SIPAT SUPER THERMAL POWER PROJECT SIPAT STAGE # 1 BOILER ECO. O/L - - PowerPoint PPT Presentation

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SIPAT SUPER THERMAL POWER PROJECT SIPAT STAGE # 1 BOILER ECO. O/L - - PowerPoint PPT Presentation

Oct 02, 2023 409 likes •757 views

SIPAT SUPER THERMAL POWER PROJECT SIPAT STAGE # 1 BOILER ECO. O/L LINKS ECONOMISER TO 1 ST PASS TOP HEADERS : OUTLET HEADERS VERTICAL WALL INTERMITTENT HEADERS ECO. JUNTION HEADERS ECO. MIXING PIECE SPIRAL WALL ECONOMISER BOTTOM RING

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SLIDE 1

SIPAT SUPER THERMAL POWER PROJECT

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SLIDE 2

SIPAT STAGE # 1 BOILER

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SLIDE 3
  • ECO. JUNTION

HEADERS ECO I/L HDR ECONOMISER

  • ECO. O/L LINKS
  • ECO. MIXING

PIECE BOTTOM RING HEADER SPIRAL WALL INTERMITTENT HEADERS VERTICAL WALL OUTLET HEADERS

ECONOMISER TO 1 ST PASS TOP HEADERS :

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SLIDE 4

ECONOMISER :

COUNTER FLOW 4 BANKS 163 ASSEMBLIES 4 JUNCTION HEADERS 224 HANGER TUBES ECO OUTLET HEADER SA 106 C ; SA 210 C

SPIRAL AND VERTICAL WALLS :

TOTAL SPIRAL TUBES : 440 (102X2 FRONT & REAR; 108X2 LEFT & RIGHT) SPIRAL TO VERTICAL RATIO = 1:3 FRONT VERTICAL TUBES: 336 SIDE WALL TUBES: 648 REAR SCREEN TUBES : 280 REAR HANGER TUBES : 56 TUBES : T22 HEADERS : P12

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SLIDE 5

STORAGE TANK MIXING PIECE FLASH TANK CONDENSER BOILER FILL LINE FEED WATER LINE TO ECONOMISER BCP WR ZR UG STORAGE TANK MIXING PIECE FLASH TANK CONDENSER BOILER FILL LINE FEED WATER LINE TO ECONOMISER BCP WR ZR UG

START UP SYSTEM :

SEPERATOR TANKS 1ST PASS ROOF O/L HEADERS SEPERATORS I/L LINKS

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SLIDE 6

EXTENDED WALL : 2ND PASS STEAM FLOW :

BACK PASS BOTTOM RING HDR BACK PASS TOP LHS HDR BACK PASS TOP RHS HDR BACK PASS ROOF I/L HDR EXTENDED WALL HDR 1ST PASS ROOF I/L HDR EXTENDED WALL

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SLIDE 7

BACK PASS WALLS & HEADERS :

FURNACE FRONT ROOF : 168 BACK PASS ROOF : 111 BACK PASS REAR WALL : 111 BACK PASS SIDE WALL : 328 BACK PASS FRONT WALL : 167 BACK PASS SCREEN : 167 TUBES : T12 HEADERS : P12

EXTENDED WALL :

EXTENDED WALL FLOOR : 142 EXTENDED SIDE WALL : 142 TUBES : T12 HEADERS : P12 FLUID COOLED SPACER TUBES: 3

BACK PASS WALLS & HEADERS :

LINK PIPES : P12 SEPERATORS & STORAGE TANK : SA 302C

START UP SYSTEM :

LINK PIPES : P12 SEPERATORS & STORAGE TANK : SA 302C

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SLIDE 8

FROM II nd PASS BOTTOM RING LHS HDR FROM II nd PASS BOTTOM RING RHS HDR

  • DIV. PANEL I/L HDR
  • DIV. PANEL I/L HDR
  • DIV. PANEL O/L HDR
  • DIV. PANEL O/L HDR
  • DIV. PANEL
  • DIV. PANEL

II ND PASS TOP RHS HDR II ND PASS TOP LHS HDR

DIVISIONAL PANEL :

SH DIV. PANEL TUBES : 480 TUBES : T23; T91 HEADERS : P12; P23 FLUID COOLED SPACER TUBES : 6

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SLIDE 9
  • DIV. PANEL O/L HDR

PLATEN I/L HDR PLATEN O/L HDR

PLATEN COILS

  • DIV. PANEL I/L HDR
  • DIV. PANEL I/L HDR

PLATEN TO FINAL SH LINK

  • DIV. PANEL O/L HDR

FINAL SH I/L HDR FINAL SH O/L HEADERS

TO HP TURBINE FINAL SH COILS

  • DIV. PANEL TO PLATEN LINK

PLATEN AND FINAL SH :

PLATEN ASSEMBLIES : 20 NO OF TUBES : 480 TUBES : T12; T23; T91 HEADERS : P12; P23 NO OF STAGES : 2 ASSMBLIES : 2X55 NO OF TUBES : 935 TUBES : T23; T91 HEADERS : P23; P91 COUNTER FLOW DIRECTION

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SLIDE 10

LTRH BANKS

TO IPT TO IPT

FINAL RH

FROM CRH FROM CRH

REHEATERS :

NO OF BANKS : 3 NO OF TUBES : 111 TUBES : SA 210C; T12; T23 HEADERS : SA 106C; P12 NO OF ASSEMBLIES : 41 NO OF TUBES : 615 TUBES : T23; T91; SUPER 304H HEADERS : P12; P91

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SLIDE 11

HPT IPT LPT

C O N D E N S E R

FEED WATER FRS

S T O R A G E T A N K

SEPARATOR

BWRP MS LINE HRH LINE VERTICAL WW

ECO I/L ECO JUNCTION HDR ECO HGR O/L HDR FUR LOWER HDR

FUR ROOF I/L HDR DIV PANELS SH PLATEN SH FINAL RH FINAL SH LTRH ECONOMISER

290°C, 302 KSC 411°C, 277Ksc 411°C, 275 Ksc 492°C, 260 Ksc 540°C, 255 Ksc 305°C, 49 Ksc 457°C, 49 Ksc 568°C, 47 Ksc

G

LPT

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SLIDE 12

FEATURES OF SUPER CRITICAL BOILER :

  • 1. ONCE THROUGH OPERATION :

FEED WATER PUMP ECONOMISER WATER WALL/ EVAPORATOR SEPERATOR SUPERHEATER STORAGE TANK RECIRCULATION PUMP

CONSTANT WATER WALL FLOW (below 30% load)

FEED WATER PUMP ECONOMISER WATER WALL/ EVAPORATOR SEPERATOR SUPERHEATER

ONCE THROUGH FLOW OPERATION (above 30% load)

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SLIDE 13
  • 2. CONSTANT PRESSURE OPERATION :

Above 90% & below 30%

  • 3. SLIDING PRESSURE OPERATION :

B/W 30% & 90%

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SLIDE 14
  • 1. No additional pressure loss between boiler and turbine
  • 2. Low Boiler Pr. at low loads
  • Less fatigue of Pr. part components
  • Longer life of all components, Less wear of components
  • Less Maintenance
  • 3. Lower thermal stresses in the turbine during load changes
  • 4. Control range of RH temp is extended
  • 5. Overall reduction in power consumption and improved heat rate

ADVANTAGES OF SLIDING PRESSURE OPERATION

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SLIDE 15

DESCRIPTION UNIT 660 MW AT BMCR S/H STEAM FLOW T/HR 2225 SH STEAM PR KG/CM2 256 SH STEAM TEMP

0C

540 RH STEAM FLOW T/HR 1742 RH STEAM TEMP INLET

0C

299 RH STEAM TEMP OUTLET

0C

568 RH STEAM PRESS OUTLET KG/CM2 46.61 FEED WATER TEMP

0C

289.64 SECONDARY AIR FLOW T/HR 1732 PRIMARY AIR FLOW T/HR 946 TOTAL COAL FLOW T/HR 472

660MW PARAMETERS :

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SLIDE 16

FEATURES OF 660 MW- STEAM QUALITY PARAMETERS

S.NO. PARAMETER STEAM QUALITY AT SG OUTLET DURING START UP DURING NORMAL OPERATION 1 TDS 20 2 2 SILICA 20 2 3 SODIUM 10 2 4 CHLORIDES 2 5 COPPER 20 1 6 IRON 10 5 7 CATION CONDUCTIVITY <0.2 to 0.25 micro siemens /cm <-0.2 micro siemens / cm 8 PH 6~8

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SLIDE 17

COMMISSIONING NETWORK

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SLIDE 18

ID FAN # 1A TRIAL RUN FD FAN # 1A TRIAL RUN SAPH # 1A TRIAL RUN BRP TRIAL RUN SACNNER AIR SYSTEM READINESS FURNACE READINESS FUEL OIL SYSTEM READINESS DDCMIS FSSS READINESS MFT CHECKING GATES, DAMPERS / VALVES TG : SG : SG ECW SYSTEM CW SYSTEM READINESS CHEMICAL CLEANING OF BOILER MS Line Welding Completion CRH Line Welding Completion HRH Line Welding Completion MS Line Hanger Erection Cold Setting CRH Line hangers Cold Setting HRH Line Hangers Cold Setting MS Line Insulation CRH Line Insulation HRH Line Insulation MS Line HT CRH Line HT HRH Line HT COMPRESSED AIR SYSTEM READINESS AUX PRDS READINESS ACW System

Temporary Piping Completion

Boiler Light Up & Steam Blowing

MDBFP Trial CEP Trial TG ECW System HOT Well Readiness

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SLIDE 19

LIST OF APPROVED PROCEDURES

Boiler Commissioning is carried out based on the guide lines of Corporate commissionin groups. OS) These are the list of approved commissioning procedures which are followed in sipat commissioning activities

  • 1. BOILER HYDRO TEST
  • 2. OIL FLUSHING OF ROTARY MACHINES
  • 3. BOILER & DUCTS AIR TIGHTNESS TEST (ATT)
  • 4. ESP AIR IN LEAK TEST
  • 5. ESP GAS DISTRIBUTION (GD) TEST
  • 6. BOILER CHEMICAL CLEANING
  • 7. BOILER COLD AIR VELOCITY TEST
  • 8. CLEAN AIR FLOW TEST
  • 9. LDO & HFO SYSTEMS COMMISSIONING
  • 10. BOILER & AUX LINES STEAM BLOWING
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SLIDE 20

COMMISSIONING MILE STONES

  • 1. BOILER HYDRO TEST :

HP SYSTEM : Hydro test done on 20.12.2006 HP system hydro test is done at 410 KSC. HP system consists of Economiser, boiler 1st & 2nd pass, divisional panel, platen & final super heater upto boiler stop valves. MP SYSTEM : Hydro test done on 26.03.2008 MP system hydro test is done at 80.1 KSC. MP system consists of CRH isolator to LTRH, Final Reheater upto HRH isolators.

  • 2. BURNER TILT, OIL GUNS & IGNITOR CHECKING :

Checking is completed on 24.12.2007 Burner tilt checking is done from inside the boiler in which burner limits +300 &

  • 300 angles adjusted. Oil guns & ignitors clearances are checked inside the

boiler.

  • 3. FD, ID & PA FANS COMMISSIONING :

FD Fan # 1A trial run taken on 03.03.2010 ID Fan # 1A trial run taken 15.03.2010 PA Fan # 1A trial run taken 18.03.2010

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SLIDE 21

COMMISSIONING MILE STONES

  • 3. FD, ID & PA FANS COMMISSIONING :

FD Fan # 1B trial run taken on 22.06.2010 ID Fan # 1B trial run taken 21.06.2010 PA Fan # 1B trial run taken 22.06.2010 Fans commissioning involves following steps:

  • Lube oil flushing of lube oil skid, lube oil lines with flushing oil (32 grade)

(bearings bypassed) (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)

  • Lube oil flushing through bearings (32 grade)
  • Lube oil flushing through bearings (68 grade oil)
  • Blade pitch commissioning & discharge gate commng.
  • Cooling water lines flushing & charging
  • Fan trial
  • 4. AIR PREHEATERS COMMISSIONING :

SAPH # 1A trial run taken on 27.03.2010 SAPH # 1B trial run taken on 20.04.2010

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SLIDE 22
  • 4. AIR PREHEATERS COMMISSIONING :

PAPH # 1A trial run taken on 29.03.2010 PAPH # 1B trial run taken on 20.04.2010 Air Preheaters commissioning involves following steps:

  • Lube oil motors & main motor no load trial
  • Lube oil flushing of Support & Guide bearings with 32 oil (Completion criterion

is Moisture & Mechanical impurities should be below 100 ppm)

  • Lube oil flushing through bearings (32 grade)
  • Lube oil flushing through bearings (680 grade oil)
  • Air motor service air line blowing
  • Cooling water lines flushing & charging
  • Air preheater trial with air motor & electrical motor
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SLIDE 23
  • 4. BOILER & DUCT ATT :

Secondary air duct ATT is completed on 01.04.2010 Primary air duct ATT is completed on 05.05.2010 Flue gas air duct ATT is completed on 24.04.2010 Furnace ATT completed on

  • ATT of boiler & ducts is done at 150 mm of water column.
  • Secondary air duct & boiler pressurisation is done by FD Fan.
  • Primary air duct pressurisation is done by PA fan.
  • Flue gas duct pressurisation is done by using temporary blowers
  • 5. ESP COMMISSIONING :

ESP Air In Leak test: All passes air in leak test completed on 09.11.2008 The test is done to prove that air in leak into ESP is with in guaranteed value of 1%

  • f design gas flow rate.

ESP Rapping system commng. : All passes rapping systems commng. completed on 21.07.2010 Each Pass has 18 nos. collecting electrodes rapping system, 18 nos emitting electrode rapping system & 2 nos. gas distribution plates rapping system.

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SLIDE 24
  • 5. ESP COMMISSIONING :

ESP Fields charging ESP GD test completed on 25.08.2010 This is done to verify uniform flow distribution inside the ESP Chambers.

  • 6. BOILER CAVT :

CAVT (Cold Air Velocity Test) is completed on 03.09.2010 This test is done to check flue gas flow patterns inside the boiler.

  • 7. AIR BALANCE TEST (ABT):
  • 8. BOILER CHEMICAL CLEANING :

Boiler Chemical cleaning is completed on 30.09.2010 Chemical cleaning involves following steps:

  • Flushing
  • Acid Cleaning
  • Rinsing
  • Pre Neutralization
  • Neutralization
  • Passivation
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SLIDE 25
  • Main chemicals used are formic acid (10%), sorbic acid, coronil 200S
  • Boiler chemical cleaning is completed in 7 days.
  • 9. BRP (Boiler Recirculation Pump) COMMISSIONING :

BRP trial completed on 13.10.2010 BRP commissioning involves following steps:

  • Cavity filling line flushing (until Conductivity & Turbidity reaches required

parameters)

  • Flushing through motor cavity & through cooler
  • ECW lines water flushing
  • Pump trial
  • 10. BOILER LIGHT UP :

Boiler is Lighted Up on 27.10.10 Boiler is lighted up with LDO and all 4 corner oil guns were proven.

  • 11. STEAM BLOWING : It has following steps

PRE STEP1: Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Tailpipe to atmosphere Blowing is done from 40 KSC to 20 KSC

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SLIDE 26
  • 11. STEAM BLOWING :

Steam blowing consists of following steps: 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 Blowing is done from 40 KSC to 20 KSC 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 Blowing is done from 80 KSC to 40 KSC 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 Blowing is done from 80 KSC to 40 KSC

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SLIDE 27

11.PF SYSTEM COMMISSIONING: (a) Seal air fan & its dampers (b) Mills commissioning:

  • Lube oil pumps load trial
  • Lube oil flushing of oil line with 32 oil bypassing gear box & bearings

(Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)

  • Lube oil flushing through bearings & gear box(32 grade)
  • Lube oil flushing through bearings (320 grade oil)
  • Cooling water lines flushing & charging
  • Roller & Bowl gap adjustment
  • Spring tension adjustment
  • P&I checks & Mill solo run.
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SLIDE 28

11.PF SYSTEM COMMISSIONING: (C) RC Feeders

  • Motor checks
  • P&I checking
  • Feeder belt trial with clean out conveyor.

(D)Commissioning of gates & dampers

  • Commng of HAD, CAD, HAG, CAG, BIG, MDV from remote

(E) Clean air flow test of mills as per approved procedure

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SLIDE 29

PROBLEMS & MODIFICATIONS

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SLIDE 30
  • 1. Provision of manholes in ducts & hoppers
  • 2. Oil gun cleaning system
  • 3. BRP fill line from boiler fill pump
  • 4. FD, ID & PA fans blade pitch local indication
  • 5. Black Start Up line in unit # 1
  • 6. Additional vents are provided in SGECW system
  • 7. Boiler headers & links replacement
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SLIDE 31

BOILER HEADERS REPLACEMENTS

  • Some of the super heater headers were replaced with higher grade

materials.

  • 5 nos. of headers & link pipes of Gr P23 were replaced with Gr P91.
  • This material replacement is done to avoid probable material failure in

the pipes and fittings of the boiler subjected to very high temperature and pressures.

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SLIDE 32
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SLIDE 33