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DOCUMENT COVER SHEET

 
 

PROJECT NAME

: SIPAT SUPER THERMAL POWER PROJECT

 
 

STAGE-I (3 x 660MW)

 
 

CONTRACT NO. I T E M

:

: N) PERFORMANCE PROCEDURE

 

DOCUMENTTITLE : 1.9 Boiler & aux. Pipe lines Steam Blowing

 

E

07/02/22

Change pressure value at pre-step and add VGB R513 completion criteria

SWKang

SWKang

S.J.SA

Y.T.Seo

D

06/08/25

Revised based on Joint meeting

SWKang

SWKang

   

C

06/05/26

Added sampling calculation

SWKang

SWKang

SCSong

YTSeo

B

05/12/05

 

Second issue

SWKang

SWKang

 

K.T.Son

A

05/05/11

 

First issue

SWKang

 

K.T.Son

H.J.Hyu

 

n

REV.

DATE

 

DESCRIPTION

DGN

CHK

REVIEW

APPR

 

NTPC Limited

 

(A GOVERNMENT OF INDIA ENTERPRISE)

 
 

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO., LTD.

 
 

DOOSAN DOCUMENT NO.

   

T04019-SY-M0003

 
 

NTPC DOCUMENT NO.

 

9518-108-11-KO-PVM-W-065

 

SHEET

REV.

 

CATEGORY

APPROVAL

 

26

 

E

Rev

Date

A 2005.05.11

B 2005.12.05

C 2006.05.26

D 2006.08.25

E 2007.02.22

Record of Revisions

Page affected

Description of Revision

First Issue NTPC comment Added CFR sample calculation Revised based on Joint meeting discussions and NTPC comments Change the pressure value of Pre-steps and add VGB R513 Code of completion criteria

This Document is the property of Doosan Heavy Industries and Construction Co., Ltd., Chang-won, KOREA, and is to be used only for the purpose of the agreement with Doosan pursuant to which it is furnished.

STEAM LINE BLOWING

TABLE OF CONTENTS

TITLE PAGE NO.

STEAM LINE BLOWING PROCEDURE

4

1. Introduction

4

2. Principle of Steam blowing

4

3. Precautions

4

BLOWING PROCEDURES

5

1. Phase 1: Pre–Step Flushing

5

2. Phase 2: Main–Step Cleaning

6

PREPARATIONS FOR STEAM BLWING

8

1. Readiness/Completion of major Equipments/Systems/Activities

8

2. Preparing items

9

3. Check points

9

BOILER START-UP AND OPERATION

12

PROCEDURE FOR STEAM BLOWING

16

DRAIN LINE BLOW OUT PROCEDURE

21

1. Requirements 21

2. Procedure

22

STEAM LINE BLOWING - FLOW DIAGRAM

23

ATTACHMENTS

1. ISOMETRIC DRAWING ………………………………………………………….8 SHEETS

2. PIPING ARRANGEMENT DRAWING…

3

………………………………………3

SHEETS

STEAM LINE BLOWING PROCEDURE

STEAM LINE BLOWING PROCEDURE

1. Introduction

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

2. Principle of Steam blowing

To ensure that sufficient cleaning forces are applied to the piping, the steam momentum during the steam blow must be equal to or greater than the steam momentum at normal maximum load condition. The Cleaning Force Ratio (CFR) is typically used to evaluate if satisfactory blow conditions are obtained.

CFR = ( v b / v mcr ) x ( F b / F mcr ) 2

> 1.00

Where

v b = specific volume at steam blowing condition

v mcr = specific volume at maximum load condition

F b = steam mass flow rate at blowing condition

F mcr = steam mass flow rate at maximum load condition

Steam line cleanliness is determined by the appearance of polished target plates that are mounted in the pipe during the final steam blows. The acceptance criteria for maximum number and size of pits in the target plate are typically specified by the turbine supplier.

The design of the temporary piping and supports is the responsibility of Doosan. This procedure is a suggested method of steam line blowing and does not attempt to address all aspects of the blowing operation that will be required. The Commissioning-in-charge has the ultimate responsibility for the comprehensive steam line blowing procedure or implementation at the Project Site after due approval of NTPC site.

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E

3. Precautions

The process of steam line blowing imposes abnormal and severe conditions upon the unit and steam piping. Large, rapid temperature changes occur during each blowing cycle, which is far more severe than is incurred in normal operation. Thermal stresses may be high in the thick walled portions of the unit. It is prudent to consider this fact when performing this procedure and to limit the number of blowing cycles to the minimum consistent with cleaning the system.

cycles to the minimum consistent with cleaning the system. CAUTION: The operators must continuously monitor pressure

CAUTION: The operators must continuously monitor pressure in the temporary and permanent piping and be ready to take action to prevent over pressurization.

STEAM LINE BLOWING PROCEDURE

Since the temporary piping may be designed for a lower pressure than the steam generator, care must be taken to prevent over-pressurization during the entire steam blow operation.

over-pressurization during the entire steam blow operation. CAUTION: Prevent the introduction of wet steam or

CAUTION: Prevent the introduction of wet steam or de-superheater spray water into the SH or RH assemblies. Poor distribution of the water particles into the Superheater or Reheater assemblies causes excessive temperature differentials resulting in bowing or overstressing damage in attachments or supports. Therefore, the steam entering any SH or RH section must be superheated at all times.

The temperature of steam entering sections that are downstream of de-superheating points, and subject to injection of water, should be monitored; a minimum of 14 ° C(25 ° F) above the saturation temperature existing at that point should be maintained at all times.

The piping system and headers upstream of all SH and RH sections should be drained and free of condensate at all times during the blowing operation.

The initial blow of each phase should be done at reduced pressure in order to check the temporary piping anchors and supports.

Steam blowing operation is the first occasion on which the unit is fired at significant rate, therefore special attention must be paid to the start-up and operation at all times. The unit must be started much slower the initial time while all equipment is checked for expansion movement.

BLOWING PROCEDURES

The steam line blowing procedure is divided into two (2) phases. Phase 1 consists of two (2) pre-step blows, and phase 2 consists of two (2) main-step blows. In each phase, specific sections of piping will be cleaned.

1. Phase 1: Pre–Step

The steam lines to be cleaned in the pre-step are the main steam line, the HP bypass lines, and the cold RH lines. These are cleaned first in order to avoid carrying debris into the RH assemblies and possibly causing tube blockage and subsequent overheating problems. Since there will be no flow through the RH during this phase, the firing rate must be limited such that the gas temperature at the furnace outlet does not exceed 537 °C. Use the Furnace Gas Temperature Probe (at DDCMIS) to monitor the furnace outlet temperature.

The unit is started up in accordance with normal start-up procedures. The two (2) martyr valves located in the temporary piping downstream of the MSV will initially be closed and

STEAM LINE BLOWING PROCEDURE

the bypass valve is opened. The pressure at the separator outlet will be raised to the value calculated to produce the desired blowing flow (approximate 40 kg/cm2(g)). Elevation AB oil burners will be used for the pressure and temperature raising. When the required separator pressure is attained and stabilized, the oil burners are shut off and the BCP will be stopped. Immediately the martyr valves will be opened wide to get the maximum possible steam blowing flow. When the pressure has reduced to approximately

20 to 40 kg/cm2(g), the martyr valves are reset to the closed position. Oil firing is then re-

started and the process is then repeated until clean white smoke is observed at the

exhaust of tailpipe.

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E

The suggested steam flow path is as follows: The final steam flow paths will be determined based on discussions and mutual agreement between DOOSAN, NTPC and Turbine supplier.

(Note: Temporary blanks or valves may be required to establish the suggested flow path).

Pre-step 1 : Separator SH main steam line MSV temporary pipe martyr valve tailpipe to atmosphere.

Pre-step 2: Separator SH main steam line HP Bypass Cold RH line backward flush through drain pot near RH inlet header temporary pipe tailpipe to atmosphere.

Note: During pre-step 2, the isolators at CRH line are kept open and the isolators at HRH line are kept in closed position.

The pre-step steam blowing out operation shall be carried out with a Cleaning Force Ratio below 1.0.

2. Phase 2: Main–Step Cleaning

There are two (2) phases of main-step cleaning. The firing required will be about 15%TMCR firing Light Oil/Heavy Fuel Oil. The suggested steam parameters for steam blowing are as indicated elsewhere in this section. The firing rate is not limited to 537 °C at the furnace outlet in this case because sufficient steam is flowing through the RH.

The unit is started up in accordance with normal start-up procedures. The two (2) martyr valves located in the temporary piping downstream of the MSV will initially be closed and

the bypass valve is open. The pressure at the separator outlet is raised to approximately

80 kg/cm2(g) while firing Light Oil/HFO. Elevation AB and CD oil burners will be used for

the pressure raising. The feed water flow, firing rate, and steam pressure will then be

increased in coordinated fashion until the desired steam production is achieved.

The SH and RH outlet temperatures are controlled by the burner tilts and the respective de-superheating stations, as required.

The estimated steam conditions for this main step are:

STEAM LINE BLOWING PROCEDURE

Main steam flow

App. T/hr

1310

Separator outlet Pressure

Kg/cm2g

80

SHO Temp

Deg. C

390

RHO Temp

Deg. C

370

Feed water temp

Deg. C

120

Firing rate

%TMCR

15

NOTE: These operating conditions are estimated only. The actual steam flow, pressure, and temperature in the steam lines during the steam blow must be evaluated to determine if the minimum cleaning forces have been obtained. It may be necessary to adjust these operating conditions as actual blow conditions dictate.

It is assumed that the feedwater temperature is maintained at 120 °C. Variation from this temperature will have an impact on the firing rate required to generate the target steam flow.

When the required steam parameters are attained and stabilized, the oil burners are shut off and the BCP will be stopped. Immediately the martyr valves will be opened wide to get the maximum possible steam blowing flow. When the pressure has reduced to approximately to 40 kg/cm 2 g, the martyr valves are reset to the closed position. Oil firing is then re-started and the process is then repeated until clean target plate is achieved and the appearance of the target plate is acceptable to the turbine supplier.

The duration of each main-step blow may be for about three (3) minutes.

The main step steam blowing out operation shall be carried out with a Cleaning Force Ratio above 1.0.

The suggested steam flow path is as follows: The final steam flow paths will be determined by the NTPC / Turbine Supplier.

Main Step 1:

Separator-SH-main steam line-MSV-temporary pipe with martyr-valve- NRV-CRH-RH-HRH-IPT Stop Valve-temporary pipe-target-tailpipe to atmosphere

Main Step 2: Separator-SH-main steam line-MSV-temporary pipe with martyr-valve- NRV-CRH-RH-HRH-LP Bypass valve-temporary pipe-tailpipe to atmosphere

Main Step 3: As determined by discussions and mutual agreement between DOOSAN, NTPC and Turbine supplier, the cleaning of BFP turbine lines, turbine steam seal lines, and other auxiliary lines will be done.

STEAM LINE BLOWING PROCEDURE

PREPARATIONS FOR STEAM BLOWING

1. Readiness/Completion of major Equipments/Systems/Activities

Before

/activities are scheduled to be completed.

taking up the steam blowing operation, the following major equipments / systems

A. All structural steel work

B. Boiler proper & accessories 1) Casing 2) Buckstay 3) Hanger of Boiler 4) Header 5) Waterwall tube 6) Superheater assembly 7) Reheater assembly 8) Economiser assembly 9) Separator & storage tank

C. Link & Connection

D. Refactories, Insulation & Cladding

E. Main steam, Cold Reheat, Hot Reheat, HP & LP BP, Auxiliary steam & Interconnection piping and valves

F. Soot blowing system

G. Draft system including SCAPH, Duct and dampers

H. Fuel Oil & Firing system

I. Miscellaneous system 1) Equipment for Oxygenation Treatment 2) LP Dosing system 3) Equipment for Cooling Water system 4) Chemical cleaning equipment 5) Lifting device 6) Garbage Chute

J. Electrical, Controls & Instrumentation for SG

The following major activities are scheduled to be completed before commencing steam blowing operation.

A. Hydraulic Test

B. Readiness of SG C&I for Boiler

C. Boiler Light up & Chemical cleaning

STEAM LINE BLOWING PROCEDURE

2. Preparing Items

A. Temporary Piping

B. Temporary Motor Operated Valve

C. Blind Plate & Flange

D. Test Piece (Target Plate-Mild Carbon Steel of roughness of surface 0.8 microns & having mirror like finish)

E. Test Piece and Flange assembly and de-assembly facilities.

F. Tele-communication facility

G. Recording Sheet

H. 415V AC Power Distribution Local Panel

3. Check points

A. Care should be exercised not to over-pressurize the unit during steam blowing operation since the temporary piping may designed for a lower pressure than boiler.

B. All welded connection should be done 100%RT for safety and confirm the flange connections.

C. Install steam piping/temporary piping with proper hanger, support and expansion provisions.

D. Temporary piping will be insulated locally (only insulation without cladding) at

measurement

locations

&

target

plate

location

where

personnel

movement

is

expected.

E. To check the drain valve for main steam line and Hot/Cold reheat line for steam blowing.

Install the temporary piping at drip pot of main steam line and Hot/Cold reheat line in order to drain the foreign materials easily.

Confirm that the drain lines for boiler and turbine piping are not blocked due to flange or intentional blockage.

F. Confirm that well ground test pieces are ready and check the ease of insert and tacking-off of test piece.

G. Test piece should be installed in the temporary piping with horizontal direction.

H. Check the condition of temporary motor valve and bypass valve of temporary motor valve.

(1)

Check the torque set value of temporary motor valve.

(2)

Paint to reduce the friction between valve stem and gland.

(3)

Check the valve’s open / close time.

I. During steam blowing operation period following inter-lock should not be worked in order to prevent from being broken with frequent start and stop of auxiliary equipment according to the burner firing and extinguishment.

(1)

All BFP stop inter-lock by MFT

(2)

MFT inter-lock by feed water flow low//low-low

(3)

MFT inter-lock by all burner putting-off

STEAM LINE BLOWING PROCEDURE

(4)

Purge inter-lock when all burner putting-off.

J. Boiler feed water pump with motor operation should be kept operating condition until ending of steam blowing to hot banking. Boiler feed water pump with motor operation should be kept operating at minimum feed water supplying condition when boiler does not need feed water.

K. Check all instruments to be used during steam blowing, its attachment condition and calibration.

L. Check all boiler expansion indicator should be adjusted as “o” point.

M. Confirm adjustments of the following instruments to be used during steam blowing.

(1)

Indications and Alarms

a. Economizer Inlet Feed Water Temp.

b. Furnace Inlet Temp.

c. Separator Inlet Temperature

d. Separator Metal Temperature

e. Separator Storage Tank Level

f. BRP Inlet Temperature

g. BRP Diff. Pressure

h. BRP Motor casing Temperature

i. Finish SH Outlet Temp.

j. No.1 SH Spray Water Flow

k. No.2 SH Spray Water Flow

l. RH De-superheater Flow

TE LAB50CT001, T002

TE HAC30CT003

TE HAD30CT001 ~ 008

MTE HAD40CT001 ~ 003 MTE HAD45CT001 ~ 003 LT HAD50CL001 ~ 003 LIE HAD50CL501 ~ 502 TE HAG20CT001

PDT HAG20CP01 ~ 003

TE HAG50CT003 ~ 005

TE LBA11CT001 ~ 002

TE LBA12CT001 ~ 002

FT LAE51CF001 ~ 002

FT LAE52CF001 ~ 002

FT LAE61CF001 ~ 002

FT LAE62CF001 ~ 002

FT LAF51CF001, 002

FT LAF52CF001, 002

m. Feed Water Tank Level

LATER

n. De-aerator Pressure

LATER

o. Condensate Flow

LATER

p. Warm-up Light Oil Flow

FT EGD50CF001

q. Atomizing Air Pressure

PT HJN50CP001 ~ 003

r. FD Fan A Air Flow

FT HLA30CF001 ~ 003

s. FD Fan B Air Flow

FT HLA40CF001 ~ 003

STEAM LINE BLOWING PROCEDURE

t. Flue Gas O2 Content

u. Furnace Temperature

v. Flue Gas Temperature Outlet Eco.

w. Flue Gas Temp. Outlet of

x. Flue Gas Temp. Outlet of Sec. GAH B

y. Sec. Air Inlet Temperature GAH A

Sec. GAH A

AP HNA10CA001, 003 ~ 005

AP HNA10CA006, 008 ~ 010

TX HBK10CT001 ~ 010 TE HBK10CT021

TE HBK20CT021

TE HNA12CT001 ~ 004

TE HNA13CT001 ~ 004

TX HBK10CT001 ~ 003

TX HBK20CT001 ~ 003

TE HNA12CT005 ~ 008

TE HNA13CT005 ~ 008

TE HLA10CT002 ~ 005

aa.

Sec. Air Inlet Temperature GAH B

TE HLA20CT002 ~ 005

bb.

DP Windbox to Furnace

PDT HLA30CP001

 

PDT HLA40CP001

cc.

Furnace Pressure

PT HBK10CP001, 002

 

PT HBK10CP 006, 007 PT HBK20CP 001, 002, 003 PT HBK20CP 005, 006

dd.

Feed Water Flow

FT LAB50CF001, 002

(2) Recordings and Alarms

a. Eco. Inlet Flow

FT LAB50CF001 ~ 002

b. Eco. Outlet Temp.

TE HAC30CT001 ~ 003

c. Separator Outlet Temp.

TE HAH10CT001 ~ 004

d. Separator Outlet Pressure

PT HAH10CP001 ~ 004

e. Separator Storage Tank Water Level

LT HAD50CL001 ~ 003

f. Finish SH Outlet Pressure

PT LBA11CP003

PT LBA12CP003

g. MSV Inlet Pressure

PT LBA31CP001

PT LBA32CP001

h. HP Turbine Outlet Pressure

PT LBC11CP001

PT LBC12CP001

i. Primary RH Inlet Pressure

PT LBC21CP001

j. Finish RH Outlet Pressure

PT LBB21CP001, 002, 003

STEAM LINE BLOWING PROCEDURE

k. IPT Stop Valve Inlet Pressure

l. Flue Gas Temp. Eco. Outlet

m. Flue Gas Temp. Outlet of Sec. GAH A/B

n. Secondary Air Inlet Temp. GAH A/B

PT LBB31CP001, 002

PT LBB32CP001, 002

TE HNA12CT001 ~ 004

TE HNA13CT001 ~ 004

TE HNA12CT005 ~ 008

TE HNA13CT005 ~ 008

TE HLA10CT002 ~ 005

TE HLA20CT002 ~ 005

N. Check the preparation and readiness of tele-communication facility.

O. Keep the safety area around steam blowing outlet and steam blowing facilities. Clear of all obstructions and personnel.

P. Check other necessary things for steam blowing. If there are any discrepancies / problems associated with steam blowing procedure/operation, consult DOOSAN site representative

BOILER START-UP AND OPERATION

A. The following facilities should be checked before steam blowing.

(1)

Water Treatment System

(2)

Condensate Transfer Pump

(3)

Condenser & Condensate Pump

(4)

Motor Driven Feed Water Pump

(5)

Condenser Level Measurement

(6)

Feed Water System and Feed Water Control System

(7)

HP Bypass System

(8)

Boiler Start-up System and Drain Transfer Pumps

(9)

Gas Air Pre-heater and Soot Blower System

(10) Steam Coil Air Heater (11) Oil Burners and Flame Scanning System (12) FD Fan, ID Fan, PA Fan, Scanner Cooling Air Fan (13) Electrostatic Precipitator: The Electro Static Precipitators are not in Doosan’s scope of work. During steam blowing operation, at least two (2) electro static Precipitators must be available for service with all controls and instrumentation in place. (14) All Necessary Ancillaries and Aux. Systems (Cooling Water, Compressed Air, etc.) (15) Fire Fighting System (16) Control Air (17) CCTV (18) Light Oil / heavy Fuel Oil Supply System (19) Auxiliary Steam System (20) All boiler protection and inter-locks checked.

STEAM LINE BLOWING PROCEDURE

B. Boiler Start-up and Operation

Hot start-up is performed during steam blowing. Keep the boiler hot during night by boxing up the unit. The following procedure shall be followed from light-off to raising pressure.

Please refer to the operating manual for details.

(1)

Checkup before boiler water filling.

The following are check points for boiler proper, Boiler circulation pump system, separator storage tank before filling boiler water.

-

Boiler Vent Station Valve (Economizer / Water Wall / SH / RH) Open

-

Boiler proper each kind Drain Valve Close (Economizer / Water Wall & Intermediate Header)

-

SH / RH Drain Valves Open at boiler proper

-

SH / RH Spray Temp Control Valves Close

-

BCP operating mode switched to manual and BCP inlet/outlet MOV open

-

Warm-up Control Valve Close and Circulation Line Vent Valve Open.

-

Open the MOV upstream of WR / ZR valve.

(2)

Boiler water filling and improving water quality

To fill up the boiler water and to improve water quality BFP-M is used.

-

Start boiler filling at 10%TMCR of feed water flow with BFP-M

-

Increase 10% to 30%TMCR of feed water flow when WR valve is open due to separator storage tank level increasing.

-

Boiler filling water is finished when WR valve is full open (100%) and ZR valve is open over 30% for a duration of 2 minutes.

-

Boiler water flows through WR/ZR and flash tank and then goes to condenser.

-

Until satisfactory water quality is obtained, repeat above steps.

-

After boiler filling, reduce the feed water to a minimum flow of 110 ton/hr.

(3)

Starting BCP operation

BCP will be started when the boiler water filling is over. The following are regarded as pre-check and start-up.

-

The motor cooling water is more than 300 lit/min and the BCP motor temperature should be less than 65.

-

Open the following valves : Circulation Line Vent Valve (HAG10-AA051), BCP inlet/outlet MOV (HAG20-AA051, HAG20-AA053) and BCP Shut Off MOV (HAG10-

AA052)

-

When BCP is on after BCP operating mode switches from manual to auto, the UG valve is closed to minimum to enable BCP start.

-

UG valve is changed to auto and then follows the economizer inlet flow, 596 t/hr.

-

Confirm that whether the pressure differential of BCP is kept over 9.4 kg/cm 2 and close the circulation line vent valve.

-

Close Economizer Outlet Link Vent Valve (HAC30-AA551, AA552).

-

If water quality is too bad to use as boiler water it is drained after discussing with client. If water quality is not good for boiler water but it can be used after discussing with client, only some part of boiler water is sent to the water treatment facility.

STEAM LINE BLOWING PROCEDURE

(4)

Preparations for the operation of the draft system:

-

Check the tank level, oil pump and the temperature of the lubrication oil system of FD & ID Fans.

-

Check the operation of the ESP.

-

Check the closed cooling water systems

-

Check the damper of the draft system

(5)

Startup of draft system train “A” (GAH, IDF, FDF)

-

When the GAH Train “A” start-up SQC is switched auto, the lube oil pump is started. The start-up motor is started and then the main drain motor will be started 300 seconds later.

-

When the GAH Train “A” operation’s IDF Train “A” Start-up SQC is set to auto the lube oil pump is started. The sealing/cooling fan is started and the IDF Train “A” entrance damper is closed. Then the IDF Train “A” pitch blade position is set to minimum when starting the IDF Train “A”.

-

IDF Train “A” is started then the IDF entrance damper is opened, after this the pitch blade is switched to auto to control the furnace pressure as -12mmH 2 O.

-

In case of FDF Train “A” start-up SQC is switched to auto with the condition of operating the IDF Train “A”, the lube oil pump is started. After the FDF Train “A” exit damper is closed, the FDF is started on the condition of FDF Train “A” pitch blade is set to minimum position.

-

After the FDF Train “A” is started, the FDF exit damper is opened, and the pitch blade is set to auto and air flow is supplied as 30%~40%TMCR airflow.

(6)

Start-up of draft system Train “B” (GAH, IDF, FDF) The same as a Train “A”.

(7)

Start-up of SCAH Train “A”, “B”

-

Check the pre-heating and pressure of the SCAH Aux-steam piping, and check the SCAH drain pump lube oil levels and the cooling water amount.

-

Change the operation mode of the drain tank level control valve and the SCAH drain pump to auto.

-

Open the SCAPH’s temp control valve manually to pre-heat the SCAPH. Then raise the secondary air temp by at least 10. Than ignite the boiler and control the temp.

control valve manually until the mean temp of the GAH cold end reaches 70, then

the temp. control valve is switched to auto.

(8)

Purge

-

When the purge ready conditions are satisfied the purge start should be turned on.

-

Purge is carried on for 10 minutes and then purge is done, MFT is reset again.

-

Auxiliary Air damper is switched to auto. That means the differential pressure between Windbox and Furnace is changed depending on the load increase.

(9)

Check points before ignition

- The operation of Air pre-heater soot blowing

- Confirming a drain in the main body of a boiler and the operation of a Vent Valve

- The normalization of Light oil system after the light oil pump operate, the pressure of Header is increased to approximately 18 to 21 Kg/cm 2 g by controlling the Pressure Control Valve.

STEAM LINE BLOWING PROCEDURE

If the operating condition is good, Light Oil Leak test is conducted.

- The pressure of Atomizing Air is kept at 6kg/cm 2 g by controlling the pressure Control Valve

- Confirmation of Elevation Oil Ball Valve Open in site and inspection of Oil Gun Remote Position.

(10) The ignition of a boiler

- The Nozzle Tilt is kept horizontal initially. After the oil burners are ignited, tilt is put into Auto.

- The Air flow is maintained around 35%TMCR flow.

- If the AB and CD Elevations Start/Stop turn on, the Oil guns are ignited in a sequence namely corners 1,3, 2 & 4 with 15 sec time interval.

- For introduction of oil elevations AB/CD/ EF, please refer to the fuel start up sequence recommended under start up and shut down procedure. Once auxiliary steam is available at 16 kg/cm2(a) and 310required for steam atomization of Heavy Fuel Oil, Light Diesel Oil firing can be replaced by Heavy Fuel Oil firing.

- Inspect the flame on CCTV and confirm the sensing of flame by Flame Scanner

- Check up that the furnace pressure is maintained around -12 mmWC by adjusting the pressure and flow rate of Light Oil.

(11) Operation/inspection checks after ignition

- Confirming that the state of SH & RH Spray Control Valve is auto.

- Keeping the adequate amount of feed water in Economizer at 600 t/h and Storage Tank Level at approximately 9m.

(12) Temperature and Pressure Rising

- SH & RH Temperature is set the range 370~ 390 in manual operation mode .

- The main Drain and Vent Valve operation is as followings.

- More than 1.0 Kg/cm2g at the separator pressure : The Separator inlet of boiler, S/H and RH Vent Valves should be closed

- More than 3.5kg/cm2g at the separator pressure : The backpass Lower side Drain valves(SH MV 02,03) should be closed

- More than 3.5kg/cm2g at the hot reheat pipe pressure : The Cold R/H Drain Valves(CR MV 51A, 51B) should be closed

- Boiler pressure increasing rate is maintained like this.

Pressure 0~10kg/cm 2 g

:

0.5kg/cm 2 per minute

Pressure 10~20kg/cm 2 g

:

1.0kg/cm 2 per minute

Pressure 20~80kg/cm 2 g

:

2.0kg/cm 2 per minute

- Combustion rate in pre-step can be increased maintaining furnace exit temperature below 538 ˚ C.

- During main step steam blowing, boiler pressure and combustion rate increasing is as follows:

If BLR separator pressure is 50kg/cm2(g), oil burner of CD elevation is ignited in sequence as corner #1, 3, 2, & 4 with 15 sec time interval. In main step, it is not necessary to limit the furnace exit temperature 537 ˚ C, because steam flows through re-heater. Combustion rate is maintained about 15%TMCR.

STEAM LINE BLOWING PROCEDURE

C. HOT BOXING-UP

During steam blowing, box-up the unit to conserve heat at night, and operate hot start up in the morning. For more details, it is recommended to follow Boiler operating manual. The step to shut down is as follows:

(1) After igniting boiler and increasing boiler pressure as a next step of final steam blowing on that day, put out the burner and operate purge. (2) When final oil burner gun scavenge and furnace purge are finished, stop the BCP after maintaining the UG valve at minimum point. (3) Stop the BFP-M after closing BFP-M exit flow control valve manually. (4) Drain valve of main steam system will be closed during boxing- up. (5) Stop the steam coil air heater. (6) Stop FDF and IDF, and control the damper of air/gas system to box- up mode.

PROCEDURE FOR STEAM BLOWING

A.

General

(1) After igniting Oil Burner and raising boiler pressure, according to the recommended range for Pre-step and Main Step, steam blowing is operated following temporary MOV installed in temporary piping Open/Close signal.

(2) To prevent any equipment damage during steam blowing, the steam pressure shall be maintained as suggested such that-during Pre-step, Cleaning Force Ratio should be maintained less than 1.0, and during Main Step, Cleaning Force Ratio should be kept greater than 1.0.

(3) The final evaluation of steam cleaning is decided by inspection of the target plate installed in temporary pipe for steam blowing

(4) During cold start-up, drain of every piping should be fully operated so that Steam Hammering phenomenon would not occur.

(5) During steam blowing, feed water is fed to boiler by motor operated BFP. Oil burner is ignited and boiler pressure raised after securing re-circulation flow. Burner is extinguished and stopped before starting steam blowing. The steam blowing operation is repeated till successful completion.

B.

Steam condition of steam blowing

(1) During steam cleaning, the recommended steam pressure to ensure desired Cleaning Force Ratio at each section is 40 ~ 80 kg/cm 2 g range of pressure at Separator outlet.

(2) The steam pressure for initial test blow is approximately 20 Kg/cm 2 g. For the pre- step blowing operation, the steam pressure is maintained as 40 Kg/cm 2 g and for

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E

STEAM LINE BLOWING PROCEDURE

the main step blowing, the pressure is maintained approximately 80 Kg/cm 2 g. The required Cleaning Force Ratio is calculated during each blowing operation.

(3) Loss of standard pressure for comparison with Cleaning Force Ratio is listed as below

Item

Pressure instrument location

Loss of standard pressure

From

To

Main steam pipe

10LBA11CP003

10LBA31CP001

7.29kg/cm 2

10LBA12CP003

10LBA32CP001

Low-temp

reheat

10LBC11CP001,

10LBC31CP001

0.76

kg/cm 2

steam pipe

10LBC12CP001

10LBC32CP001

 

High-temp

reheat

10LBB11CP003

10LBB31CP002

0.97

kg/cm 2

steam pipe

10LBB12CP003

10LBB32CP002

 

* Cleaning Force Ratio is evaluated by standard pressure loss calculated at VWO operation condition, and p v represents calculation pressure loss between pressure instrument locations.

(4) Steam Pressure & Temperature condition for each process (reference)

Process

Pressure

Temp.()

Estimated

Blowing

Remark

(kg/cm^2g)

Discharge

Force

rate (ton/h)

Pre-

Operating

~40

~370

~ 212

< 1

Separator

step

martyr

outlet base

valve

Main

Operating

~80

~ 390

1310~1400

> 1

Separator

Step

martyr

outlet base

valve

~80

~ 390

1310~1400

> 1

Separator

outlet base

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Above Cleaning Force Ratio table is only for reference. Actual operation must be

done after finding the right pressure which satisfies Cleaning Force Ratio of each sector by gradually increasing pressure for each stage of Steam Blowing. Sample Calculation for Cleaning Force Ratio:

1. Steam flow at VWO

2. Specific volume of main steam at 255 kg/cm2(a) & 540˚ C

3. Estimated Pr. Drop in main steam pipe

4. Estimated steam flow at 80 kg/cm2(g) separator outlet pressure

5. Pr. Drop in main steam pipe for (4) (Value to be read from pr. Transmitters mentioned in table under (3)

kg/hr

:

2160000

m3/kg :

 

0.012429

kg/cm 2 :

7.29

kg/hr

:

1310000

kg/cm 2 :

(1310000/2160000)² x 7.29 = 2.68

STEAM LINE BLOWING PROCEDURE

6. Specific volume of steam at 80 kg/cm2(g) and 390 ˚C

7. Cleaning Force Ratio CFR = ( v b / v mcr ) x ( F b / F mcr ) 2

> 1.00

m3/kg

= (0.033789/0.012429) x (2.68/7.29) = 1.0

:

0.033789

8. Hence, from the Pr. Drop values read from the Pr. Transmitters located in the main steam piping, cold reheat piping & hot reheat piping, the CFR can be calculated as above. Depending on the pre step/main step blowing, the CFR has to maintained less than or greater than 1.0

C. Cautions

Following cautions must be strictly followed in order to protect operating personnel during the process of Steam Blowing.

(1) Control room Operators and field personnel must be in close communication. (2) The First Steam Blowing for each stage of Steam Blowing process must be done in lower pressure than setting pressure in order to check (protect) Temporary Piping, Supports, Anchor Bolts. (3) BFP-M must be operated under curve given by BFP-M manufacture, for the safety of operation. One must check that motor driven feed water pump trips when it operates beyond its limit.

D. Pre-step

(1) Steam Blowing circuit

Blowing sequence of Pre-Step stage is as given below:

- Pre-step 1: Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV tailpipe to atmosphere

- Pre-step 2 : Separator Superheater Main Steam Line HP Bypass Valve Cold RH line backward flush through drain pot near RH inlet header Temporary Piping tailpipe to atmosphere Note: During pre-step 2, the isolators at CRH line are kept open and the isolators at HRH line are kept in closed position.

(2) Start up & Washing

In order to prevent impurities entering into Reheater coils, flushing of boiler pressure parts namely water walls, separator, Superheater, main steam line and HP Bypass piping is carried out. During the flushing operation, there is no flow

STEAM LINE BLOWING PROCEDURE

through Reheater coils. Hence, the firing rate is controlled so that the furnace

outlet temperature is maintained below 538. Elevation AB Oil guns are put into

service maintaining approximately 10%TMCR firing. Boiler pressure is slowly increased till the separator outlet pressure is approximately 40 Kg/cm 2 g. Oil firing is put off and BCP is turned off. The temporary MOV is open and flushing the steam flow path as in Pre-step-1 is carried out for 30 seconds.

For the pre-step steam cleaning, start up & operation of boiler is as per boiler operation manual and the procedures outlined as above.

Order

Step

Operation & confirmation

note

1

Boiler filling

-- Set WR, ZR and UG valve on auto.

 

- Start boiler filling at 10% BMCR feed water with BFP-M

- After boiler water filling, Start BCP with UG valve set at minimum position

- UG valve follows ECO inlet water flow, 596 ton/hr.

2

Oil burner firing Operation of vent/drain valve

- After Furnace purging, Start Oil Elevation AB burners according to the sequence of corner numbers #1,3,2,4 (with 15 secs time interval).

 

- Keep the firing rate about 10 ~ 15% TMCR.

- When separator outlet pressure is higher than 1.0 kg/cm 2 g, close the vent valve at separator outlet, SH and RH.

- When separator outlet pressure is higher than 3.5 kg/cm 2 g, close the vent valve backpass lower side drain valves.

- When RH outlet pressure is higher than 3.5 kg/cm 2 g, close the cold RH drain valves. (LBC31- AA451, LBC32-AA451)

3

Start

raising

Raise the boiler pressure slowly. The temporary MOV will be in closed condition and bypass valve will be kept open to preheat the steam flow path.

 

pressure

4

Depute personnel Carry out checks

Ensure that trained operating personnel are ready in their assigned places in control room and field. Check measurement instruments & safety zones.

 

5

Check for steam condition

Check that steam pressure at separator outlet is approximately 40 Kg/cm 2 g and steam flow rate is adequate to give a Cleaning Force Ratio of below

 

1.0.

STEAM LINE BLOWING PROCEDURE

Order

 

Step

Operation & confirmation

note

6.

Putting off firing

Put off the Oil burners in service.

 

7

Operation of UG valve, WR/ZR valves

UG-valve will be set to minimum position WR/ZR valves will be on MANUAL mode and will be closed. The BCP will be shut off. The BFP-M exit steam control vale is manually closed and the BFP-M is stopped The drain valve of the boiler main steam system is closed

 

8

Steam

blowing

- The steam cleaning temporary MOVs are manipulated in the order of: slightly opened -> Full open -> closed - The time maintained in the Full Open position is decided by the blowing force or kept under 3 minutes.

 

out

9

Test Piece Take- off and Insertion

Confirm the following items and perform the test piece insertion and take-off.

 

- Close the steam blowing valve and bypass valve. Open the bypass valve after inserting the test piece.

- Confirm that the steam issues at the tailpipe outlet. To start with, the initial steam blow outs will be done without target plate. Subsequent steam blow outs, the target plate will be inserted for every alternate blow out. During the final blow outs, the target plate will be inserted for each and every blow out until NO MARKS are seen on the target plate.

10

End

of

steam

Purge the boiler for 10 minutes. Prepare the unit for next steam blowing process as above

 

blowing

E. Main Step

 

(1)

Blowing path

 

- Main Step 1 : Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Non-return Valve Cold Reheat Line Reheater Hot Reheat Line IPT Stop Valve Tailpipe to atmosphere

- Main Step 2 : Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Non-return Valve Cold Reheat Line Reheater Hot Reheat Line LP Bypass Valve Tailpipe to atmosphere

STEAM LINE BLOWING PROCEDURE

(2)

Start-Up and blowing Process

Start-up and blowing process for main step are same as that of pre-step except that the steam blowing path and steam blowing pressure are different.

Steam blowing is fulfilled with Cleaning Force Ratio above 1.0 and also checking that the pressure drop in main steam piping is over 7.29 Kg/cm 2 at selected measurement points. The amount of Pressure drop in Cold Reheat piping and Hot Reheat Piping should be satisfied over 0.76 Kg/cm 2 and 0.97 Kg/cm 2 respectively, so that the Cleaning Force Ratio is over 1.0 in those lines.

It is important to increase pressure step by step to find out proper Cleaning Force Ratio before steam blowing. It is necessary to check the pipe and equipment after each steam blowing.

F. Decision on successful Blowing Out:

After performing the Blowing operations as outlined above, the target plate is removed for inspection of maximum number and size of pits in accordance with VGB R513 Code(German VGB guideline, first issue 2000) and decision to continue steam blowing out is taken in consultation with turbine supplier.

-VGB R513 Completion Criteria ; No impacts with an diameter larger than 1 mm Not more than 4 impacts with an diameter larger than 0.5 mm Not more than 10 impacts with an diameter of 0.2 to 0.5 mm

DRAIN LINE BLOW OUT PROCEDURE

1. Requirements

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E

Each boiler drain line must be blown free of debris with steam water prior to boiler operation at full pressure. Utilize the following procedure while boiler pressure is between 10 and 20 Kg/cm2g. The best time to perform this procedure is while raising pressure in preparation for steam line blowing as outlined in the previous procedures. Failure to adequately blow out the lines will result in debris damage to the seating surfaces on the drain valves.

2. Procedure

NOTE: Ensure that all drain valves are closed, except for those needed to correctly fire and raise pressure on the boiler.

STEAM LINE BLOWING PROCEDURE

1. Walk down the drain line that is to be blown out with steam/water. Ensure that there are no closed valves, blanks or other obstructions except the two drain valves located at the header.

2. Open the root or upstream valve (the valve closest to the header) on the drain line to be blown out.

3. Fully open the second or downstream valve SLOWLY in order to allow the line to warm up. This should take no more than 2 minutes.

4. Verify that there is flow in the line by checking the temperature of the second or downstream drain valve. The valve should be noticeably hot. If not then report this to the Site Representative immediately.

5. Close the second or downstream drain valve.

6. Wait 2 minutes and then open the second or downstream drain valve wide open.

7. Wait 5 minutes, then close the second or downstream drain valve.

8. Wait 5 minutes, then open the second or downstream drain valve.

9. Wait 5 minutes, then close the second or downstream drain valve.

10. Close the first or upstream drain valve.

11. Ensure that there is no leakage through the two valves when closed. If flow is suspected, immediately inform the Site Representative.

Move on to the next drain line and repeat steps 1 to 11. Do this for each drain line. Refer to applicable P&ID's.

STEAM LINE BLOWING PROCEDURE

STEAM LINE BLOWING - FLOW DIAGRAM

OPEN
OPEN
From HP Cyl. Separator, MSV Superheater HP-Bypass
From
HP Cyl.
Separator,
MSV
Superheater
HP-Bypass

CLOSED

RSV NRV RCV IP/LP Cyl.
RSV
NRV
RCV
IP/LP Cyl.
LP-Bypass
LP-Bypass
CLOSED OPEN Martyr Valve Temporary Pipe
CLOSED
OPEN
Martyr Valve
Temporary Pipe
NRV RCV IP/LP Cyl. LP-Bypass CLOSED OPEN Martyr Valve Temporary Pipe Spectacle Flange FIGURE 1: PRE

Spectacle Flange

NRV RCV IP/LP Cyl. LP-Bypass CLOSED OPEN Martyr Valve Temporary Pipe Spectacle Flange FIGURE 1: PRE

FIGURE 1: PRE – STEP 1

23

STEAM LINE BLOWING PROCEDURE

STEAM LINE BLOWING PROCEDURE Martyr Valve RSV NRV RCV Temporary Pipe HP-Bypass CLOSED MSV HP Cyl.
Martyr Valve RSV NRV RCV
Martyr Valve
RSV
NRV
RCV

Temporary Pipe

HP-Bypass CLOSED MSV HP Cyl. CLOSED HP-Bypass
HP-Bypass
CLOSED
MSV
HP Cyl.
CLOSED
HP-Bypass
IP/LP Cyl.
IP/LP Cyl.
LP-Bypass
LP-Bypass

From

Separator,

Superheater

FIGURE 2 : PRE – STEP 2

24

STEAM LINE BLOWING PROCEDURE

Target Plate CLOSED OPEN CLOSED RSV OPEN NRV Spectacle Flange RCV From RH IP/LP Cyl.
Target Plate
CLOSED
OPEN
CLOSED
RSV
OPEN
NRV
Spectacle Flange
RCV
From
RH
IP/LP Cyl.
MSV
HP Cyl.
Separator,
Superheater
OPEN
LP-Bypass
HP-Bypass
CLOSED
OPEN
Temporary Pipe
CLOSED
Martyr Valve
Target Plate
Spectacle Flange

25

FIGURE 3 : MAIN STEP 1

STEAM LINE BLOWING PROCEDURE

Target Plate CLOSED Temporary Pipe OPEN OPEN RSV CLOSED NRV Spectacle Flange RCV From RH
Target Plate
CLOSED
Temporary Pipe
OPEN
OPEN
RSV
CLOSED
NRV
Spectacle Flange
RCV
From
RH
IP/LP Cyl.
HP Cyl.
Separator,
MSV
Superheater
CLOSED
LP-Bypass
HP-Bypass
OPEN
OPEN
Temporary Pipe
CLOSED
Martyr Valve
Target Plate
Spectacle Flange

FIGURE 4 : MAIN STEP 2

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