When the superheat steam pressure is up to 2.05MPa, the electromagnetic release valve automatically opens. 10.25.1..5 When the superheat steam pressure is up to 2.25MPa, the safety valve at the outlet of superheater starts to work. 10.25.1..6 When the superheat steam pressure is up to 20.62MPa, the safety valve of the drum starts to work. 10.25.1.7 After the electromagnetic release valve or the safety valve starts to work, the water level in the drum first goes up and then drops. 10.25.2 Causes 10.25.2.1 The load is declined abruptly. 10.25.2.2 The safety valve fails to move. 10.25.2..3 The first valve of the electromagnetic release valve fails to open or the electromagnetic release valve has not been shifted to automatic status. 10.25.2.4 Coal feeding controller (automatic combustion control) of the boiler is not dislocated or the turbine speed regulating system fails. 10.25.2.5 The adding of high pressure bypass and the low pressure bypass is not successful. 10.25.2.6 Pulverizing system works at an abnormal status. 10.25.2.7 Automatic control system fails. 10.25.3 Countermeasures 10.25.3.1Immediately take depressurization measurements: a) Reduce coal feeder rotation speed and add oils for facilitating combustion according to the combustion situation in the furnace. Stop the pulverizing system if necessary. b) c) Open high pressure bypass valve and low pressure bypass valve of the turbine. Manually open electromagnetic release valve.

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10.25.3.2 Shift the operation mode of CCS coordination control system to boiler basic mode. 10.25.3.3 When the pressure in drum surpasses the safety valve working pressure and the safety valve fails to move, stop the boiler manually and takes corresponding measurements to reduce the pressure. 10.25.3.4 When the boiler pressure is recovered, close the electromagnetic release valve and contact the turbine group to close the high pressure bypass valve and low pressure bypass valve. 10.25.3.5 Pay close attention to the work conditions of the automatic regulation control device of the drum water level and the steam temperature and shift the mode to manual mode to regulate it manually if necessary. 10.26 10.26.1 Auxiliary Failure Faults and countermeasures of air preheater

10.26.1.1 Too low rotating speed 1) Faults a) When the rotating speed of the air preheater during operation is as low as 0.2rpm, the main motor trips and the red and yellow lamps flash. b) c) Alarm for too low revolution is sounded. The low speed motor is automatically started and if the over low speed lasts more than 80s, the low speed motor will automatically stop and the baffle plates of flue and air are closed. d) 2) If the control power fails, the main motor trips and the low speed motor starts.

Countermeasures a) b) c) d) e) Check whether the main motor and hydraulic coupling work normally; Notice thermal operation personnel to check the rotating speed detector; Check whether there is jamming or bump in the air preheater; Control the continuous rotation on spot for a necessary period if possible for cooling; Confirm the baffle plate of the inlet of the flue and the first thermal air baffle plate and the second thermal air baffle plate are closed when the air preheater fails and is shut down.

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10.26.1.2 High bearing temperature (60) 1) Faults a) b) 2) Alarm is sound for high temperature of bearing (TSH15, TSH25) Lubricating oil pump starts automatically.

Countermeasures a) When the bearing temperature is not less than 60 and the lubricating oil pump fails to start, manually start it on DCS. b) c) Check whether the oil pump runs normal and the oil level and the oil quality are regular. If the temperature shows no decline after the starting of oil pump for a long time, check whether the oil pressure difference of the filter is normal on site. If the pressure difference is too large, shift to another filter and ask for maintenance of the filter at the trouble side. d) Check whether the cooling water flows smoothly and whether there is leakage on the oil pipeline. e) f) The oil pump is automatically stopped when the oil temperature is declined to 50. Check whether the air duct leaks, if any, notice relative personnel for maintenance.

10.26.1.3 Bearing oil pump trip 1) Faults a) b) 2) Yellow lamp and red lamp on the oil pump flash Alarm is sound for high temperature of bearing

Causes a) b) Oil pump motor fails or leak electrically The mechanical part fails

3)

Countermeasures a) b) Notice relative personnel to eliminate the motor troubles timely Recover 380V power supply

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c) d)

BOILER & AUXILIARIES OPERATION MANUAL

Eliminate the mechanical part troubles Strictly monitor the air preheater bearing oil temperature and take necessary measures to cool the oil.

10.26.1.4 Complete shutdown of the air preheater 1) Faults a) b) MFT operation; Interlocking trip happens to various auxiliary equipments and flameout happens in the boiler; c) d) 2) Sector-shaped sealing baffle plate withdraws automatically; The alarm that air preheater systems A and B fail is sounded from the alarm window.

Causes a) b) The power of air preheater motor is lost; The rotating speed of the air preheater is lower than 0.2rpm and the low speed motor fails to start within 80s.

3)

Countermeasures a) b) c) Resolve it according to the method for MFT. Confirm the air preheater is stopped; Confirm the flue baffle plate of the air preheater inlet and the second thermal air baffle plate of the outlet are closed; d) Find out the reason and remove the trouble. Prepare the boiler for restart. Trip of one air preheater

10.26.1.5 1) Faults a) b) c)

Lamp at the trip side of the air preheater flash and the alarm trump is sounded; Induced draft fan, force fan and primary air fan at the corresponding side trip; The alarm that air preheater fails at the trip side is sounded from the alarm window;

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d) FEE and FEI trip. 2) Causes a) b) c) 3)

BOILER & AUXILIARIES OPERATION MANUAL

The load is recovered to 50% of MCR, and six pulverizer coal feeders including FEA,

Mechanical jamming happens to the air preheater at the trip side; The motor of the tripping air preheater fails or losses power; Shutdown button or emergency button is pressed by mistake.

Countermeasures a) The load is automatically inclined to 50% of MCR, the load of the set is turned to 50% of MCR and the alarm is trigged. b) Confirm the flue baffle plate of the air preheater inlet and the primary and the second thermal air baffle plates of the outlet are closed, otherwise close them manually. c) Air fan at the corresponding side automatically trips and the baffle plate at the outlet and the inlet automatically close; otherwise close them manually. d) Six pulverizer coal feeders including FEA, FEE and FEI trip automatically; otherwise trip them manually. e) f) Provide a proper amount of oil gun torches to facilitate and stabilize combustion. Find out trip Causes and start relative equipment again after they are inspected and proved to be normal. g) h) Monitor the shutdown side. Control the flue temperature and the air temperature at the inlet and the outlet of the air preheater. i) Send out a fire alarm. Induced draft fan faults and countermeasures

10.26.2

10.26.2.1 Complete shutdown of two induced draft fans 1) Faults a) MFT

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b) automatically closed. c)

BOILER & AUXILIARIES OPERATION MANUAL

The motors of the two induced draft fans are powered off and the outlet baffle plate is

If the electric protections system starts to work, the alarm that induced draft system fails is sounded from the alarm window.

d)

The two force fans are interlocked and the two primary fans are stopped completely, the total air amount and the air pressure are dropped to zero instantly.

e) 2)

The negative pressure in the furnace changes greatly and the fire in the boiler goes out.

Causes a) When the furnace pressure is not less than 41mbar or not more than -25mbar, MFT fails to start within 5s. b) The number of the secondary air baffle plates of spark plug which is opened is less than 18. c) d) e) All force fans trip. All air preheaters trip. The motor power is cut off.

3)

Countermeasures a) b) Dispose it according to the countermeasures to MFT. When the baffle plates of the inlet and the outlet fail to open, open them timely or slowly open the regulation baffle plate, keep the furnace draft pressure between 0Pa and 100Pa and the ventilation in the furnace balanced to prevent furnace explosion. c) If the induced draft fan fails to recover to start, keep the furnace in natural ventilation for above 15min. d) If the induced fan recovers to start, strictly conform to the furnace cleaning procedures when the boiler recovers to start.

10.26.2.2 Trip of one induced draft fan 1) Faults a) Alarm that induced draft fan fails at the trip side is sounded from the alarm window.

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b) closed automatically. c) d) 2)

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The inlet baffle plate and the outlet baffle plate of the induced draft fan at the trip side are

The furnace draft pressure turns positive. Force draft fan and primary air fan at the side corresponding to the interlinking trip.

Causes a) b) c) d) e) f) g) h) The fan vibration is not less than 120m The shutdown button is pressed by mistake Electric baffle plate of the outlet is automatically closed The electric protection system starts to work Mechanical faults The air preheater at the corresponding side trips The drive power supply at the corresponding side is cut off The shift of air fan rotating speed fails

3)

Countermeasures a) b) If MFT takes place, shoot it according to the troubleshooting method for MFT. The load should be automatically reduced to 50% of MCR, the alarm that the set load is recovered to 50% of MCR is sounded from the alarm window. c) Six pulverizer coal feeders of FEA, FEE and FEI trip automatically; otherwise shut down the six pulverizer coal feeders of FEA, FEE and FEI manually. d) Provide a proper amount of oil gun torch for facilitating combustion. After the combustion is stable, determine whether to stop the pulverizer coal feeder according to its rotating speed to avoid that the feeding is not proper due to the low rotating speed. e) If the force fan and the primary air fan at the corresponding side fail to trip automatically, stop them manually but keep the air preheater at the corresponding side running. f) After the cause for tripping is found out, and the induced draft fan is inspected and proved to be normal, the induced draft fan then can be restarted.

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g)

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Monitoring at the shutdown side:

Monitor the flue temperature and the air temperature at the inlet and the outlet of the preheater and fire alarm. Check the induced draft fan bearing temperature and the temperature of the motor coil and the bearing. 10.26.2.3 High temperature at bearing and coil 1) Alarm is sounded when the air fan bearing temperature TE01B, TE01D and the motor bearing temperature TE01F, TE01H are high. 2) Find out the cause of high temperature at the bearing when the alarm is sounded and remove it immediately. 3) 4) 5) If the bearing temperature is up to 95, the induced draft fan should be stopped. Alarm is sounded when the motor coil temperature TE01I, TE01L and TE01M is high. Find out the cause of high temperature at the coil when the alarm is sounded and remove it immediately. 6) 7) 8) Check whether the motor is over loaded Check whether the air cooler is normal and whether the filter screen at the inlet is blocked. If the coil temperature is up to 120, the induced draft fan should be stopped Force fan faults and countermeasures

10.26.3

10.26.3.1 Complete shutdown of two force fans 1) Faults a) b) c) d) Tripping; The baffle plates of the inlet and the outlet of the force fan are automatically closed; The total air pressure and the total air amount are dropped to zero; If the force fan trips due to accidents, the induced draft fans should be automatically stopped completely as well as the primary air fans e) Alarm that force fan systems A and B fail is sounded from the alarm window.

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2) Causes a) b) c)

BOILER & AUXILIARIES OPERATION MANUAL

All induced draft fans trip; All air preheaters trip; The furnace pressure is more than 41mbar or less than -25mbar while the MFT does not starts within 5s.

d) 3)

The motor power is cut off.

Countermeasures a) b) Dispose it according to the countermeasures to MFT. If the force fan outlet baffle plate is closed, open it manually in time to keep ventilation in the furnace and prevent furnace from explosion. c) If the force fan fails to recover to start, keep the furnace in natural ventilation for above 15min. furnace If the force fan recovers to start, strictly conform to the cleaning procedures when the boiler recover to start.

10.26.3.2 Trip of one force fan 1) Faults a) b) c) The baffle plates of the tripped force fan inlet and outlet are closed automatically; The cooling air balance disconnection damper is closed; The load of the force fan in operation is increased. When it is running at a low speed, it should be automatically shifted to high speed; d) e) f) 2) The negative pressure of the furnace is increased instantly, which may cause MFT; The load is automatically reduced to 50% of MCR; Pulverizer coal feeder of FEA, FEE and FEI automatically trip.

Causes a) b) c) Air fan vibration is not less than 120m; The air preheater at the corresponding side trips; The air preheater at the draft fan trips;

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d) e) f) g) h) 3)

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Electric protection system starts to work; Mechanical faults; Shutdown button or emergency button is pressed by mistake; The outlet baffle plate of the air fan during operation is automatically closed; The drive power supply is cut off.

Countermeasures a) b) Dispose it according to the countermeasures to MFT. The load is automatically dropped to 50% of MCR, the load of the set is turned to 50% of MCR and the alarm is trigged. c) Six pulverizer coal feeders including FEA, FEE and FEI trip automatically; otherwise shut them down manually. d) Provide After a proper amount of oil gun torches for facilitating combustion.

the combustion is stable, determine whether to stop the pulverizer coal feeder

according to its rotating speed to avoid that the feeding is not even due to the low rotating speed. e) The baffle plates of the tripped air fan outlet and inlet are automatically closed as well as cool air balance baffle plate; otherwise it should be closed manually. f) After the cause for tripping is found out, and the force fan is inspected and proved to be normal, it then can be restarted. g) Monitor the shutdown side:

Monitor the flue temperature and the air temperature at the inlet and the outlet of the preheater and fire alarm. Check the temperature of the force fan motor and the bearing. 10.26.4 Faults and countermeasures of primary air fan 10.26.4.1 Outage of two sets of primary air fans 1) Faults a) b) c) Alarm that primary air pressure is very low is given. MFT takes place, pulverizer coal feeding is stopped and boiler is in fire-off. Furnace draft maximizes instantly.

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d) e)

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Auto shutdown of inlet baffle plate and outlet baffle plate of primary air fan as well as hot primary air baffle plate. Alarm of fault of primary air system is given.

2) Causes a) b) c) Outage of all induced draft fans Outage of all air preheaters Power failure

3) Countermeasures a) Solve by the countermeasure to MFT

10.26.4.2 Tripping of one primary air fan 1) Faults a) Auto shutdown of inlet and outlet baffle plate of the tripping air fan and auto shutdown of hot primary air baffle plate of the air pre-heater at the corresponding side b) c) Instant increase of furnace draft which may result in MFT Primary air pressure decreases, maybe to very low degree and MFT takes place if the pressure does not recover in 10 seconds. d) e) f) Auto decrease of loading to 50%of MCR Alarm window gives alarm of fault of primary air fan at tripping side. Auto tripping of six sets of FEA, FEE, FEI pulverizer coal feeders.

2) Causes a) b) c) d) e) f) Tripping of air pre-heater at the corresponding side Tripping of induced draft fan at the corresponding side Fan vibration80m Electric protection Mechanical failure Auto shutdown of outlet baffle plate of fan during operation

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g)

BOILER & AUXILIARIES OPERATION MANUAL

Shutdown button or emergency button is pushed by mistake.

3) Countermeasures a) b) Solve by the countermeasure to MFT. If loading auto decreases to 50% of MCR, alarm window gives alarm that unit loading recovers to 50% of MCR. c) Inlet and outlet baffle plates of fan trip, hot primary air baffle plate auto shuts down, otherwise, manually shut it down. d) Six sets of FEA, FEE, FEI pulverizer coal feeders auto shut down, otherwise, manually shut them down. e) Put proper oil gun torch to support combustion, judge whether to shut down pulverized coal feeder according to rotating speed of pulverized coal feeder after the combustion is stabilized, and avoids uneven power feeding due to low rotating speed of pulverizer coal feeder. f) The machine can only be started up after ascertaining tripping reason and make sure there is no other fault through checking up. g) Monitoring of shutdown side

Smoke temperature and air temperature at the inlet and outlet of air pre-heater as well as fire alarm Temperature of primary air fan and motor bearing 10.26.5 Faults and countermeasures of coal pulverizing system 10.26.5.1 Emergency shutdown of coal pulverizing system 1) Coal pulverizing system should be shut down by emergency shutdown (HSXH001) in case one of the following happens: a) b) c) d) MFT takes place but coal pulverizing system dose not trip. Coal pulverizing system is on fire and in explosion danger or explosion takes place. Rotor emits violent vibration and impact sound. People and equipment are endangered.

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e)

BOILER & AUXILIARIES OPERATION MANUAL

Cyclone separator is blocked and exhaust air is filled with lots of pulverized coal, which results in quick rise of steam temperature and steam pressure of boiler.

f)

Coal pulverizer does not trip when one condition for coal pulverizer tripping exists.

2) Coal pulverizer should be shut down in case one of the following happens: a) b) Power of main motor abnormally increases or decreases. Outlet temperature cannot be monitored due to display failure of outlet temperature of coal pulverizer. c) d) e) f) Cyclone separator is blocked. Cyclone separator is seriously blocked. There is abnormal metal impact sound in coal pulverizer. During pulverized coal pouring, pulverized coal conveyer trips but guiding baffle plate does not auto guide to pulverized coal bunker. 10.26.5.2 Spontaneous combustion or explosion of coal pulverizing system 1) Faults a) Outlet negative pressure of coal pulverizer and inlet negative pressure of pulverized coal exhauster change in large fluctuation. b) c) d) Outlet temperature of coal pulverizer rises abnormally. Spark is found at inspection hole and untight places of system. During explosion, pulverized coal leakage and smoke leakage are found at untight places of system, explosion valve protrudes or exposes furnace changes into positive pressure. e) Metal wall temperature of pulverized coal bunker rises abnormally during spontaneous combustion of pulverized coal in pulverized coal bunker. 2) Causes a) b) Pulverized coal deposits for a long time in coal pulverizing system. The temperature at broken coal outlet of coal pulverizer is over high. and negative pressure at

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c)

BOILER & AUXILIARIES OPERATION MANUAL

Raw coal is of high volatile matter and outlet temperature of coal pulverizer in running is not reduced correspondingly.

d) e)

There is foreign fire or explosive in system. Over high oxygen content in the system

3) Countermeasures a) In case of spontaneous combustion reduce at inlet of coal coal pulverizer, amount at properly loop of

increase

coal feeding

amount,

pulverized

classifier, reduce or cut off system draft and stop coal feeder; apply firefighting equipment to put out a fire on occasion and all damper baffle plates should be closed if gas fire-fighting equipment is applied. b) In case horizontal tube at coal pulverizer inlet is on fire, coal pulverizing system should be stopped running to extinguish fire. c) In case of spontaneous combustion of pulverized coal bunker, coal pulverizing system or pulverized coal conveyer should be stopped running immediately. Must not convey pulverized coal towards the pulverized coal bunker and close moisture absorption piping towards the pulverized coal bunker to reduce pulverized coal completely; after pulverized coal level is reduced to certain height, increase pulverized coal level immediately and press pulverized coal to extinguish fire; apply fire-fighting equipment if pulverized coal press does not work (clean and dry pulverized coal bunker after application). d) After coal pulverizing system explodes, emergency shutdown of coal pulverizing system should be carried out, close hand-operated valve and coupling cock valve for moisture absorption door. e) Normal coal pulverizing can only be carried out after water in the system is drained away as far as possible and the system is fully ventilated and dried if fire water is applied during the fir fighting process. 10.26.5.3 Coal interruption in coal pulverizer 1) Faults a) b) Coal interruption alarm is given and pulverized coal feeder trips after 30 seconds. Noise level of coal pulverizer increases. piping of pulverized coal bunker, confirm tight closing of all damper baffle plates, extinguish internal and external fire source and repair explosion

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c)

BOILER & AUXILIARIES OPERATION MANUAL

Outlet temperature of coal pulverizer rises; outlet temperature first reduces and then rises if pulverized coal bunker is empty.

d) e)

Negative pressure at pulverized coal bunker decreases. Rotating speed of pulverized coal feeder maximizes during auto rotation.

2) Causes a) b) c) d) There is no coal in raw coal bunker. Raw coal bunker is blocked. Driving part of pulverized coal feeder is in fault and driving belt skips or loosens. Scraper chain for pulverized coal feeder breaks and falls down.

3) Countermeasures a) Control outlet temperature of coal pulverizer at setting value and properly turns down regulation baffle plate at inlet of exhaust air fan. b) Note man on duty for combustion and conveying to feed coal or dredge coal bunker (start up air gun). c) d) Note maintenance personnel to eliminate equipment fault. In case coal interruption lasts for 15 minutes and coal feeding cannot be recovered, coal pulverizer should be shut down and pulverized coal exhauster and exhaust air fan should be shut down on condition. 10.26.5.4 Coal jamming in coal pulverizer 1) Faults a) b) c) d) Negative pressure at all points of system increase. Power of coal pulverizer increases and power decreases in serious condition. Noise of coal pulverizer decreases. Pulverized coal runs out at inlet and outlet of coal pulverizer.

2) Causes a) Coal feeding amount is over larger.

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BOILER & AUXILIARIES OPERATION MANUAL

b) Noise measurement signal is incorrect and speed controller of coal feeding does not work. c) d) Measurement of rotating speed of coal feeding is incorrect. Water content of raw coal is large, grindability decreases and hot smoke air temperature at inlet is over low. e) f) Ventilation decreases and coal feeding amount is not reduced during manual operation. Bypass valve of coal pulverizer is opened by mistake, which results in over low of ventilation in coal pulverizer and low temperature. 3) Countermeasures a) b) Decrease coal feeding amount or shut down pulverized coal feeder on occasion. Properly turn up baffle plate at inlet of exhaust air fan to increase system ventilation and carry out pulverized coal pumping and attention should be paid to maintaining outlet temperature of coal pulverizer at 110 DEG C. c) d) Turn down coal pulverizer bypass at normal position. In case outlet temperature of coal pulverizer increases, close hot smoke air manual baffle plate HV001 on occasion and manually open cold air baffle plate TCV62B. e) In case all above countermeasures do not work, shut down main motor of coal pulverizer and restart up to carry out pulverized coal pumping after turning runs for 30 minutes. f) In case pulverized coal pumping does not work, coal pulverizing system should be shut down and manual drainage towards coal pulverizer should be carried out after relevant departments approve and there are definite and effective countermeasures. 10.26.5.5 Blocking of classifier 1) Faults a) b) c) Negative pressure at outlet of coal pulverizer decreases. Negative pressure at inlet of pulverized coal exhauster increases. Exhaust air volume decreases.

2) Causes

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a) pulverized power. b)

BOILER & AUXILIARIES OPERATION MANUAL

Air lock for pulverized coal returning pipe is blocked due to over large amount of returning

Large humidity of returning pulverized coal results in blockage.

3) Countermeasure a) Decrease maintaining b) coal feeding amount and attention should be paid to

outlet temperature of coal pulverizer at setting value.

Knock pulverized coal returning pipe and air lock to dredge pulverized coal returning pipe.

c)

If the above countermeasure does not work, coal pulverizing system should be shut down and note maintenance personnel to repair.

10.26.5.6 Blockage of pulverized coal separator 1) Faults a) Negative pressure at outlet of coal pulverizer decreases and negative pressure at inlet of pulverized coal exhauster increases obviously. b) When becoming series, pulverized coal exhausting amount and pulverized coal filled in exhaust air increase, steam temperature and steam pressure rise at the same time and oxygen content in fuel gas reduces. c) d) Rotating speed of pulverized coal feeder reduces during self movement of total fuel. Lock air under cyclone separator at blocking side does not work.

2) Causes a) Pulverized coal is over damp, which results in blockage of pulverized coal pipe of cyclone separator. b) c) d) Lock air under separator does not work. Coal pulverizing system is not shut down in time when pulverized coal bunker is full. Pulverized coal conveyer trips and guiding baffle plate does not guide towards pulverized coal bunker during pulverized coal preparation. e) Guiding baffle plate guides towards pulverized coal conveyer by mistake.

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f)

BOILER & AUXILIARIES OPERATION MANUAL

During pulverized coal pouring, aerodynamic gate (UV06) from pulverized coal conveyer to pulverized coal bunker is not opened.

3) Countermeasure a) b) c) Knock position of air lock to dredge pulverized coal discharging pipe. Coal pulverizing system should be shut down if pulverized coal bunker is full. Have guiding baffle plate guide towards pulverized coal bunker if guiding baffle plate moves by mistake. d) In case pulverized coal conveyer trips during pulverized coal pouring and guiding baffle plate does not guide towards pulverized coal bunker, have guiding baffle plate guide towards pulverized coal bunker immediately and coal pulverizing system should be shut down if guiding baffle plate cannot be rotated for being pressed by pulverized coal. e) After coal pulverizer is shut down during serious blockage, maintain

pulverized coal exhausting and operate exhaust air fan, however, baffle plate at inlet of exhaust air fan cannot be over opened to guarantee normal operation of pulverized separator. 10.26.5.7 Tripping of exhaust air fan or coal pulverizer 1) Faults a) b) c) d) e) Tripping signal is given, green light lights and red light and yellow light sparks. Fan is out of operation. Negative pressure at all points of system reduces to zero. Exhaust air volume reduces to zero. Hot smoke baffle plate is closed and coal pulverizer and pulverized coal feeder trip. coal feeder and dredge pulverized coal discharging pipe of cyclone

2) Causes a) b) c) Power and motor are in failure. There are tripping conditions. Local shutdown button is pressed by mistake.

3) Countermeasure

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a) Pulverized coal feeder and coal pulverizer are shut down and turning gear is put into service. b) Check out tripping reason and restart up after solving fault.

10.26.6 Faults and countermeasures of pulverized coal feeder 10.26.6.1 Pulverized coal feeder cannot be started up 1) Causes a) b) c) Without starting up conditions Primary air aerodynamic overall opening signal is not received. Motor of pulverized coal feeder is not powered.

2) Countermeasures a) b) c) Start up once starting up conditions are held. Clear the fault that primary air aerodynamic overall valve cannot be opened in place. Note power department to power motor of pulverized coal feeder.

10.26.6.2 Rotating of pulverized coal feeder cannot be speeded after starting up 1) Causes a) b) Switch for local rotating speed control cabinet is not put in place of ON. Rotating speed regulator is in fault or not powered.

2) Countermeasures a) b) c) Put switch for local rotating speed control cabinet in place of ON. Contact heat engineering personnel and clear fault. Rotating speed regulator is powered.

10.26.6.3 Over large fluctuation of rotating speed of pulverized coal feeder in service 1) Faults a) Over large fluctuation of rotating speed of pulverized coal feeder

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b) in auto operation. 2) Causes a) b) c)

BOILER & AUXILIARIES OPERATION MANUAL

Rotating speed increases or decreases abnormally when all pulverized coal feeders are

Unsmooth blockage of scraper for pulverized coal feeder Damage of mechanical part of pulverized coal feeder Fault of rotating speed regulator

3) Countermeasures a) Pulverized coal feeder is shut down at once to clear fault 10.26.6.4 Blockage of primary air pipe and pulverized coal discharging pipe 1) Faults a) b) Primary air pressure of single pipe is abnormal and alarm is given in DCS, PSH or PSL. Rotating operation. c) Outer wall temperature of blocking primary air pipe and pulverized coal discharging pipe is lower than that of normal pipes and is obviously lower than that of normal pipes during serious blocking or equal to room temperature. d) Pipe makes a clunk when being knocked. speed of all pulverized coal feeders during auto operation is

increased abnormally and boiler temperature and steam pressure reduce during auto

2) Countermeasure a) The pulverized coal feeder is shut down and primary air aerodynamic valve and hand operated valve are closed. b) Dredge the primary air pipe and pulverized coal discharging pipe.

10.26.6.5 Pulverized coal feeder does not discharge pulverized coal 1) Faults a) Rotating is boiler speed during of all pulverized and steam coal feeders during and auto operation of

increased abnormally

temperature

steam

pressure

manual operation reduce.

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b) c)

BOILER & AUXILIARIES OPERATION MANUAL

Temperature of the primary air pipe is lower than or close to room temperature. Pipe makes a hollow sound when being knocked.

2) Countermeasures a) b) c) Make sure all pulverized coal discharging gates should be all opened. Knock upper wall of pulverized coal bunker to exhaust air of pulverized coal. Contact maintenance personnel to check out whether mechanical parts of pulverized coal feeder are in fault. d) Carry out pulverized coal drop of pulverized coal bunker regularly subject to regulations.

10.26.7 Faults and countermeasures of fire detector cooling fan 10.26.7.1 Faults 1) Alarm that air pressure at air pressure outlet is low is given and MFT takes place when air pressure is low to 70mbar. 2) 220V direct fan auto starts up.

10.26.7.2 Causes 1) 2) 3) 4) Driving belt of fan loosens and skips. Screen at fan inlet is blocked by impurities. Hand operated valve at fan outlet is closed by mistake. Electric protection takes place or power is off.

10.26.7.3 Countermeasure 1) When AC fan is in fault and trips or alarm of low outlet air pressure is given, DC fan should auto start up, otherwise, manual starting up should be carried out at once. 2) In case DC fan cannot auto start up, air pressure is low to 70mbar and MFT does not take place, emergency boiler shutdown button should be pressed to stop boiler operation. 3) Take effective measure to prevent flame scanner from being damaged.

10.26.8 Faults and countermeasures of oil gun cooling fan 10.26.8.1 Low air pressure

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1) Faults a) b)

BOILER & AUXILIARIES OPERATION MANUAL

Alarm of low air pressure When interlock is put into operation, standby fan is linked.

2) Causes a) b) c) d) Air leakage of air system Shedding of connecting hose Tripping of fan in operation Driving belt of fan loosens and skips.

3) Countermeasure a) b) c) After standby fan is started up, find out the reason for low air pressure. In case standby fan is not started up, it should be started up manually at once. If the fault is caused by air leakage or mechanical reason, report to man on duty and note maintenance personnel to clear the fault as soon as possible. 10.26.8.2 Tripping of fan 1) Faults a) b) Yellow light of tripping fan sparks and red light sparks. Alarm of low air pressure is given; when interlock is put into operation, standby fan is started up. 2) Causes a) b) Jam fault of machine and overcurrent of motor Motor is off power or in fault.

3) Countermeasure a) b) c) Operate standby fan and clear fault of fan. When standby fan is not started up, standby should be started up at once. Find out reason for motor and power fault and clear faults.

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10.26.9 Faults and countermeasures of steam air heater 10.26.9.1 High water level of condensation water tank 1) Faults a) b) Alarm of high water level of condensed water tank (LSH03) is given. High water level of local condensed water tank water level gauge

2) Countermeasure a) Make sure normal operation of water level control valve LCV05A on-site and open hand operated valve thereof. b) Make sure normal operation of water level control valve LCV05B on-site and open hand operated valve thereof. c) Contact heat personnel to inspect whether water level controller is in normal operation.

10.26.9.2 Low water level of condensation water tank 1) Faults a) b) 2) Alarm of low water level of condensed water tank is given. Low water level of local water level gauge for condensed water tank

Countermeasure a) b) Check out whether water drain valve is closed. Check out whether water level control valve is in normal operation.

10.26.9.3 High steam pressure 1) Faults Alarm of high steam pressure (PSH57) is given. 2) Countermeasure a) b) c) Check out whether steam control valve TCV57A is in normal operation. Check out whether bypass valve HV015 thereof is closed. Make sure control valve for water level of condensed water tankand hand operated valve

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thereof are opened, otherwise, manually open HV004 to release pressure. d) In case steam control valve is in fault, inlet and outlet hand operated valves should be closed and bypass hand operated valve should be opened to regulate manually. 10.26.9.4 Low steam pressure 1) Faults Alarm of low steam pressure (PSL57) is given. 2) Countermeasure a) b) Check out whether steam control valve PCV57A is in normal operation. Average temperature of air smoke of air per-heater is over setting valve and opening degree of steam control valve is small, steam air heater can be shut down. c) Check out positions of all valves of system and make sure there is no leakage.

10.26.10 Faults and countermeasures of boiler water circulating pump 10.26.10.1 Two sets of boiler water pump trip, a standby pump is not started up or a boiler water pump is in operation with differential pressure<1bar 1) Faults a) b) c) MFT takes place. Emergency indicating light for boiler water pump lights. Alarm of boiler water pump fault is given.

2) Causes a) b) c) d) Closed cooling water is interrupted or closed cooling water <27m3 /h (for 20 seconds). Electric fault makes pump motor power off. Temperature for boiler water pump65 DEG C. After two pumps trip, standby pump does not have starting up conditions (temperature of standby pump>55 DEG C). e) Boiler water pump sub-control shutdown button is pressed by mistake.

3) Countermeasure

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a) b)

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After MFT takes place, solve by the countermeasure to MFT. Comprehensively inspect boiler water pump system at once to find out tripping causes and take countermeasure.

c)

Eliminate tripping reason and restart up boiler water pump after making sure there is no other fault.

d)

In case closed cooling water pump trips and reclosing is not carried out successfully, emergency enhance water feeding three-way valve should water be opened have at once; cooling to emergency tank, closed

water operate as soon as possible and prevent over high temperature of boiler water pump which results in motor. 10.26.10.2 Two sets of boiler water pump trip, a standby pump is started up or a boiler water pump trips but standby pump is not started up. 1) Faults a) b) Loading auto reduces to 60% of MCR and alarm of loading recovering is given. FEA, FEE, FEI pulverized coal feeders auto trip.

2) Causes a) b) c) d) e) Standby pump does not standby condition (temperature of pump>55 DEG C). Closed cooling water amount of motor of tripping pump<27m3 /h. Temperature of tripping pump65 DEG C. Independent shutdown button of pump in operation is pressed by mistake. Power for tripping pump motor is off.

3) Countermeasure a) Alarm that loading auto recovers to 60% of MCR and alarm window unit loading to 60% of MCR is given. b) FEA, to c) FEI pulverized coal feeders auto trip, otherwise, they trip due

manual interruption.

Put proper oil gun torch to support combustion, judge whether to shut down pulverized coal feeder according to rotating speed of pulverized coal feeder after the combustion is

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feeder. d) Comprehensively take e)

BOILER & AUXILIARIES OPERATION MANUAL

stabilized, and avoids uneven power feeding due to low rotating speed of pulverizer coal

inspect

tripping

pipe,

find

out

reason

for

tripping

and

some countermeasure.

After fault is cleared and make sure there is no other fault, a boiler water pump can only be started up and gradually recover system.

10.26.10.3 A boiler water pump strips and standby pump is successfully started up Find out tripping reason, eliminate the cause as soon as possible and put the pump into interlocking and standby status.

11 11.1

Appendix The contrastive list of the absolute pressure and temperature in saturated states pressure Saturation (DEG C) 45.83 60.09 69.12 75.88 81.34 85.95 89.96 93.51 96.71 99.63 102.32 104.81 107.13 109.32 111.37 113.32 115.17 116.93 118.62 120.23 127.43 133.54 temperature Absolute pressure (Mpa) 1.80 1.90 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00 8.50 9.00 9.50 10.00 10.60 11.00 11.60 Saturation (DEG C) 207.11 209.80 212.38 223.94 233.84 242.54 250.33 257.41 263.91 269.93 275.55 280.82 285.79 290.55 294.97 299.23 303.31 307.21 310.96 315.30 318.05 322.10 temperature

Absolute (Mpa) 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.25 0.30

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0.35 0.40 0.45 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 138.87 143.62 147.92 151.84 158.83 164.96 170.42 175.36 179.88 184.07 187.96 191.61 195.04 198.29 201.37 204.31

BOILER & AUXILIARIES OPERATION MANUAL 12.00 12.60 13.00 13.60 14.00 14.50 15.00 15.50 16.00 16.50 17.00 18.00 19.00 20.00 21.00 22.00 324.65 328.40 330.83 334.40 336.64 339.40 342.13 344.80 347.33 349.80 352.26 356.96 361.43 365.70 369.78 373.69

11.2

Boiler Cold start-up Curve

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11.3 11.3.1 Boiler Hot star-tup Curve Boiler Warm star-tup Curve

2300 MW Anthracite Coal

Fired Power Station BOILER & AUXILIARIES OPERATION MANUAL

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Shanghai Electric (Group) Corporation


11.3.2 Boiler Hot star-tup Curve

2300 MW Anthracite Coal

Fired Power Station BOILER & AUXILIARIES OPERATION MANUAL

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Shanghai Electric (Group) Corporation


11.3.3 Boiler Very Hot star-tup Curve

2300 MW Anthracite Coal

Fired Power Station BOILER & AUXILIARIES OPERATION MANUAL

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Shanghai Electric (Group) Corporation


11.4 Boiler drume level vs load Curve

2300 MW Anthracite Coal

Fired Power Station BOILER & AUXILIARIES OPERATION MANUAL

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11.5

VIETNAM QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2300 MW Anthracite Coal Fired Power Station BOILER & AUXILIARIES OPERATION MANUAL

Boiler O2 in flue gas vs load Curve

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