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Appendix D
JAS4061
Energy from Waste with Combined Heat and Power Facility, Oxwellmains
Blank
Presented by:
TEST PLAN
1.
PROGRAMME ............................................................................................................................................... 2
2.
3.
HOT COMMISSIONING............................................................................................................................... 4
4.
5.
COMMENT: This document is for typical use only. Project specific periods, durations
and conditions of commissioning/testing, as stated in POYRI Schedules 9 and 11
and agreed upon between TPSCo and Keppel Seghers prevail.
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January 2008
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1. PROGRAMME
One month before the scheduled start of COLD COMMISSIONING, the
CONTRACTOR will provide a detailed programme for the COLD COMMISSIONING,
HOT COMMISSIONING, RELIABILITY TEST, and PERFORMANCE TEST.
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2. COLD COMMISSIONING
COLD COMMISSIONING is defined as the period when individual items of the
INSTALLATION, electrical systems, control and instrumentation systems are checked
and tested.
During this period, activities such as boiler cleaning, refractory drying, cleaning of
pipe work and tank internals are carried out.
Test Sheets shall be developed by the CONTRACTOR to show what tests, checks
and recordings have been carried out. Such Test Sheets shall be submitted to the
EMPLOYER within two weeks after completion of any test.
During the COLD COMMISSIONING, the EMPLOYER will provide a full team of
operators to the CONTRACTOR for training on-site.
Starting Criteria
Mechanical Completion
Ending Criteria
Result of Completion
Note
Depending on the delivery schedule of the turbine, the cold commissioning of the
turbine may take place later than the cold commissioning of the incineration line. If
this occurs, the start of the hot commissioning of the incineration line shall not be
delayed by the turbine.
The cold commissioning and hot commissioning of the incineration line can take
place with steam being sent over the by-pass, i.e. RDF is being incinerated, but
electricity production has not yet started.
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3. HOT COMMISSIONING
HOT COMMISSIONING is started after completion of COLD COMMISSIONING.
During HOT COMMISSIONING the plant will be operated with waste within the
boundaries of the combustion diagram.
The HOT COMMISSIONING tests shall be carried out by the CONTRACTOR and
shall cover in general the following topics :
-
Starting Criteria
Ending Criteria
Result of Completion
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January 2008
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4. RELIABILITY TEST
The purpose of the Reliability Test is to demonstrate that the plant is capable of safe
and reliable operation while complying with the emission limits. During this period,
operations and control functions shall be demonstrated to the EMPLOYER.
During the Reliability Test period of two weeks, the trial runs shall include the
following tests :
-
stable run at various loads with the design range, under automatic control;
The CONTRACTOR shall provide all necessary supervision for these procedures.
Commissioning supervisors will be present on site on a 24h basis during the
scheduled period for the Reliability Test. It is the EMPLOYERs responsibility to
provide a full staff of skilled operators in shift operation.
Minor defects, such as instrument faults or equipment faults which require the
standby operation of auxiliary equipment, shall not constitute a failure of the
Reliability Test, provided that the INSTALLATION continues to operate satisfactorily.
Note: During the first months of operation, too much heat may be extracted from the furnace
due to insufficient fouling and incomplete drying of the refractory lining. The fact that it takes
time to reach the normal fouling degree of furnace and boiler may have consequence for every
point of the combustion diagram. Practice has shown that auxiliary fuel can be necessary
during this period within the complete combustion diagram (and thus also at 100% load) in
order to meet the flue gas residence time requirement (850C/2s).
Starting Criteria
Duration
2 weeks
Ending Criteria
Result of Completion
Result of Failure
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January 2008
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5. PERFORMANCE TEST
Starting Criteria
Duration
see table
Success Criteria
Result of Success
Final Acceptance
Result of Failure
Repetition of tests or
Liquidated Damages for failure to achieve guaranteed
performance
1.
2.
The performance test shall show that all the performance guarantees as
specified are fulfilled.
3.
4.
5.
Each Party shall carry its own costs for the Performance tests.
6.
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7.
8.
If the Performance Test fails as a whole or in part, parties shall analyse the
reason together and define the responsible party/parties as soon as possible.
The responsible party/parties shall take immediate action to remedy the
cause(s) and will announce their readiness to recommence or continue the
tests
as
soon
as
possible.
Depending on the nature and characteristics of the failure of the tests, the
Performance Tests will be redone completely and for the full duration or in part
and for a shorter duration. This matter is to be addressed in general in the
aforementioned protocol but the actual decision is to be reached by agreement
with all parties immediately after the occurrence of the failure.
All parties shall grant their full co-operation to the repetition / extension of the
Performance Tests.
9.
The plant has to be operated in accordance with the combustion diagram and in
accordance with the CONTRACTORs operation and maintenance manuals.
10.
11.
12.
13.
Before a test is carried out, the plant operating conditions shall have been
stable for at least 2 hours (uninterrupted). The stability of the operation will be
verified by means of representative operational parameters (e.g. steam
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production, RDF throughput, oxygen contents exit boiler). The limits on the
allowable variation will be included in the aforementioned protocol. The
CONTRACTOR must have the opportunity during at least 4 days to verify the
tuning parameters of the process before the Performance tests start.
14.
All parameters shall be continuously recorded during the performance test with
a frequency of at least once a minute.
15.
16.
Plant
Test Duration
Remarks
24 hours
Performance Test
Capacity
24 hours
Steam production
24 hours
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January 2008
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8
Presented by:
CONTRACTOR).
Gross
Electricity 24 hours
Production
Carbon in Ash
Emissions
24 hours
Combustion
Official
independent
measurement
Consumables:
Water
24 hours
Noise
Version / Date
January 2008
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9
COMMISSIONING MANUAL
PART N1 :
PRE- AND COLD COMMISSIONING
WASTE-TO-ENERGY PLANT
TYPICAL
by:
10-01-08
RPI
Preliminary
Rev.
Date
By
Description
Check
Appr.
WASTE-TO-POWER PLANT
TYPICAL
1. TABLE OF CONTENT
1.
2.
INTRODUCTION ........................................................................................................................................... 4
3.
4.
3.1.
DEFINITIONS .............................................................................................................................................. 6
3.2.
PRE-COMMISSIONING ............................................................................................................................. 10
4.1.
5.
PRE-REQUISITES ...................................................................................................................................... 10
4.1.1.
General .......................................................................................................................................... 10
4.1.2.
4.2.
4.3.
COLD-COMMISSIONING ......................................................................................................................... 13
5.1.
PRE-REQUISITES ...................................................................................................................................... 13
5.2.
5.3.
5.4.
5.5.
5.6.
5.6.1.
5.6.2.
Ash extractor.................................................................................................................................. 16
5.6.3.
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6.
5.6.4.
5.6.5.
5.6.6.
Hydraulic group............................................................................................................................. 18
5.6.7.
Burners .......................................................................................................................................... 18
5.6.8.
ANNEXES...................................................................................................................................................... 23
6.1.
6.2.
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2. INTRODUCTION
This document outlines the sequence of activities required to take the plant from a completed
installation to a fully operational and commissioned plant. The pre-requisites, necessary for
each stage of the commissioning, are described.
The commissioning will, in general, follow the sequence herebelow :
1. Pre-Commissioning (or Unit test): the checking and testing of equipment prior to
their cold commissioning with power and air. Such works shall consist of testing the
alignment and direction of rotating parts, the verification of the wiring and cabling, the
verification of the PLC system, verification of correct mounting of piping, verification of
correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.
Pre-commissioning checks, when completed, will release individual items of equipment to
be powered up and made available for inclusion in the cold commissioning phase.
2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors
and other electrical equipment, flushing and cleaning of tanks and piping if applicable,
adjustment and regulation of protective devices, functional tests, leakage and pressure
tests, inspection of bearings, etc.) and operation of equipment for a period of time. This
will be mainly as individual items, but may involve running some of the equipment in
sequence.
3. Hot Commissioning: this will include the introduction of fuel (waste), process gas and
reagent (including the boiling out of pressure parts, curing of the refractory, blowing of
steam pipe to turbine, etc). The whole plant will be tested, operating in sequence under
full load conditions.
The Commissioning Manual (part n1) includes instructions for the Pre-commissioning and
the Cold Commissioning of the equipment in the Contract.
The Commissioning Manual (part n2) includes instructions for the Hot Commissioning of the
equipment in the Contract. This second part contains specific information for the first startup, which differs from a normal plant start-up. For the general operating procedures (allowing
to start-up, operate and shut down the plant under normal conditions), please refer to the
Operation and Maintenance manuals.
Responsibility: Operating instructions specified in this manual are typical procedures. It is
impossible to cover all eventualities, which might occur during the start-up of the plant.
Keppel Seghers cannot take responsibility for damage to any part of the plant, which could
have been avoided if instructions had been followed.
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On the other hand, conditions may arise in which actions must be taken without sticking
strictly to the instructions in this manual, provided that such actions result in safe operation.
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A standard form (pdf-format) is available for each type of mechanical equipment (pump, silo,
fan, etc.) within the Unit. The inspection sheet is a checklist to verify if the Unit is
mechanically complete, and ready for further cold commissioning.
Punch lists
The punch lists give an overview of items in the Sub-system, which have to be remediated /
solved. The outstanding items on the lists get a qualification of 1, 2 or 3, depending on their
critical character :
Qualification 1 (= pre-acceptance) : prevents the Unit from being released for further
commissioning, to be solved before startup of the equipment. E.g. wrong rotation
direction of a motor, packing missing, lack of pressure safety valve, etc.
Qualification 2 (= post-acceptance) : item can be solved after startup of the equipment.
E.g. tag plate missing, wrong colour, tidiness of the area, etc.
Qualification 3 (= to be discussed) : can not be qualified under 1 or 2. E.g. scope unclear,
general remark or question, discussion between parties about qualification, etc.
A punch list can be made up for a whole Sub-system or for each Unit, this is left to the
convenience of the KEPPEL SEGHERS engineer.
Each punch list that is updated and filed in the Commissioning Status Report is to be dated,
initialed and signed by the KEPPEL SEGHERS engineer.
When a punch list is the result of an inspection round together with the Client and/or a
Subcontractor, it is important that their representatives counter sign the Punch List. This
punch list is then communicated to them for further action / information.
Functional descriptions
The functional description of each Sub-system enables a better understanding of the P&ID,
and it is the basis for the functional tests of the Sub-system.
Interlock list / autoconditions
The Interlock list (including autoconditions, alarm settings, start / stop sequences, loop
controllers, etc.) forms the basis for the cold commissioning of the Sub-systems (I/O tests or
loop testing, sequence testing, etc.).
Test reports
These will include, amongst other :
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Etc.
It should be stressed that the most important documents of the Commissioning Status Reports
are the Status List and the Punch Lists. The Status List for the formal registration of all tests
and inspections, the Punch Lists for the formal registration of outstanding items. The other
documents (P&ID, inspection sheets, ) are tools.
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4. PRE-COMMISSIONING
4.1. PRE-REQUISITES
4.1.1. General
The control panels and the panels for motors up to 3 kW will have been tested
100% by KEPPEL SEGHERS engineers during the FAT tests in the factory of the
panel manufacturer. This means that each IO signal has been checked from the bit
in the PLC up to the input or output terminal for connection of the field wires. This
testing will be reported in the FAT Inspection report.
The electrical panels (MCC) for motors from 3 kW will have been tested 100% by
the responsible during the FAT tests in the factory of the MCC panel manufacturer.
This testing will be reported in the FAT Inspection report.
The electrical site wiring to the plant has to be complete and must have been fully tested
by the electrical contractors. See next section (4.1.2) about testing of wiring and cabling.
The instruments shall be installed and properly connected. This shall be documented by
the instrument installer on the I/O and SAT tests of control panel lists with the
following items for each instrument : mechanical installation, process connection,
pneumatic connection, electrical connection, tag plate.
The DCS system for operator interface of the installation must be available and FAT
tested in the presence of an KS automation engineer. Testing reported in a FAT inspection
report.
No gas or reagent, hot or cold, should have been through the equipment.
The responsible for the erection of the cabling shall execute tests in order to check all
cable and wire connections. . Only after the completion of these tests, the precommissioning and cold commissioning can start under the supervision of KEPPEL
SEGHERS.
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For connections between control panel at one side and instruments, valves and all
other equipment at the other side : before connection to the instrument/equipment and
before connection to the control panel, all wires will be invividually shortcircuited
at the instrument/equipment side, and the shorcircuit will be measured at the control
cabinet side. Only after this test, the instrument/equipment may be connected.
For connections between control panel and motor control and protections circuits :
before connection to the motor contol centre (MCC) and before connection to the
control panel, all wires will be invividually shortcircuited at the MCC side, and the
shorcircuit will be measured at the control cabinet side. Only after this test, a MCC
unit may be connected to the signal cable.
The result of each test will be documented by checkmarking on the I/O and SAT tests of
control panel and the I/O and SAT tests of electrical panel lists . After completion, this
lists will be signed and stamped by the responsible of the cabling (installer).
I/O and SAT tests of control panel (one per panel) with the following items for each
instrument : mechanical installation, process connection, pneumatic connection, power
cable connection, instrument cable connection. I/O test.
I/O and SAT tests of electrical panel (one per panel) with the following items for each
electrical user : mechanical installation, power cable connection, control cable
connection, insulation test, I/O test.
For each item (reference is made to the TAG-), the commissioning company will complete the
check-out list to give documentary proof that each item of the P&ID has been installed.
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Any missing item or equipment is to be chipped on the check-out list as NOK. It will then
be reported as an open item on the punch list and will be checked together with the KeppelSeghers commissioning supervisor.
Every inspection round will be listed on the Status List (date, initials, signature and eventual
remarks). A new check-out list can be used for every new P&ID check.
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5. COLD-COMMISSIONING
5.1. PRE-REQUISITES
The electrical supply should be available and the MCC should have been tested by the
electrical contractors and be ready for service.
The PLC control system should be available and the PLC programming be complete.
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When a loop test is positive, the EIA engineer will date, initial and sign the loop scheme for
approval. Only the approved loop schemes will be included in the Commissioning Status
Report of the Sub-system, as a proof that the I/O test has been successfully executed. I/O
tests which are not successful remain in the file of the EIA engineer.
When all the loop tests within a Sub-system are executed, the EIA engineer will confirm this
on the Status List (date, initials, signature), before one can proceed with the functional tests.
5.4.
MOTOR TESTS
For each motor the following tests on the power part will be executed:
Isolation test of the power circuit (with the motor connected). Important remark :
for frequency convertors (variable speed drives), these tests will be executed
without the cable connected to the drive unit.
These tests are the responsibility of the electrical contractor ; only mechanical supervision
from KEPPEL SEGHERS.
Results will be indicated on the I/O and SAT tests of electrical panel lists.
5.5.
FUNCTIONAL TESTS
When all Units within a Sub-system are pre-commissioned and loop tested, each Sub-system
can individually be submitted to functional tests : the programmed software in the PLC
system - already FAT tested - is to be site tested (SAT) by checking all functionalities and
interlocks in the field.
The functional tests will be done under the supervision of KEPPEL SEGHERS. The Client
will dispatch sufficient technical staff to perform the tests.
The tests will consist in verifying :
-
Control loops
Sequences
as described in the Functional Description and the Interlock list (including autoconditions,
alarm settings, start / stop sequences, controllers, etc.).
Most control loops or sequences can be tested under empty or dry conditions by simulating in
the PLC the presence of reagent or product in the Unit. For some of the tests, it will be
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necessary to add reagent or products to the Units or Sub-system (e.g. pumps or mixers that are
not allowed to run dry or empty).
It is imperative to thoroughly follow the instructions in the Operation & Maintenance
Manual of the specific Sub-system, before executing functional tests with reagent or
products.
For some Units, some additional specific functional tests have to be done, as further detailed
under 5.6. Specific functional controls.
The first fillings of all bearings were done by the constructor during pre-assembly of the
grates.
Because of the large period of time between grate pre-assembly and
commissioning, all grease points will be verified by adding grease before moving the
grate elements. Refer to the O&M manual regarding the grease qualities (make and type)
of the grease nipples. The greasing positions are shown on the drawing XXXX_239_003.
Once the hydraulic unit has been fully checked for correct mounting and the hydraulic oil
circuit has been completely flushed (see section 5.6.6), the movement of the feeding- and
combustion grates should be tested during at least 8 consecutive hours. During this test, one
has to pay attention to:
Check the fixed time for the tumbling movement (normally between 3 and 6 sec), the time
for withdrawing the feeding grates (typical between 5 - 20sec) and the time for
withdrawing the sliding tiles (typical between 2 to 10 sec).
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Caution: Special attention has to be taken not to run the grates during the furnace
warm-up. In this case, the feeding grates have to stay in their withdrawn
position and the combustion grate must be covered by insulation material.
The cold commissioning of the grate must be supervised by Keppel Seghers qualified
personnel.
When the hydraulic is connected, all moving parts must be checked to move properly:
movements of the pusher.
After a dry run of a few hours without water, the ash extractor is filled with water and its
movement can be tested during 8 consecutive hours (or more). During this test, one has to pay
attention that:
The level control device in the water tank is properly adjusted so that the water seal is
realized at the sifting ash hoppers
The inspection work on the ash extractor must be supervised by Keppel Seghers qualified
personnel.
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5.6.3. Refractory lining
Reference is also made to the Refractory Lining Supplier Erection & Commissioning Manual.
After installation of the refractory lining, the work must be inspected and approved by
qualified personnel :
Hammer test to check the lining for holes, grains, accumulation, etc.
When checks are completely finished, release notes have to be handed over fully signed by contractor, supplier and clients
representatives.
Activate the greasing device by screwing in the ring bolt in the grease container
Stretch the chain. To do that the conveyor must be started up (dont forget to check the
direction of rotation) and let it run for a while. The chain is sufficiently stretched when
the carriers are leaving the return part without a bang. A bang will occur if the chain is
too slack. On the other hand, if it is stretched too hard the carriers will be lifted before
they reach the bend.
After a couple of days, all of the carriers screw joints is to be follow up drafted, and the
stretching of the chain must be checked.
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5.6.6. Hydraulic group
Reference is also made to the Operation & Maintenance Manual.
Before the first start-up of the hydraulic plant, the installation (including all piping) must be
flushed and cleaned to eliminate all contaminants from the system and achieve the required
degree of purity of the oil. The supplier will be responsible for the first cleaning of the
hydraulic equipment and piping, as well as the first filling with hydraulic oil.
The minimum requirements for the hydraulic oil are :
Hydraulic oils with corrosion, oxidation and wear additives : HLP oils according to DIN
51524 part 2
A list of potential mineral oil makes that can be used for the hydraulic group is annexed in the
O&M manual. Other makes are possible provided that they have similar characteristics.
Commissioning of the hydraulic system will be done under the supervision of the supplier.
This start up will cover (not limitative) :
Pressure testing
Test run of all the equipment, especially for verification of the proper functioning of the
pressure compensated hydraulic proportional flow control valves.
5.6.7. Burners
Reference is also made to the Operation & Maintenance Manual.
The start up and commissioning of all burners will be done during drying and baking of the
refractory lining of the furnace, and during boiling out of the boiler and blowing out of the
steam piping (see part 2 of the Commissioning manual).
Drying of the refractory lining will be done by means of the start up burners. During
drying of the refractory lining, the start up burners will be operated at low thermal load.
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At the beginning of this period, the start up burners can be tuned rather roughly, because
operation at maximum thermal load is not allowed, or only during short periods (e.g. some
minutes). The burners will be tuned in a way they can be started and stopped in a reliable
way, and in a way the combustion is visually complete (no formation of soot). Finetuning (e.g. to attain good and complete combustion along the complete working range of
the burners) is not yet required and not yet possible. This rough fine-tuning is expected to
last one working day.
When baking of the refractory lining has started, the load of the start up burners can be
increased gradually. At the end of this period, a fine-tuning of the burner can be allowed,
because operation at maximum load is possible during long time. As drying of the
refractory lining can last some days (at low burner load), and the temperature increase
after drying is very slow, it is possible that there will be some days between the first
commissioning of the start-up burners, and the fine-tuning.
During baking of the refractory lining and boiling-out of the boilers, the auxiliary burners
will be started and operated at low thermal load. At the beginning of this period, the
auxiliary burners can be tuned rather roughly, because operation at maximum thermal
load is not allowed, or only during short periods (e.g. some minutes). The burners will be
tuned in a way they can be started and stopped in a reliable way, and in a way the
combustion is visually complete (no formation of soot). Fine-tuning (e.g. to reach the
required CO- or NOx-emission limits, or to verify the fuel/air ratio curves at different
loads) is not yet required and not yet possible. This rough fine-tuning is expected to last
one working day.
When baking of the refractory lining is finished (and the furnace is still hot), auxiliary
burner operation at maximum load can be allowed, as long as temperature changes in the
furnace can be restricted up to the values allowed by the refractory supplier (10 up to 25
C/hr). During this period, a fine-tuning of the burner can be allowed (to reach the
guaranteed emission levels, and to determine the fuel/air ratio curves at all burner loads).
If this fine tuning requires several succeeding intervention days of the burner supplier, it
is advised to combine this activities with the blowing of the steam piping, because
frequent burner modulation can be allowed in this period, and there is enough time
available (one can expect that the auxiliary burners will be operational during at least one
week).
During this period, presence of qualified personnel of the burner supplier will be required.
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5.6.8. Smoke testing of the flue gas cleaning
(a) General
The intent of smoke testing is to detect leaks in the flue gas path of the plant, means from the
outlet of the furnace up to the baghouse filter. Leaks mean that during normal operation, cold
outside air is draught into the system (in underpressure) causing corrosion at the inlet area,
loss of flue gas temperature and an increase in flue gas flow, resulting in a higher electrical
consumption of the ID-fan.
Since it is very difficult to detect these leaks during operation, a smoke bomb test should be
performed during the plant cold commissioning phase as well as after plant start-up on a
regular basis (for instance every year during the annual shutdown)
Smoke testing is performed by blowing a high volume of very low-pressure smoke into the
system at one or more manholes. Plugs, valves, temporary blind flanges are used to confine
the smoke to the section or sections of system being tested. Observation of the emergence of
smoke enables the crew to detect sources of inflow.
The plant building will usually have one or more roof vents from which smoke will emerge.
The roof vents will be used to evacuate the outcoming smoke. The residents and fire
departments must be told to ignore the smoke as well.
Because testing to large sections is less effective and gives the crew too much area to observe
during the relatively short life of the smoke bombs (3 or 5 minutes), it is advised to have
several tests along the flue gas path:
Section 1 : from the combustion chamber (furnace) up to the inlet of the baghouse filter,
Section 2 : from the baghouse filter up to the stack inlet, if there is possibility to confine
this system at the stack side (otherwise the smoke test II will be limited to the baghouse
filter outlet)
(b) Equipment
Smoke testing can be performed using:
Blowers suitable for smoke testing have a circular flange or plate for mounting on an open
manhole and are gasoline engine driven. Blowers recommended for smoke testing have a freeair delivery of at least 3.000 m/h.
The static pressure capability of the blowers is less than 2,5 mbar.
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(c) Smoke
Smoke used is cold and very visible (white). The smoke is not hazardous and is free of oil
and coloured particles, which could leave residue and stains. Smoke bombs recommended
for smoke testing are usually 3- or 5-minute duration.
Smoke is introduced into the system either by placing a smoke bomb at the blower inlet or
by lowering the smoke bomb into a manhole in a bucket and blowing air in from above.
The inspector should understand that the smoke bombs are not dangerous and have a limited
shelf life. Once opened, a package of smoke bombs should be used. Smoke bombs exposed to
moisture or humidity may be difficult, if not impossible, to ignite.
(d) Advance notices
Prior to performing smoke testing, plant personnel and residents are notified of the purpose
and approximate date of the work. Residents are told that they will see smoke emerging from
the roof vents.
Local fire and police departments should be advised daily of the areas being tested. Personnel
handling telephone inquiries should be acquainted with the purposes of the smoke-testing
program.
(e) Smoke test procedures
1. Advance notice is given to residents, fire and police departments.
2. The inlet and outlet of the system ducting are blocked, i.e.:
For section 1: hopper feeding chute valve - inlet valves of the baghouse filter
For section 2, inlet of the baghouse filter - inlet of the stack (by means of
temporary flanged plates)
3. The manhole sections to be tested are isolated (sifting ash hoppers, combustion chamber,
feeding grate casing, boiler, flue gas duct, reactor, baghouse filter).
4. The ash extractor and the sifting ash conveyors (in section 1) are filled with water
5. The gate valve for the residue extraction (boiler hoppers, reactor cone, filter hopper) must
be closed
6. The combustion air fans (for primary air, secondary air and for burners) are started in
section 1. In section 2, a smoke blower is set up at an open manhole in the filter and started.
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7. A smoke bomb is ignited, placed in a bucket and lowered into the manhole. The blower is
then positioned on the open manhole and set at full throttle.
8. In less than a minute, smoke will be issuing from the roof vents of buildings and any
directly connected points of inflow.
9. A smoke testing crew usually consists of three persons. One individual operates and
maintains the blower while the other two walk the test area to locate and document inflow
sources indicated by emerging smoke.
10. The crew documents significant and identifiable points of inflow. Sketches, field notes,
portable tape recordings, digital pictures and movies could be used to record test results.
11. Those firms bidding on this type of work should have a documented history of five years
of successful smoke testing. References and dates are to be submitted with bids.
12. All bidders will be licensed contractors and perform a minimum of 60 percent of the
contract.
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6. ANNEXES
6.1. ANNEX 1 : LIST OF SUB-SYSTEMS
See also Error! Reference source not found. on page Error! Bookmark not defined..
- tbd during detailed engineering
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COMMISSIONING MANUAL
PART N2 :
HOT COMMISSIONING
WASTE-TO-ENERGY PLANT
TYPICAL
by:
10-01-08
RPI
Preliminary
Rev.
Date
By
Description
Check
Appr.
WASTE-TO-POWER PLANT
TYPICAL
1. TABLE OF CONTENT
1.
2.
INTRODUCTION ........................................................................................................................................... 4
3.
GENERAL ....................................................................................................................................................... 6
4.
FURNACE ................................................................................................................................................... 7
4.1.1.
4.1.2.
Grate .................................................................................................................................................... 7
4.1.3.
4.1.4.
Start-up burner..................................................................................................................................... 8
4.1.5.
4.1.6.
4.2.
4.3.
4.4.
5.
6.
7.
8.
8.2.
8.2.1.
8.2.2.
8.2.3.
8.3.
8.4.
8.5.
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8.6.
9.
9.2.
SAFETY.................................................................................................................................................... 28
9.3.
PREPARATIONS ........................................................................................................................................ 29
9.4.
9.4.1.
9.4.2.
9.4.3.
9.4.4.
9.4.5.
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2. INTRODUCTION
This document outlines the sequence of activities required to take the plant from a completed
installation to a fully operational and commissioned plant. The pre-requisites before each
stage of the operation can be commenced are described.
The commissioning will normally follow the sequence below:
1. Pre-Commissioning (or Unit test): the checking and testing of equipment prior to
their cold commissioning with power and air. Such works shall consist of testing the
alignment and direction of rotating parts, the verification of the wiring and cabling, the
verification of the PLC system, verification of correct mounting of piping, verification of
correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.
Pre-commissioning checks, when completed, will release individual items of equipment to
be powered up and made available for inclusion in the cold commissioning phase.
2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors
and other electrical equipment, flushing and cleaning of tanks and piping if applicable,
adjustment and regulation of protective devices, functional tests, leakage and pressure
tests, inspection of bearings, etc.) and operation of equipment for a period of time. This
will be mainly as individual items, but may involve running some of the equipment in
sequence.
3. Hot Commissioning: this will include the introduction of process gas and reagent
(including the boiling out of pressure parts, curing of the refractory, blowing of steam
pipe to turbine, etc). The whole plant will be proved, operating in sequence under full
load conditions.
The Commissioning Manual (part n1) includes instructions for the Pre-commissioning and
the Cold Commissioning of the equipment in the contract.
The Commissioning Manual (part n2) includes instructions for the Hot Commissioning of the
equipment in the contract. These second part contains specific information for the first startup, which differ from a normal plant start-up. For the general operating procedures (allowing
to start-up, operate and shut down the plant), please refer to the Operation and Maintenance
manuals.
Responsibility: Operating instructions specified in this manual are typical procedures. It is
impossible to cover all eventualities, which might occur during the start-up of the plant.
Keppel Seghers cannot take responsibility for damage to any part of the plant which could
have been avoided, had instructions been followed.
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On the other hand, conditions may arise in which actions must be taken without sticking
completely to the instructions in this manual, provided that such actions result in safe
operation.
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3. GENERAL
The first start up procedure of the furnace-boiler is strongly different from a general start up
procedure. The reason is that the refractory lining has to be dried and baked in order to reach
its desired strength, and physical and chemical properties.
For this purpose, the temperature in the furnace and the post combustion zone has to be
increased according to a strictly defined procedure. A general sequence for the first start-up is
shown in the figure below with indication of duration of each individual action.
900
800
Drying
700
Baking
Blasting f(#cycles)
Start-up
Boiling
600
500
O P R
400
300
E
200
C
100
A-B
0
0
10
12
14
16
18
20
Time (day)
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Before starting the drying-out and the baking procedure, a test has to be done to check the
amount of leakage air entering the furnace. During this test, the primary air fan will be
started without using the ID-fan. An overpressure will be created in the furnace. Air leaks
can be checked now by applying liquid soap at welding and other connection elements.
Air leaks have to be repaired before starting the drying-out and baking procedure.
All measurement systems in the furnace zone has to be operational (temperature, pressure,
). All temperature trendings in furnace and post combustion zone have to be printed
and saved.
All sight glasses, measurement systems, cameras, or other elements with a protection
against high temperatures by means of sweeping air, have to be cooled during drying-out
and baking procedure.
4.1.2. Grate
In normal operation, the tiles are cooled by primary air and thermally protected by a waste
layer, which acts as an insulating layer. Since drying-out of the refractory is not possible
and not allowed by waste, the burners have to be used. The grate tiles are not designed to
be exposed to the full heat of the burners; therefore the tiles need to be protected. This
protection remains in the furnace during the entire warm-start up, being the refractory
drying, the boiler boiling-out and the blowing-out of the boiler and steam piping.
The entire feeding and the combustion grates element 1 to 3 must be covered by means of
insulating material (rockwool), thickness at least 100 mm. Above the insulating material a
layer of about 5 cm of sand is put (can be sprayed with a pump). The sand is used to avoid
that the insulating material would fly away due to the draft of the ID-fan. It should be
carefully checked that the complete surface is evenly filled. Also the side wall tiles of the
combustion grate and the inlet guide tiles of the feeding grate have to be completely
covered.
The grate element which are most intensively exposed to heat are grate element number 4
and 5 (at furnace outlet), since the start-up burner is positioned in the back wall. These
elements must be covered with ceramic fiber, with thickness at least 100 mm.
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Caution: The temperature of the feeding and combustion grate may not arise above its
design value (feeding grate = surrounding temperature, combustion grate =
primary air preheating temperature), otherwise severe damage can be caused
to the mechanical structure and the hydraulic drive system (caused by limited
thermal expansion). The procedure to protect the grate, like described below,
has strictly to be followed.
Before starting the drying-out and baking procedure, it is advised to have a final check on
the clearances of the combustion grate tiles. This is necessary to be sure that the
clearances have not been changed during mounting of the grate elements. If clearances
have become smaller than advised on the drawings, there is a risk of blockage of the grate
tiles at normal operating conditions of the grate.
It is advised to test the operation (movement) of the grate elements before drying-out and
baking, to check whether everything works properly. All combustion and feeding grate
elements have to be withdrawn to their rest position.
The feeding grate has to be cooled by opening the inspection door at the back side of the
feeding grate housing. In this way, heat release to the feeding grate can be evacuated to
the environment.
To protect the feeding hopper and the feeding chute cover plate system against too high
temperatures, they have to be protected by means of a temporary cover. A frame inside
the chute is made with iron bars. On this framework, hard insulating plates (thickness 4050 mm) are put with some bricks to avoid that the plates will fly away. All gaps have to
be closed by means of insulation material (in order to prevent the escape of hot flue
gases). The cover is placed just above the feeding grate where the steel part of the chute
starts to allow drying and baking of the refractory lining in the feeding chute.
The closing gate of the feeding hopper has to be opened, to be able to evacuate the
released heat to the environment.
The chute (closed loop) water circuit must be enabled to allow cooling of the steel plate
through the water jacket.
The start-up burner should be checked that its flame will never (at each working point of
the burner) touch the grate or the insulation put above it.
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4.1.5. Ash extractor and sifting ash conveyors
To prevent heat loss through the ash extractor, the water seal on the ash extractor has to
be operational. Also the water supply system to the ash extractor has to be operational,
because it has to compensate the water loss due to evaporation. The water also protects
the ash extractor against too high temperatures.
The same applies for the wet sifting ash conveyors under the grate.
Caution: The availability of water to the ash extractor and sifting ash conveyors must
be checked regularly (two times per eight hours) as well as their casing
temperature.
4.1.6. Primary, secondary
The butterfly valves of the primary and secondary air are opened partially. This allows
air coming in by suction of the ID-fan. This air can help to evacuate for instance the
water that is evaporated in the air gap of the side wall cooling system of the furnace. It
also protects the air ducts against too high temperatures (sweeping air).
Caution: No primary air can be used during the drying-out and blowing-out
procedure, because the sand and the insulating material might be blown
away and thus exposing the grate directly to the radiant heat of the burners.
The side wall cooling fan has to be operational. It is possible that during the drying-out
and baking procedure, the side wall cooling has to be started.
Before hot commissioning several measures need to be taken to to protect the critical
items of the boiler. The main steam check valve internals should be removed and steam
flow measurement orifice should be replaced by a temporary simple design plate. Note
that the steam flow needs to be determined during steam blasting in order to evaluate the
blast impuls. The demister of the steam drum should be removed (during boiling-out) and
the insulation bricks of the manholes need to be removed.
All control and safety equipment and plant interlocks required for the activities of hot
commissioining should be operational.
A release note for hot commissioning of the boiler from the local inspection authority
should be available
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All measurement systems in the boiler (water-steam side) and post combustion zone (flue
gas side) have to be operational (temperature, pressure, ). All temperature trending
have to be printed and saved.
The support burners must be operational / released. For more detail, refer to O&M
Manual from supplier.
Fuel oil circulation pumps must be operational / released to allow feeding to the support
and start-up burners.
Boiler feeding water pumps must be operational / released. For more detail, refer to
O&M Manual from supplier. Temporary start-up filters can be installed instead of the
(fine) normal filters.
The demin water preparation system must be operational / released to allow feeding of the
pressure parts through the boiler feeding water pumps
The boiler water conditioning system (dosing of sodium phosphate) must be operational /
released.
The flue gas cleaning system has to evacuate the hot flue gases. To protect the flue gas
cleaning against too high temperatures, one can open manholes in the flue gas ducts or at
the reactor, in order to insert air, sucked by the underpressure created by the ID-fan.
The ID-fan has to be operational. The automatic control loop to regulate the furnace
pressure and interlocks should be operational .
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5. HEATING-UP PROCEDURE
This procedure is the heating up procedure, as given by the refractory supplier .
Temperature in the furnace room and boiler first empty pass will be monitored during heatingup of the furnace. Measurements will be recorded and the actual heating curve will be set up
(only for control and approval by the refractory supplier).
Sufficient supply of consumables should be available: demin water (boiler feed water), fuel,
chemicals for boiler cleaning
Heating up procedure is represented on the curve hereafter :
TEMPERATURE(
600
550
550
500
360
400
300
250
360
250
200
150
110
100
110
25
25
0
0
33
47
71
78
114
127
151
167
215
TI ME SCHEDULE( Hr )
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6. Staying at a constant temperature of 360C during 36 hours. This is the second baking step
of the refractory material.
7. Heating up at 25C/hr until a temperature is reached of about 550C.
8. Staying at a constant temperature of 550C during at least 24 hours.
9. After baking and drying-out, the refractory can be cooled down at a rate of about 2530C/hrAll above parameters are valid for the refractory in the furnace. Concerning the
boiler refractory lining, the exact value of these parameters depends on the refractory
materials applied in the boiler. Only the refractory supplier can give a guaranteed dryingout and baking procedure.
Caution: A drying-out and baking procedure is a continuous procedure, 24 hours / 24
hours, 7 days / 7 days. It can not be stopped halfway, and a sudden stop (a
sudden decrease in temperature) can cause damage to the refractory lining.
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900
850
850
800
TEMPERATURE(
700
600
500
400
300
200
100
25
25
0
0
16
16
TI ME SCHEDULE( Hr )
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6. BOILING-OUT PROCEDURE
Before boiling-out it is advisable to flush the entire boiler one time with demin water to
remove all loose particles still present in the boiler from erection works. The draining of the
boiler after the final pressure test can be considered as the flushing, provided the quality of
the drain water was good (no big particles in the water), the boiler was conserved in a good
way (see related procedures) and no more welding or repair works on pressure parts were
carried out (is not allowed after pressure test).
Boiling-out of the boiler aims at the removal of mechanical impurities, grease and possible
other contamination, if any, from the internal surfaces of the boiler tubes. The superheater is
not boiled-out (is cleaned with flushing and afterwards during steam blasting).
Both processes (boiling-out vs. drying-out/baking) may be carried-out simultaneously
providing that the resulting prolongation of the process, as well as the increase of temperature
and pressure, will not have negative influence upon the results of the boiling-out process.
Caution: The procedure hereafter described is given as an example. The operation of
the boiler during boiling-out should strictly follow the operating instruction
of the boiler supplier.
To ensure uniform concentration of chemical agents in all boiler elements that are included in
the process of boiling-out, an auxiliary installation can be provided consisting in one
circulating pump connected at the suction port with the drains of boiler evaporator bottom
headers, while pump discharge will be connected to the drains of economiser inlet header (see
typical sketch in annex). This pump will also be used for introducing chemical solution into
the boiler from a small tank. The circulation pump will run about 4 times a day during 1 hour.
The pH of the solution in the boiler will be measured each time after the circulation pumps
have been operating.
Note that the superheaters are not boiled out..
Typical composition of boiling-out solution and amount of chemicals:
Chemical agent
Concentration
Amount
:
:
:
Fill up the boiler to the lowest operational level in the steam drum. Note that the
superheaters are not allowed to be filled up with the alkaline boiling-out solution.
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Prepare the concentrated solution of NaOH and Na-phosphate in the tank (pH of about
11-12).
Start the temporary circulating pump and establish circulation within the system
(circulating pump- economiser- boiler drum- evaporator- circulating pump).
Fire the boiler and proceed to refractory drying procedure (see 5).
During the initial stage of drying-out procedure (until the drum pressure does not exceed
4 bar), the boiler evaporator should be blown-down every 6 hours (bottom headers drain
valves to be fully opened one by one for few seconds and than closed again).
The circulating pump should be operated for 30 min. every 6 hours during this stage. At
the drum pressure above 4 bar, the circulating pump suction and discharge isolating
valves should be kept closed. Each time after circulation, the pH of the boiler water
should be checked and the dosing of the chemicals to be adapted accordingly.
The drain (boiling-out) water is contaminated with chemicals and should therefore be
disposed taking into account the applicable environmental legislation/regulations.
After cooling-down, the steam drum is made empty and is opened and cleaned /inspected
for the presence of impurities. Loose impurities, if any, should be removed manually.
Inner surfaces of the drum to the operational water level should be free from contaminants
(oil, sand, grease, etc.).
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Item to check
Feeding chute
Boiler
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5. Flue gases must be kept at a constant temperature of 110 - 120C during at least 24 hours.
This is drying-out period.
6. Boiler is heated up to a water temperature between 110 - 120C, with max. 15C/hr. This
is boiling-out period.
7. Flue gases are heating up at 15C/hr until a temperature is reached of about 260C. To
reach that temperature, auxiliary burners (in the post combustion zone) will be started up
when the flue gas temperature is about 200C, because the start-up burner is not powerful
enough (1 x 4,5 MW). As soon as the support burners are started, the flue gas temperature
that is checked, is the one in the post combustion zone, about 4 to 6 m above the support
burners.
8. Flue gases are kept at a constant temperature of about 360C during at least 36 hours. This
is the baking period (1st step).
10. Flue gases are heating up at 25C/hr until a temperature is reached of about 550C.
11. Flue gases are again kept at a constant temperature of 550C during at least 24 hours. This
is baking period (2d step).
Caution: During the baking period the flue gas temperature before the superheater
must be kept below 450 - 480C
12. Now the drying-out and baking period is done, the flue gas temperature is lowered at
25C/hr up to ambient temperature.
13. The boiler can now be emptied in order to drain dirty water. First check that one boiler
cannot be filled with water the other boiler being drained (through blow-down system).
14. Open all vents:
Between superheaters
15. When the boiler temperature dropped under 60C, the boiler can be fully drained by
opening the intermittent blow-down system, which can be by-passed. When water stops
flowing, all drains from the lower boiler parts must be opened. Note that the boiling-out
water is contaminated with chemicals and need to be disposed/drained according to the
applicable environmental regulations.
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16. Check the quality of the drain water (with filter at drain pipe). If the quality is
unsatisfactory, boiler shall be filled up again and drained.
Caution: Not all drains are flowing to the blow-down vessel and they therefore need to
be led to drain gutter using flexible hoses
17. Open the drains from the economiser, the superheaters and the evaporator to the blowdown vessel. Then open the continuous blow-down system to evacuate boiler water to the
blow-down vessel
18. These operations can be repeated twice or three times after the boiler is refilled with demin
water (until pH of about 9). It is advised to have water circulating between two cleaning
sequences. After the last cleaning, inspection must be made to the pressure parts of the
boiler (drum, header, ).
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K1 =
(Gd x vd)
(Gn x vn)i
K2 =
(Gd x vd)
(Gn x vn)
where:
Gd
Gn
vd
vn
The parameters (pressure + temperature) for the calculation of the steam specific volume shall
be measured just before the turbine / turbine bypass valve.
8.2.2. Calculation method
In order to determine the steam flow during blowing in absence of the flow measuring orifice,
the following calculation method is applied.
The flow is calculated, based on the measured pressure drop during blasting versus the
pressure drop in the boiler + piping during normal operation at maximum load.
A. Pressure drop formula:
1P = 0
w x .
2g
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with . =
1P = 0
1
v
w
w
=k
v 2g
v
with w =
Dv
F
Dv
)
F
= ko D v
1P = k
v
(
with:
1Pb = ko Db vb
with:
vb : steam specific volume (to be evaluated from steam tables, based on measured steam
temperature and pressure at piping outlet during blowing)
1Pn = ko Dn vn
D. Steam flow during blowing
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The steam flow during blowing is calculated from the ratio of the pressure drop at normal
operation versus the pressure drop during blowing:
1Pn ko Dn vn
=
1Pb ko Db vb
Db = Dn
vn 1Pb
x
vb 1Pn
Start-up burner
1 x 4,5 MWth
Auxiliary burners :
1 x 7,5 MWth
Another limitation of the blowing parameters is the pressure drop in the temporary piping and
silencer. Therefore, a silencer should be selected with a low pressure drop (maximum 4 bar),
so that high steam velocities can be obtained.
The lower pressure limitation by the silencer resistance and the upper limitation resulting
from the thermal power of the auxiliary burners, determine the K1 and K2 factors.
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8.3. IMPACT BLOWING OF BOILER - PIPING
Next to the method of the continuous blowing, impact blowing could be applied for the
cleaning of the superheaters.
The boiler should be fired-up (with burners) in accordance with the prescriptions of the
boiler manual.
The gradient of saturation temperature increase in the drum (drum pressure increase)
should be not higher than indicated in the boiler manual/instruction. The heating-up of the
boiler should not exceed the requirements of the refractory (heating-up curve).
The firing-up will be performed with the start-up valve or the temporary valve partially
opened
In case of the combination of the continuous and impact blowing the following procedure is
followed:
By gradual increasing the power of the burners, the pressure and temperature in the boiler
is raised. The temporary valve in the blow-out piping is partially opened. One has to make
sure that the opening of the valve is done in harmony with the burner thermal power so
that the pressure and temperature keep increasing.
Once the parameters for continuous blowing are reached, the blowing-out should be
continued for about 10 min. Afterwards, the temporary gate valves will be partially closed
in order to reach the required drum pressure for impact blowing (24-30 bar).
When the drum pressure is 24-30 bar the temporary valve will be opened at once until a
drum pressure of about 10 bar = impact blowing
Temporary valve will be closed and burner capacity is gradually decreased according to
the cooling down curve of the refractory.
The next blowing procedure should not start earlier than the skin temperature of the
piping has dropped to about 150-200C.
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8.5. PRACTICAL MATTERS
-
Just before start of impact blowing the level in the steam drum shall be adjusted to low
level. During impact blowing the water level will raise instantly due to the quick
reduction of pressure.
In normal practice, 2 to 3 steam blastings per day can be carried out. More steam blastings
is not efficient since the cooling down of the superheater, steam piping is very important
(cracking effect). Overnight a thorough cooling down should be carried out.
Steam blasting will be performed at a flue gas temperature (measured in 1st pass) of about
500-550C.
If the flue gas temperature at the exit of the 1st pass (above the refractory lining) exceed a
temperature of 450C a small amount of steam should be blown off (via PCV ) to ensure a
safe and trouble-free natural circulation of the boiler. If the temperature of the flue gases
before the final superheater reaches 400C, it is required to blow off a small amount of
steam to ensure a good cooling of the superheater tubes. More steam needs to be blown
off when the flue gas temperature further increases
Before steam blasting, the steam parameters (pressure and temperature) are gradually
increased by increasing the capacity of the burners and by secondary air injection (typical
steam conditions for steam blasting : T = 360-375C, P = 24-30 bar). Meanwhile the
steam piping is preheated up till the silencer. When steam parameters are reached, the
temporary steam blasting valve is fully opened (as quick as possible)
Cooling down of the boiler after steam blasting should be at approximately 50C/hr
Before firing up the boiler for start of steam blasting, the following heating-up curve
should be followed (only first part is relevant from 25 to 550C in 32 hrs.).
Temporary installation for steam blasting consists of temporary steam pipe (should be
very clean), a silencer (low pressure drop), 2 temporary manual open/close valves (1 for
piping to turbine and 1 for piping turbine bypass valve), 2 sample holders for target
plates, sufficient number of target plates, drain valve for temporary piping and connection
for water injection (to reduce noise)
The cleaning processes and subsequent starting with waste should preferably be executed
in a consecutive way. In case it is not executed in a consecutive, continuous way a proper
conservation of the boiler should be carried out.
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600
550
500
TEMPERATURE(
550
550
500
500
400
300
200
150
150
100
25
0
0
12
32
38
44
50
56
TI ME SCHEDULE( Hr )
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(b) Permitted rise in pressure at the water side (to be confirmed by boilers supplier)
The mentioned pressures and temperatures are always measured on the steam drum.
Start-up with cold boiler (ambient temperature - c. 20 C and on atmospheric pressure).
1 5 bara in 45 minutes
9.2. SAFETY
Check the alignment very carefully before starting any equipment. E.g. shut-off valves of
measuring instruments and switches have to be opened, discharge and air-relieve valves
have to be closed, in-line valves have to be opened, bypass valves on
measurements/accessories closed.
Check the sense of rotation of motors when works on the power supply or connections
have been carried out.
Before closing equipment, always check whether there are no strange objects left inside
the equipment (keys, rags, ...).
After start-up always check on site if the process parameters are within normal values
(e.g. pressure side of pumps, cooling water flow at feeding chute, etc.). See the nominal
values mentioned on the PFDs.
Before beginning start-up by means of the general start-up procedure, the operator has to
read the detailed operating instructions per P&ID and locate the equipment, accessories,
measuring instruments, etc. in the installation, so that he can act quickly and is aware of
the situation. The general start-up procedure is written on the assumption that the operator
knows the individual operating instructions per P&ID.
The operator in charge of start-up has to have the tables and procedures below with him at
start-up. He preferably coordinates start-up from the control room (in order to have an
overview of the complete situation) or keeps in touch with qualified staff in the control
room when he is in the installation.
Safety equipment
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Before starting the installation it has to be checked if all safety measures are operational:
Fire protection: ensure the supply of fire extinguishing water to all reels, hydrants, fire
extinguishers in the bunker, spray nozzles in feeding hoppers. Functioning of emergency
centre.
Safety showers
UPS-stand-by
9.3. PREPARATIONS
All equipment and auxiliary installations have to be on stand-by.
The order of the various preparations obviously depends on the start-up order when putting
the installation into operation. However, the basic rule is that the preparations and start-up of
the various auxiliary installations are carried out as quickly as possible after finishing the
various cleaning, inspections and/or repairs, to be able to deal with any start-up problems on
time.
Remove sand/insulatnig material from furnace + all temporary equipment used for the
refractory drying - boiling out steam blasting and restore to normal operational conditions.
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9.4.2. Start-up common parts
1.
2.
3.
4.
Cooling water circuit and distribution in operation. Rem.: check the cooling
water flow to the various installation parts to be cooled: pumps, temperature
control device,
5.
6.
Feeding chute filled up with water It is important to fill up the chute before
firing the furnace on fuel because the chute is not protected by a layer of
waste as in normal operation.
7.
8.
9.
10.
Start agitator
Check the supply of cleaning water on lime milk circulation pump before
start-up
13. Start lime milk pump and pressurise main ring pipe. Start one of both lime
milk circulation pumps and put the pressure control on the lime milk main
ring into operation.
15. Pump leakage water from ash bunker. Start-up after the ash extractor has
been fed with hot ashes (otherwise this wastewater does not evaporate, and
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When low pressure steam is available, first the low pressure heat exchanger will be started
(valves with TAG-number #LBG10# and #LCN10#). When the low pressure heat exchanger
is in operation, the high pressure heat exchanger (valves with TAG-number #LBG20# and
#LCN20#) can be started.
C. Start-up : no low pressure steam available
1. The globe valves in the upstream steam lines (*LBG10AA201, *LBG20AA201 and
*LBG20AA202) are closed.
2. The temperature control valve *LBG20AA001 will come into operation, but as long as the
steam supply line remains closed, the primary air will not be preheated, and the control valve
will go to fully opened position.
3. The sequence primary air must be in normal operation. The temperature control valve
*LBG20AA001 is released for control and normally fully opened due to the low primary air
temperature. Check that the control valve is open !
4. Close the by-pass valves (*LBG20AA205 and *LBG20AA206) over the temperature
control valve *LBG20AA001.
5. Open (slightly) the drain valves *LCN20AA901 and *LCN20AA902 to evacuate the
condensate collected in the heat exchanger. Do not open the valves completely, because steam
will come in the next steps. It is also possible that steam flows back from the condensate
return vessel.
6. As soon as it is clear that most of the water in the high pressure side of the heat exchanger
is drained, the globe valve *LBG20AA201 and *LBG20AA202 on the steam supply side can
be opened smoothly (to avoid water/steam hammer). Steam will slightly come into the heat
exchanger, condense and start to preheat the primary air. As soon as the primary air
temperature rises, the temperature control valve *LBG20AA001 will start to control.
7. The drain valve *LCN20AA901 and *LCN20AA902 must be closed as soon as steam is
coming out.
8. The globe valve LBG20AA201 and *LBG20AA202 on the steam supply side can be
completely opened when the primary air temperature control is in stable operation. This
stable operation will be reached more quickly, when one starts with a low setpoint for the
primary air preheating temperature (e.g. 80 C). As soon as the gate valve on the steam
supply side is fully opened, one can start further increasing the primary air temperature
setpoint.
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1. Gradually decrease the temperature setpoint until the setpoint has reached the ambient
temperature. The control valves will gradually close.
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Bag filter :
Close all openings and entries to furnace, boiler, flue gas cleaning and flue
gas ducts. Check whether no strange objects, scaffolding, etc. are still
present in the installation. Check whether any staff is still present in the
installation.
3.
4.
5.
Fill ash extractor with water through manual bypass valve and then put the
automatic level regulation into operation. Check water seal on site (through
overflow tank).
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6.
Fill grate siftings conveyers with water through manual bypass valve and
then put the automatic level regulation into operation. Check water seal on
site (through inspection cover on top).
7.
cooling sight-glasses
cooling camera
cooling burn-out controls
8.
Atomiser: start cooling air supply (fan) for protection of atomiser when the
installation is fired by support and start-up burners. The atomiser may
NEVER come into contact with hot flue gases when the fan is not working.
9.
All boiler feed water pumps have to be aligned (automatic take-over in case
of failure of one pump).
Supply all pumps with cooling water and verify the cooling water flow.
Check whether the suction filters are clean (especially at first start-up or
after important repairs in de-aerator or suction pipes).
Close all drains. Open the suction valves. Open the valves in the minimum
flow pipe.
If there is no boiler feed water in the pressure pipe, this has to be de-aerated
first. Start the boiler feed water pumps through the minimum flow pipe
with closed delivery valves. Open the vent valves on top of the boiler and
close the water supply to the economiser. Open the delivery valve very
gradually to pressurise the boiler feed water pipe. Close the vent holes on
top of the boiler immediately when there is water coming out (pressurised
water !!).
When de-aerating the boiler feed water pipe, water is sent through the
bypass over the level control valve. Open the valves in bypass only a little
to reduce the pressure of the pumps sufficiently when de-aerating.
After filling the boiler (see below) stop the pumps again. The pumps may
only run continuously after start-up of the level control on the steam drum.
Before that they are only started if necessary to fill up the boiler.
10. Fill up steam boiler according to procedure of boiler manufacturer; below you
can find the most important items for start-up from atmospheric pressure and
temperature when there is boiler water in economiser and evaporator (for startup with completely empty boiler : see above):
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12. Purge the boiler at the flue gas side with air by means of the ID fan, the
primary air fans and/or secondary air fans and/or the fans of the support
burners.
13. When flushing of the boiler is finished, both support burners have to remain
in cool operation (i.e. their fans have to keep running at minimum speed).
14. Close all manual and/or automatic valves primary air, secondary air and side
wall cooling to limit leakage air (and the corresponding CO production by
the burners).
15. Start start-up burners (locally); temperature rise at the side of the flue gases
according to instructions supplier refractory lining; pressure rise boiler at the
water side according to instructions boiler manufacturer (to control with
start-up valve boiler as long as main steam valves are closed, afterwards with
turbine bypass).
16. From 200 to 300 C flue gas temperature, start the auxiliary burner manually
at minimum load. Then, the operator has two alternatives :
Either stop the start-up burner and withdraw the start-up burner immediately
from the furnace.
Important notice : when the start-up burner is stopped, the burner should be
withdrawn from the furnace immediately.
17. Further actions at start-up boiler :
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Between 0 and 1 barg steam pressure on the steam drum the local level
gauges on the drum have to be blown out. Open both drain valves
beneath the level gauge and then close them. Normally the water level in
the level gauge has to fluctuate, if not then there probably is a blockage
somewhere.
Close vent valves of steam pipes as soon as steam is flowing out (at 1 to 3
barg); start at the vent holes on top of the drum and go to the vent on the
superheaters.
Close drains superheaters from 5 barg; start at superheater 1 (closest to the
steam drum) and go on until superheater 2.1 (closest to HP steam pipe).
From 10 barg on steam drum: put one-point level control drum into
operation; boiler feed pumps keep on running continuously from now on.
Start ammonia dosing (immediately after boiler feed pumps start running
continuously).
Start sulphite/polyphosphate dosing (same as above).
Start-up steam condensate circuit on the basis of rising boiler pressure.
Check pressure rise boiler; if necessary open start-up valve (controlled
steam blow-off); as soon as turbine bypass is in operation: control pressure
rise through turbine bypass and set start-up valve automatically with
setpoint 0.5 barg above nominal pressure on steam network.
Be careful with excessive steam blow-off through the start-up valve (max.
supply demin water !!); if necessary increase less fast with support burners.
Start up three-point control level steam drum at sufficient steam flow (min.
30 %).
18. Put discontinuous blow-down into operation; in the beginning the
discontinuous blow-down valve has to be opened during a short period. This
purching of the boiler feed water will continue until the boiler water quality
meets the normal criteria.
19. Start control steam temperature before waste incineration and before the
steam temperature rises above 350 C. Also when the temperature between
the superheaters exceeds 350 C the steam temperature control has to be put
into operation.
20. Start hydraulic group (locally). Check oil level, oil temperature, and
pressure after the pumps as well as pressure on the circuit to the grates/ash
extractor.
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23. Start boiler ash extraction (empty passes and superheater/eco section)
Shredder reactor
25. Start equipment to prevent bridge formation in reactor and bag filter
(pneumatic hammers)
26. Start the secondary air injection. As a result of the high oxygen content at
the exit of the boiler in this stage of start-up the sequence will be put on
hold and nothing will happen (fan remains out of service). The secondary
air will then automatically start operating when the waste incineration
develops sufficient thermal capacity.
27. Start the temperature control of the flue gas at boiler exhaust. Therefore, the
burners have to be running at full load. Check the correct alignment of the
three-way valve (a.o. bypass valve has to be closed now).
28. Put the start-up burners at a higher load approximately 1 hour before the
waste incineration is started (i.e. at c. 810 C post-combustion temperature).
They have to preheat the furnace to help ignite the waste.
29. From a flue gas temperature of 120 to 130C (measured at inlet of bag filter)
the bag filter is taken out of bypass in the following way:
If any inspection openings are still open, they have to be closed before
start-up.
The bypass valve is closed and the flue gas valve in the main flue gas duct
is opened. The sealing air fan is started.
The recirculation system is taken out of service: the recirculation fan and
electrical heater stop and the main shut-off valve closes.
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Check whether the heated ambient air on the heating circuit is operational
(and whether the temperature is high enough).
Check whether the bypass valve shuts off correctly (local dP measurement).
If not, this valve has to be adjusted by means of the spindle. Check also if
there is sealing air present.
Start cleaning sequence bags at the latest when the waste incineration is
started.
Check if any pre-coating has to be carried out on the bag filter (see further
instructions concerning pre-coating).
Do not start the reactor before the support burners run at full load and the
exit temperature of the boiler is sufficiently high. The exit temperature of
the boiler can be increased by partly preheating boiler feed water.
Start atomiser with water injection (for a first start-up, this has to take place
locally in close contact with the control room. If there are no
abnormalities, the automatic operation can be switched on. By injecting
water, the temperature of the bag filter can be brought within the normal
operation level (around 180 C as long as only water is injected).
Start lime injection and control exit temperature reactor only when the
incineration plant is operating stably at full load. With injection of lime
milk the exit temperature of the reactor can be reduced to ca. 150 C. If any
inspection openings are still opened, they have to be closed before start-up.
Power plug
Control plug
Cooling water in
Lime milk in
Cooling air
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Lift the atomiser over the shaft by means of the hoist. Remove the closing
cover of the shaft and lower the atomiser into the shaft until it reaches its
seatings.
IMPORTANT remark: when the atomiser fails for whatever reason, it has
to be removed immediately from the hot flue gas flow.
31. If temperature post-combustion > 850 C, differential pressure over the bag
filter larger > 0 (bag filter coated) and no dust detection after the bag filter :
start waste incineration; here following actions have to be carried out shortly
after each other to avoid and/or limit emission exceeding :
Place one full grab of waste on the start-up valve in the feeding chute. Keep a
grab of waste stand-by above the feeding hopper.
Temperature incinerator 850C and complete flue gas cleaning in service : open
the feeding chute flap. When the start-up valve is completely open, drop the
waste into the feeding hopper.
Start filling the feeding chute (Note: Close the flap during crane grapple
movements in the refuse bunker to avoid cooling down the furnace too much as
long as no seal has been created).
Open the primary air valves and (manually) operate the feeding and combustion
grate to introduce the waste on to the combustion grate.
Put bag filter into operation and start lime milk injection in reactor with
automatic emission control HCl and SO2
As soon as waste starts to incinerate, the cleaning sequences of the flue gas
cleaning plant have to be started up, this implies a.o. that the dosing of
chemicals is started, that the cleaning of the bag filter is started, etc.
Feed waste into the furnace by local operation of feeding grate and the sliding
grates; do NOT supply any primary air yet
At increasing intensity of the flames the primary air may be put into operation
MANUALLY (including air preheating); put the valves on the pressure side of
the fan in the correct (throttle) position (first/last element: 50%, element 2-3-4
c. 60-70% open); gradually increase the primary air flow without blowing out
the fire or cooling down the furnace too much (oxygen boiler < 9 vol.%, max.
10 vol.%, if not CO !); put the fan of the last grate into operation last and only
when the fire reaches it. Remark : when opening valves primary air, air is
already drawn in by underpressure in furnace.
Start side wall cooling before the furnace temperature exceeds 500 C; put
valves side wall cooling in correct position: grates 1, 2, 3 : 100% open; grates
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4, 5 : 75% open.
Secondary air fan was already started up (sequence was on hold because
oxygen content was too high, see above). They will automatically be put into
operation as soon as the thermal load of the furnace is high enough.
Gradually push up feeding speed, grate speed and primary air; support burners
(100% !) and start-up burners keep on running up to nominal steam flow.
Put support burners in automatic. They will switch off as soon as the furnace
has been heated up sufficiently. Pay attention to start-up with a clean or cleaned
boiler : one of the typical behavioural patterns of a clean/cleaned installation is
that the control of the support burners and the control of the secondary air start
overlapping each other (i.e. the secondary air has not yet halted before the
support burners are started to guard 850 C). In that case it is better to operate
the burners manually.
Reduce the auxiliary burner load to minimum load and stop the auxiliary fuel
burner.
Put primary air and grate control in SIGMA as soon as the support burners
(automatic) are stopped, the furnace is running stably, the flame front is all
right, and the furnace temperatures are high enough.
32. Start active carbon injection after start-up lime milk injection.
33. Start/Release the cleaning system of the steam boiler. Pay attention to startup of a clean or cleaned installation: the cleaning system on the superheaters
may be started immediately, the other is best left out of service for a while
because otherwise the steam temperature and the flue gas temperature exit
boiler will remain too low for a longer period of time. The cleaning system
on the protective evaporator is only started when the steam temperature is
high enough (i.e. 400 C nominal steam temperature can be reached at full
load) or sooner when the steam temperature between the superheaters
becomes too high; the cleaning system on the economisers is started as soon
as the flue gas temperature exit boiler is high enough (at least 210 C). For
specific information, see O&M manual soot blowing system.
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Note:
mm
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Energy from Waste with Combined Heat and Power Facility, Oxwellmains
JAS4061
ST003_KSBEIS
Keppel Seghers technical standard for Waste-to-Energy
Testing and sampling procedure to determine the Loss on Ignition of
bottom ashes
0
REV
First issue
DESCRIPTION OF MODIFICATION
DOC REFERENCE
21.08.2007
DATE
RDP
AUTHOR
BA
CHECK
BR
APPROVED
1.
inerts
metals
unburned
ashes
All identifiable objects should be separated in one of the first three fractions,
irrespective of their size or weight. Next, the remaining fraction should be sieved
(mesh size 20x20 mm) and all objects larger than the mesh size should be
inspected (if necessary after breaking open) and added to one of the first three
fractions.
The fraction after sieving will be referred to as sorted bottom ashes.
Page 2/5
1.3.
Grinding and homogenisation
Through a series of consecutive grinding/mixing/dividing-steps a representative
sample of the sorted bottom ashes is obtained.
1.4.
Drying at 105C
A representative sample of at least 5 g of the sorted, ground and homogenised
bottom ashes from step 3 is heated for at least 24 hours to 105C in a drying
oven until constant mass1 is achieved. The mass loss determines the residual
moisture content. Based upon this moisture content and that of step 1, the total
moisture fraction of the complete sample is determined.
1.5.
Determination of the ignition loss
The ignition loss of the dried, sorted, ground and homogenised ashes is
determined by inserting a precisely weighed sample of 4 g in a furnace at a
temperature of 550C for two hours (in agreement with EAWAG V-4002).
Afterwards, the sample is transferred to an exsicator to cool down to ambient
temperature. The ignition loss is determined as the ratio of the mass loss after
heating to 550C to the initial mass of the sorted, dried, ground and homogenised
ashes, expressed as a percentage with respect to the dry matter.
Note
Experience has indicated that it is crucial to operate with identical cool down
periods. This holds for the weighing of the empty crucible (without sample) and
the weighing after heating to 550C.
The report accompanying the analysis should cover all of the above steps
separately. This implies that at least the following results should be included:
the ignition loss of the dried, sorted, ground and homogenised ashes
(step 5)
In agreement with DIN 38414 S2, the mass of the sample is considered as constant if additional
drying at 105C during half an hour does not result in a mass loss exceeding 2 mg.
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Remarks
1.
In the standard case, the total ignition loss of the bottom ashes will be
determined by means of a weighted average (according to their mass
fraction) in which the ignition loss of the unburned fraction is assumed to be
100% and that of the inert and the metal fraction 0%. If necessary, the
ignition loss of this fraction can be determined separately and used to
replace the above assumptions.
2.
If no other procedure is prescribed, the sample of the bottom ashes is
obtained by taking a sample of approximately 1 kg at a fixed location and
during a total period of 6 hours with a frequency of once every half hour. In
order to avoid stratification effects, it is preferred to take the sample at a
location where the ashes are falling from one transport system to another.
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2.
1.
2.
3.
4.
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Energy from Waste with Combined Heat and Power Facility, Oxwellmains
JAS4061
EXTRACT FROM
ST003_KSBEIS
FUNCTIONAL DESCRIPTION
BOILER FLUE GAS SIDE
DEMONSTRATION OF THE 850C/2S REQUIREMENT
Page 1/5
1.1
1.1.1
The flue gas temperature at the top of the first empty pass of the boiler is measured : four
thermocouples are installed, from which three thermocouples are used (the operator deselects
one of the four measurements on the supervision screens). The median value of the three
remaining measurements xxxx is used for auxiliary burner control (allowing that at least one
measurement can drift away without disturbing the control loop).
This median temperature will be used both for start/stop control and load control of the
auxiliary burners.
1.1.2
The 2 seconds temperature xxxx is calculated based on the temperature measurements in the
top of the first empty pass of the boiler.
Information
temperature value xxxx which is used to control the burners. The latter is the median value of
the three measurements in the top of the first empty pass, see 1.1.1 above.
In order to calculate the flue gas temperature after 2 seconds residence time, the following
reference levels are defined (see Figure 1) :
1. H2 : Top of the first empty pass of the boiler : +xx,x m
2. H0 : Secondary air injection level : +xx,x m
3. H1 : End of post-combustion zone1 : +xx,x m (used as a reference level in the
calculation formulas)
End of conical part at the outlet of the furnace towards the first empty
pass of the boiler.
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H2, m
Cross section S, m
Volume V, m (between
H0 and H1)
H1, m
Figure 1 : first empty pass of the boiler and levels for 2 seconds calculation
First of all, the temperature difference T between level H1 and level H2 is calculated (see
Equation 1). This temperature difference is strongly dependent from the boiler load, and also
slightly dependent from the fouling of the first empty pass of the boiler. Therefore, the
parameters used in Equation 1 have to be checked when initial fouling of the first empty pass
of the boiler has been built up.
Equation 1 : T = A + B/TL4minTOTAL
With :
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TL4minTOTAL : continuous running average value of the thermal load of the furnace,
averaged over 4 minutes. See functional description SIGMA combustion control
system process calculations for the calculation of the thermal load of the plant. The
thermal load considers both heat released by the combustion of refuse, and heat
released by the auxiliary burners. The thermal load, used in Equation 1, will never
pass the limits xx MWth and yy MWth. When the calculated thermal load is lower than
xx MWth, the value xx is used in Equation 1, and when the calculated thermal load is
more than yy MWth, the value yy is used in Equation 1.
A and B : those parameters must be determined during commissioning, after reaching
initial fouling. Based on the boiler calculations at minimum and maximum load, the
following start values can be given : A = xx C, B = xxxx MWth C.
Example : the plant runs at xx MWth, and the temperature at the top of the first empty pass of
the boiler (T2) is xx C. The calculated temperature difference T is xx C, and the
temperature T1 at reference level H1 is xx C.
On both temperatures (measured T2 and calculated T1), a positive correction is applied for
the so-called shield-effect, before they are further used in the formulas below. The shieldeffect considers the fact that the temperature, measured by means of the thermocouples in
the top of the first empty pass, is not the real flue gas temperature, but an equilibrium
temperature which is somewhat lower than the real flue gas temperature. This equilibrium
temperature originates from the heat balance of the thermocouple : heat input occurs by flue
gas radiation; heat output occurs by thermocouple radiation and thermocouple conduction
towards the relatively colder side membrane walls of the boiler. Based upon experience from
reference plants, the required correction for this shield-effect is estimated to be between +50
and +100 C. In principle, this shield-effect can be determined for each specific installation
once it is sufficiently long in operation : either by recalculating the boiler (making the heat
balance over the convective part allows for determining the temperature profile in the radiation
part), either by on-site measurements by means of a temporarily installed extraction
pyrometer.
The volume of the post-combustion zone (i.e. the zone between level H0 and level H1) is
equal to xx m (total conical volume) xx m (volume of the upper part of the prism if present,
the part which is situated in the conical volume) = xx m (V, see also Figure 1).
The cross sectional area of the first empty pass (starting from level H1) is aa m x bb m = AA
m (S, see also Figure 1).
The flue gas flow Q (Nm/h), obtained when leaving the auxiliary zone, is calculated based on
the total combustion air flow and the auxiliary burner load (see functional description SIGMA
combustion control system process calculations).
The flue gas flow Q has to be recalculated towards Qreal (m/sec), taking into account the
average flue gas temperature. For the same example as above, a flue gas flow of xxxx Nm/h
will become
Based on this information, the level H2sec where the flue gases reach a residence time of 2
seconds, can be calculated by using Equation 2.
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Equation 2 : H 2 sec = H 1 + 2
V
Qreal
Qreal
S
With :
H2sec : level where the flue gases reach a residence time of 2 seconds (m)
H1 : reference level at the end of the post-combustion zone, as defined above (+xx,x
m).
V : volume of the post-combustion zone (xx m)
Qreal : real flue gas flow (m/sec)
S : cross sectional area of the first empty pass of the boiler, starting at level H1 (xx,x
m).
For the same example, the following result is obtained for H2sec = xx,xx m.
Note : in case the calculation result from Equation 2 would be lower than H1 (this might be
possible in case of very low flue gas flows in startup phase or in trip conditions), H2sec is set
equal to H1 as a minimum value.
The flue gas temperature after 2 seconds of residence time T2sec can be calculated by linear
interpolation between H1/T1 and H2/T2, see Equation 3 (T1 and T2 first to be corrected for
the shield-effect as mentioned above).
Equation 3 : T 2 sec = T 1 + shieldeffect +
T 2 T1
(H 2 sec H1)
H 2 H1
Giving the following result for the example above : T2sec = xx,xx C.
Other example : thermal load xx MWth, temperature in top of first pass xxx C, calculated flue
gas flow xxxx Nm/h.
Temperature T1 at level H1 = xx C
Real flue gas flow = xx m/sec
2 seconds level H2sec = xx m
2 seconds temperature T2sec = xx C.
The calculated 2 seconds temperature (xxxx) is shown on the overview screen of the furnace
and the boiler in central control room.
The shield-effect offset parameter is a fixed value in the process control system (start value
+50 C, until verification during first startup of the plant).
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Presented by:
TEST PLAN
1.
PROGRAMME ............................................................................................................................................... 2
2.
3.
HOT COMMISSIONING............................................................................................................................... 4
4.
5.
COMMENT: This document is for typical use only. Project specific periods, durations
and conditions of commissioning/testing, as stated in POYRI Schedules 9 and 11
and agreed upon between TPSCo and Keppel Seghers prevail.
Version / Date
January 2008
Test Plan
Page
1
Presented by:
1. PROGRAMME
One month before the scheduled start of COLD COMMISSIONING, the
CONTRACTOR will provide a detailed programme for the COLD COMMISSIONING,
HOT COMMISSIONING, RELIABILITY TEST, and PERFORMANCE TEST.
Version / Date
January 2008
Test Plan
Page
2
Presented by:
2. COLD COMMISSIONING
COLD COMMISSIONING is defined as the period when individual items of the
INSTALLATION, electrical systems, control and instrumentation systems are checked
and tested.
During this period, activities such as boiler cleaning, refractory drying, cleaning of
pipe work and tank internals are carried out.
Test Sheets shall be developed by the CONTRACTOR to show what tests, checks
and recordings have been carried out. Such Test Sheets shall be submitted to the
EMPLOYER within two weeks after completion of any test.
During the COLD COMMISSIONING, the EMPLOYER will provide a full team of
operators to the CONTRACTOR for training on-site.
Starting Criteria
Mechanical Completion
Ending Criteria
Result of Completion
Note
Depending on the delivery schedule of the turbine, the cold commissioning of the
turbine may take place later than the cold commissioning of the incineration line. If
this occurs, the start of the hot commissioning of the incineration line shall not be
delayed by the turbine.
The cold commissioning and hot commissioning of the incineration line can take
place with steam being sent over the by-pass, i.e. RDF is being incinerated, but
electricity production has not yet started.
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3. HOT COMMISSIONING
HOT COMMISSIONING is started after completion of COLD COMMISSIONING.
During HOT COMMISSIONING the plant will be operated with waste within the
boundaries of the combustion diagram.
The HOT COMMISSIONING tests shall be carried out by the CONTRACTOR and
shall cover in general the following topics :
-
Starting Criteria
Ending Criteria
Result of Completion
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4. RELIABILITY TEST
The purpose of the Reliability Test is to demonstrate that the plant is capable of safe
and reliable operation while complying with the emission limits. During this period,
operations and control functions shall be demonstrated to the EMPLOYER.
During the Reliability Test period of two weeks, the trial runs shall include the
following tests :
-
stable run at various loads with the design range, under automatic control;
The CONTRACTOR shall provide all necessary supervision for these procedures.
Commissioning supervisors will be present on site on a 24h basis during the
scheduled period for the Reliability Test. It is the EMPLOYERs responsibility to
provide a full staff of skilled operators in shift operation.
Minor defects, such as instrument faults or equipment faults which require the
standby operation of auxiliary equipment, shall not constitute a failure of the
Reliability Test, provided that the INSTALLATION continues to operate satisfactorily.
Note: During the first months of operation, too much heat may be extracted from the furnace
due to insufficient fouling and incomplete drying of the refractory lining. The fact that it takes
time to reach the normal fouling degree of furnace and boiler may have consequence for every
point of the combustion diagram. Practice has shown that auxiliary fuel can be necessary
during this period within the complete combustion diagram (and thus also at 100% load) in
order to meet the flue gas residence time requirement (850C/2s).
Starting Criteria
Duration
2 weeks
Ending Criteria
Result of Completion
Result of Failure
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5. PERFORMANCE TEST
Starting Criteria
Duration
see table
Success Criteria
Result of Success
Final Acceptance
Result of Failure
Repetition of tests or
Liquidated Damages for failure to achieve guaranteed
performance
1.
2.
The performance test shall show that all the performance guarantees as
specified are fulfilled.
3.
4.
5.
Each Party shall carry its own costs for the Performance tests.
6.
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7.
8.
If the Performance Test fails as a whole or in part, parties shall analyse the
reason together and define the responsible party/parties as soon as possible.
The responsible party/parties shall take immediate action to remedy the
cause(s) and will announce their readiness to recommence or continue the
tests
as
soon
as
possible.
Depending on the nature and characteristics of the failure of the tests, the
Performance Tests will be redone completely and for the full duration or in part
and for a shorter duration. This matter is to be addressed in general in the
aforementioned protocol but the actual decision is to be reached by agreement
with all parties immediately after the occurrence of the failure.
All parties shall grant their full co-operation to the repetition / extension of the
Performance Tests.
9.
The plant has to be operated in accordance with the combustion diagram and in
accordance with the CONTRACTORs operation and maintenance manuals.
10.
11.
12.
13.
Before a test is carried out, the plant operating conditions shall have been
stable for at least 2 hours (uninterrupted). The stability of the operation will be
verified by means of representative operational parameters (e.g. steam
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production, RDF throughput, oxygen contents exit boiler). The limits on the
allowable variation will be included in the aforementioned protocol. The
CONTRACTOR must have the opportunity during at least 4 days to verify the
tuning parameters of the process before the Performance tests start.
14.
All parameters shall be continuously recorded during the performance test with
a frequency of at least once a minute.
15.
16.
Plant
Test Duration
Remarks
24 hours
Performance Test
Capacity
24 hours
Steam production
24 hours
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CONTRACTOR).
Gross
Electricity 24 hours
Production
Carbon in Ash
Emissions
24 hours
Combustion
Official
independent
measurement
Consumables:
Water
24 hours
Noise
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COMMISSIONING MANUAL
PART N1 :
PRE- AND COLD COMMISSIONING
WASTE-TO-ENERGY PLANT
TYPICAL
by:
10-01-08
RPI
Preliminary
Rev.
Date
By
Description
Check
Appr.
WASTE-TO-POWER PLANT
TYPICAL
1. TABLE OF CONTENT
1.
2.
INTRODUCTION ........................................................................................................................................... 4
3.
4.
3.1.
DEFINITIONS .............................................................................................................................................. 6
3.2.
PRE-COMMISSIONING ............................................................................................................................. 10
4.1.
5.
PRE-REQUISITES ...................................................................................................................................... 10
4.1.1.
General .......................................................................................................................................... 10
4.1.2.
4.2.
4.3.
COLD-COMMISSIONING ......................................................................................................................... 13
5.1.
PRE-REQUISITES ...................................................................................................................................... 13
5.2.
5.3.
5.4.
5.5.
5.6.
5.6.1.
5.6.2.
Ash extractor.................................................................................................................................. 16
5.6.3.
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6.
5.6.4.
5.6.5.
5.6.6.
Hydraulic group............................................................................................................................. 18
5.6.7.
Burners .......................................................................................................................................... 18
5.6.8.
ANNEXES...................................................................................................................................................... 23
6.1.
6.2.
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2. INTRODUCTION
This document outlines the sequence of activities required to take the plant from a completed
installation to a fully operational and commissioned plant. The pre-requisites, necessary for
each stage of the commissioning, are described.
The commissioning will, in general, follow the sequence herebelow :
1. Pre-Commissioning (or Unit test): the checking and testing of equipment prior to
their cold commissioning with power and air. Such works shall consist of testing the
alignment and direction of rotating parts, the verification of the wiring and cabling, the
verification of the PLC system, verification of correct mounting of piping, verification of
correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.
Pre-commissioning checks, when completed, will release individual items of equipment to
be powered up and made available for inclusion in the cold commissioning phase.
2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors
and other electrical equipment, flushing and cleaning of tanks and piping if applicable,
adjustment and regulation of protective devices, functional tests, leakage and pressure
tests, inspection of bearings, etc.) and operation of equipment for a period of time. This
will be mainly as individual items, but may involve running some of the equipment in
sequence.
3. Hot Commissioning: this will include the introduction of fuel (waste), process gas and
reagent (including the boiling out of pressure parts, curing of the refractory, blowing of
steam pipe to turbine, etc). The whole plant will be tested, operating in sequence under
full load conditions.
The Commissioning Manual (part n1) includes instructions for the Pre-commissioning and
the Cold Commissioning of the equipment in the Contract.
The Commissioning Manual (part n2) includes instructions for the Hot Commissioning of the
equipment in the Contract. This second part contains specific information for the first startup, which differs from a normal plant start-up. For the general operating procedures (allowing
to start-up, operate and shut down the plant under normal conditions), please refer to the
Operation and Maintenance manuals.
Responsibility: Operating instructions specified in this manual are typical procedures. It is
impossible to cover all eventualities, which might occur during the start-up of the plant.
Keppel Seghers cannot take responsibility for damage to any part of the plant, which could
have been avoided if instructions had been followed.
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On the other hand, conditions may arise in which actions must be taken without sticking
strictly to the instructions in this manual, provided that such actions result in safe operation.
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A standard form (pdf-format) is available for each type of mechanical equipment (pump, silo,
fan, etc.) within the Unit. The inspection sheet is a checklist to verify if the Unit is
mechanically complete, and ready for further cold commissioning.
Punch lists
The punch lists give an overview of items in the Sub-system, which have to be remediated /
solved. The outstanding items on the lists get a qualification of 1, 2 or 3, depending on their
critical character :
Qualification 1 (= pre-acceptance) : prevents the Unit from being released for further
commissioning, to be solved before startup of the equipment. E.g. wrong rotation
direction of a motor, packing missing, lack of pressure safety valve, etc.
Qualification 2 (= post-acceptance) : item can be solved after startup of the equipment.
E.g. tag plate missing, wrong colour, tidiness of the area, etc.
Qualification 3 (= to be discussed) : can not be qualified under 1 or 2. E.g. scope unclear,
general remark or question, discussion between parties about qualification, etc.
A punch list can be made up for a whole Sub-system or for each Unit, this is left to the
convenience of the KEPPEL SEGHERS engineer.
Each punch list that is updated and filed in the Commissioning Status Report is to be dated,
initialed and signed by the KEPPEL SEGHERS engineer.
When a punch list is the result of an inspection round together with the Client and/or a
Subcontractor, it is important that their representatives counter sign the Punch List. This
punch list is then communicated to them for further action / information.
Functional descriptions
The functional description of each Sub-system enables a better understanding of the P&ID,
and it is the basis for the functional tests of the Sub-system.
Interlock list / autoconditions
The Interlock list (including autoconditions, alarm settings, start / stop sequences, loop
controllers, etc.) forms the basis for the cold commissioning of the Sub-systems (I/O tests or
loop testing, sequence testing, etc.).
Test reports
These will include, amongst other :
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Etc.
It should be stressed that the most important documents of the Commissioning Status Reports
are the Status List and the Punch Lists. The Status List for the formal registration of all tests
and inspections, the Punch Lists for the formal registration of outstanding items. The other
documents (P&ID, inspection sheets, ) are tools.
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4. PRE-COMMISSIONING
4.1. PRE-REQUISITES
4.1.1. General
The control panels and the panels for motors up to 3 kW will have been tested
100% by KEPPEL SEGHERS engineers during the FAT tests in the factory of the
panel manufacturer. This means that each IO signal has been checked from the bit
in the PLC up to the input or output terminal for connection of the field wires. This
testing will be reported in the FAT Inspection report.
The electrical panels (MCC) for motors from 3 kW will have been tested 100% by
the responsible during the FAT tests in the factory of the MCC panel manufacturer.
This testing will be reported in the FAT Inspection report.
The electrical site wiring to the plant has to be complete and must have been fully tested
by the electrical contractors. See next section (4.1.2) about testing of wiring and cabling.
The instruments shall be installed and properly connected. This shall be documented by
the instrument installer on the I/O and SAT tests of control panel lists with the
following items for each instrument : mechanical installation, process connection,
pneumatic connection, electrical connection, tag plate.
The DCS system for operator interface of the installation must be available and FAT
tested in the presence of an KS automation engineer. Testing reported in a FAT inspection
report.
No gas or reagent, hot or cold, should have been through the equipment.
The responsible for the erection of the cabling shall execute tests in order to check all
cable and wire connections. . Only after the completion of these tests, the precommissioning and cold commissioning can start under the supervision of KEPPEL
SEGHERS.
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For connections between control panel at one side and instruments, valves and all
other equipment at the other side : before connection to the instrument/equipment and
before connection to the control panel, all wires will be invividually shortcircuited
at the instrument/equipment side, and the shorcircuit will be measured at the control
cabinet side. Only after this test, the instrument/equipment may be connected.
For connections between control panel and motor control and protections circuits :
before connection to the motor contol centre (MCC) and before connection to the
control panel, all wires will be invividually shortcircuited at the MCC side, and the
shorcircuit will be measured at the control cabinet side. Only after this test, a MCC
unit may be connected to the signal cable.
The result of each test will be documented by checkmarking on the I/O and SAT tests of
control panel and the I/O and SAT tests of electrical panel lists . After completion, this
lists will be signed and stamped by the responsible of the cabling (installer).
I/O and SAT tests of control panel (one per panel) with the following items for each
instrument : mechanical installation, process connection, pneumatic connection, power
cable connection, instrument cable connection. I/O test.
I/O and SAT tests of electrical panel (one per panel) with the following items for each
electrical user : mechanical installation, power cable connection, control cable
connection, insulation test, I/O test.
For each item (reference is made to the TAG-), the commissioning company will complete the
check-out list to give documentary proof that each item of the P&ID has been installed.
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Any missing item or equipment is to be chipped on the check-out list as NOK. It will then
be reported as an open item on the punch list and will be checked together with the KeppelSeghers commissioning supervisor.
Every inspection round will be listed on the Status List (date, initials, signature and eventual
remarks). A new check-out list can be used for every new P&ID check.
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5. COLD-COMMISSIONING
5.1. PRE-REQUISITES
The electrical supply should be available and the MCC should have been tested by the
electrical contractors and be ready for service.
The PLC control system should be available and the PLC programming be complete.
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When a loop test is positive, the EIA engineer will date, initial and sign the loop scheme for
approval. Only the approved loop schemes will be included in the Commissioning Status
Report of the Sub-system, as a proof that the I/O test has been successfully executed. I/O
tests which are not successful remain in the file of the EIA engineer.
When all the loop tests within a Sub-system are executed, the EIA engineer will confirm this
on the Status List (date, initials, signature), before one can proceed with the functional tests.
5.4.
MOTOR TESTS
For each motor the following tests on the power part will be executed:
Isolation test of the power circuit (with the motor connected). Important remark :
for frequency convertors (variable speed drives), these tests will be executed
without the cable connected to the drive unit.
These tests are the responsibility of the electrical contractor ; only mechanical supervision
from KEPPEL SEGHERS.
Results will be indicated on the I/O and SAT tests of electrical panel lists.
5.5.
FUNCTIONAL TESTS
When all Units within a Sub-system are pre-commissioned and loop tested, each Sub-system
can individually be submitted to functional tests : the programmed software in the PLC
system - already FAT tested - is to be site tested (SAT) by checking all functionalities and
interlocks in the field.
The functional tests will be done under the supervision of KEPPEL SEGHERS. The Client
will dispatch sufficient technical staff to perform the tests.
The tests will consist in verifying :
-
Control loops
Sequences
as described in the Functional Description and the Interlock list (including autoconditions,
alarm settings, start / stop sequences, controllers, etc.).
Most control loops or sequences can be tested under empty or dry conditions by simulating in
the PLC the presence of reagent or product in the Unit. For some of the tests, it will be
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necessary to add reagent or products to the Units or Sub-system (e.g. pumps or mixers that are
not allowed to run dry or empty).
It is imperative to thoroughly follow the instructions in the Operation & Maintenance
Manual of the specific Sub-system, before executing functional tests with reagent or
products.
For some Units, some additional specific functional tests have to be done, as further detailed
under 5.6. Specific functional controls.
The first fillings of all bearings were done by the constructor during pre-assembly of the
grates.
Because of the large period of time between grate pre-assembly and
commissioning, all grease points will be verified by adding grease before moving the
grate elements. Refer to the O&M manual regarding the grease qualities (make and type)
of the grease nipples. The greasing positions are shown on the drawing XXXX_239_003.
Once the hydraulic unit has been fully checked for correct mounting and the hydraulic oil
circuit has been completely flushed (see section 5.6.6), the movement of the feeding- and
combustion grates should be tested during at least 8 consecutive hours. During this test, one
has to pay attention to:
Check the fixed time for the tumbling movement (normally between 3 and 6 sec), the time
for withdrawing the feeding grates (typical between 5 - 20sec) and the time for
withdrawing the sliding tiles (typical between 2 to 10 sec).
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Caution: Special attention has to be taken not to run the grates during the furnace
warm-up. In this case, the feeding grates have to stay in their withdrawn
position and the combustion grate must be covered by insulation material.
The cold commissioning of the grate must be supervised by Keppel Seghers qualified
personnel.
When the hydraulic is connected, all moving parts must be checked to move properly:
movements of the pusher.
After a dry run of a few hours without water, the ash extractor is filled with water and its
movement can be tested during 8 consecutive hours (or more). During this test, one has to pay
attention that:
The level control device in the water tank is properly adjusted so that the water seal is
realized at the sifting ash hoppers
The inspection work on the ash extractor must be supervised by Keppel Seghers qualified
personnel.
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5.6.3. Refractory lining
Reference is also made to the Refractory Lining Supplier Erection & Commissioning Manual.
After installation of the refractory lining, the work must be inspected and approved by
qualified personnel :
Hammer test to check the lining for holes, grains, accumulation, etc.
When checks are completely finished, release notes have to be handed over fully signed by contractor, supplier and clients
representatives.
Activate the greasing device by screwing in the ring bolt in the grease container
Stretch the chain. To do that the conveyor must be started up (dont forget to check the
direction of rotation) and let it run for a while. The chain is sufficiently stretched when
the carriers are leaving the return part without a bang. A bang will occur if the chain is
too slack. On the other hand, if it is stretched too hard the carriers will be lifted before
they reach the bend.
After a couple of days, all of the carriers screw joints is to be follow up drafted, and the
stretching of the chain must be checked.
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5.6.6. Hydraulic group
Reference is also made to the Operation & Maintenance Manual.
Before the first start-up of the hydraulic plant, the installation (including all piping) must be
flushed and cleaned to eliminate all contaminants from the system and achieve the required
degree of purity of the oil. The supplier will be responsible for the first cleaning of the
hydraulic equipment and piping, as well as the first filling with hydraulic oil.
The minimum requirements for the hydraulic oil are :
Hydraulic oils with corrosion, oxidation and wear additives : HLP oils according to DIN
51524 part 2
A list of potential mineral oil makes that can be used for the hydraulic group is annexed in the
O&M manual. Other makes are possible provided that they have similar characteristics.
Commissioning of the hydraulic system will be done under the supervision of the supplier.
This start up will cover (not limitative) :
Pressure testing
Test run of all the equipment, especially for verification of the proper functioning of the
pressure compensated hydraulic proportional flow control valves.
5.6.7. Burners
Reference is also made to the Operation & Maintenance Manual.
The start up and commissioning of all burners will be done during drying and baking of the
refractory lining of the furnace, and during boiling out of the boiler and blowing out of the
steam piping (see part 2 of the Commissioning manual).
Drying of the refractory lining will be done by means of the start up burners. During
drying of the refractory lining, the start up burners will be operated at low thermal load.
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At the beginning of this period, the start up burners can be tuned rather roughly, because
operation at maximum thermal load is not allowed, or only during short periods (e.g. some
minutes). The burners will be tuned in a way they can be started and stopped in a reliable
way, and in a way the combustion is visually complete (no formation of soot). Finetuning (e.g. to attain good and complete combustion along the complete working range of
the burners) is not yet required and not yet possible. This rough fine-tuning is expected to
last one working day.
When baking of the refractory lining has started, the load of the start up burners can be
increased gradually. At the end of this period, a fine-tuning of the burner can be allowed,
because operation at maximum load is possible during long time. As drying of the
refractory lining can last some days (at low burner load), and the temperature increase
after drying is very slow, it is possible that there will be some days between the first
commissioning of the start-up burners, and the fine-tuning.
During baking of the refractory lining and boiling-out of the boilers, the auxiliary burners
will be started and operated at low thermal load. At the beginning of this period, the
auxiliary burners can be tuned rather roughly, because operation at maximum thermal
load is not allowed, or only during short periods (e.g. some minutes). The burners will be
tuned in a way they can be started and stopped in a reliable way, and in a way the
combustion is visually complete (no formation of soot). Fine-tuning (e.g. to reach the
required CO- or NOx-emission limits, or to verify the fuel/air ratio curves at different
loads) is not yet required and not yet possible. This rough fine-tuning is expected to last
one working day.
When baking of the refractory lining is finished (and the furnace is still hot), auxiliary
burner operation at maximum load can be allowed, as long as temperature changes in the
furnace can be restricted up to the values allowed by the refractory supplier (10 up to 25
C/hr). During this period, a fine-tuning of the burner can be allowed (to reach the
guaranteed emission levels, and to determine the fuel/air ratio curves at all burner loads).
If this fine tuning requires several succeeding intervention days of the burner supplier, it
is advised to combine this activities with the blowing of the steam piping, because
frequent burner modulation can be allowed in this period, and there is enough time
available (one can expect that the auxiliary burners will be operational during at least one
week).
During this period, presence of qualified personnel of the burner supplier will be required.
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5.6.8. Smoke testing of the flue gas cleaning
(a) General
The intent of smoke testing is to detect leaks in the flue gas path of the plant, means from the
outlet of the furnace up to the baghouse filter. Leaks mean that during normal operation, cold
outside air is draught into the system (in underpressure) causing corrosion at the inlet area,
loss of flue gas temperature and an increase in flue gas flow, resulting in a higher electrical
consumption of the ID-fan.
Since it is very difficult to detect these leaks during operation, a smoke bomb test should be
performed during the plant cold commissioning phase as well as after plant start-up on a
regular basis (for instance every year during the annual shutdown)
Smoke testing is performed by blowing a high volume of very low-pressure smoke into the
system at one or more manholes. Plugs, valves, temporary blind flanges are used to confine
the smoke to the section or sections of system being tested. Observation of the emergence of
smoke enables the crew to detect sources of inflow.
The plant building will usually have one or more roof vents from which smoke will emerge.
The roof vents will be used to evacuate the outcoming smoke. The residents and fire
departments must be told to ignore the smoke as well.
Because testing to large sections is less effective and gives the crew too much area to observe
during the relatively short life of the smoke bombs (3 or 5 minutes), it is advised to have
several tests along the flue gas path:
Section 1 : from the combustion chamber (furnace) up to the inlet of the baghouse filter,
Section 2 : from the baghouse filter up to the stack inlet, if there is possibility to confine
this system at the stack side (otherwise the smoke test II will be limited to the baghouse
filter outlet)
(b) Equipment
Smoke testing can be performed using:
Blowers suitable for smoke testing have a circular flange or plate for mounting on an open
manhole and are gasoline engine driven. Blowers recommended for smoke testing have a freeair delivery of at least 3.000 m/h.
The static pressure capability of the blowers is less than 2,5 mbar.
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(c) Smoke
Smoke used is cold and very visible (white). The smoke is not hazardous and is free of oil
and coloured particles, which could leave residue and stains. Smoke bombs recommended
for smoke testing are usually 3- or 5-minute duration.
Smoke is introduced into the system either by placing a smoke bomb at the blower inlet or
by lowering the smoke bomb into a manhole in a bucket and blowing air in from above.
The inspector should understand that the smoke bombs are not dangerous and have a limited
shelf life. Once opened, a package of smoke bombs should be used. Smoke bombs exposed to
moisture or humidity may be difficult, if not impossible, to ignite.
(d) Advance notices
Prior to performing smoke testing, plant personnel and residents are notified of the purpose
and approximate date of the work. Residents are told that they will see smoke emerging from
the roof vents.
Local fire and police departments should be advised daily of the areas being tested. Personnel
handling telephone inquiries should be acquainted with the purposes of the smoke-testing
program.
(e) Smoke test procedures
1. Advance notice is given to residents, fire and police departments.
2. The inlet and outlet of the system ducting are blocked, i.e.:
For section 1: hopper feeding chute valve - inlet valves of the baghouse filter
For section 2, inlet of the baghouse filter - inlet of the stack (by means of
temporary flanged plates)
3. The manhole sections to be tested are isolated (sifting ash hoppers, combustion chamber,
feeding grate casing, boiler, flue gas duct, reactor, baghouse filter).
4. The ash extractor and the sifting ash conveyors (in section 1) are filled with water
5. The gate valve for the residue extraction (boiler hoppers, reactor cone, filter hopper) must
be closed
6. The combustion air fans (for primary air, secondary air and for burners) are started in
section 1. In section 2, a smoke blower is set up at an open manhole in the filter and started.
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7. A smoke bomb is ignited, placed in a bucket and lowered into the manhole. The blower is
then positioned on the open manhole and set at full throttle.
8. In less than a minute, smoke will be issuing from the roof vents of buildings and any
directly connected points of inflow.
9. A smoke testing crew usually consists of three persons. One individual operates and
maintains the blower while the other two walk the test area to locate and document inflow
sources indicated by emerging smoke.
10. The crew documents significant and identifiable points of inflow. Sketches, field notes,
portable tape recordings, digital pictures and movies could be used to record test results.
11. Those firms bidding on this type of work should have a documented history of five years
of successful smoke testing. References and dates are to be submitted with bids.
12. All bidders will be licensed contractors and perform a minimum of 60 percent of the
contract.
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6. ANNEXES
6.1. ANNEX 1 : LIST OF SUB-SYSTEMS
See also Error! Reference source not found. on page Error! Bookmark not defined..
- tbd during detailed engineering
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COMMISSIONING MANUAL
PART N2 :
HOT COMMISSIONING
WASTE-TO-ENERGY PLANT
TYPICAL
by:
10-01-08
RPI
Preliminary
Rev.
Date
By
Description
Check
Appr.
WASTE-TO-POWER PLANT
TYPICAL
1. TABLE OF CONTENT
1.
2.
INTRODUCTION ........................................................................................................................................... 4
3.
GENERAL ....................................................................................................................................................... 6
4.
FURNACE ................................................................................................................................................... 7
4.1.1.
4.1.2.
Grate .................................................................................................................................................... 7
4.1.3.
4.1.4.
Start-up burner..................................................................................................................................... 8
4.1.5.
4.1.6.
4.2.
4.3.
4.4.
5.
6.
7.
8.
8.2.
8.2.1.
8.2.2.
8.2.3.
8.3.
8.4.
8.5.
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8.6.
9.
9.2.
SAFETY.................................................................................................................................................... 28
9.3.
PREPARATIONS ........................................................................................................................................ 29
9.4.
9.4.1.
9.4.2.
9.4.3.
9.4.4.
9.4.5.
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2. INTRODUCTION
This document outlines the sequence of activities required to take the plant from a completed
installation to a fully operational and commissioned plant. The pre-requisites before each
stage of the operation can be commenced are described.
The commissioning will normally follow the sequence below:
1. Pre-Commissioning (or Unit test): the checking and testing of equipment prior to
their cold commissioning with power and air. Such works shall consist of testing the
alignment and direction of rotating parts, the verification of the wiring and cabling, the
verification of the PLC system, verification of correct mounting of piping, verification of
correct mounting of valves and actuators, cold pressure testing of piping and vessels, etc.
Pre-commissioning checks, when completed, will release individual items of equipment to
be powered up and made available for inclusion in the cold commissioning phase.
2. Cold-Commissioning: the no-load, dynamic testing (including the starting-up of motors
and other electrical equipment, flushing and cleaning of tanks and piping if applicable,
adjustment and regulation of protective devices, functional tests, leakage and pressure
tests, inspection of bearings, etc.) and operation of equipment for a period of time. This
will be mainly as individual items, but may involve running some of the equipment in
sequence.
3. Hot Commissioning: this will include the introduction of process gas and reagent
(including the boiling out of pressure parts, curing of the refractory, blowing of steam
pipe to turbine, etc). The whole plant will be proved, operating in sequence under full
load conditions.
The Commissioning Manual (part n1) includes instructions for the Pre-commissioning and
the Cold Commissioning of the equipment in the contract.
The Commissioning Manual (part n2) includes instructions for the Hot Commissioning of the
equipment in the contract. These second part contains specific information for the first startup, which differ from a normal plant start-up. For the general operating procedures (allowing
to start-up, operate and shut down the plant), please refer to the Operation and Maintenance
manuals.
Responsibility: Operating instructions specified in this manual are typical procedures. It is
impossible to cover all eventualities, which might occur during the start-up of the plant.
Keppel Seghers cannot take responsibility for damage to any part of the plant which could
have been avoided, had instructions been followed.
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On the other hand, conditions may arise in which actions must be taken without sticking
completely to the instructions in this manual, provided that such actions result in safe
operation.
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3. GENERAL
The first start up procedure of the furnace-boiler is strongly different from a general start up
procedure. The reason is that the refractory lining has to be dried and baked in order to reach
its desired strength, and physical and chemical properties.
For this purpose, the temperature in the furnace and the post combustion zone has to be
increased according to a strictly defined procedure. A general sequence for the first start-up is
shown in the figure below with indication of duration of each individual action.
900
800
Drying
700
Baking
Blasting f(#cycles)
Start-up
Boiling
600
500
O P R
400
300
E
200
C
100
A-B
0
0
10
12
14
16
18
20
Time (day)
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Before starting the drying-out and the baking procedure, a test has to be done to check the
amount of leakage air entering the furnace. During this test, the primary air fan will be
started without using the ID-fan. An overpressure will be created in the furnace. Air leaks
can be checked now by applying liquid soap at welding and other connection elements.
Air leaks have to be repaired before starting the drying-out and baking procedure.
All measurement systems in the furnace zone has to be operational (temperature, pressure,
). All temperature trendings in furnace and post combustion zone have to be printed
and saved.
All sight glasses, measurement systems, cameras, or other elements with a protection
against high temperatures by means of sweeping air, have to be cooled during drying-out
and baking procedure.
4.1.2. Grate
In normal operation, the tiles are cooled by primary air and thermally protected by a waste
layer, which acts as an insulating layer. Since drying-out of the refractory is not possible
and not allowed by waste, the burners have to be used. The grate tiles are not designed to
be exposed to the full heat of the burners; therefore the tiles need to be protected. This
protection remains in the furnace during the entire warm-start up, being the refractory
drying, the boiler boiling-out and the blowing-out of the boiler and steam piping.
The entire feeding and the combustion grates element 1 to 3 must be covered by means of
insulating material (rockwool), thickness at least 100 mm. Above the insulating material a
layer of about 5 cm of sand is put (can be sprayed with a pump). The sand is used to avoid
that the insulating material would fly away due to the draft of the ID-fan. It should be
carefully checked that the complete surface is evenly filled. Also the side wall tiles of the
combustion grate and the inlet guide tiles of the feeding grate have to be completely
covered.
The grate element which are most intensively exposed to heat are grate element number 4
and 5 (at furnace outlet), since the start-up burner is positioned in the back wall. These
elements must be covered with ceramic fiber, with thickness at least 100 mm.
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Caution: The temperature of the feeding and combustion grate may not arise above its
design value (feeding grate = surrounding temperature, combustion grate =
primary air preheating temperature), otherwise severe damage can be caused
to the mechanical structure and the hydraulic drive system (caused by limited
thermal expansion). The procedure to protect the grate, like described below,
has strictly to be followed.
Before starting the drying-out and baking procedure, it is advised to have a final check on
the clearances of the combustion grate tiles. This is necessary to be sure that the
clearances have not been changed during mounting of the grate elements. If clearances
have become smaller than advised on the drawings, there is a risk of blockage of the grate
tiles at normal operating conditions of the grate.
It is advised to test the operation (movement) of the grate elements before drying-out and
baking, to check whether everything works properly. All combustion and feeding grate
elements have to be withdrawn to their rest position.
The feeding grate has to be cooled by opening the inspection door at the back side of the
feeding grate housing. In this way, heat release to the feeding grate can be evacuated to
the environment.
To protect the feeding hopper and the feeding chute cover plate system against too high
temperatures, they have to be protected by means of a temporary cover. A frame inside
the chute is made with iron bars. On this framework, hard insulating plates (thickness 4050 mm) are put with some bricks to avoid that the plates will fly away. All gaps have to
be closed by means of insulation material (in order to prevent the escape of hot flue
gases). The cover is placed just above the feeding grate where the steel part of the chute
starts to allow drying and baking of the refractory lining in the feeding chute.
The closing gate of the feeding hopper has to be opened, to be able to evacuate the
released heat to the environment.
The chute (closed loop) water circuit must be enabled to allow cooling of the steel plate
through the water jacket.
The start-up burner should be checked that its flame will never (at each working point of
the burner) touch the grate or the insulation put above it.
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4.1.5. Ash extractor and sifting ash conveyors
To prevent heat loss through the ash extractor, the water seal on the ash extractor has to
be operational. Also the water supply system to the ash extractor has to be operational,
because it has to compensate the water loss due to evaporation. The water also protects
the ash extractor against too high temperatures.
The same applies for the wet sifting ash conveyors under the grate.
Caution: The availability of water to the ash extractor and sifting ash conveyors must
be checked regularly (two times per eight hours) as well as their casing
temperature.
4.1.6. Primary, secondary
The butterfly valves of the primary and secondary air are opened partially. This allows
air coming in by suction of the ID-fan. This air can help to evacuate for instance the
water that is evaporated in the air gap of the side wall cooling system of the furnace. It
also protects the air ducts against too high temperatures (sweeping air).
Caution: No primary air can be used during the drying-out and blowing-out
procedure, because the sand and the insulating material might be blown
away and thus exposing the grate directly to the radiant heat of the burners.
The side wall cooling fan has to be operational. It is possible that during the drying-out
and baking procedure, the side wall cooling has to be started.
Before hot commissioning several measures need to be taken to to protect the critical
items of the boiler. The main steam check valve internals should be removed and steam
flow measurement orifice should be replaced by a temporary simple design plate. Note
that the steam flow needs to be determined during steam blasting in order to evaluate the
blast impuls. The demister of the steam drum should be removed (during boiling-out) and
the insulation bricks of the manholes need to be removed.
All control and safety equipment and plant interlocks required for the activities of hot
commissioining should be operational.
A release note for hot commissioning of the boiler from the local inspection authority
should be available
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All measurement systems in the boiler (water-steam side) and post combustion zone (flue
gas side) have to be operational (temperature, pressure, ). All temperature trending
have to be printed and saved.
The support burners must be operational / released. For more detail, refer to O&M
Manual from supplier.
Fuel oil circulation pumps must be operational / released to allow feeding to the support
and start-up burners.
Boiler feeding water pumps must be operational / released. For more detail, refer to
O&M Manual from supplier. Temporary start-up filters can be installed instead of the
(fine) normal filters.
The demin water preparation system must be operational / released to allow feeding of the
pressure parts through the boiler feeding water pumps
The boiler water conditioning system (dosing of sodium phosphate) must be operational /
released.
The flue gas cleaning system has to evacuate the hot flue gases. To protect the flue gas
cleaning against too high temperatures, one can open manholes in the flue gas ducts or at
the reactor, in order to insert air, sucked by the underpressure created by the ID-fan.
The ID-fan has to be operational. The automatic control loop to regulate the furnace
pressure and interlocks should be operational .
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5. HEATING-UP PROCEDURE
This procedure is the heating up procedure, as given by the refractory supplier .
Temperature in the furnace room and boiler first empty pass will be monitored during heatingup of the furnace. Measurements will be recorded and the actual heating curve will be set up
(only for control and approval by the refractory supplier).
Sufficient supply of consumables should be available: demin water (boiler feed water), fuel,
chemicals for boiler cleaning
Heating up procedure is represented on the curve hereafter :
TEMPERATURE(
600
550
550
500
360
400
300
250
360
250
200
150
110
100
110
25
25
0
0
33
47
71
78
114
127
151
167
215
TI ME SCHEDULE( Hr )
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6. Staying at a constant temperature of 360C during 36 hours. This is the second baking step
of the refractory material.
7. Heating up at 25C/hr until a temperature is reached of about 550C.
8. Staying at a constant temperature of 550C during at least 24 hours.
9. After baking and drying-out, the refractory can be cooled down at a rate of about 2530C/hrAll above parameters are valid for the refractory in the furnace. Concerning the
boiler refractory lining, the exact value of these parameters depends on the refractory
materials applied in the boiler. Only the refractory supplier can give a guaranteed dryingout and baking procedure.
Caution: A drying-out and baking procedure is a continuous procedure, 24 hours / 24
hours, 7 days / 7 days. It can not be stopped halfway, and a sudden stop (a
sudden decrease in temperature) can cause damage to the refractory lining.
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900
850
850
800
TEMPERATURE(
700
600
500
400
300
200
100
25
25
0
0
16
16
TI ME SCHEDULE( Hr )
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6. BOILING-OUT PROCEDURE
Before boiling-out it is advisable to flush the entire boiler one time with demin water to
remove all loose particles still present in the boiler from erection works. The draining of the
boiler after the final pressure test can be considered as the flushing, provided the quality of
the drain water was good (no big particles in the water), the boiler was conserved in a good
way (see related procedures) and no more welding or repair works on pressure parts were
carried out (is not allowed after pressure test).
Boiling-out of the boiler aims at the removal of mechanical impurities, grease and possible
other contamination, if any, from the internal surfaces of the boiler tubes. The superheater is
not boiled-out (is cleaned with flushing and afterwards during steam blasting).
Both processes (boiling-out vs. drying-out/baking) may be carried-out simultaneously
providing that the resulting prolongation of the process, as well as the increase of temperature
and pressure, will not have negative influence upon the results of the boiling-out process.
Caution: The procedure hereafter described is given as an example. The operation of
the boiler during boiling-out should strictly follow the operating instruction
of the boiler supplier.
To ensure uniform concentration of chemical agents in all boiler elements that are included in
the process of boiling-out, an auxiliary installation can be provided consisting in one
circulating pump connected at the suction port with the drains of boiler evaporator bottom
headers, while pump discharge will be connected to the drains of economiser inlet header (see
typical sketch in annex). This pump will also be used for introducing chemical solution into
the boiler from a small tank. The circulation pump will run about 4 times a day during 1 hour.
The pH of the solution in the boiler will be measured each time after the circulation pumps
have been operating.
Note that the superheaters are not boiled out..
Typical composition of boiling-out solution and amount of chemicals:
Chemical agent
Concentration
Amount
:
:
:
Fill up the boiler to the lowest operational level in the steam drum. Note that the
superheaters are not allowed to be filled up with the alkaline boiling-out solution.
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Prepare the concentrated solution of NaOH and Na-phosphate in the tank (pH of about
11-12).
Start the temporary circulating pump and establish circulation within the system
(circulating pump- economiser- boiler drum- evaporator- circulating pump).
Fire the boiler and proceed to refractory drying procedure (see 5).
During the initial stage of drying-out procedure (until the drum pressure does not exceed
4 bar), the boiler evaporator should be blown-down every 6 hours (bottom headers drain
valves to be fully opened one by one for few seconds and than closed again).
The circulating pump should be operated for 30 min. every 6 hours during this stage. At
the drum pressure above 4 bar, the circulating pump suction and discharge isolating
valves should be kept closed. Each time after circulation, the pH of the boiler water
should be checked and the dosing of the chemicals to be adapted accordingly.
The drain (boiling-out) water is contaminated with chemicals and should therefore be
disposed taking into account the applicable environmental legislation/regulations.
After cooling-down, the steam drum is made empty and is opened and cleaned /inspected
for the presence of impurities. Loose impurities, if any, should be removed manually.
Inner surfaces of the drum to the operational water level should be free from contaminants
(oil, sand, grease, etc.).
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Item to check
Feeding chute
Boiler
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5. Flue gases must be kept at a constant temperature of 110 - 120C during at least 24 hours.
This is drying-out period.
6. Boiler is heated up to a water temperature between 110 - 120C, with max. 15C/hr. This
is boiling-out period.
7. Flue gases are heating up at 15C/hr until a temperature is reached of about 260C. To
reach that temperature, auxiliary burners (in the post combustion zone) will be started up
when the flue gas temperature is about 200C, because the start-up burner is not powerful
enough (1 x 4,5 MW). As soon as the support burners are started, the flue gas temperature
that is checked, is the one in the post combustion zone, about 4 to 6 m above the support
burners.
8. Flue gases are kept at a constant temperature of about 360C during at least 36 hours. This
is the baking period (1st step).
10. Flue gases are heating up at 25C/hr until a temperature is reached of about 550C.
11. Flue gases are again kept at a constant temperature of 550C during at least 24 hours. This
is baking period (2d step).
Caution: During the baking period the flue gas temperature before the superheater
must be kept below 450 - 480C
12. Now the drying-out and baking period is done, the flue gas temperature is lowered at
25C/hr up to ambient temperature.
13. The boiler can now be emptied in order to drain dirty water. First check that one boiler
cannot be filled with water the other boiler being drained (through blow-down system).
14. Open all vents:
Between superheaters
15. When the boiler temperature dropped under 60C, the boiler can be fully drained by
opening the intermittent blow-down system, which can be by-passed. When water stops
flowing, all drains from the lower boiler parts must be opened. Note that the boiling-out
water is contaminated with chemicals and need to be disposed/drained according to the
applicable environmental regulations.
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16. Check the quality of the drain water (with filter at drain pipe). If the quality is
unsatisfactory, boiler shall be filled up again and drained.
Caution: Not all drains are flowing to the blow-down vessel and they therefore need to
be led to drain gutter using flexible hoses
17. Open the drains from the economiser, the superheaters and the evaporator to the blowdown vessel. Then open the continuous blow-down system to evacuate boiler water to the
blow-down vessel
18. These operations can be repeated twice or three times after the boiler is refilled with demin
water (until pH of about 9). It is advised to have water circulating between two cleaning
sequences. After the last cleaning, inspection must be made to the pressure parts of the
boiler (drum, header, ).
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K1 =
(Gd x vd)
(Gn x vn)i
K2 =
(Gd x vd)
(Gn x vn)
where:
Gd
Gn
vd
vn
The parameters (pressure + temperature) for the calculation of the steam specific volume shall
be measured just before the turbine / turbine bypass valve.
8.2.2. Calculation method
In order to determine the steam flow during blowing in absence of the flow measuring orifice,
the following calculation method is applied.
The flow is calculated, based on the measured pressure drop during blasting versus the
pressure drop in the boiler + piping during normal operation at maximum load.
A. Pressure drop formula:
1P = 0
w x .
2g
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with . =
1P = 0
1
v
w
w
=k
v 2g
v
with w =
Dv
F
Dv
)
F
= ko D v
1P = k
v
(
with:
1Pb = ko Db vb
with:
vb : steam specific volume (to be evaluated from steam tables, based on measured steam
temperature and pressure at piping outlet during blowing)
1Pn = ko Dn vn
D. Steam flow during blowing
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The steam flow during blowing is calculated from the ratio of the pressure drop at normal
operation versus the pressure drop during blowing:
1Pn ko Dn vn
=
1Pb ko Db vb
Db = Dn
vn 1Pb
x
vb 1Pn
Start-up burner
1 x 4,5 MWth
Auxiliary burners :
1 x 7,5 MWth
Another limitation of the blowing parameters is the pressure drop in the temporary piping and
silencer. Therefore, a silencer should be selected with a low pressure drop (maximum 4 bar),
so that high steam velocities can be obtained.
The lower pressure limitation by the silencer resistance and the upper limitation resulting
from the thermal power of the auxiliary burners, determine the K1 and K2 factors.
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8.3. IMPACT BLOWING OF BOILER - PIPING
Next to the method of the continuous blowing, impact blowing could be applied for the
cleaning of the superheaters.
The boiler should be fired-up (with burners) in accordance with the prescriptions of the
boiler manual.
The gradient of saturation temperature increase in the drum (drum pressure increase)
should be not higher than indicated in the boiler manual/instruction. The heating-up of the
boiler should not exceed the requirements of the refractory (heating-up curve).
The firing-up will be performed with the start-up valve or the temporary valve partially
opened
In case of the combination of the continuous and impact blowing the following procedure is
followed:
By gradual increasing the power of the burners, the pressure and temperature in the boiler
is raised. The temporary valve in the blow-out piping is partially opened. One has to make
sure that the opening of the valve is done in harmony with the burner thermal power so
that the pressure and temperature keep increasing.
Once the parameters for continuous blowing are reached, the blowing-out should be
continued for about 10 min. Afterwards, the temporary gate valves will be partially closed
in order to reach the required drum pressure for impact blowing (24-30 bar).
When the drum pressure is 24-30 bar the temporary valve will be opened at once until a
drum pressure of about 10 bar = impact blowing
Temporary valve will be closed and burner capacity is gradually decreased according to
the cooling down curve of the refractory.
The next blowing procedure should not start earlier than the skin temperature of the
piping has dropped to about 150-200C.
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8.5. PRACTICAL MATTERS
-
Just before start of impact blowing the level in the steam drum shall be adjusted to low
level. During impact blowing the water level will raise instantly due to the quick
reduction of pressure.
In normal practice, 2 to 3 steam blastings per day can be carried out. More steam blastings
is not efficient since the cooling down of the superheater, steam piping is very important
(cracking effect). Overnight a thorough cooling down should be carried out.
Steam blasting will be performed at a flue gas temperature (measured in 1st pass) of about
500-550C.
If the flue gas temperature at the exit of the 1st pass (above the refractory lining) exceed a
temperature of 450C a small amount of steam should be blown off (via PCV ) to ensure a
safe and trouble-free natural circulation of the boiler. If the temperature of the flue gases
before the final superheater reaches 400C, it is required to blow off a small amount of
steam to ensure a good cooling of the superheater tubes. More steam needs to be blown
off when the flue gas temperature further increases
Before steam blasting, the steam parameters (pressure and temperature) are gradually
increased by increasing the capacity of the burners and by secondary air injection (typical
steam conditions for steam blasting : T = 360-375C, P = 24-30 bar). Meanwhile the
steam piping is preheated up till the silencer. When steam parameters are reached, the
temporary steam blasting valve is fully opened (as quick as possible)
Cooling down of the boiler after steam blasting should be at approximately 50C/hr
Before firing up the boiler for start of steam blasting, the following heating-up curve
should be followed (only first part is relevant from 25 to 550C in 32 hrs.).
Temporary installation for steam blasting consists of temporary steam pipe (should be
very clean), a silencer (low pressure drop), 2 temporary manual open/close valves (1 for
piping to turbine and 1 for piping turbine bypass valve), 2 sample holders for target
plates, sufficient number of target plates, drain valve for temporary piping and connection
for water injection (to reduce noise)
The cleaning processes and subsequent starting with waste should preferably be executed
in a consecutive way. In case it is not executed in a consecutive, continuous way a proper
conservation of the boiler should be carried out.
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600
550
500
TEMPERATURE(
550
550
500
500
400
300
200
150
150
100
25
0
0
12
32
38
44
50
56
TI ME SCHEDULE( Hr )
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(b) Permitted rise in pressure at the water side (to be confirmed by boilers supplier)
The mentioned pressures and temperatures are always measured on the steam drum.
Start-up with cold boiler (ambient temperature - c. 20 C and on atmospheric pressure).
1 5 bara in 45 minutes
9.2. SAFETY
Check the alignment very carefully before starting any equipment. E.g. shut-off valves of
measuring instruments and switches have to be opened, discharge and air-relieve valves
have to be closed, in-line valves have to be opened, bypass valves on
measurements/accessories closed.
Check the sense of rotation of motors when works on the power supply or connections
have been carried out.
Before closing equipment, always check whether there are no strange objects left inside
the equipment (keys, rags, ...).
After start-up always check on site if the process parameters are within normal values
(e.g. pressure side of pumps, cooling water flow at feeding chute, etc.). See the nominal
values mentioned on the PFDs.
Before beginning start-up by means of the general start-up procedure, the operator has to
read the detailed operating instructions per P&ID and locate the equipment, accessories,
measuring instruments, etc. in the installation, so that he can act quickly and is aware of
the situation. The general start-up procedure is written on the assumption that the operator
knows the individual operating instructions per P&ID.
The operator in charge of start-up has to have the tables and procedures below with him at
start-up. He preferably coordinates start-up from the control room (in order to have an
overview of the complete situation) or keeps in touch with qualified staff in the control
room when he is in the installation.
Safety equipment
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Before starting the installation it has to be checked if all safety measures are operational:
Fire protection: ensure the supply of fire extinguishing water to all reels, hydrants, fire
extinguishers in the bunker, spray nozzles in feeding hoppers. Functioning of emergency
centre.
Safety showers
UPS-stand-by
9.3. PREPARATIONS
All equipment and auxiliary installations have to be on stand-by.
The order of the various preparations obviously depends on the start-up order when putting
the installation into operation. However, the basic rule is that the preparations and start-up of
the various auxiliary installations are carried out as quickly as possible after finishing the
various cleaning, inspections and/or repairs, to be able to deal with any start-up problems on
time.
Remove sand/insulatnig material from furnace + all temporary equipment used for the
refractory drying - boiling out steam blasting and restore to normal operational conditions.
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9.4.2. Start-up common parts
1.
2.
3.
4.
Cooling water circuit and distribution in operation. Rem.: check the cooling
water flow to the various installation parts to be cooled: pumps, temperature
control device,
5.
6.
Feeding chute filled up with water It is important to fill up the chute before
firing the furnace on fuel because the chute is not protected by a layer of
waste as in normal operation.
7.
8.
9.
10.
Start agitator
Check the supply of cleaning water on lime milk circulation pump before
start-up
13. Start lime milk pump and pressurise main ring pipe. Start one of both lime
milk circulation pumps and put the pressure control on the lime milk main
ring into operation.
15. Pump leakage water from ash bunker. Start-up after the ash extractor has
been fed with hot ashes (otherwise this wastewater does not evaporate, and
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When low pressure steam is available, first the low pressure heat exchanger will be started
(valves with TAG-number #LBG10# and #LCN10#). When the low pressure heat exchanger
is in operation, the high pressure heat exchanger (valves with TAG-number #LBG20# and
#LCN20#) can be started.
C. Start-up : no low pressure steam available
1. The globe valves in the upstream steam lines (*LBG10AA201, *LBG20AA201 and
*LBG20AA202) are closed.
2. The temperature control valve *LBG20AA001 will come into operation, but as long as the
steam supply line remains closed, the primary air will not be preheated, and the control valve
will go to fully opened position.
3. The sequence primary air must be in normal operation. The temperature control valve
*LBG20AA001 is released for control and normally fully opened due to the low primary air
temperature. Check that the control valve is open !
4. Close the by-pass valves (*LBG20AA205 and *LBG20AA206) over the temperature
control valve *LBG20AA001.
5. Open (slightly) the drain valves *LCN20AA901 and *LCN20AA902 to evacuate the
condensate collected in the heat exchanger. Do not open the valves completely, because steam
will come in the next steps. It is also possible that steam flows back from the condensate
return vessel.
6. As soon as it is clear that most of the water in the high pressure side of the heat exchanger
is drained, the globe valve *LBG20AA201 and *LBG20AA202 on the steam supply side can
be opened smoothly (to avoid water/steam hammer). Steam will slightly come into the heat
exchanger, condense and start to preheat the primary air. As soon as the primary air
temperature rises, the temperature control valve *LBG20AA001 will start to control.
7. The drain valve *LCN20AA901 and *LCN20AA902 must be closed as soon as steam is
coming out.
8. The globe valve LBG20AA201 and *LBG20AA202 on the steam supply side can be
completely opened when the primary air temperature control is in stable operation. This
stable operation will be reached more quickly, when one starts with a low setpoint for the
primary air preheating temperature (e.g. 80 C). As soon as the gate valve on the steam
supply side is fully opened, one can start further increasing the primary air temperature
setpoint.
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1. Gradually decrease the temperature setpoint until the setpoint has reached the ambient
temperature. The control valves will gradually close.
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Bag filter :
Close all openings and entries to furnace, boiler, flue gas cleaning and flue
gas ducts. Check whether no strange objects, scaffolding, etc. are still
present in the installation. Check whether any staff is still present in the
installation.
3.
4.
5.
Fill ash extractor with water through manual bypass valve and then put the
automatic level regulation into operation. Check water seal on site (through
overflow tank).
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6.
Fill grate siftings conveyers with water through manual bypass valve and
then put the automatic level regulation into operation. Check water seal on
site (through inspection cover on top).
7.
cooling sight-glasses
cooling camera
cooling burn-out controls
8.
Atomiser: start cooling air supply (fan) for protection of atomiser when the
installation is fired by support and start-up burners. The atomiser may
NEVER come into contact with hot flue gases when the fan is not working.
9.
All boiler feed water pumps have to be aligned (automatic take-over in case
of failure of one pump).
Supply all pumps with cooling water and verify the cooling water flow.
Check whether the suction filters are clean (especially at first start-up or
after important repairs in de-aerator or suction pipes).
Close all drains. Open the suction valves. Open the valves in the minimum
flow pipe.
If there is no boiler feed water in the pressure pipe, this has to be de-aerated
first. Start the boiler feed water pumps through the minimum flow pipe
with closed delivery valves. Open the vent valves on top of the boiler and
close the water supply to the economiser. Open the delivery valve very
gradually to pressurise the boiler feed water pipe. Close the vent holes on
top of the boiler immediately when there is water coming out (pressurised
water !!).
When de-aerating the boiler feed water pipe, water is sent through the
bypass over the level control valve. Open the valves in bypass only a little
to reduce the pressure of the pumps sufficiently when de-aerating.
After filling the boiler (see below) stop the pumps again. The pumps may
only run continuously after start-up of the level control on the steam drum.
Before that they are only started if necessary to fill up the boiler.
10. Fill up steam boiler according to procedure of boiler manufacturer; below you
can find the most important items for start-up from atmospheric pressure and
temperature when there is boiler water in economiser and evaporator (for startup with completely empty boiler : see above):
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12. Purge the boiler at the flue gas side with air by means of the ID fan, the
primary air fans and/or secondary air fans and/or the fans of the support
burners.
13. When flushing of the boiler is finished, both support burners have to remain
in cool operation (i.e. their fans have to keep running at minimum speed).
14. Close all manual and/or automatic valves primary air, secondary air and side
wall cooling to limit leakage air (and the corresponding CO production by
the burners).
15. Start start-up burners (locally); temperature rise at the side of the flue gases
according to instructions supplier refractory lining; pressure rise boiler at the
water side according to instructions boiler manufacturer (to control with
start-up valve boiler as long as main steam valves are closed, afterwards with
turbine bypass).
16. From 200 to 300 C flue gas temperature, start the auxiliary burner manually
at minimum load. Then, the operator has two alternatives :
Either stop the start-up burner and withdraw the start-up burner immediately
from the furnace.
Important notice : when the start-up burner is stopped, the burner should be
withdrawn from the furnace immediately.
17. Further actions at start-up boiler :
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Between 0 and 1 barg steam pressure on the steam drum the local level
gauges on the drum have to be blown out. Open both drain valves
beneath the level gauge and then close them. Normally the water level in
the level gauge has to fluctuate, if not then there probably is a blockage
somewhere.
Close vent valves of steam pipes as soon as steam is flowing out (at 1 to 3
barg); start at the vent holes on top of the drum and go to the vent on the
superheaters.
Close drains superheaters from 5 barg; start at superheater 1 (closest to the
steam drum) and go on until superheater 2.1 (closest to HP steam pipe).
From 10 barg on steam drum: put one-point level control drum into
operation; boiler feed pumps keep on running continuously from now on.
Start ammonia dosing (immediately after boiler feed pumps start running
continuously).
Start sulphite/polyphosphate dosing (same as above).
Start-up steam condensate circuit on the basis of rising boiler pressure.
Check pressure rise boiler; if necessary open start-up valve (controlled
steam blow-off); as soon as turbine bypass is in operation: control pressure
rise through turbine bypass and set start-up valve automatically with
setpoint 0.5 barg above nominal pressure on steam network.
Be careful with excessive steam blow-off through the start-up valve (max.
supply demin water !!); if necessary increase less fast with support burners.
Start up three-point control level steam drum at sufficient steam flow (min.
30 %).
18. Put discontinuous blow-down into operation; in the beginning the
discontinuous blow-down valve has to be opened during a short period. This
purching of the boiler feed water will continue until the boiler water quality
meets the normal criteria.
19. Start control steam temperature before waste incineration and before the
steam temperature rises above 350 C. Also when the temperature between
the superheaters exceeds 350 C the steam temperature control has to be put
into operation.
20. Start hydraulic group (locally). Check oil level, oil temperature, and
pressure after the pumps as well as pressure on the circuit to the grates/ash
extractor.
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23. Start boiler ash extraction (empty passes and superheater/eco section)
Shredder reactor
25. Start equipment to prevent bridge formation in reactor and bag filter
(pneumatic hammers)
26. Start the secondary air injection. As a result of the high oxygen content at
the exit of the boiler in this stage of start-up the sequence will be put on
hold and nothing will happen (fan remains out of service). The secondary
air will then automatically start operating when the waste incineration
develops sufficient thermal capacity.
27. Start the temperature control of the flue gas at boiler exhaust. Therefore, the
burners have to be running at full load. Check the correct alignment of the
three-way valve (a.o. bypass valve has to be closed now).
28. Put the start-up burners at a higher load approximately 1 hour before the
waste incineration is started (i.e. at c. 810 C post-combustion temperature).
They have to preheat the furnace to help ignite the waste.
29. From a flue gas temperature of 120 to 130C (measured at inlet of bag filter)
the bag filter is taken out of bypass in the following way:
If any inspection openings are still open, they have to be closed before
start-up.
The bypass valve is closed and the flue gas valve in the main flue gas duct
is opened. The sealing air fan is started.
The recirculation system is taken out of service: the recirculation fan and
electrical heater stop and the main shut-off valve closes.
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Check whether the heated ambient air on the heating circuit is operational
(and whether the temperature is high enough).
Check whether the bypass valve shuts off correctly (local dP measurement).
If not, this valve has to be adjusted by means of the spindle. Check also if
there is sealing air present.
Start cleaning sequence bags at the latest when the waste incineration is
started.
Check if any pre-coating has to be carried out on the bag filter (see further
instructions concerning pre-coating).
Do not start the reactor before the support burners run at full load and the
exit temperature of the boiler is sufficiently high. The exit temperature of
the boiler can be increased by partly preheating boiler feed water.
Start atomiser with water injection (for a first start-up, this has to take place
locally in close contact with the control room. If there are no
abnormalities, the automatic operation can be switched on. By injecting
water, the temperature of the bag filter can be brought within the normal
operation level (around 180 C as long as only water is injected).
Start lime injection and control exit temperature reactor only when the
incineration plant is operating stably at full load. With injection of lime
milk the exit temperature of the reactor can be reduced to ca. 150 C. If any
inspection openings are still opened, they have to be closed before start-up.
Power plug
Control plug
Cooling water in
Lime milk in
Cooling air
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Lift the atomiser over the shaft by means of the hoist. Remove the closing
cover of the shaft and lower the atomiser into the shaft until it reaches its
seatings.
IMPORTANT remark: when the atomiser fails for whatever reason, it has
to be removed immediately from the hot flue gas flow.
31. If temperature post-combustion > 850 C, differential pressure over the bag
filter larger > 0 (bag filter coated) and no dust detection after the bag filter :
start waste incineration; here following actions have to be carried out shortly
after each other to avoid and/or limit emission exceeding :
Place one full grab of waste on the start-up valve in the feeding chute. Keep a
grab of waste stand-by above the feeding hopper.
Temperature incinerator 850C and complete flue gas cleaning in service : open
the feeding chute flap. When the start-up valve is completely open, drop the
waste into the feeding hopper.
Start filling the feeding chute (Note: Close the flap during crane grapple
movements in the refuse bunker to avoid cooling down the furnace too much as
long as no seal has been created).
Open the primary air valves and (manually) operate the feeding and combustion
grate to introduce the waste on to the combustion grate.
Put bag filter into operation and start lime milk injection in reactor with
automatic emission control HCl and SO2
As soon as waste starts to incinerate, the cleaning sequences of the flue gas
cleaning plant have to be started up, this implies a.o. that the dosing of
chemicals is started, that the cleaning of the bag filter is started, etc.
Feed waste into the furnace by local operation of feeding grate and the sliding
grates; do NOT supply any primary air yet
At increasing intensity of the flames the primary air may be put into operation
MANUALLY (including air preheating); put the valves on the pressure side of
the fan in the correct (throttle) position (first/last element: 50%, element 2-3-4
c. 60-70% open); gradually increase the primary air flow without blowing out
the fire or cooling down the furnace too much (oxygen boiler < 9 vol.%, max.
10 vol.%, if not CO !); put the fan of the last grate into operation last and only
when the fire reaches it. Remark : when opening valves primary air, air is
already drawn in by underpressure in furnace.
Start side wall cooling before the furnace temperature exceeds 500 C; put
valves side wall cooling in correct position: grates 1, 2, 3 : 100% open; grates
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4, 5 : 75% open.
Secondary air fan was already started up (sequence was on hold because
oxygen content was too high, see above). They will automatically be put into
operation as soon as the thermal load of the furnace is high enough.
Gradually push up feeding speed, grate speed and primary air; support burners
(100% !) and start-up burners keep on running up to nominal steam flow.
Put support burners in automatic. They will switch off as soon as the furnace
has been heated up sufficiently. Pay attention to start-up with a clean or cleaned
boiler : one of the typical behavioural patterns of a clean/cleaned installation is
that the control of the support burners and the control of the secondary air start
overlapping each other (i.e. the secondary air has not yet halted before the
support burners are started to guard 850 C). In that case it is better to operate
the burners manually.
Reduce the auxiliary burner load to minimum load and stop the auxiliary fuel
burner.
Put primary air and grate control in SIGMA as soon as the support burners
(automatic) are stopped, the furnace is running stably, the flame front is all
right, and the furnace temperatures are high enough.
32. Start active carbon injection after start-up lime milk injection.
33. Start/Release the cleaning system of the steam boiler. Pay attention to startup of a clean or cleaned installation: the cleaning system on the superheaters
may be started immediately, the other is best left out of service for a while
because otherwise the steam temperature and the flue gas temperature exit
boiler will remain too low for a longer period of time. The cleaning system
on the protective evaporator is only started when the steam temperature is
high enough (i.e. 400 C nominal steam temperature can be reached at full
load) or sooner when the steam temperature between the superheaters
becomes too high; the cleaning system on the economisers is started as soon
as the flue gas temperature exit boiler is high enough (at least 210 C). For
specific information, see O&M manual soot blowing system.
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Note:
mm
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Energy from Waste with Combined Heat and Power Facility, Oxwellmains
JAS4061
ST003_KSBEIS
Keppel Seghers technical standard for Waste-to-Energy
Testing and sampling procedure to determine the Loss on Ignition of
bottom ashes
0
REV
First issue
DESCRIPTION OF MODIFICATION
DOC REFERENCE
21.08.2007
DATE
RDP
AUTHOR
BA
CHECK
BR
APPROVED
1.
inerts
metals
unburned
ashes
All identifiable objects should be separated in one of the first three fractions,
irrespective of their size or weight. Next, the remaining fraction should be sieved
(mesh size 20x20 mm) and all objects larger than the mesh size should be
inspected (if necessary after breaking open) and added to one of the first three
fractions.
The fraction after sieving will be referred to as sorted bottom ashes.
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1.3.
Grinding and homogenisation
Through a series of consecutive grinding/mixing/dividing-steps a representative
sample of the sorted bottom ashes is obtained.
1.4.
Drying at 105C
A representative sample of at least 5 g of the sorted, ground and homogenised
bottom ashes from step 3 is heated for at least 24 hours to 105C in a drying
oven until constant mass1 is achieved. The mass loss determines the residual
moisture content. Based upon this moisture content and that of step 1, the total
moisture fraction of the complete sample is determined.
1.5.
Determination of the ignition loss
The ignition loss of the dried, sorted, ground and homogenised ashes is
determined by inserting a precisely weighed sample of 4 g in a furnace at a
temperature of 550C for two hours (in agreement with EAWAG V-4002).
Afterwards, the sample is transferred to an exsicator to cool down to ambient
temperature. The ignition loss is determined as the ratio of the mass loss after
heating to 550C to the initial mass of the sorted, dried, ground and homogenised
ashes, expressed as a percentage with respect to the dry matter.
Note
Experience has indicated that it is crucial to operate with identical cool down
periods. This holds for the weighing of the empty crucible (without sample) and
the weighing after heating to 550C.
The report accompanying the analysis should cover all of the above steps
separately. This implies that at least the following results should be included:
the ignition loss of the dried, sorted, ground and homogenised ashes
(step 5)
In agreement with DIN 38414 S2, the mass of the sample is considered as constant if additional
drying at 105C during half an hour does not result in a mass loss exceeding 2 mg.
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Remarks
1.
In the standard case, the total ignition loss of the bottom ashes will be
determined by means of a weighted average (according to their mass
fraction) in which the ignition loss of the unburned fraction is assumed to be
100% and that of the inert and the metal fraction 0%. If necessary, the
ignition loss of this fraction can be determined separately and used to
replace the above assumptions.
2.
If no other procedure is prescribed, the sample of the bottom ashes is
obtained by taking a sample of approximately 1 kg at a fixed location and
during a total period of 6 hours with a frequency of once every half hour. In
order to avoid stratification effects, it is preferred to take the sample at a
location where the ashes are falling from one transport system to another.
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2.
1.
2.
3.
4.
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Energy from Waste with Combined Heat and Power Facility, Oxwellmains
JAS4061
EXTRACT FROM
ST003_KSBEIS
FUNCTIONAL DESCRIPTION
BOILER FLUE GAS SIDE
DEMONSTRATION OF THE 850C/2S REQUIREMENT
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1.1
1.1.1
The flue gas temperature at the top of the first empty pass of the boiler is measured : four
thermocouples are installed, from which three thermocouples are used (the operator deselects
one of the four measurements on the supervision screens). The median value of the three
remaining measurements xxxx is used for auxiliary burner control (allowing that at least one
measurement can drift away without disturbing the control loop).
This median temperature will be used both for start/stop control and load control of the
auxiliary burners.
1.1.2
The 2 seconds temperature xxxx is calculated based on the temperature measurements in the
top of the first empty pass of the boiler.
Information
temperature value xxxx which is used to control the burners. The latter is the median value of
the three measurements in the top of the first empty pass, see 1.1.1 above.
In order to calculate the flue gas temperature after 2 seconds residence time, the following
reference levels are defined (see Figure 1) :
1. H2 : Top of the first empty pass of the boiler : +xx,x m
2. H0 : Secondary air injection level : +xx,x m
3. H1 : End of post-combustion zone1 : +xx,x m (used as a reference level in the
calculation formulas)
End of conical part at the outlet of the furnace towards the first empty
pass of the boiler.
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H2, m
Cross section S, m
Volume V, m (between
H0 and H1)
H1, m
Figure 1 : first empty pass of the boiler and levels for 2 seconds calculation
First of all, the temperature difference T between level H1 and level H2 is calculated (see
Equation 1). This temperature difference is strongly dependent from the boiler load, and also
slightly dependent from the fouling of the first empty pass of the boiler. Therefore, the
parameters used in Equation 1 have to be checked when initial fouling of the first empty pass
of the boiler has been built up.
Equation 1 : T = A + B/TL4minTOTAL
With :
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TL4minTOTAL : continuous running average value of the thermal load of the furnace,
averaged over 4 minutes. See functional description SIGMA combustion control
system process calculations for the calculation of the thermal load of the plant. The
thermal load considers both heat released by the combustion of refuse, and heat
released by the auxiliary burners. The thermal load, used in Equation 1, will never
pass the limits xx MWth and yy MWth. When the calculated thermal load is lower than
xx MWth, the value xx is used in Equation 1, and when the calculated thermal load is
more than yy MWth, the value yy is used in Equation 1.
A and B : those parameters must be determined during commissioning, after reaching
initial fouling. Based on the boiler calculations at minimum and maximum load, the
following start values can be given : A = xx C, B = xxxx MWth C.
Example : the plant runs at xx MWth, and the temperature at the top of the first empty pass of
the boiler (T2) is xx C. The calculated temperature difference T is xx C, and the
temperature T1 at reference level H1 is xx C.
On both temperatures (measured T2 and calculated T1), a positive correction is applied for
the so-called shield-effect, before they are further used in the formulas below. The shieldeffect considers the fact that the temperature, measured by means of the thermocouples in
the top of the first empty pass, is not the real flue gas temperature, but an equilibrium
temperature which is somewhat lower than the real flue gas temperature. This equilibrium
temperature originates from the heat balance of the thermocouple : heat input occurs by flue
gas radiation; heat output occurs by thermocouple radiation and thermocouple conduction
towards the relatively colder side membrane walls of the boiler. Based upon experience from
reference plants, the required correction for this shield-effect is estimated to be between +50
and +100 C. In principle, this shield-effect can be determined for each specific installation
once it is sufficiently long in operation : either by recalculating the boiler (making the heat
balance over the convective part allows for determining the temperature profile in the radiation
part), either by on-site measurements by means of a temporarily installed extraction
pyrometer.
The volume of the post-combustion zone (i.e. the zone between level H0 and level H1) is
equal to xx m (total conical volume) xx m (volume of the upper part of the prism if present,
the part which is situated in the conical volume) = xx m (V, see also Figure 1).
The cross sectional area of the first empty pass (starting from level H1) is aa m x bb m = AA
m (S, see also Figure 1).
The flue gas flow Q (Nm/h), obtained when leaving the auxiliary zone, is calculated based on
the total combustion air flow and the auxiliary burner load (see functional description SIGMA
combustion control system process calculations).
The flue gas flow Q has to be recalculated towards Qreal (m/sec), taking into account the
average flue gas temperature. For the same example as above, a flue gas flow of xxxx Nm/h
will become
Based on this information, the level H2sec where the flue gases reach a residence time of 2
seconds, can be calculated by using Equation 2.
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Equation 2 : H 2 sec = H 1 + 2
V
Qreal
Qreal
S
With :
H2sec : level where the flue gases reach a residence time of 2 seconds (m)
H1 : reference level at the end of the post-combustion zone, as defined above (+xx,x
m).
V : volume of the post-combustion zone (xx m)
Qreal : real flue gas flow (m/sec)
S : cross sectional area of the first empty pass of the boiler, starting at level H1 (xx,x
m).
For the same example, the following result is obtained for H2sec = xx,xx m.
Note : in case the calculation result from Equation 2 would be lower than H1 (this might be
possible in case of very low flue gas flows in startup phase or in trip conditions), H2sec is set
equal to H1 as a minimum value.
The flue gas temperature after 2 seconds of residence time T2sec can be calculated by linear
interpolation between H1/T1 and H2/T2, see Equation 3 (T1 and T2 first to be corrected for
the shield-effect as mentioned above).
Equation 3 : T 2 sec = T 1 + shieldeffect +
T 2 T1
(H 2 sec H1)
H 2 H1
Giving the following result for the example above : T2sec = xx,xx C.
Other example : thermal load xx MWth, temperature in top of first pass xxx C, calculated flue
gas flow xxxx Nm/h.
Temperature T1 at level H1 = xx C
Real flue gas flow = xx m/sec
2 seconds level H2sec = xx m
2 seconds temperature T2sec = xx C.
The calculated 2 seconds temperature (xxxx) is shown on the overview screen of the furnace
and the boiler in central control room.
The shield-effect offset parameter is a fixed value in the process control system (start value
+50 C, until verification during first startup of the plant).
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