Professional Documents
Culture Documents
DEPARTMENT
HRSG
ApprovedTai Dechun
Chapter 1. 4
Article 1 Brief Introduction. 5
Article 2 Design Criterion of HRSG.. 8
Article 3 Boiler Protection Set Value. 20
Chapter 2. 23
Article 1 LP steam and water system.. 24
Article 2 HP steam and water system.. 35
Article 3 Deaerator system.. 46
Article 4 HP bypass system.. 49
Article 5 LP bypass system.. 60
Article 6 Water drain and steam exhaust system.. 70
Article 7 Service water system.. 76
Article 8 Intermittent blowdown flash tank system.. 78
Article 9 Local boiler drum level meter wash. 81
Chapter 3. 84
Article 1 Accidents disposal principles 85
Article 2 Emergency shutdown. 87
Article 3 Accident shutdown. 88
Article 4 Accidents disposal 89
Chapter 4. 109
Article 1 Hydraulic boiler set 110
Article 2 Safety valves floating. 120
Article 3 Maintenance after shutdown. 123
Chapter 5. 140
Appendix 1: Sketch Map of HP and LP Drum Water Level Fixed Value 141
Appendix 2: Sketch Map of Deaerator Water Level Fixed Value 142
Appendix 3: The control set value of HP Drum Positive Pressure Gradient 143
Appendix 4. Check List of Steam Saturated Temperature. 144
Appendix 5 Common Unit Conversion Table. 147
Appendix 6 Equipments Periodical Tests and Periodical Transferring Table 150
Chapter 1
Brief Introduction and Design Criterion of HRSG
bypass outlet flue ductinlet flue duct of HRSG. In the inlet flue duct, the flue flow is
changed from horizontal to vertical, up into boiler body to flush the 3 rd layer modules, 2nd
layer modules and 1st layer modules and finally exhausted to the air through the outlet flue
duct and chimney.
3rd layer modules: HP superheater 2 (SHP2), HP superheaters 1 (SHP1);
2nd layer modules: HP vaporizer (VHP), HP coal economizer 3 (EHP3), LP superheater
(SLP), HP coal economizer 2 (EHP2)
1st layer modules: LP vaporizer (VLP), HP coal economizer 1 (EHP1), preheater (PREH)
of
HRSG
(performance
unit
Flue gas
flow
kg/h
SHP2
SHP1
VHP1
EHP3
SLP1
EHP2
VLP1
EHP1
PREH
Flue gas
7912
heat output Mcal/h
23077
64533
4561
1903
16963
21806
5168
25936
Inlet flue
temp.
541.1
521.6
465.2
304.0
292.4
287.5
244.0
187.4
173.9
Outlet flue
temp.
521.6
465.2
304.0
292.4
287.5
244.0
187.4
173.9
105.3
Flue gas
temp. drop
19.5
56.4
161.2
11.6
4.9
43.5
56.6
13.5
68.6
Flue gas
pressure
drop
Pa
220.2
204.6
788.3
136.8
37.3
246.3
302.1
203.6
306.4
Flue gas
flow speed
m/s
16.20
15.85
17.51
12.32
12.94
11.99
11.15
9.90
10.05
SHP2
SHP1
VHP1
EHP3
SLP1
EHP2
VLP1
EHP1
PREH
Heat
balance at
steam side
Steam
140000
181179 179953
179953 39509.5 179953 330000 179953 278198
(water) flow kg/h
0
Heat absorb
at steam Mcal/h 7872
side
22962
64211
4538
1894
16878
21698
5142
25807
Heat
exchanging
rate
99.5
99.5
99.5
99.5
99.5
99.5
99.5
99.5
99.5
Stem
(water) inlet
temp.
449.6
292.0
292.4
266.0
172.8
180.9
172.9
153.3
55.0
Stem
(water)
outlet temp.
523.0
457.3
292.4
286.4
258.5
266.0
172.9
180.9
147.0
Steam
(water)
temp. rise
74.0
165.2
0.0
20.5
86.5
85.0
0.0
27.6
92.0
Node
temp.
17.1
64.4
11.6
17.5
33.1
21.5
14.5
6.5
26.9
Approachin
g point
temp.
Stem
(water) inlet bara
pressure
5.9
29.3
75.3
76.8
77.4
89.3
8.5
89.8
9.1
90.2
10.0
Stem
(water)
outlet
pressure
bara
73.0
76.1
77.1
89.1
7.5
89.3
8.5
89.8
8.7
Stem
(water)
pressure
drop
bara
0.84
0.65
0.34
0.25
0.46
0.44
0.58
0.41
1.29
m/s
15.74
13.51
3.30
1.31
43.44
1.25
14.10
1.09
1.63
Stem
(water) flow
speed
Cubage rate
of flue gas
content
N2
74.87
O2
13.72
H2O
7.19
Ar
0.89
CO2
3.33
25.7
Atmosphere pressure
1.005bar
Humidity
74%
Turbine fuel
Natural gas
Turbine backpressure
3980 Pa
2370.25 t/h
541.1
113
74.87
CO2
3.33
H2O
7.19
O2
13.72
SO2
0.00
Ar
0.89
3. Steam parameter
HP part
Max. continuous rating
179.11 t/h
7.3 MPa
523
LP part
Max. continuous rating
39.5 t/h
0.75 MPa
257.5
31
55
213.7
Flow
240 t/h
separator and the 2nd stage one is wire demister. Also inside the drum, the feeding water
distribution pipes, emergency water draining pipes, intermittent and continuous blowdown
pipes are set. On drum, local water meters, balance tank, electric contact water meters,
pressure gauges, safety valves and other necessary appurtenances and instruments.
Under boiler max. continuous output, the time from normal drum water level to low low
level is:
HP: 3min;
LP: 8min.
4.1.2
HP
drum
Design parameter:
Designed pressure (MPa)
7.2
7.2
Designed temp. ()
321
Working temp. ()
313
30
6380
2480mm
90
Spec.
248090
Material
SA299
2.83
2.35
Designed temp. ()
235
Deaerat
or
4.1.3
Working temp. ()
223
29.6
6700
2040mm
20
Spec.
125020
Material
SA-516Gr70
0.97
0.36
Designed temp. ()
140
Working temp. ()
177
30.19
7780
3040mm
20
Spec.
304020
Material
16MnR
HP drum
0
Normal level
Low level I
650mm
Low level
800mm
High level I
500mm
High level
550mm
High level
650mm
LP drum
Deaerator
Normal level
-100mm
Low level I
500mm
Low level
650mm
High level I
350mm
High level
400mm
High level
500mm
Normal level
-100mm
Low level I
1600mm
Low level
1750mm
High level I
500mm
High level
700mm
Fin
type
materials
SA213- T91
No
tooth
SUH409L
38x2.9
SA213- T22
No
tooth
SUH409L
Stagger
44.5x2.6
SA210- A1
Open
tooth
08AL
HP coal
economizer 3
(EHP3)
Stagger
44.5x2.6
SA210- A1
Open
tooth
08AL
HP coal
economizer 2
(EHP2)
Stagger
44.5x2.6
SA210- A1
Open
tooth
08AL
HP coal
economizer 1
(EHP1)
Stagger
44.5x2.6
SA210- A1
Open
tooth
08AL
LP superheater
(SLP)
Stagger
44.5x2.6
SA210- A1
Open
tooth
08AL
LP vaporizer
(VLP)
Stagger
44.5x2.6
SA210- A1
Open
tooth
08AL
44.5x2.6
SA210- A1
Open
tooth
08AL
Location
Type
Pipes
Spec.
Pipes
Materials
HP superheater 2
(SHP1)
Stagger
38x2.9
HP superheater 1
(SHP1)
Stagger
HP Vaporizer
(VHP)
Name
HP system
No.
Parts Names
Capacity m3
HP superheaters system
23.8
HP vaporizing system
63.7
44.6
HP drums
41
HP system pipes
10
183.1
Deaerator
No.
Parts Names
Capacity m3
32.4
1
2
2.4
22.4
3.7
Deaerator HP drums
15.1
15
91
LP system
No.
Parts Names
Capacity m3
LP superheater system
10.3
LP vaporizing system
30.7
53.1
LP drums
60.2
LP system pipes
162.3
YD30.25-H
5500mm5500mm
5500mm5500mm
5500mm5500mm
3800mm
3200mm
3800mm
P=30mmH2O
P=8mmH2O
600mmH2O
Design temperature:
600
30 years
8500h/year
330times/year
CGC-290K-HYDR-SCH
4
9-26
6762m3 /h
Total pressure:
Motor Power:
Protection level:
5180 Pa
18.5kw2
IP55
JKXL1-411
RIC(B)-02
In boiler chimney, the electric chimney dampers are erected to isolate HRSG from
atmosphere to retain the HRSG temperature as long as possible after shutdown. At
the same time, the climate dampers can prevent rain and release the pressure.
The electric chimney dampers have mechanical safety functions to prevent damaging
HRSG and GT. If over pressure appears in HRSG, the dampers can be opened;
4.4.3.10 Structure illumination of boiler flue duct
Boiler adopts complete seal structure. The inlet flue duct, vertical flue duct and outlet
duct of boiler are frame cover made up of U shape steel plates. The frame cover is
connected with HRSG steal structure to hold the boiler seal performance and also
increase the rigidity of HRSG.
At the bottom frame cover of horizontal flue duct, an exhaust port is set. When HRSG
stopped, we can check the leakage of HRSG pressure-containing members through
exhaust port;
At the place where header goes through frame cover, an expansion joint is set to
maintain the tightness and overall performance of frame cover and allow the header
to have some expansion displacement compared to frame cover.
2.0mol/L
Oxygen
7g/L
Ferrum
30g/L
Copper
5g/L
Oil
0.3mg/L
PH (25)
9.09.
Hydrazine \
1050g/L
5.2
0mol/L
SiO2
20g/kg
Conductivity (25)
0.2s/cm
210mg/L
Salt content
100mg/L
Conductivity (25)
150s/cm
SiO2
2.0mg/kg
PH (25)
9.010.5
10g /kg
SiO2
20g/kg
Ferrum
20g/kg
Copper
5g/kg
Conductivity (25)
0.3s/cm
No.
Description
Set
value
Unit
Action
600
mmwc
Alarm
600
Alarm
180
Alarm
GT speed
MIN1(Combined Cycle)
100
RPM
HP FDW isolating
valves open
automatically
GT speed
MIN1(Combined Cycle)
100
RPM
HP FDW bypass
isolating valves open
automatically
GT speed
MIN1(Combined Cycle)
100
RPM
HP FDW adjusting
isolating valves open
automatically (startup)
GT speed
MIN1(Combined Cycle)
100
RPM
LP FDW adjusting
isolating valves open
automatically (startup)
GT speed
MIN1(Combined Cycle)
100
RPM
HP main steam
drainage valves open
automatically
GT speed
MIN1(Combined Cycle)
100
RPM
10
GT speed
MIN1(Combined Cycle)
100
RPM
11
GT speed
MIN1(Combined Cycle)
100
RPM
Deaerator regulating
valves and isolating
valves open
automatically
RPM
HP main steam
drainage valves open
automatically (if level
low)
100
RPM
GT speed
MIN2(Combined Cycle)
20
RPM
15
540
Alarm
16
650
mm
Alarm
17
500
mm
Alarm
18
550
mm
Alarm
19
600
mm
Alarm
20
350
mm
Alarm
21
400
mm
Alarm
22
mm
Alarm
mm
Alarm
12
GT speed
MIN1(Combined Cycle)
13
GT speed
MIN1(Combined Cycle)
14
23
100
+700
24
800
mm
Trip
25
650
mm
Trip
26
650
mm
Trip
27
500
mm
Trip
28
mm
Trip
29
700
mm
Trip
30
0.498
KPa
Trip
31
HP superheater outlet
temp. high value II
550
Trip
Chapter 2
HRSG System Operation
Model
GR320-60
Type
Qty.
Rated flow
320m3/h
Lift
60m
Speed
2950r/min
4.8m
Motor power
65KW
Direction
Efficiency
80%
On DCS or in site, start recirculation pump and open the reject valves of the pump.
The reject valves are not allowed to be closed for long time to prevent pump damaged caused
by overheating;
2.3 Normal startup of preheater recirculation pump
2.3.1 Check all bolts and pipes firm;
2.3.2 Check all instruments, valves and meters normal;
2.3.3 Check lub oil pressure normal and oil return smooth;
2.3.4 Open air relief valve and observe the oil slinger on right position;
2.3.5 Check the suction valves opened;
2.3.6 When conditions satisfied, start the recirculation pump on DCS or in site and open the
reject valves at once. The reject valves are not allowed to be closed for long time to prevent
pump damaged caused by overheating;
2.4 Stop of preheater recirculation pump
2.4.1
Close the reject valves of the pump to min flow and pay attention that the suction
The thermal resistance adopts Pt100 3-line system (two parse insulation), the thrust
bearing has independent survey points (single Pt100); the analogue signal is 4 20mA
DC (the accepted analogue signal by buyer should have isolation functions); the
discrete is dry contact point without resources, and the contact point type is DPDT,
whose capacity is 230V AC, 5A, 220V DC, 3A.
Transporting Medium Characteristics
Medium:
Boiler FDW
PH value of water:
8.8-9.3
0umol/L
Type
562 SVTL 12
Output power
1306KW
Input power
1355KW
Output speed
2925rpm
Input speed
2985rpm
Slid difference
2%
Rolling direction
Oil cooler
Flat cooler
Max. 39 at inlet
20.9m3/h
Model
HGC 5/7
Driven
Rolling direction
>9.0
0.02
152
Density
0.9149 kg/dm3
Inlet pressure
0.616 MPa(g)
Outlet pressure
11.87 MPa(g)
Outlet flow
311.07 t/h
NPSHr
6.937m
Capacity
340.0 m3/h
Min capacity
89.87 m3/h
Efficiency
81.47%
1305.4KW
Pump speed
2925 rpm
1011rpm
4.2.1 On LP FDW system display, start LP FDW pump and open the outlet;
4.2.2 On LP FDW system display, open LP FDW 3-way valves to LP FDW preheater;
4.2.3 Start preheater recirculation pump and open the outlet;
4.2.4 Set the automatic adjustment setting value of FDW at startup value and on auto
position;
4.2.5 When LP drums at startup water level, FDW is finished;
Description
Set
value
Unit
Action
105
Alarm
110
Preheater
recirculation pump
trip
105
Alarm
110
Preheater
recirculation pump
trip
75
Alarm
80
Preheater
recirculation pump
trip
RPM
Preheater
recirculation pump
trip
Description
Set
Unit
Action
value
1
105
Alarm
110
105
Alarm
110
75
Alarm
80
75
Alarm
80
Description
Set
value
Unit
Action
10
bar
LP FDW pressure
13
bar
350
mm
intermittent blowdown
valves; safely close LP FDW
regulating valves
400
mm
500
mm
HRSG trip
mm
-450
mm
-500
mm
-650
mm
HRSG trip
10
11
bar
Alarm
11
bar
12
0.5
bar
13
8.5
bar
Alarm
14
9.0
bar
HRSG trip
15
t/h
16
800
mm
17
50
mm
bar
Alarm
2. Equipments Spec.
2.1 HP FDW pump unit
3 x 50% horizontal multi-stage sub-sectional centrifugal constant speed LP FDW pump:
one is for backup. At the inlet pipe of FDW pump, Y type fine filters are equipped whose
resistance scope is within 0.020.03MPa).
Cooling water quality: the working oil coolers for FDW pumps motors and lub oil coolers
adopt closed cooling water. Under design working conditions, the cooling water temp. is
19 ; under check working conditions, the cooling water temp. is 32 and under hot
season working condition, the cooling water temp. is 46 .
Lub oil system of pump unit
In pump unit design, there is a perfect lub oil system and the seller should provide
complete lub oil equipments. The lub oil system includes working oil pump, lub oil pump,
AUX. AC oil pump, working oil cooler, lub oil cooler and oil filter instruments and meters.
The system can ensure all shafts and pads not damaged when auxiliary power lost;
The thermal resistance adopts Pt100 3-line system (two parse insulation), the thrust
bearing has independent survey points (single Pt100); the analogue signal is 4 20mA
DC (the accepted analogue signal by buyer should have isolation functions); the
discrete is dry contact point without resources, and the contact point type is DPDT,
whose capacity is 230V AC, 5A, 220V DC, 3A.
2.2Transporting Medium Characteristics
Medium:
Boiler FDW
PH value of water:
8.8-9.3
Conductivity:
SiO2:
0umol/L
< 20g/L
Manufacturer
Voith Turbo,Crailsheim
Type
562 SVTL 12
Output power
1306KW
Input power
1355KW
Output speed
2925rpm
Input speed
2985rpm
Slid difference
2%
Rolling direction
Oil cooler
Flat cooler
Max. 39 at inlet
20.9m3/h
Model
HGC 5/7
Driven
Rolling direction
>9.0
0.02
152
Density
0.9149 kg/dm3
Inlet pressure
0.616 MPa(g)
Outlet pressure
11.87 MPa(g)
Outlet flow
311.07 t/h
NPSHr
6.937m
Capacity
340.0 m3/h
Min capacity
89.87 m3/h
Efficiency
81.47%
1305.4KW
Pump speed
2925 rpm
1011rpm
driving motor bearing oil level normal, and the lub oil pressure over 0.1MPa;
3.2.5 Check the LP drum water level normal and the water level adjustment on auto position;
3.2.6 If there is no backwash on HP boiler steam header, the backwash valves should be on
close position;
4.2.5 On HP FDW system display, set the automatic adjustment setting value of FDW at
startup value and on auto position;
4.2.6 On HP FDW system display, put the adjustment valve from HP FDW pipes to LP boiler
on auto position;
4.2.7 Check whether the LP drum water level is normal;
4.2.8 When HP drums at startup water level, FDW is finished;
Description
Set
value
Unit
Action
105
Alarm
110
105
Alarm
110
90
Alarm
95
90
Alarm
95
150
Alarm
155
11
75
Alarm
12
80
13
75
Alarm
14
80
15
um
Alarm
16
7.1
um
17
um
Alarm
18
7.1
um
19
No.
Description
69
bar
HP FDW pressure
90
bar
Action
Automatically start one
spare HP FDW pump
Allow to open HP FDW
regulating valves and
isolating valves
Pressure difference
between front and back
of HP FDW main isolating
valves
bar
Alarm
500
Automatically open HP
drum intermittent
mm blowdown valves; safely
close HP FDW
regulating valves
550
mm
650
mm
HRSG trip
mm
-600
mm
-650
mm
10
-800
mm
HRSG trip
11
83
bar
Alarm
12
bar
Automatically close HP
drum air relief valves
13
0.5
bar
Automatically close HP
drum air relief valves
(when startup)
14
77
bar
Alarm
15
79
bar
HRSG trip
16
36
t/h
17
36
t/h
Safely close HP
desuperheating water
regulating valves and
automatically close HP
desuperheating water
isolating valves
18
800
mm
Automatically open
HPS2 inlet draining
valves
19
50
mm
Automatically close
HPS2 inlet draining
valves
20
HP desuperheating inlet
steam temp. high
470
21
529
22
550
HRSG trip
23
800
mm
Automatically open HP
main steam draining
valve
24
mm
Automatically close HP
main steam draining
valve
50
for
deaerator
safety
operation
(including
instruments,
valves
and
supplementary), and also the remote signal interfaces of pressure, temp., and level
(including balance tanks) should be obligated. The deaerator has one suit of magnetic
tripper level meter (for camera and TV) and one suit of electric contact level meter.
3. Design requirements of deaerator system
Under 100% HRSG performance guaranteed working condition, the deaerator max.
output should be not less than FDW when HP and LP vaporizing sections are 105%;
The design pressure of deaerator and its water tank will ensure the deaerator operation
safely, and the pressure will not be more than max. heating steam pressure 1.25 times.
The water tank capacity can satisfy the max. continuous vaporizing of HRSG for 10min.
The safety valves are erected on the top of deaerator head and water tank. The max burst
size and reaction force can be calculated according to Power Plant Pressure Type
Deaerator Safety Technology Regulations. The max. burst size should not be less than the
max. input of deaerator.
At the inlet of deaerator, if no oxygen content limit, under startup and various other
operation working conditions, when the output of deaerator within 25%-100% of max.
output scope, the outlet oxygen content of deaerator should be7g/l
4. Deaerator system equipments materials
The deaerator head and water tank materials should meet ASME standard and the same
level standard;
(1) Drum materials of deaerator head:
(2) Drum materials of water tank:
(3) Breakwater materials:
(4) Nozzle materials:
(5) clapboard materials:
16MnR
16MnR
16MnR
1Cr18Ni9Ti
carbon steel
(6) Interface materials: the contact head of water pipe is steel 20, the contact head of
steam pipe which is over 430, is alloy steel;
(7) The spray tray deaerator adopted, the heated tray is stainless steel.
Description
Set
value
Unit
Action
Deaerator temp.
over set value I
105
Deaerator temp.
below set value I
105
Deaerator pressure
high value I
4.5
bar
Alarm
Deaerator pressure
high value
4.7
bar
550
mm
Deaerator at normal
level
mm
Deaerator at startup
-1550
level
mm
mm
Deaerator level
below low value I
-1600
mm
10
Deaerator level
below low value II
-1750
mm
Bypass valves
Spray
regulating
valves
Spray
isolating
valves
Model
Type
angle
Driving mode
hydraulic
hydraulic
hydraulic
Design pressure
7.7
Design temp.
528
60
60
Test pressure
11.6
Valves materials
12Cr1MoV
15CrMo
15CrMo
Nozzle materials
0Cr18Ni10Ti
closed
open
Hold
MPa
2.2
2.2
520
29
29
MPa
0.6
1.6
2.2
160
29
29
MPa
2.2
2.2
t/h
174.1
47.3
47.3
t/h
205
55
55
inlet
outlet
Close
difference
pressure
Rated
value
flow
Max.
Rem
a
r
k
s
Unit
Bypass valves
spray
regulating
valves
spray isolating
valves
Manufacturer
Xinhua Huiyi
Xinhua Huiyi
Xinhua Huiyi
model
YG200
YG64
YG64
Oil pressure
MPa
16
16
16
diameter
mm
200
64
64
transect square
mm2
21800
2250
2250
Working force
KN
350
36
36
stroke
mm
105
45
45
400
114
100
Reacting
time of
complete
stroke
Fast
Open
S
Fast
close
Weight
Kg
name
Item
Unit
Oil pump
Model
PV15/PV028I1K1T1VMM
Value
C
Type
Constant pressure
variable
Qty.
Set
MPa
16
Rated flow
l/min
45
Speed
r/min
1450
Manufacturer
Denison/Parker
Model
Oil tank
Qty.
set
Working pressure
MPa
0.1
Working capacity
350
400
Model
Materials
3
filter
Oil pump
motor
Fabric
Aperture
10
Permissive
pressure difference
MPa
0.35
Appearance Size
mm
100*200
Set
Model
Qty.
Power
kw
15
Voltage
400
Frequency
Hz
50
Speed
r/min
1450
Manufacturer
ABB (Shanghai)
Model/Spec.
L/Set
Qty.
Set
Capacity
10/25
Working pressure
MPa
16
Safety valves
action pressure
MPa
21
Buffer
medium\pressure
/MPa
Min
Regeneration
materials
Set
Regeneration time
Qty.
unit
Power
KW
1.5
Voltage/Power
V/Hz
400/50
Charger
Buffer
6
Regeneration
equipments
Electric heater
Oil quality
requirements
No.
Name
Oil name
No.
FRYQUEL/EHC
Fyrquel
proportion 20
kg/l
1.12-1.21
viscosity 40
mm2/s
45-50
Viscosity index
Flash point
235
Burning point
352
Auto flashing
temperature
595
Organic
phosphate
EHC
Freezing point
-21
10
Water content
(weight)
0.15Max
11
chloride content
(cl)
ppm
150
12
Mechanical
impurity content
mg/l
Nas1383
Class7
4.3 When turbine HP cylinder loading load, if the turbine main control valves are located
before inlet pressure control mode and the main control valves open over 95%, the set
value of HP bypass pressure regulating valves will be risen gradually to prevent the main
control valves open fully;
4.4 When HP bypass pressure regulating valves open at 10%, DCS transfers GT control
mode from stress control to inlet pressure control and the HP bypass pressure regulating
valves will be closed to 10% open at constant speed;
Description
Functions
Set value
Unit
HP bypass downstream
steam pressure
0.07
MPa
500
mm
50
mm
20%
HP bypass downstream
steam temp. high high
160
One of conditions to
automatically close
pneumatic drain valves
before HP bypass valves
50
One of conditions to
automatically close or open
drain valves before HP
pipes main steam valves
50
No.
Description
Position
Auto
Auto
Auto
Auto
Open
Open
Open
Open
Close
10
Open
11
Open
Model
C7z63Y-PN1.6
Tp7Z64Y-4.0C
Tp764Y-4.0C
Type
angle
Straight
Straight
Driving mode
hydraulic
hydraulic
hydraulic
Design pressure
0.8
Design temp.
262.5
60
60
Test pressure
1.2
Valves materials
20
20
20
Nozzle materials
0Cr18Ni10Ti
closed
closed
Hold
MPa
0.65
2.2
2.2
255.5
29
29
MPa
0.15
1.3
2.2
115
29
29
2.2
2.2
inlet
outle
t
Close
difference
pressure
MPa
Rated
value
t/h
36.8
3.9
3.9
Max.
value
t/h
46
4.8
4.8
flow
Unit
Bypass
valves
spray
regulating
valves
spray
isolating
valves
Manufacturer
Xinhua or
Huiyi
Xinhua or
Huiyi
Xinhua or
Huiyi
model
YG84
YG64
YG64
Oil pressure
MPa
16
16
16
diameter
mm
84
64
64
2250
2250
transect square
mm2
3450
Working force
KN
55
36
36
stroke
mm
85
55
25
Reacting
time of
complete
stroke
Fast
Open
S
Fast
close
name
Item
Unit
Oil pump
Model
PV15/PV028I1K1T1VM
Value
MC
Type
Constant pressure
variable
Qty.
Set
Rated oil
pressure
MPa
16
Rated flow
l/min
45
Speed
r/min
1450
Manufacturer
Denison/Parker
Model
Qty.
Oil tank
set
MPa
0.1
Working
capacity
350
400
Working
pressure
Model
Materials
Fabric
Aperture
10
Permissive
pressure
difference
MPa
0.35
Appearance
Size
mm
100*200
filter
Model
Oil pump
motor
Qty.
set
Power
kw
15
Voltage
400
Frequency
Hz
50
Speed
r/min
1450
Manufacturer
ABB (Shanghai)
Model/Spec.
L/Set
Qty.
set
Capacity
10/25
MPa
16
Safety valves
action pressure
MPa
21
Buffer
medium\pressur
e
/MPa
Retain time
after power lost
Min
Regeneration
materials
set
Regeneration
time
Working
pressure
5
Charger
Buffer
Regeneration
equipments
Qty.
unit
Power
kw
1.5
Voltage/Power
V/Hz
400/50
Electric
heater
Oil quality
requirements
No.
Name
Oil name
No.
FRYQUEL/EHC
Fyrquel
proportion 20
kg/l
1.12-1.21
viscosity 40
mm2/s
45-50
Viscosity index
Flash point
235
Burning point
352
Auto flashing
temperature
595
Organic
phosphate
EHC
Freezing point
-21
10
0.15Max
11
ppm
150
12
Mechanical impurity
content
mg/l
Nas1383; Class7
4.3 When LP bypass pressure adjusting valve set value up to the value over max normal
operating pressure, LP bypass pressure adjusting valve is on close position;
Description
Functions
Unit
value
500
mm
50
mm
HRSG LP superheater
drain isolating valve close
20%
160
Description
Position
Auto
Auto
Auto
Auto
Open
Open
Open
Open
Close
control valve
10
Open
11
Open
2. Water drain and steam exhaust system operation during cold startup:
2.1 Operations before GT ignition:
Atmosphere steam exhaust valves of HPS header open;
Atmosphere steam exhaust valves of LPS header open;
HPS drain valve open;
LPS drain valve open;
2.2 Operations after warming-up finished (on DCS)
2.2.1When HP (deae.) drum pressure over 0.5bar, HP (deae.) superheaters air valves will be
opened, which will be closed while the pressure over 2.0bar.
2.2.2Open HPS drain valves and HPS desuperheater drain valve in turn;
2.2.3 When HP drum pressure over 1.5bar, the HP pipe drain valves at HP bypass pressure
regulating valves inlet will be opened;
2.2.4When HP drum pressure over 10bar, HPS and HPS desuperheater drain valves are on
half open state;
2.2.5 When HP drum pressure over 1.5bar and HPS drain valves already on half open
position or fully open position over 3min at least, HP pipe drain valves at superheater
outlet, HP pipe drain valves at HP steam flow element inlet, HP pipe drain valves at
main steam downstream of HP bypass contact and HP pipe drain valves at turbine main
control valves inlet will be opened;
2.2.6 When HP drum pressure over 10bar, HP pipe drain valves at HP steam flow element
inlet and main steam downstream of HP bypass contact are on half open position;
2.2.7 When HP drum pressure over 17bar and HPS drain valves, HPS desuperheater drain
valves and superheater outlet drain valves on half or full open position over 3min at
least, close them in turn (HP pressure at 0.07MPa or steam flow meets requirements,
superheater drain valves can be closed according to Hangzhou Boiler documents)
2.2.8 When HP pipe drain valves at HP bypass HP valve inlet opened over 3min at least and
HP bypass HP valves open over 20%, close the valves;
2.2.9 When HP pipes drain valves at HP bypass pressure regulating valves and turbine main
control valves inlet opened 3min at least and HP pipes drain valves at superheaters
outlet, HP steam flow element inlet, HP bypass contact main steam flow downstream on
half open or full open position for 2.5min at least, HP water draining is finished;
2.2.10 When main control valves open over 30%, the following drain valves turn to full close
position gradually;
2.2.11 When turbine main control valves open at 20% at least, the HP pipe drain valves at
main control valves inlet, HP steam flow elements inlet and main steam flow downstream of
HP bypass contact and the drain isolating valves at reheating system will be closed in turn
and there is 30s delay within every two valves close;
2.2.12 With HP main control valves opening and HP steam into turbine HP cylinder and
deaerator cylinder, LP cylinder inlet pressure will be up too. When LP cylinder inlet pressure
over cooling steam pressure set value, the cooling steam pressure regulating valves will be
closed; with cooling steam pressure regulating valves closing, LP main steam pressure will be
down and turbine LP control valves will be closed. When turbine LP control valves closed to
min position, the inlet drain valves will be opened;
2.2.13 After GT warming-up finished, LPS drain valves, LPS outlet drain valves and LP
bypass pipe drain valves at bypass pressure regulating valves inlet will opened;
2.2.14 After GT warming-up finished, when LP drum pressure over 1bar and LPS drain valves
and LPS outlet drain valves opened for 3min at least, the drain valves at LP steam flow
element inlet and LP steam inverted valves inlet will be opened;
2.2.15 After GT warming-up finished, when LP drum pressure over 0.5barg, LPS air valves
will be opened and after the LP drum pressure over 1.0barg, the air valves will be closed;
2.2.16 When LPS drain valves open for 3min at least and LP bypass pressure regulating
valves open at 20% at least, HRSG LPS drain isolating valves will be closed;
2.2.17 After LPS outlet drain valves and LP steam flow element inlet drain valves opened for
3min at least and LP bypass pressure regulating valves open at 20% at least, they are
allowed to be closed;
2.2.18 When HRSG LPS drain valves, LPS outlet drain valves and LP steam flow element
inlet drain valves opened for 3min at least, LP draining is finished;
2.2.19 After LP main isolating valves opened fully, drain valves at LP inverted valves inlet will
be closed;
2.2.20 When turbine LP control valves open at 20% at least, drain valves at turbine LP control
valves inlet will be closed;
4.3 When HP drum pressure below 0.07MPa, boiler steam exhaust and water discharge can
be operated;
2. Equipments parameter
2.1 Service water pump
2. Equipment parameter
Parameter
Design
pressure
Design temp.
Working
pressure
Working temp.
Unit
MPa
MPa
cubage
m3
Action
pressure of
safety valves
MPa
Model
---
5.3 Check the intermittent blowdown flash tank level on DCS agrees with the indication in site;
5.4 Check the intermittent blowdown flash tank pressure;
5.5 Check the service water temp. and pressure normal;
5.7 Take one intermittent blowdown in every shift;
5.8 Before blowdown, check the intermittent blowdown flash tank level normal. Open
blowdown valves gradually and focus on FDW pressure, drum water level and water flow
variety to ensure the drum level normal;
5.9 During blowdown, if boiler accidents happen, stop blowdown at once (except drum level
high or priming)
5.4 Close local Lv. meter C secondary drain valve at steam side on HP drum #1 and open
local Lv. meter C secondary drain valve at water side on HP drum #1 slightly to wash
water connecting pipes for 30s.
5.5 Open local Lv. meter C secondary drain valve at steam side on HP drum #1 and local Lv.
meter C secondary drain valve at water side on HP drum #1. Pay attention to the time to
ensure the valves closed at the same time.
5.6 Close local Lv. meter C secondary drain valve on HP drum #1 and then the primary drain
valves on HP drum #1. After the wash finished, recover Lv. meter normal operation.
Chapter 3
Accidents and Faults Disposal of HRSG
1.3.5 If the water level indicates on level meter again, close the electric drum intermittent
blowdown valves properly or fully. Maintain normal level and after causes found and
removed, recover the boiler normal operation;
2 Lack of water
2.1 Causes:
2.1.1 Auto regulating devices of FDW unavailable or regulating actuators on fault, which is not
found and disposed in time;
2.1.2 FDW pumps trip;
2.1.3 FDW pressure too low;
2.1.4 FDW or coal economizers pipes burst;
2.1.5 Boiler pressure up and safety valves not back to seat after turbine load rejection;
2.1.6 Boiler blowdown pipes valves leak and blowdown is heavy;
2.2 Phenomena:
2.2.1 Water level indicates low and water level low signals alarm;
2.2.2 FDW flow abnormal lower than steam flow;
2.3 Disposal:
2.3.1 When level down to -75mm (compared with normal level), send out level low alarm; at
this time, the operators should judge the causes and take disposal;
2.3.2 Transfer auto regulations to manual to increase FDW flow if necessary;
2.3.3 If the disposal not available, when level down to low value II, level protection will act and
boiler trips first and then trips turbine and GT interlocked;
2.3.4 If the protection not acts, shut down the boiler manually;
3 Priming
3.1 Causes:
3.1.1 Boiler water quality not satisfies the standard: too much suspended substance or salt
content;
4.3 Disposal:
4.3.1 If water surge sound heard during feeding steam, close the valves to stop feeding
steam; then drain water in pipes and finally open valves slowly to feed steam;
4.3.2 If the vibration caused by horizontal pipes brackets loosened, fix the pipes brackets and
straps;
4.3.3 If the water boiled in coal economizers, reduce GT flue temp. and increase FDW
properly.
5 Auxiliaries faults
5.1 General disposal principles
5.1.1 After auxiliaries trip on fault, check whether all auxiliaries in service automatically; if not,
put the auxiliaries into service manually;
5.1.2 If the auxiliaries abnormal in operation, such as abnormal sound, vibration heavy,
bearing temp. high, output deficit, lub oil leakage and so on, report to shift engineer at
once, transfer the spare auxiliaries and inform the maintainers to take disposal;
5.1.3 After auxiliaries trip, the operators should go to the site the check the equipments and
restart the equipments after no abnormity confirmed;
5.1.4 It is forbidden to take startup if the following situations happen:
5.1.4.1 Trip causes not clear;
5.1.4.2 Equipments faults not removed;
5.1.4.3 Continually trip operation;
5.2 HP and LP FDW pumps faults
Causes and disposal measures:
No.
faults
disposal
No.
faults
disposal
when erected
Suction pipes
jammed
Bubble in pipes
Pumps reverse
10
Accelerate
pressure
11
12
or
impellers
and
increase
No.
faults
disposal
impellers (b)
13
15
(b)(c)
16
Seal damaged
17
18
19
20
21
22
23
24
No.
faults
disposal
25
oil
oil
26
27
28
29
30
31
Bearing damaged
32
34
35
dynamic
Notice:
(a) Before disposed, no pressure must be ensured on the pumps pressure-containing
members;
(b) Contact with KSB;
(c) The fault can be removed through modify the impellers diameter;
5.3 LP preheaters circulation pumps faults
Fault
Causes
Disposal
a.
b.
Bearing
heating
a.
b.
c.
d.
e.
f. vibration
c.
d.
ensure CW flow at
normal requirements;
e.
f.
a.
seal plates of shaft housing
a.
change new parts;
Shaft
damaged;
housing
leaks
b.
take annealing and
b.
seal plates too hard or not
inside
rubdown
flat;
a.
b.
c.
Impellers jammed;
No water
out from
d.
pumps
e.
a.
Start pumps;
b.
Check motors;
c.
Clean impellers flow
passage
d.
Clean
pipelines;
Impellers damaged;
e.
f.
Rotating
correct
Flow or a.
output
pressure b.
too low
suction
directions
Change impellers;
not
f.
Change
rotating direction
direction
c.
d.
e.
Impellers jammed;
Change impellers or
f.
Impellers damaged or seal f.
seal rings;
rings worn;
g.
Impellers damaged
g.
a.
a.
Regulate the pumps
and motors concentricity;
b.
Proportion larger;
b.
Motors c.
Grating happens at rotating
c.
overload parts;
Change
direction
rotating direction
Change operation;
Repair grating parts;
d.
Check suction and
d. Devices resistance becomes
exhaust pipes pressure
lower and rotating points deviates
variety
compared
with
to big flow point;
original pressure;
Notice: NPSH means pure suction head. The suction head is higher than
the value of hydraulic vaporization pressure transported by pumps. So
when pumps under running, the NPSH of devices are not allowed to be
smaller than pump NPSH.
7.3.1 Report at once and strengthen the checks and focus on accidents development;
7.3.2 If not damaged heavily, it is allowed to maintain normal running for a short time and
apply for boiler shutdown for maintenance;
7.3.3 If damaged heavily, shutdown the boiler to prevent from damaging adjacent pipes and
accidents developing by lots of steam sprayed out from crevasse.
7.3.4 After shut down boiler, the normal drum level should be retained;
9.1.1 When the pipes leak slightly, there is some sound and heat preservation layer will be
wet, leak steam or water drop;
9.1.2 If pipes burst, there is loud sound and steam and water sprayed out;
9.1.3 Steam and FDW flow is changed abnormally. If the burst place in front of flow meter, the
meter indication will be decreased; if in back of the meter, the indication will be
increased;
9.1.4 Steam or FDW pressure is down;
9.2 Causes:
9.2.1 Heavily water surge caused by inadequately steam pipes warming-up;
9.2.2 Steam pipes are running with over temp. and the creep exceeds the limit or the
operation time is too long, the metal intensity is down;
9.2.3 Unqualified FDW results in pipes walls rust;
9.2.4 Parts of FDW pipes surged and walls become thin;
9.2.5 The brackets of pipes are not erected correctly which affect free expansion of pipes;
9.2.6 The pipes are not erected correctly or pipes have bugs, materials or welding not
qualified;
9.3 Disposal:
9.3.1 When the steam and FDW pipes leak slightly, if the boiler FDW can be held and the
faults wont be extended, the shot-time operation can be taken;
9.3.2 If the faults even worse and may risk human or equipments safety, the disposal should
be taken after shut down boiler;
Chapter 4
HRSG Tests and Maintenance after Shutdown
4. Participants
The hydraulic boiler set should be taken according to Electric Industrial Boiler Supervision
Regulations, which is charged by maintenance director or some appointed personnel. The
relative personnel should participate in and the shift engineer command operators; but the
overpressure test should be presided over by general engineer and relative personnel
should participate in;
8 HP hydraulic set:
8.1 Re. to hydraulic set system valves status table, operate valves to hydraulic set position;
8.2 Start condensing pumps, HP FDW pumps, open isolating valves and isolating valves in
front and back of FDW bypass regulating valves to boost pressure to HP system;
8.3 Regulate opening of valves and control boosting speed 0.3MPa/min;
8.4 When pressure up to 10% of test pressure, HP system is 1.634MPa, pause boost to take
primary checks; if no leakage or abnormity, keep on boosting; if slight leakage found,
record the leakage parts and then continue boosting;
8.5 When pressure up to working pressure, HP system is 10.89MPa; stop boosting to check
completely; make signs and record the found bugs and leakage and then report to
leaders; if no leakage or other abnormity, keep on boosting;
8.6 Before overpressure test, the following work should be done:
8.6.1 All test participants should stop pressure-containing members checks and be out of
furnace or dangerous zones;
8.6.2 Check DCS display and boiler top pressure gauges indication: HP system test pressure
takes HP drum pressure as standard;
8.6.3 Supervise drum wall temp. on DCS and ensure the temp. 21 ;
8.7 When pressure up to overpressure test pressure, HP system is 11.34MPa; close outlet
valves of HP FDW pumps as well as FDW pump at the same time and record time; hold
the pressure for 5min to observe pressure drop;
8.8 After test pressure held for 5min, reduce pressure to working value, then take a complete
check and make record; after checks finished, reduce pressure slowly and then the HP
hydraulic set finished;
9.6.3 Supervise drum wall temp. on DCS and ensure the temp.21
9.7 When pressure up to overpressure test pressure, Deae. system is 4.14MPa; close outlet
valves of Deae. FDW pumps as well as FDW pump at the same time and record time;
hold the pressure for 5min to observe pressure drop;
9.8 After test pressure held for 5min, reduce pressure to working value, then take a complete
check and make record; after checks finished, reduce pressure slowly and then the HP
hydraulic set finished;
After the test successful, either discharging water or making up water to startup level is
available;
14 Precautions in test:
The test can not be taken in rainy days;
During the test, it is forbidden to open valves at random or knock pressure-containing
members;
During a system hydraulic test, the relative valves should be hanged with warning signs,
locked or removed with handle wheels;
During pressure holding, pressure rising should be defended which caused by thermal
expansion;
The test pressure should not be over rated test value;
When leakage points found out, take signs and then take maintenance after pressure
release; when the maintenance finished, take the hydraulic set;
After hydraulic set, record test procedures and results;
During the hydraulic set, the inspectors can not stand in front of welded end cap, side face
or welding line of flange;
After hydraulic set finished, the water for the test should be diluted by water to PH value
within 6-9 and then the blowdown can be taken to prevent environment pollution;
Before overpressure test, the parts which not in the test must be de-paralleled and some
measures should be take to prevent safety valves open;
15 Qualified standards:
15.1 After FDW stopped, pressure drop value is 0.098MPa/min and preheater pressure drop
value is 0.049MPa/min;
15.2 There is no moisture, bead or leakage on metal walls and welding lines of pressurecontaining members;
15.3 There is no residual deformation on pressure-containing members.
4. Process:
4.1 The maintainers should set the action pressure at floating value according to relationship
between spring stroke and pressure under cold state;
4.2 Except verified safety valves, other safety valves should be locked by thimbles to prevent
faulty action;
4.3 The safety valves floating sequence is from high floating value to low one;
4.4 After safety valves floating finished, record the floating results and release pressure as
normal speed (<1bar/min);
4.5 During safety valves floating, if abnormity found, stop the test at once and after the faults
removed, keep on the floating;
Syste
m
No.
Deae.
LP
part
Designed
Acting
pressure
Designed
Reseating
pressure
Release
value
7.62 MPa
7.5MPa
88 kg/h
HP drum safety
valve 1
8.5 MPa
8.156MPa
88t/h
HP drum safety
valve 2
8.57MPa
8.348MPa
90t/h
safety valve 1
0.53 MPa
2.421t/h
safety valve 2
0.53 MPa
2.421t/h
safety valve 3
0.5 MPa
2.815t/h
10
0.97MPa
0.903MPa
15t/h
1.2 MPa
1.148MPa
15.64t/h
HP
part
Name
11
LP drum safety
valve 1
12
LP drum safety
valve 2
1.3MPa
1.244 MPa
26.319t/h
(1)
(2)
(3)
When ferrum contacts water, the reaction (1) will be acting. When metal (anode)
absorb negative electron, Fe 2+ will be water-soluble and after the metal polar has
polarity, the reaction will be stopped;
On surface of metal (cathode), reaction (2) and (3) will be acting;
The balance of the reactions will be decided by OH - concentration (water pH value) in
the water. Moreover, reaction (3) can be decided by oxygen content;
The electron from anode (reaction 1) has tendency to into metal cathode: reaction (1)
balance will be broken and the ion will be water-soluble continuously to be Fe 2+;
3 Wet protection
Two Types:
Complete wet protection and partial wet Nitrogen blanketing protection
3.1 Complete wet protection
3.1.1 Standard:
Oxygen content
limit
<20ppb
2 weeks
>20ppb
9<pH<10
If the shutdown time over above limit, water drain must be taken and dry Nitrogen blanketing
protection should be adopted.
4. Nitrogen blanketing
During Nitrogen blanketing, the furnace pressure should be 10-50 mbar more than
atmosphere pressure;
Whether Nitrogen blanketing will be adopted can be decided before
boiler shutdown, so Nitrogen blanketing will be started boiler hot
state;
If Nitrogen blanketing started under cold state (unintended shutdown), special Nitrogen
blanketing in instruction book should be undertaken;
4.1 Nitrogen blanketing operation under boiler hot state
4.1.1 Before boiler unloading
At 2h before boiler unloading, dose NH 3 to ensure boiler water pH value over 10, so the
being shutdown boiler water quality will be good. Pay attention that if condenser
materials have aldary, pH value should be controlled at 9.2, so the partial wet nitrogen
blanketing maintenance time just is 2 weeks. Moreover, if aluminum contained in any part
of condenser or steam and water circulation, the chemicals should be decided by
chemical personnel research because of special requirements;
The secondary operation at 2h before boiler unloading is open continuous blowdown
valves of drums to remove the slat and alkali dissolved in boiler water furthest before
boiler maintenance;
Continuous blowdown valves of HP drum: 11HAA10 AA408
Continuous blowdown valves of LP drum: 11HAA30 AA408
4.1.2 Boiler shutdown
Reduce GT load and isolate HRSG and turbine through steam bypass station;
4.1.3 Boiler cooling down
Through steam bypass, control HP and LP drum pressure drop gradient (max.:
-2bar/min, make the inner pressure of shutdown boiler drum down to 10bar (psig);
4.1.4 Isolation of boiler
In boiler control room, operators transfer boiler to shutdown maintenance to prevent
water draining and air relief during pressure down. During boiler shutdown, water
draining and air relief valves should be closed and the drums should be isolated from
phosphate dosing system;
During shutdown, the following water drain and air relief valves should be kept on
close position:
Inlet water drain valve of HPS 2: 11HAH11AA402
HP steam water drain valve: 11LBA70AA402
FDW
pump
outlet
isolating
valves:
11LAB31AA003,
11LAB32AA003,
11LAB33AA003
Drums continuous blowdown valves must be closed:
HP Drums continuous blowdown valve: 11HAA10 AA408
LP Drums continuous blowdown valve: 11HAA30 AA408
4.1.5 Nitrogen blanketing
The nitrogen blanketed can be supplied by fixed or mobile devices which should be
connected with nitrogen blanketing pipes and at the nitrogen supply side, pressure
reducing valves should be equipped;
If the safety can be ensured, the soft pipes which can support 10-50 mbar nitrogen
pressure can be used to connect nitrogen valves with boiler proper nitrogen blanketing
points. When boiler pressure within 2-5bar (psig), the nitrogen pipes should be fixed
and nitrogen blanketing isolating valves should be opened to prevent air in when boiler
pressure and temp. down;
Open HP drum nitrogen blanketing valve: 11HAH10 AA452
Open LP drum nitrogen blanketing valve: 11HAH30 AA452
Open deaerator nitrogen blanketing valve: 11LCA90 AA452
Open preheater nitrogen blanketing valve: 11LCA70 AA452
Open HPE nitrogen blanketing valve: 11LAB20 AA002
With steam condensed and furnace pressure down, nitrogen will be sucked into
equipments;
The most important point of succeeding nitrogen blanketing is ensuring the boiler
sealed completely. If seal not good, nitrogen will be lost due to leakage;
Moreover, nitrogen content should be 1% lower than oxygen content (as volume ratio);
In order to get the above requirements, keep drum nitrogen pressure over atmosphere
a little bit (10-50mbar);
4.1.6 Operation during boiler shutdown
During HRSG shutdown maintenance, check the water quality and nitrogen periodically;
As far as boiler under warm state, steam in superheaters and steam pipes will be kept
on condensed; due to the volatility of ammonia, condensing water pH value is lower than
drum water pH value, so the anti-corrosion ability against superheaters is weak;
Open the following superheaters drain valves for a few minutes to drain out the
condensing water and then close the valves:
HPS 2 inlet drain valve: 11HAH11 AA402
HP main steam drain valve: 11LBA70 AA402
LP main steam drain valve: 11LBA80 AA402
4.1.7 Transferred to dry nitrogen blanketing protection
If the shutdown time of HRSG exceeds above max. period (2 weeks according to
chemical characteristics of boiler water), the boiler is required to discharge water
completely and to be kept under dry nitrogen blanketing state. At this time, we suggest
closing all manual isolating valves for instruments, water drain and steam exhaust pipes
to ensure boiler air tightness;
4.1.8 Water quality requirements
This partial wet maintenance mode is adequate for short-time shutdown and the
sampling and analysis should be taken every week;
The water quality requirements during boiler shutdown:
4.1.8.1 pH value over 10 or within 9 and 10 and oxygen content lower than 20ppb;
4.1.8.2 CL-<2ppm
4.1.8.3 SO41ppm
4.1.8.4 NaOH<0.5ppm
It should be avoided to deviate from above target heavily or long time to ensure good
protection for boiler;
4.2 Partial wet nitrogen blanketing protection under cold state
When this protection used under cold state, the following steps should be taken to ensure
boiler air exhausted out:
4.2.1 Feed DM water (pH value over 10) into drum to high high level;
4.2.2 Blanket Nitrogen into superheaters and air exhausted from main steam drain pipes:
blanket nitrogen intermittently till oxygen content below 1%. Enough nitrogen pressure is
required during the operations;
4.3 Steps of dry nitrogen blanketing under cold state
4.3.1 Used standard: it is used in long-time shutdown situation, which can not only be used
directly after boiler shutdown, also can be used after partial wet protection or boiler
maintenance;
If environmental temp. below zero and boiler parts are easy to be frozen to affect safety,
dry protection can be used;
4.3.2 Dry protection is not limited by shutdown time;
4.4 Operations sequence:
4.4.1
Before shutdown:
At 2h before boiler unloading, open drum continuous blowdown valves fully to
discharge water-soluble slat and alkali. Before boiler shutdown, dose phosphate all
the time into drums;
HP drums continuous blowdown valve: 11HAA10 AA408
LP drums continuous blowdown valve: 11HAA30 AA408
Through steam bypass, control HP and LP drum pressure drop gradient (max.:
-2bar/min, make the inner pressure of shutdown boiler drum down to 10bar (psig);
4.4.4 Isolation of boiler
In boiler control room, operators transfer boiler to shutdown maintenance to prevent
water draining and air relief during pressure down. During boiler shutdown, water
draining and air relief valves should be closed and the drums should be isolated from
phosphate dosing system;
During shutdown, the following water drain and air relief valves should be kept on close
position:
Inlet water drain valve of HPS 2: 11HAH11 AA402
HP steam water drain valve: 11LBA70 AA402
LP steam water drain valve: 11LBA80 AA402
Main steam isolating valves must be closed:
HP main steam isolating valve: 11LBA70 AA001
LP main steam isolating valve: 11LBA80 AA001
FDW isolating valves must be closed:
HP FDW pump outlet isolating valves: 11LAB11AA003, 11LAB12AA003, 11LAB13AA003
LP
FDW
pump
outlet
isolating
valves:
11LAB31AA003,
11LAB32AA003,
11LAB33AA003
Drums continuous blowdown valves must be closed:
HP Drums continuous blowdown valve: 11HAA10 AA408
LP Drums continuous blowdown valve: 11HAA30 AA408
4.4.5 Nitrogen blanketing
The nitrogen blanketed can be supplied by fixed or mobile devices which should be
connected with nitrogen blanketing pipes and at the nitrogen supply side, pressure
reducing valves should be equipped;
If the safety can be ensured, the soft pipes which can support 10-50 mbar nitrogen
pressure can be used to connect nitrogen valves with boiler proper nitrogen blanketing
points. When boiler pressure within 2-5bar (psig), the nitrogen pipes should be fixed
and nitrogen blanketing isolating valves should be opened to prevent air in when boiler
pressure and temp. down;
Open HP drum nitrogen blanketing valve: 11HAH10 AA452
Open LP drum nitrogen blanketing valve: 11HAH30 AA452
Open deaerator nitrogen blanketing valve: 11LCA90 AA452
Open preheater nitrogen blanketing valve: 11LCA70 AA452
Open HPE nitrogen blanketing valve: 11LAB20 AA002
With steam condensed and furnace pressure down, nitrogen will be sucked into
equipments;
The most important point of succeeding nitrogen blanketing is ensuring the boiler sealed
completely. If seal not good, nitrogen will be lost due to leakage;
Moreover, nitrogen content should be 1% lower than oxygen content (as volume ratio);
In order to get the above requirements, keep drum nitrogen pressure over atmosphere a
little bit (10-50mbar);
4.4.6. Boiler water drain
When boiler pressure a little low (psig <2bar), drain boil water out. In order to ensure
draining smooth, open all regulating valves and drain valves of heat exchangers. Then
the boiler water will be drained out and replaced by nitrogen. What keep certain nitrogen
pressure in drums can prevent air in.
HP FDW regulating valves: 11HAC10 AA101, 11HAC10 AA102, 11HAC10 AA103
LP FDW regulating valves: 11LAB40 AA101, 11LAB40 AA102, 11LAB40 AA103
3-way regulating valve: 11LCA70 AA101
4.4.7 Operation during boiler shutdown
During HRSG shutdown maintenance, check the water quality and nitrogen periodically;
As far as boiler under warm state, steam in superheaters and steam pipes will be kept
on condensed; due to the volatility of ammonia, condensing water pH value is lower
than drum water pH value, so the anti-corrosion ability against superheaters is weak;
Open the following superheaters drain valves for a few minutes to drain out the
condensing water and then close the valves:
HPS 2 inlet drain valve: 11HAH11 AA402
HP main steam drain valve: 11LBA70 AA402
HP main steam drain valve: 11LBA80 AA402
4.4.8 Steps of dry nitrogen blanketing under cold state
When take dry nitrogen blanketing protection under cold state, the following methods
should be taken to ensure no residual air in boiler parts:
4.4.9 Feed DM water (pH value over 10) into drum to high high level;
4.4.10 Blanket Nitrogen into coal economizers and superheaters, then air or water
discharged from main steam drain valves: blanket nitrogen intermittently till oxygen
content below 1%. Enough nitrogen pressure is required during the operations;
4.4.11 Keep nitrogen pressure and take coal economizers and drums water draining.
Chapter 5
Appendix
Saturated temperature
0.0009
6.699
0.0015
12.737
0.0019
17.204
0.0024
20.779
0.0029
23.755
0.0034
26.362
0.0039
28.645
0.0044
30.69
0.0049
32.53
0.0058
35.83
0.0069
38.66
0.0078
41.16
0.0088
43.41
0.0098
45.45
0.0108
47.33
0.0118
49.06
0.0127
50.67
0.0137
52.18
Saturated temperature
0.0147
56.60
0.0196
59.67
0.0245
64.56
0.029
68.68
0.039
75.42
0.049
80.86
0.0588
85.45
0.0686
89.45
0.0784
92.99
0.088
96.18
0.098
99.09
0.108
101.76
0.118
104.25
0.127
106.56
0.137
180.74
0.147
110.79
0.157
112.73
0.167
114.5
0.176
116.33
Saturated temperature
0.186
118.01
0.196
119.62
0.206
121.16
0.216
122.64
0.225
124.08
0.235
125.45
0.245
126.79
0.255
128.08
0.265
129.34
0.275
130.55
0.284
131.73
0.29
132.88
0.30
134.00
0.31
135.08
0.32
136.14
0.33
137.18
0.34
138.19
0.35
139.18
Saturated temperature
0.36
140.15
0.37
141.09
0.38
142.02
0.39
142.92
0.4
143.81
0.41
144.68
0.42
145.54
0.43
146.38
0.44
147.20
0.49
151.11
0.588
158.08
0.686
164.17
0.784
169.61
0.88
174.53
0.98
179.04
1.078
183.21
1.176
187.08
1.27
190.71
Saturated temperature
1.37
194.13
1.47
197.37
1.57
200.43
1.67
203.36
1.76
206.15
1.86
208.82
1.96
211.39
2.06
213.85
2.16
216.24
2.25
218.53
2.35
220.76
2.45
222.90
2.55
224.99
2.65
227.01
2.75
228.98
2.84
230.89
2.94
232.76
3.14
236.35
Saturated temperature
3.33
239.77
3.53
243.04
3.73
246.17
3.92
249.18
4.12
252.07
4.31
254.87
4.51
257.56
4.71
260.17
4.90
262.90
5.39
268.69
5.88
274.28
6.37
279.54
6.86
284.17
7.35
289.17
7.87
293.61
8.33
297.86
8.82
301.91
9.31
305.80
Saturated temperature
9.80
309.53
10.78
316.53
11.76
323.15
12.75
329.31
13.73
335.10
14.71
340.57
15.69
345.75
16.67
350.67
17.65
355.35
18.63
359.81
19.61
364.10
Poun
Pa
bar
N/m2
Bar
kgf/cm2
atm
mmH2
O
mmHg
psi
0.00001
0.0000102
0.0000099
0.102
0.0075
0.000145
100000
1.02
0.99
10200
750
14.5
/inch2
98000
0.98
0.9678
10000
735.56
14.2233
101325
1.01325
1.033
10330
760
14.696
9.8
0.000098
0.0001
0.00009678
0.07356
0.001422
33
133.322
0.001333
22
0.00136
0.001316
13.6
0.019336
6890
0.0689
0.07031
0.06805
701
51.715
erg/s
kgfm/s
hp
kcal/h
btu/h
ftlbf/s
1E7
0.102
0.00136
0.86
3.412
0.73756
1E-7
1.02E-8
1.36E-10
8.6E-8
3.412E-7
7.38E-8
9.807 9807E7
0.01333
8.4322
33.4617
7.233
735.5
7.355E
9
75
632.415
2509.6
542.476
163
163E7
0.1186
0.00158
3.9683
0.8578
0.293 2.93E6
0.0299
0.000398
0.251996
5
0.21616
1.3558 1.356E
2 7
0.1383
0.001843
4.6263
erg
kgfm
hph
1E7
0.102
3.777E-7
1E-7
1.02E-8 3.78E-14
kwh
1658
kcal
2.778E-7 0.000239
btu
ftlbf
0.000947
8
0.73756
9.81
9.81E7
3.704E-6
264780
2.65E13 270000
0
7.233
0.7355
632.415
2509.63
1.953E6
360000
0
3.6E13
367100
1.36
860
3412.14
2.655E6
4186.8
4.187E1
0
427
0.00158
0.001163
3.9684
3088
1055
1.055E1
0
107.6
0.0003985
778.17
1.35582 1.356E7
0.1383
5.12E-7
0.000293
0.251196
1
3.77E-7
0.000324 0.001285
cm3
ft3
in3
lmp.gal
u.s.gal
bbl
1E6
1000
35.315
61024
220
264.2
6.874151
1E-6
0.001
1000
0.0035335
6
61.013
0.21997
0.2642 6.874E-3
0.0283
28300
28.3
1728
6.2288
7.4805 0.194539
0.0000163
9
16.39
0.004546
4546
4.546
0.1605
277.42
1.201
0.03125
0.003785
3785
3.785
0.1337
231
0.8327
0.02381
0.145472
159100
159.1
5.14
8875.656
32
42
0.001 3.53356E-5
0.0163
0.0005787
9
0.061
cm
mm
ft
in
scruple
yd
100
1000
3.2808
39.37
314.96
0.01
10
0.032808
0.3937
3.1496 0.0109361
0.001
0.1
3.28083E-3
0.03937
0.3149 1.09361E6 3
0.3048
30.48
304.8
12
96
0,3333
0.0254
2.54
25.4
0.02778
0.00317
5
0.3175
3.175
0.0104166
0.125
3.47222E3
0.9144
91.44
914.4
36
288
0R=+459.67
=5/9(-32)
=9/5+32
1.0936
Purpose
Regulate operators to take spare and running equipments test and transferring
periodically to find out equipments faults and potential problems and test the correctness
of main equipments and auxiliaries protections in and out to ensure equipments normal
backup and long-time safe and reliable running according to 3 sheets and 2 systems;
2. Scope
The system is adequate for main equipments and periodically test and transferred
equipments in Zhangjiagang Huaxing Electric Power Co., Ltd.
3. System Execution
According to detail test items, test methods, operation steps, relative rules and requirements
of relative operation regulations, the trial operation department lists periodically transferred
and test items table. After authorized by all relative departments and general engineer, the
operators should carry out as this system;
4. Executing process
4.1 Periodical test and transferring should be compiled according to operation times and
healthy conditions of spare and running equipments and also the intervals of last
equipments maintenance;
4.2 Before equipments periodical test and transferring, detail transferring and test plans
should be made. Also the accidents forecasting and protective measures should be
taken.
4.3 Before periodical test, the test plan should be compiled according to test equipments, last
test sequence, contents and results. The important tests must be reported to relative
leaders and departments for authority;
4.4 During equipments transferred, start important equipments firstly and then stop them, viz.
transferring load, to prevent system waving and unstable;
4.5 Important equipments transferring and test should be arranged at low load period;
4.6The periodical tests and transferring which need maintenance and other departments
tested or transferred on time, the operators should strengthen the inspection and check
on running equipments which are waiting for test or transferring;
Name
Date
1st day
HP FDW pump
16th day
2nd day
LP FDW pump
17th day
Recirculation Pump of
Preheater
3rd
18th day
Wash on
4th day
Wash on
19th day
Wash on
5th day
Wash on
20th day
Wash on
6th day
Wash on
21st day
Wash on
Results
Operator
Remarks
7th day
boiler #4 and
deaerator
Wash on
22nd day
1. Model: UG-PG9171E-R
Type: Double-pressure, no afterburning and reheating, self integrative vertical natural
circulation HRSG
Manufacturer: Wuxi Boiler Factory
Assorted Turbine: PG9171E
Size: Height: 29.6m, Width 13.05m;
The elevation of HP steam drum center is 22.95m;
The elevation of LP steam drum center is 22.70m;
The elevation of deaerator center is 23.20m;
The elevation of boiler chimney is 45 m and the bypass chimney elevation is 40m;
2. Summarization
Check whether all parts and zones erected, flue gas ducts connected well, inner lining,
flue dampers and pressure members expand freely and all scrap iron and other rubbish
cleaned out; check whether separators in drum erected correctly and internals, such as
pipes supported firmly; check whether all pipes supports fixed correctly, boiler weight
loaded by base completely and all bolts of steel structure erected firmly; the pipes
supports should be signed with cold and hot state set value, after boiler at basic load,
recheck and confirm the thermal state set value;
3. Valves
Check whether all valves erected in right position; then check the valves stroke, valves
seats and gland packing tightness. Before boiler startup, all electric and pneumatic valves
and equipments should be trial operated to remove all electric or mechanical problems.
Check electric and instruments air; the exhausted steam and drained water from safety
valves should be led to discharge place where valves free expansion wont be disturbed;
4. Control equipments
Check all control equipments erected correctly, properly and reliably; check maneuverability
of electric system (electric and control) and control air supply system; regulate valves
opening and electric signals relationship within valves full stroke through control panel.
Check whether the signals sent out from the electric transmitters (flow, level, pressure and
temp.) accepted by terminal equipments (controllers and monitors). Check the polar and
transmitting correctness of water meter column/level meters components which should be
taken when level transmitters are being checked; check local pressure gauges/temp.
meters applicability and erection correctness;
The level indicating devices are used to display drum level, alarm and shut down boiler.
Alarm and shutdown setting is on Inner Devices Diagrams of each drum. Before put into
service normally, check whether they are set correctly;
Warning: it may damage boiler if drum at low low level, so the boiler should be shut down
emergently;
1. General Introduction
After erected, hydraulic set must by taken on each pressure stage of boiler and all inner
connecting pipes regulated in ASME criterion by install department and supervised by AI;
Within boiler life, if any modification or recovery taken within the scope regulated by ASME
criterion, after the modification or recovery, the test should be done;
The large capacity feeding equipments should be used to finish FDW into boiler as fast
as possible and then exhaust air with best mode.
2.6
During FDW, all air relief valves should be opened to exhaust system air;
2.7
If it is a potential icy day, feed hot water (Notice: there are max. permissive metal temp.
regulations for hydraulic set in ASME criterion); in order to prevent freezing, we can adopt
inner heating or other measures. Anti-freeze measures are not considered in the 2 nd
phase project in Nigeria;
2.8
After the test, correct boiler maintenance must be taken to prevent rusting or freezing;
unless treated water adopted during hydraulic set and chemical maintenance adopted
during maintenance, boiler water must be drained out to keep boiler quit dry;
2.9
During boiler water draining, the correct protective measures should be taken to ensure
water drained out completely;
Warning: hydraulic set water may cause boiler rusting or freezing damage if it is remained in
boiler;
1 General Introduction
To clean pipes inner is to make inner surface of pipes clean and be passivated equably.
Passivation is forming a Fe3O4 protective layer on wet surface which can prevent inner
surface from eroding during normal running;
Oil, grease and rust may cause Fe 3O4 layers unequal or flaking away. So before running,
they must be cleaned;
2 Clean mode
According to boiler conditions, operating scopes and local equipments, there are various
clean techniques. But the general cleaning methods are as following and the final
cleaning can be parts or all of them:
2.1 Manual clean
It the first step of cleaning. Open manholes of all headers and drums and try to clean out
grease, oil and other sundries. Careful manual clean can reduce other clean time;
2.2 Organic clean
After manual clean, any other residual organic matters (such as oil, grease or pipes
protective layers) must be cleaned from inner surface of boiler, otherwise the residual
organic matters will disturb the heat exchanging, metal normal passivation and acid clean.
Moreover, the sundries left on pipes inner surface must be washed. If there is oil or
grease, acid cleaning can not be used and alkali clean is necessary before acid clean;
Some pipes which human can go into can be cleaned with mechanical method, such as
vaporizers, HP water gun or scraper;
3. Alkali Clean
3.1 Feed alkali solution into boiler and coal economizers to normal running level: 1.8KG
Na2HPO4-7H2O, 3.6KG Na4PO4-12H2O and scaler (prepared according to capacity
0.05-0.1%) in 454KG water. The scaler usage on precautions;
3.2 Start GT and load to rotary load and according to boiler selected pressure, it may be
1.0Mpa in 4 hours. During this time, the drum level will be up, so the blowdown value
should be controlled to prevent water level over level meter top. During complete alkali
cleaning, the drums pressure should be remained at 1.0Mpa and sample saturated
steam from sampling nozzles to supervise steam purity (conductivity) that low indication
means there is no water in steam. The alkali solution should be sampled every hour and
analysis about alkalinity, phosphate and dissolved solid should be taken as well as oil
content in sampling. If boiler water alkalinity and phosphate concentration down to half of
original value, dose alkali cleaning chemicals to remover original concentration;
3.3 If alkali solution analysis shows that alkalinity, phosphate and dissolved solid get balance
and no oil content in sampling, stop GT and release HRSG pressure;
3.4 HRSG pressure down to zero and alkali solution cooled down to normal temp. and then
take water draining. After alkali solution discharged completely, feed heated 77 82
clean water into boiler to top of level meters glass. During feeding clean water into boiler,
take backwash on superheaters through superheaters outlet headers with condensing
water or DM water (Precautions) till water overflows to drums. Because there are residual
chemicals, superheaters should be fed with condensing water or DM water and the wash
water can be discharged after being cooled down enough in boiler;
3.5 Precautions of alkali cleaning
Solid chemicals should be avoided for cleaning. From heat transmitting and rusting
viewpoints, it is harmful if there are settled solids in superheaters. If there are hydrate and
chloride in stainless steel superheaters, there is obvious damage on the stress corrosion;
If alkali cleaning failed and grease still exists, then the following acid cleaning will be
invalid. So after alkali cleaning failed, check boiler drums and down water drums inner; if
not clean enough, repeat the alkali cleaning;
4. Acid cleaning
4.1 The acid cleaning takes diluted (about 5% weight ratio) anticorrosive hydrochloric acid as
base;
We suggest that the acid cleaning is started as soon as alkali cleaning and checks
finished. Feed clean water into boiler o normal level. Because of unequal cooling speed
between thin pipes, thick drums and thick headers, considering thermal capacity and loss
of boiler metal, before acid solution into boiler, the metal temp. should be controlled at
82. After boiler water discharged, close all furnace doors apertures and dampers to
keep heat;
4.2 Before acid cleaning, the following items should be checked:
4.2.1 Superheaters are full of cooling condensing water or DM water and no residual alkali
cleaning matters sampled at superheaters water draining and vent outlet;
4.2.2 Furnace door apertures and dampers closed;
4.2.3 Open all steam exhaust valves on drums; except special illumination, the positions of
valves should be as the same as in alkali cleaning;
4.2.4 Recirculation pipes valves of coal economizers opened;
4.2.5 All boiler blowdown valves and dosing valves closed;
4.3 When metal temp. at 77, feed anticorrosive acid solution (5-6% hydrochloric acid) into
to boiler. We suggest that according to poidometer, dose 0.25% hydrofluoric acid
(NH4HF2) into anticorrosive acid solution as energizing agent and silica scavenging
agent. The mixed up solution temp. by diluted acid water and steam should be kept
within 7177;
4.4 Acid cleaning precautions
4.4.1 Although nitrogen is not harmful, human breath can not be satisfied. After nitrogen used
during boiler discharging water, if human into boiler, ventilation must be taken firstly;
4.4.2 After cleaning finished, start boiler at once. If inner devices and orifice plates of boiler
not started at once after erected, the condensing water which contains 200PPm
hydrazine at least should be dosed into boiler and superheaters and then regulate PH
value to 10 through ammonia; moreover, boiler should be fed with positive pressure
nitrogen (0.020.034Mpa psig);
4.4.3 Before dosing acid into boiler, the validity of anticorrosive agent in acid should be
checked. One method is a simple test: soak a lucidus carbon steel card in acid whose
concentration is properly regulated and temp. at 82 ; if there are one or more bunches
of air bubbles but not dissociative air bubbles appearing, the acid is not available till
enough anticorrosive agents supplied and test qualified. Another method is that soak one
artifactitious surface square known boiler steel test sample in anticorrosive acid whose
concentration and temp. are the same as cleaning acid for 30min; then survey the weight
loss and the weight loss in each square centimeter should not be more than 1mg. The
acid cleaning must be operated by experienced personnel;
4.4.4 Potential accident in acid cleaning is partial metal temp. may be too high. Most
hydrochloric anticorrosive agents are not available if temp. over 88 ; moreover, too high
temp. also will increase corrosion. The valid cleaning temp. is at 66 at least, so pay
attention to confirm proper metal and solution temp.;
4.4.5 The steam exhausted from GT may transmit heat to parts of boiler and even establishes
boiler water circulation, which may cause partial metals of inner pipes over heated. So if
the boiler contains any acid solution, it is forbidden to start GT;
4.4.6 Take chemical analysis (conductivity, PH value) on using water to prevent pollution;
4.4.7 After cleaning finished and before GT startup, sample and check draining water at HPS,
LPS and steam pipes to prevent pollution;
4.4.8 During chemical cleaning, if alkali or acid solution overflowed into superheaters by
mistake, before ignition permitted, it must be backwashed with enough flow to ensure all
residual acid and alkali solution cleaned out;
4.4.9 During alkali cleaning, commercial detergent is used mostly, when whose concentration
over 0.1% (as cubage), the formed bubbles may bring alkali solution into superheaters.
Because stainless steel may create stress crack, pay attention and prevent lots of alkali
solution from being brought into. Because there are too many concentrations (water
dilution) in commercial detergent, if suggested concentration by manufacturer over 0.1%,
take negotiation with manufacturer;
4.4.10 All external pipes used during cleaning, including FDW storage/treatment equipments
should be cleaned when boiler being cleaned; if they can not be cleaned, it is better to
clean oxide skins after unconsolidated sediment in FDW removed;
4.4.11 The regulating valves, orifice plates, and other equipments which may be damaged in
cleaning process should be removed or bypassed during cleaning;
4.4.12 The cleaning contractor should provide necessary glass level meter for cleaning and
also they should be informed the max. working temp. and pressure of the temporary level
meter;
Warning: the glass level meters for cleaning commonly can not be used in operation, which
may hurt people caused by breaking up or damage due to pressure;
4.4.13 Because the cleaning solution circulated in boiler may be cooled down, supervise
control the cleaning solution temp. at inlet and outlet of boiler to keep valid temp. and
prevent external air into flue ducts (cover chimney and close manholes) to reduce boiler
heat loss. The cleaning medium is heated by outlaid heaters by cleaning contractor;
4.4.14 The cleaning contractor must ensure cleaning solution circulated in all boiler parts,
especially avoid the solution in vaporizers passing low resistance pipes, such as
downcomers, but not the correct pipes, so it is requested to silt up the downcomers
during chemical cleaning;
4.4.15 During chemical cleaning, the inner parts of drums can be cleaned with drums, but pay
attention that the metal mesh is made up of stainless steel plates; if the cleaning solution
is harmful to the metal mesh, it should be taken out before cleaning and then put in
before steam blowing and operating; chevron separators should be erected as the same
way if they are taken out for checks or additional cleaning;
4.4.16 The sampling pipes must be closed during steam blowing or chemical cleaning to
prevent from jamming;
4.4.17 The records of all cleaning techniques including chemicals should be saved well by
users;
4.4.18 After cleaning finished, the owners and cleaning contractors should check whether the
unit cleaned out and all tube windows water drained out;
4.4.19 The disposal cost about cleaning solution is one of important parts. The cost may be
changed when weak cleaning solution into a long-time circulation, so there may be more
corrosion/acid solution discharging fees;
4.4.20 When dispose any dangerous liquid and take acid cleaning, pay attention to human
safety specially;
Warning: after acid cleaning, flush with water thoroughly to avoid damage;
10PPm, then take boiler water draining and refeed water into boiler. After that, repeat
sample and analysis till required value reached;
5.4.9 When blowing steam pipes, dispose boiler water with volatilizable chemicals and keep
boiler water pH value within 8.5 and 9.0 with ammonia and all solids below 2.0PPm.
1. Purpose:
In order to remove all external impurities left in superheaters and steam pipes after they
are erected, we flush main steam pipes and reheating steam pipes before boiler startup.
The impurities will cause heavy accident if they are into turbine during initial operating;
Some external impurities may be left in pipes during pressure parts maintenance, so the
pipes should be flushed too after maintenance;
2. Responsibilities
Because pipes flush is taken to avoid turbine accidents, the complete flush techniques
should be confirmed by users. The temporary pipe system design, produce, erection and
protections of overpressure or over temperature of pipe flush are the users
responsibilities;
4. Precautions
4.1 There are some abnormity in boiler and steam pipes during flush. The rapid temp. variety
during flushing will cause heavier damage than during normal running, such as that there
is over heat stress in thick wall parts of drums, headers and pipes;
4.2 During flushing stop all main fuel burning, but the combustion of igniters or boiler
warming-up oil guns can be held, to recover flushing pressure fast;
4.3 The temporary steam pipes design pressure may be below the boiler vaporizing section
pressure, so the overpressure should be avoided during flushing operations. We suggest
taking overpressure protective measures on flushing pipes, such as take safety valves
floating as temporary pipes design pressure;
4.4 During steam pipes flush, it is hard to avoid water and solid impurities in drums into
superheaters during steam flushing. If the impurities settled down in superheaters, from
heat transmitting and corrosion viewpoints, it is harmful. Even caustic alkali (corrosive)
and chloride contained a few, the stainless steel is easy to be damaged; so the boiler
must be disposed with volatilizable chemicals, including keeping boiler water pH value
within 8.5 and 9.0 with ammonia and all solids below 2.0PPm. The boiler water analysis
should be taken to ensure the above conditions can be satisfied when flushing steam
pressure reached;
The temporary desuperheaters in steam flush pipes can help with controlling
temporary pipes not over design temp. At the same time, through desuperheating
medium discharged from boiler and reducing steam flow, the temporary pipes noise
can be reduced;
Boiler steam flush running is a short operation, which requests boiler operators pay
more attention. The drum level will be waved heavily if valves opening changed
during intermittent and continuous steam flush;
When two units running under header pipes system, two boilers may be under
running at the same time to satisfy the header pipes cleaning rate. And be careful,
there are no large pressure difference between two units;
During steam flush, the main steam valves must be opened 100% to prevent seal
surface worn away. The check valve core should be taken out during steam flush. If
the core not taken out and results in the check valves damaged, Wuxi Boiler Factory
will not take any responsibility;
If possible, the steam sampling devices should be taken out from steam pipes to
prevent sampling pipes jammed and the devices damaged;
If the temp. not request to be controlled in steam flush, isolate the desuperheaters
in steam pipes during steam flush;
Venturi steam flow meters (or other steam survey equipments) should be taken out
and replaced with other temporary pipes before steam flush;
Insert target plates to test whether boiler cleaning qualified; if not, insert the plates
and then restart boiler to take steam flush till it is qualified;
During steam flush, the steam can not be exhausted through main startup valves,
viz. spheroidal regulating valves which
may be damaged when dirty steam is passing them. When create steam through
startup boiler, there a temporary steam flush valve should be erected to control
pressure boosting speed;
test, then take it out to make signs and marks. The cleaning requirements (flag data and
deepness on target) are decided by users;
8. Precautions:
8.1 An important principle of boiler blowing is that: at the outlet of vaporizers, the mixing up
speed of steam and water should not be over 35m/s at any situation to prevent cavitation;
The operating restricted area of drums is as the following chart: these running limit lines
will limit GT load in pipes flush;
8.2 During flush, the pressure drop of superheaters and steam pipes will become larger;
8.3 During complete steam flush operations, the design pressure and temp. of temporary
steam exhaust pipes and valves can not be exceeded;
After flush finished, take safety valves floating, suspension bracket tightening and other
debugging according to relative operating regulations.
1. Conditions:
1.1 Boiler overhauled;
1.2 Safety valves overhauled;
1.3 When operators or maintainers consider it is necessary;
4. Process:
4.1 The maintainers should set the action pressure at floating value according to relationship
between spring stroke and pressure under cold state;
4.2 Except verified safety valves, other safety valves should be locked by thimbles to prevent
faulty action;
4.3 The safety valves floating sequence is from high floating value to low one;
4.4 After safety valves floating finished, record the floating results and release pressure as
normal speed (<1bar/min);
4.5 During safety valves floating, if abnormity found, stop the test at once and after the faults
removed, keep on the floating;
HP part
Deae.
No.
Name
Designed
Acting
pressure
Designed
Reseating
pressure
Release value
7.62 MPa
7.5MPa
88 kg/h
HP drum safety
valve 1
8.5 MPa
8.156MPa
88t/h
HP drum safety
valve 2
8.57MPa
8.348MPa
90t/h
safety valve 1
0.53 MPa
2.421t/h
safety valve 2
0.53 MPa
2.421t/h
safety valve 3
0.5 MPa
2.815t/h
LP part
10
0.97MPa
0.903MPa
15t/h
11
LP drum safety
valve 1
1.2 MPa
1.148MPa
15.64t/h
12
LP drum safety
valve 2
1.3MPa
1.244 MPa
26.319t/h
When all equipments of GT/boiler satisfy operation conditions, the unit can be started, but the
following boiler equipments and services must be reliable and proper:
Boiler control system;
Water level indicators and transmitters;
Regulating valves;
Electric valves;
Chemical dosing system;
Blowdown system;
FDW system;
Electric and air resource service;
Cooling air fans (if flue duct burners system);
During startup, certain parameters are required to be retained, so the operators should joint
in;
1 General Introduction
During boiler startup and stop, the heat stress will be created: the faster the temp. is rising,
the larger the stress will be created, so if not controlled, the boiler will be fatigue and the
life also be reduced;
1.1 The boiler input heat is controlled according to supervision of saturated temp. rising
speed (temp. rising speed) in drums of boiler each pressure system. The temp. rising
speed will be controlled by the following factors: 1) through steam exhausting during
startup or on main steam pipes or other pipes; 2) through limiting GT load, control heat
flow into boiler;
1.2 Start GT when boiler temp. at highest value. Before startup, circulate hot deoxidized
water in boiler to rise temp. approaching to saturated temp.;
1.3 The key point of boiler startup and operation is to keep correct drum level. High level
operation may cause superheaters damage but low level operation will cause vaporizers
walls overheating and damage or even forced shutdown;
1.4 The startup steam exhaust valves must be opened fully during cold startup and GT
ignited and closed after the temp. rising speed over regulated value; the startup valves
can be closed during fast startup but temp. rising speed not over value and are forbidden
to be running under any situation when the opening below 10%;
Warning: the regulating valves can not be operated when the opening below 10% to
prevent the seal surface of valves damaged;
1.5 The startup regulations of boiler service depend on the situations before unit startup. The
three situations are as the following:
Cold startup: water temp. in drums is down and below 100 (not positive pressure in
drums);
Warm startup: water temp. in drums equals to or is 55 lower than saturated temp.
under basic load normal working pressure but the water temp. still over 100 (positive
pressure);
Hot startup: the water temp. in drums has been 55 higher than saturated temp. under
basic load normal working pressure;
To adopt startup regulation according to different situations, which can reduce startup
time, protect system from damage caused by responding heat stress;
difference of water and pipes walls should be low and must be below 55 . Make for
startup, the initial water feeding must be cold to satisfy the temp. difference of water and
pipes walls; but during the complete feeding process, the water temp. should be raise
and when the drums full of water, the water temp. should be over 100 ;
2.4 Open Startup steam exhaust valves to release air; feed water continuously till water level
just in bottom observed scope or over low low level;
2.5 If there is any maintenance after lat hydraulic set, the leakage test must be taken;
2.6 If the manholes have been removed, when pressure at 0.15Mpa, they must be tightened
again and sealed completely;
2.7 If there is chimney dampers, before GT primary startup, the dampers must be opened,
otherwise they may cause boiler expansion joints damage or human injury;
Warning: if the boiler damaged during running caused by chimney dampers closed, Wuxi
Boiler Factory will not taken any responsibility;
2.8 Look up the startup limit requirements in all boiler safety measures;
Notice: in order to prevent steam pipes creating heat vibration, at the primary period of
startup, the downstream steam pipes in Wuxi Boiler Factory supply scope should be
preheated;
3. Cold startup
The article states the unit cold startup regulations when boiler under
water feeding but water temperature below boiling point;
3.1 If the unit has been fed with water for a while, consider opening the drain valves of coal
economizers and vaporizers till the settled slugs discharged out; check drums level alarm
system and set points, open superheaters drain valves to ensure all condensing water
discharged;
3.2 Start FDW pump and open the HP, IP and LP FDW shutoff valves, observe drums level at
normal value and open HP, IP and LP startup steam exhaust valves completely;
3.3 Regulate any necessary valves position according to power plant regulations;
3.4 At this moment, boiler satisfies the operation conditions and GT can be ignited and load
minimum load;
3.5 Supervise HP, IP and LP drums temp. and level; when each stage pressure system get
boiling, the drums level will be up which means the steam has been created. During
boiler primary startup, the drums level control is on auto position and the level is set at
200mm below normal level to ensure the max. level not over high high value after boiler
started. In future startup, regulate the primary startup level of drums to make the max.
value of drums level wave approaching to normal level;
3.6 After boiler started, LP part can reach rated pressure first and then IP part, HP part will be
the last one. The boiling time is about 10-45min, which depends on the startup temp. and
GT speed whereas the time reaching basic load depends on startup temp., GT speed
and unit load variety ratio;
3.7 When HP and IP part pressure at 0.07Mpa and LP part pressure at 0.035Mpa or steam
flows of each part satisfy the requirements, the operators can increase load; at this
moment, the drain valves of superheaters can be closed;
3.8 GT loading regulations and startup auto steam exhaust valves adjustment should be
taken base on the same temp. rising speed: HP part below 3.5 /min, IP part below
16.5/min and LP part below 22/min;
Warning: when auto steam exhaust valves opening below 10%, it will result in seal surface
worn which may cause leakage;
3.9 The isolating valves of desuperheaters should be opened as steam output reaching 25%
of basic load, which can ensure the steam heat can vaporize the spray water;
3.10 According to power plant facilities, there are a few methods to load full load. The most
important point is to control boiler parameters not exceeding above parameters limit. The
full load reaching time depends on GT loading arrangement whereas steam exhaust
valves position regulation depends on the power plant;
3.11 When boiler under stable operation, check the whole boiler. During running, steam flow,
pressure and temp. can not exceed design conditions regulated by design institute;
3.12 At primary startup, pay attention to parameters variety to take improvement in future
startup, especially the system boiling time and highest expansion value of drums water
level, which will be the standard for next FDW level;
4. Warm startup
In this article, we talk about the startup regulations when drums have positive pressure
and water temp. in drums is 55 higher than saturated temp. under basic load conditions;
also article 2.7-2.8 must be satisfied;
In order to reduce the startup pressure to min., before heating unit, the startup steam
exhaust valves and superheaters drain valves are not suggested to be opened;
4.1
Check water level alarm system functions and all drums level; start FDW pump and
open HP, IP and LP FDW stop valves then according to power plant regulations, regulate
the valves position;
4.2
Start GT igniting; GT starts cranking and then decelerate to flameout speed; once GT
fired, it starts full speed with no load condition (FSNL). When GT flue temp. at saturated
temp. of boiler HP drums, open superheaters drain valves in all pressure system. The
system pressure will discharge the condensing water out from superheaters. After that,
about 5-10min, close the superheaters drain valves and at the same time, open valves to
the opening where steam can be created;
4.3
Warning: cooling steam must pass superheater before boiler inlet flue temp over 370 ;
4.4
When superheaters drain valves and startup steam exhaust valves opened, the drums
may be expanded, so the operators should observe the drums level closely during
operating;
4.5
According to startup conditions, drums pressure may be down with FSNL; at this time,
load more GT load till the drums pressure falling stopped;
4.6
Start increasing load and regulate the startup steam exhaust vales to satisfy the basic
load; at the same time, observe HP, IP and LP drums temp. rising speed at 3.5 , 16.5
and 22 respectively. When GT load is increased, the opening of startup steam exhaust
valves should be wider to control startup temp. rising and ensure more cooling steam
through superheaters;
4.7
After unit taking basic load, operate according to Article 3.10-3.13 in cold startup ;
5. Hot startup
In this article, we talk about the startup regulations when drums have positive pressure
and water temp. in drums is 55 lower than saturated temp. under basic load conditions;
also article 2.7-2.8 must be satisfied;
5.1 The same as Article 4.1-4.5;
5.2 During hot startup, the boiler drums water temp. speed has no limit and the unit permits
instantaneous temp. rising at 55, however, the unit wont be damaged. But the enough
steam flow should be ensured to pass superheaters;
Warning: cooling steam must pass superheater before boiler inlet flue temp over 370 ;
5.3 Take loading up to basic load should be operated as Article 3.10-3.13;
In this chapter, we will talk about general safety principles and detailed
design limit. The responsibilities of owners are to ensure operators,
system and control devices within design parameters. During actual
operation, we need additional safety measures. On boiler, we have
additional alarm, trip and interlocks to protect other devices and
operators safety;
General Introduction
1.1
1.2
1.3
There must be a logic control system controlling boiler and shutting down equipments
automatically when design parameters exceeded;
1.4
The necessary instruments which provide control system with accurate data must be
under good working condition;
1.5
The relative operation and design requirements in O&M Manuals must be obeyed;
Detailed introduction
The follow is the protective requirements during boiler under running. If the requirements
deviate from protective requirements, the boiler guarantee by Wuxi Boiler Factory will be
invalid. The operators must know other equipments performance and human safety
requirements. On the other side, the requests for equipments and human safety should
be compiled specially according to local conditions;
2.1
Drums level
During operation, when one drum level below low low and cause pipes and headers
overheated, GT must be shut down;
When low level alarms, operators should take some measures to avoid low low level;
When operating drums level over high high level, it may cause superheaters pipes and
other downstream equipments polluted (scaled); when high high level reached, start auto
regulating devices should be started to reduce water level;
When high level alarms, operators should take measures to avoid high high level;
Warning: when drums level below low low or over high high value, it may cause boiler
damage and quality guarantee invalid;
2.2
Working pressure
Operators should ensure working pressure below design pressure;
Warning: when design pressure exceeded during running, it may cause the quality
guarantee invalid and the pressure parts damaged;
2.3
Working temp.
The outlet temp. of HPS 1 can not be over 457.3 whereas HPS 2 outlet steam temp.
must be controlled by desuperheaters but not over 523.0 ;
Warning: if the temp. over above value, it may cause the quality guarantee invalid and
the pressure parts damaged;
2.4
2.5
Chimney dampers
Before GT startup, the dampers must be opened 100% and the dampers position must
be connected to DCS by hard-wiring as the necessary condition of GT startup,
otherwise the dampers will be damaged, especially the expansion joints at flue gas
sides;
Warning: When boiler running with dampers closing, the boiler casing, expansion joints
and other parts may damaged and the quality guarantee will be invalid;
2.6
2.7
2.8
Desuperheaters faults
The design of superheaters pipes and connecting pipes do not consider the
overtemperature caused by desuperheaters fault. All desuperheaters must be
supervised to confirm whether they are normal running. When same level
desuperheaters located paralleled, if one is on fault, we can not increase another
desuperheaters output to control total outlet steam temp. When desuperheaters are on
fault, GT load must be controlled to ensure heating surface temp. within normal scope;
2.9
HPS startup
When GT flue temp. is rising, HPS pipes can not be in dry combustion. When temp. over
370, there must be steam passing HPS pipes for cooling down pipes walls. If steam
flow inadequate, the short-time overtemperature may be caused and finally the pipes
invalid;
Notice: when flue temp. of GT over 370, if no steam passing HPS pipes to cool
down pipes walls and cause pipes overtemperature and gradual deformation,
Wuxi Boiler Factory will not take any responsibility;
2.10
9%Cr material
In this boiler, some parts materials contain 9%Cr (SA-213 T91, SA-335 P91, SA-387
Grade P91, SA-234 F91 and so on). Check relative diagrams to confirm where these
materials used;
Because the materials have special welding, manufacturing and thermal treatment
techniques, unless you have ASME certificate and authorized welding skills, the
materials are not allowed to be welded (including spot welding and temporary auxiliaries
welding). DC Prod magnetic powder inspection are not allowed as well as the incorrect
unqualified welding on them, otherwise Wuxi Boiler Factory will not take any
responsibility; If there are unexpected arc welding craters, they should be rubbed and
then take nondestructive evaluation (NDE) confirm the materials not damaged;
Warning: DC Prod magnetic powder inspection are not allowed as well as the incorrect
unqualified welding on them, otherwise Wuxi Boiler Factory will not take any
responsibility;
2.12.1 During boiler startup, GT exhausting heat will be absorbed by boiler front parts but the
temp. in FDW preheaters is not increased. The relative recirculation regulating valves
opening is 100% to control water temp. in preheater at 60 ;
2.12.2 The recirculation pumps are designed to be operated under
certain outlet
pressure which equals to working substance static pressure plugging pressure drop at
preheaters working substance static pressure side. At primary period of startup, the working
substance flow passing preheaters will be small and the relative pressure drop also is small;
At primary period of startup, due to 100% opening of recirculation regulating valves and
small preheaters passing-by working substance flow, the recirculation pumps will
deviate from power curves and damage recirculation pumps motors;
If put recirculation pumps during load changing, even the motors can adapt the
condition but may be damaged, too. Go to further, recirculation operation in this period
will increase power plant additional load but no benefit;
2.12.3During boiler running, recirculation pumps can not be running with full load. At this time,
the unit has been on steady running state for enough time and the boiler even the boiler tail
has been heated completely, which is adaptable. The outlet temp. of preheaters has been
risen and higher than inlet temp. and then regulate the relative recirculation regulating valves
to supply enough outlet pressure, ensure the pumps can be operated on safety state. Wuxi
Boiler Factory suggests recirculation regulating valves opening over 10; At load
continuously reducing period, according to partial load running conditions, the boiler tail have
more heat to absorb, so the preheaters outlet temp. can be raise and over normal running
value. The recirculation pumps are designed to running better within certain temp. scope.
When over design temp., the pumps will have cavitation (details on water pumps factory
information). In such as case, the pumps should be closed;
2.13 Water treatment
Select proper blowdown rate correctly to held qualified boiler water quality and take
changing with local FDW quality and chemical treatment. The blowdown rate is the rate
of TDS in water and drums (i.e.: if drums max. permissive TDS is 50ppm and 1ppm in
water, the blowdown rate is 2%);
Water treatment: the water treatment tests should be taken to confirm blowdown rate,
intermittent blowdown time and sampling time according to TDS and purity in water and
max. TDS in drums;
Notice: different stage pressure may request different dosing valueit is very important;
Warning: All pressure-stages adopt one water treatment that will not satisfy the
requirements, which may cause boiler inner surface damage; some certificated
personnel check drums inner and other access zones to ensure crashing water
treatment. We suggest supervising ferrum content on line to know boiler
corrosion degree.
1. General Situation
The steadying of boiler running parameters are closely related to external load changing
and boiler inner factors variety. Any of above factors changed, the boiler running
stabilization and safety will be affected. So a series of control and regulating should be
taken to make the boiler parameters be adapted to external or inner changing to ensure
the boiler running safely and economically;
2. Regulation of GT load
GT load affect the safety and economy of boiler and even the whole power plant, so the
regulation should be adapted to external load requirements;
2.1 Purpose:
2.1.1 Ensure boiler steam temp., pressure and evaporation capacity stable and normal;
2.1.2 GT should take basic load possibly. If due to grid system or other reasons, the preselect
load should be as high as possible to take sufficient heat;
2.1.3 Keep most economic boiler operation;
2.2 Main contents and methods of regulation:
2.2.1 According to grid system load, keep GT base load to ensure max. HRSG thermal
efficiency and also keep the general efficiency of combined cycle max.
2.2.2 Control outlet steam temp. of superheaters not overtemperature;
2.2.3 When load changed, pay attention to regulate HRSG drums level within normal scope
and prevent trips caused by water level over set value;
2.2.4 When load changed, pay attention to regulate deaerator level of HRSG within normal
scope and prevent trips caused by water level over set value;
2.2.5 When GT transferred from base load to preselect load, pay attention to regulate HPS
steam outlet temp. not overtemperature;
3.1 The indications of local double colored level meters at both sides should be the same. If
not, take wash in time and find out causes;
3.2 All level meters must indicate correct. If there two or more in service, they should be
compared with local indication in each hour. The drums high and low level instruments
and alarm (alarm signals) should be reliable and verified periodically;
3.3 During normal running, when FDW in service automatically, strengthen supervising water
level meters; if FDW changed heavily, transfer to manual regulation to prevent lack of
water or water overfed;
3.4 When take boiler intermittent blowdown, strengthen supervising and regulating water
level;
startup and shutdown, to ensure boiler safety and reliable and even accelerate startup
and shutdown speed and emergency disposal ability;
6.1.6 The glass level meters should be blown down twice in each shift to prevent scaling;
6.1.7 Pay attention to whether there is flue gas leakage and arrange the maintenance in next
shutdown period. Especially, the headers outlets and inlets and the drain pipes which are
through boiler casing should be check to confirm whether there is leakage over there;
The design performance of this boiler will be satisfied when external input conditions
satisfied. The influence of some external conditions variety will be talked about hereinafter.
The unit and auxiliaries running and mechanical conditions can not be confirmed if there is
not complete analysis on system;
CTG is the primary heat resource of boiler. The steam exhausting flow and temperature can
affect boiler heavily. In order to reduce NO X, steam feeding flow, GV adjustment under part
load, fuel content, atmosphere pressure, humidity and CTG mechanical conditions will
affect running conditions and even boiler. Other auxiliaries, such as GT rotors coolers and
fuel heaters, may increase or reduce heat from GT into boiler. Any of above conditions may
cause boiler heat output changing;
Generally speaking, GT exhaust flow or temp. reduction may cause boiler steam flow and
temp. decreasing. Rising one parameter and reducing another will cause steam flow
increasing or decreasing;
The boiler running parameters and equipments conditions may affect performance
differently. Especially when running pressure down, steam flow will be increased but the
superheating temp. will be down. The FDW temp. must approach to design temp. to avoid
problems. Steam/water leakage or drain valves opened may reduce certain steam value
although it is not obvious. The superheating steam leakage can not be seen commonly but
it is very dangerous. The leakage at flue gas side will reduce boiler performance heavily.
Besides that, the pollution on pipes surface will reduce the heat exchanging and then
reduce steam flow.
The shutdown speed depends on whether immediate maintenance is needed. The normal
shutdown procedure should be used for those boilers which have normal maintenance,
long-time shutdown or shutdown but without maintenance. If immediate maintenance is
needed, take emergency shutdown procedure. In any case, cool down boiler rapidly will
cause boiler heat stress, so it should be avoided possibly. Other factor which may cause
shutdown speed/modes are: local water draining and FDW devices, environmental temp.
and boiler antifreeze protection;
If the unit will be shut down for long time, the shutdown maintenance contents in this
manual should be looked up. In any case, boiler should held positive pressure which may
be realized through steam or nitrogen blanketing;
Sometimes, unexpected accidents may cause the whole power plant shutdown. In this
case, the following measures which mentioned in advanced shutdown chapters can not be
carried out. In any case, take water draining and blowdown while boiler has positive
pressure to ensure draining and blowdown pipes not jammed.
2. Normal shutdown
When GT is shut down, boiler begins cooling down. Unless boiler maintenance required,
reduce boiler heat radiated and keep working substance side pressure. If the boiler
requires maintenance after normal shutdown, take the following procedures:
2.1 After CTG shutdown, close boiler main steam valves. Keep drums level over low low level
till HP drums pressure down to 0.07Mpa;
2.2 Through self ventilation cooling boiler from CGT to boiler, the startup motor of GT can
keep low speed or be shut down at the same time. The chimney dampers should be
closed as well;
2.3 In above casing, within about 24 hours, HP drums pressure may be down to 0.07Mpa;
2.4 When HP drums pressure below 0.07Mpa, boiler air relief and water draining can be
taken and if some jammed blowdown pipes found in detection before boiler shutdown,
take maintenance at this time;
3. Emergent shutdown
Only the boiler which requests intermediate maintenance can be shut down emergently.
Normal maintenance does not require emergency shutdown because emergency shutdown
will increase boiler heat stress;
3.1 Close climate flue dampers, open bypass flue dampers and isolate boiler water side;
3.2 In each pressure system, intermittent blowdown valves are used to reduce drums level to
min. seeable value. Close blowdown valves and wait for 5min and then feed hot
deoxidized water to each pressure-stage coal economizers till drums level at highest
value. After 5min, repeat the operations;
Warning:
5. Stop Disposal
During stop, no matter before or after operations, the proper boiler shutdown maintenance
must be taken to prevent corrosive and freezing damage. Because during running, the
pressure elements inners contact water, corresponding to flue gas side, the stop disposal at
boiler working substance side should be paid attention to specially (take periodical checks
on boiler flue gas side to ensure stop disposal requirements satisfied). The disposal
procedures and methods (wet or dry) at boiler working substance side should be confirmed
according to local detail conditions and while compiling, read the following instructions.
1. Maintenance purpose
1.1 If the intervals of unit startup is longer (over a week), the valid measures must be taken to
prevent thermal equipments damaged by rust, rotating machines stuck and so on to
make the unit under normal cold backup state;
Notice: RH will be changed with environmental temp., so it should be surveyed or concluded
according to survey charts at min. temp.
(1)
(2)
(3)
When ferrum contacts water, the reaction (1) will be acting. When metal (anode) absorb
negative electron, Fe2+ will be water-soluble and after the metal polar has polarity, the
reaction will be stopped;
On surface of metal (cathode), reaction (2) and (3) will be acting; The balance of the
reactions will be decided by OH- concentration (water pH value) in the water.
Moreover, reaction (3) can be decided by oxygen content; The electron from anode
(reaction 1) has tendency to into metal cathode: reaction (1) balance will be broken
and the ion will be water-soluble continuously to be Fe 2+;
2.
2.1 General principles
According to above theories, only when water and oxygen exist at the same time, the
corrosion will happen. The two below measures can remove one of the two factors:
- Nitrogen blanketing wet maintenance
- Nitrogen blanketing dry maintenance
Which maintenance measure will be adopted is decided by purpose and boiler shutdown
time;
If it is shut down for short time, such as weekend shutdown, because certain pressure
kept, no maintenance is needed;
When temp. below zero, in order to anti-freeze, dry protection must be adopted. From
other view points, dry protection has a special disadvantage, viz. refeed water into boiler
before boiler startup. So the water demand is huge and it will take long time to recover
original boiler load. This measure will be adopted for long time shutdown;
Partial wet protection has obvious advantage: no drain water in boiler, so it is easy to
recover the original load;
The general principle of shutdown maintenance is to prevent boiler water causing metal
oxidizing. If partial wet protection adopted, according to boiler water quality, when over
certain period, take water draining and then adopt dry protection;
For scheduled shutdown, the proper maintenance should be chosen according to
shutdown time before shutdown and then confirm the preparation: chemical dosing for
boiler water, Nitrogen supply and so on;
Important Notice: No matter wet or dry protection adopted, hot flue gas is not allowed into
HRSG.
3. Wet protection
Two Types:
Complete wet protection and partial wet Nitrogen blanketing protection
3.1 Complete wet protection
3.1.1 Standard:
Only used after hydraulic set;
3.1.2 Time limit
It is properly used when shutdown time within 6 weeks and pH value over 10.5, so it is
better to take DM water and dosing ammonia as (150ppm, to rise pH value) hydraulic set
water;
If the succedent boiler commissioning takes place after 6 weeks, water drain must be
taken and then adopt dry Nitrogen blanketing protection;
3.2 partial wet Nitrogen blanketing protection
3.2.1 Standard:
It is properly used after shutdown or maintenance (examines and repairs) and the climate
conditions permitted (if air temp. low, dry protection adopted)
3.2.2 Time limit
In order to prevent static water stayed in boiler for long time, the protection time limit is 2
weeks normally according to boiler water chemical characteristics;
Main parameters are the pH value and oxygen content in FDW and boiler drum water.
The protection limit is as the following table:
pH value
Oxygen content
limit
<20ppb
2 weeks
>20ppb
9<pH<10
If the shutdown time over above limit, water drain must be taken and dry Nitrogen
blanketing protection should be adopted.
4. Nitrogen blanketing
During Nitrogen blanketing, the furnace pressure should be 10-50 mbar more than
atmosphere pressure;
Whether Nitrogen blanketing will be adopted can be decided before boiler shutdown, so
Nitrogen blanketing will be started boiler hot state;
If Nitrogen blanketing started under cold state (unintended shutdown), special Nitrogen
blanketing in instruction book should be undertaken;
4.1 Nitrogen blanketing operation under boiler hot state
4.1.1 Before boiler unloading
At 2h before boiler unloading, dose NH 3 to ensure boiler water pH value over 10, so the
being shutdown boiler water quality will be good. Pay attention that if condenser
materials have aldary, pH value should be controlled at 9.2, so the partial wet nitrogen
blanketing maintenance time just is 2 weeks. Moreover, if aluminum contained in any
part of condenser or steam and water circulation, the chemicals should be decided by
chemical personnel research because of special requirements;
The secondary operation at 2h before boiler unloading is open continuous blowdown
valves of drums to remove the slat and alkali dissolved in boiler water furthest before
boiler maintenance;
Continuous blowdown valves of HP drum: 11HAA10 AA408
Continuous blowdown valves of LP drum: 11HAA30 AA408
4.1.2 Boiler shutdown
Reduce GT load and isolate HRSG and turbine through steam bypass station;
4.1.3 Boiler cooling down
Through steam bypass, control HP and LP drum pressure drop gradient (max.:
-2bar/min, make the inner pressure of shutdown boiler drum down to 10bar (psig);
4.1.4 Isolation of boiler
In boiler control room, operators transfer boiler to shutdown maintenance to prevent
water draining and air relief during pressure down. During boiler shutdown, water
draining and air relief valves should be closed and the drums should be isolated from
phosphate dosing system;
During shutdown, the following water drain and air relief valves should be kept on close
position:
Inlet water drain valve of HPS 2: 11HAH11AA402
HP steam water drain valve: 11LBA70AA402
LP steam water drain valve: 11LBA80AA402
Main steam isolating valves must be closed:
HP main steam isolating valve: 11LBA70AA001
Before shutdown:
At 2h before boiler unloading, open drum continuous blowdown valves fully to discharge
water-soluble slat and alkali. Before boiler shutdown, dose phosphate all the time into
drums;
HP drums continuous blowdown valve: 11HAA10 AA408
LP drums continuous blowdown valve: 11HAA30 AA408
4.4.2 Boiler shutdown
Reduce GT load and isolate HRSG and turbine through steam bypass station;
4.4.3 Boiler cooling down
Through steam bypass, control HP and LP drum pressure drop gradient (max.:
-2bar/min, make the inner pressure of shutdown boiler drum down to 10bar (psig);
4.4.4 Isolation of boiler
FDW
pump
outlet
isolating
valves:
11LAB31AA003,
11LAB32AA003,
11LAB33AA003
Drums continuous blowdown valves must be closed:
HP Drums continuous blowdown valve: 11HAA10 AA408
LP Drums continuous blowdown valve: 11HAA30 AA408
4.4.5 Nitrogen blanketing
The nitrogen blanketed can be supplied by fixed or mobile devices which should be
connected with nitrogen blanketing pipes and at the nitrogen supply side, pressure
reducing valves should be equipped;
If the safety can be ensured, the soft pipes which can support 10-50 mbar nitrogen
pressure can be used to connect nitrogen valves with boiler proper nitrogen blanketing
points. When boiler pressure within 2-5bar (psig), the nitrogen pipes should be fixed and
nitrogen blanketing isolating valves should be opened to prevent air in when boiler
pressure and temp. down;
During boiler running, the operators should take checks at the same time; moreover, in
order to ensure unit safe and normal running and extend the unit life, the boiler shutdown
checks are necessary. Usually, the shutdown checks will be carried out when GT takes
annual shutdown checks;
2. Min. requirements
As the minimum requirements, the checks should include the following contents:
2.1 Confirm boiler has been isolated from external steam and water resources;
2.2 Open all inspection doors of flue ducts to ensure safety maintenance in boiler;
2.3 FDW into boiler and boost pressure to check whether boiler leaks; after leakage test, held
pressure to drain water. Each header should take draining individually to ensure all
draining pipes not jammed; when all pipes draining finished, clean those jammed pipes
(back flush with compressed air or exchange pipes);
Once pressure leakage checked out, before next running, they must be repaired and the
leakage causes should be analyzed. the analysis should include the following items at
least:
2.3.1 Boiler operation including abnormity and deviation of operating points;
2.3.2Chemical treatment including abnormity and deviation of operating points;
2.3.3 GT operation including abnormity and deviation of operating points;
2.3.4 Auxiliaries operation including abnormity and deviation of operating points;
2.13 Check boiler all outside surface, pipes, electric and pneumatic lines and operation
panels;
2.14 Repair and maintain as relative check and maintenance instruction measures regulated
or commended by suppliers;
2.15 Replace inspection doors seal gaskets and close the inspection doors;
2.16 After boiler final check finished, keep boiler on spare state;
3. 3. Process
3.1 Usage of casing and inspection doors and gaskets seal;
3.1.1 Remove the doors to ensure they are safe;
3.1.2 Clean both sides of old inspection doors gaskets with wire brushed;
3.1.3 Fix treated plate on boiler casing with RTV or other materials;
3.1.4 The gaskets thickness is 3mm at least and width 50mm at least. The gaskets should be
stuck on the surface flat without folding but the materials which contain Teflon and semi
liquid layer can not be used;
3.1.5 Flat doors and fix bolts manually; tighten bolts till gaskets sealed completely (wrench
torque is 55-80N-M); no pneumatic wrench used on bolts whose diameter over 12.5mm;
3.2 Feed grease
If the anhydrous dissolved grease should be fed into drums supports for lubricating by
nozzle tip once 3 or 4 months; the boiler columns sliding panels can be fed by the same
method;
3.3 Usage of drums manholes and gaskets seal
There are two elliptical manholes covers sizes: 300400and 50450;
3.3.1
Open manholes and clean the covers and the gaskets on covers thoroughly; check
whether there is any steel pit or flute on all manholes covers and the gaskets seal
surfaces; if the pit diameter on manhole gaskets surfaces over 4.75mm or nick deepness
over 0.25mm, it should be repaired with welding or polishing instructed by ASME NB
engineers. If manholes covers damaged, replace them with new ones. The surfaces of
wound gaskets should be processed to 125RMS;
Check whether new manholes covers have bugs; the steel pit or the flute over 0.25mm
deep are founded on new ones;
3.3.2 While erecting manholes, the gaskets which meet table 3.1 and
3.4 requirements should be mounted; according to Chapter I requirements in ASME Criterion,
the bearing surface width of gaskets on manholes should be 17.5mm at least and the
thickness can not be over 6.35mm;
If the manholes covers are not articulated, the covers must be put into drums before
gaskets mounted and then connect manholes covers, gaskets and isolation links with
bolts, finally screw down the bolts. Before installation, the plate can not be bent, twisted
or deformed, otherwise the gaskets will be damaged and hardly to keep structure integer;
take gaskets alignment and lift covers to proper height to regulate gaskets position.
When covers and gaskets are in center, screw down the four diagonal bolts once a circle
till all bolts at 55N-M;
Notice: when nuts over 12.7mm, the heavy impulse driving wrench can not be used;
when screwing down nuts, it should be once a nut and once a circle as diagonal nuts till
the nuts screwed down; it is forbidden to screw the two adjacent nuts one after the other;
3.5 Now, we can boost boiler pressure. If gaskets leak, screw down nuts one by one once a
circle (as above process) till leaks stopped. With boiler heating, the inner pressure will
work on manholes covers and compress gaskets. If they are mounted correctly, the seal
established, but due to heat/boosting, the nuts should be screwed down more tightly. If
there is still leakage when the torque at 170N-M, repeat above process and mark the
leakage points. However, the slow water leakage is permitted in cold boiler. When unit at
preselected pressure, screw nuts at 170N-M;
Notice: When unit under pressure condition, the nuts can be screwed down beginning
from side if there are some protective measures;
Manholes Type
Hardware
Gaskets Type
Mechanical
processing flat
Bolts boars,
nuts and
articulation
with bolts
FLEXITALLIC or coordinate, MC
type 13/16 (width) x.0250/.0175
(thickness) wound gaskets with
GRAFOIL whose materials are
304SS
Mechanical
processing flat
Wrought
manholes
covers, nuts,
bolts and
articulations
HLENAPE
Wrought
manholes
covers, nuts,
bolts and
articulations
NLENAPE
Wrought
manholes
covers, nuts,
bolts and
articulations
THERMALSURETACKYCLOTH#62501
(width) x 3/16 (nominal
thickness)
barg
>80
70-80
7-70
<7
Manholes
Type
Hardware
Gaskets Type
Bolts boars,
nuts and
articulation
with bolts
FLEXITALLIC or coordinate, MC
type 13/16 (width) x.0250/.0175
(thickness) wound gaskets with
GRAFOIL whose materials are
barg
>80
Mechanical
processing flat
304SS
20-80
7-20
Mechanical
processing flat
Wrought
manholes
covers, nuts,
bolts and
articulations
Mechanical
processing
SLENAPE
Wrought
manholes
covers, nuts,
bolts and
articulations
Mechanical
processing
SLENAPE
Wrought
manholes
covers, nuts,
bolts and
articulations
THERMALSURETACKYCLOTH#62501
(width) x 3/16 (nominal
thickness)
<7
3.8.2 All seal connecting should be sealed with gland over 3 circles at least, normally 4
circles, but there is no upper limit;
3.8.3 Others
The packing in glass level meters should be carried out according to fitting manufacturers
instruction book;
Notice: The gaskets and glands which contain asbestos can not be used.
1. General Introduction
In this chapter, we will talk about the general maintenance process of HRSG and the
maintenance instructions of all equipments but no detailed equipments operations;
During equipments maintenance, the maintained equipments should be recorded to
confirm the overhaul or forecast potential faults and damage, which can make fittings and
parts management easier and more foresighted, so the record forms should be prepared
for each equipment;
2. Safety rules
When any equipments or auxiliaries of HRSG need maintenance, check forcibly whether
there is residual pressure inside, as well as upper and down stream of equipments to
ensure equipments on cold state and isolated from upstream or downstream equipments.
In order to avoid human injured, the rules should be carried out forcibly;
3 Maintenance
For safe and reliable operation, the equipments should be at their best, so the equipments
need periodical checks and maintenance. The present maintenance process includes the
following items:
3.1 Shift checks
The maintenance engineers should take visual determination on the whole boiler and
auxiliaries to check whether the equipments running normally and then decide whether
they need maintenance or repair;
Survey points: whether there is water/steam and flue gas leaking and whether pumps and
motors noise normal;
3.2 Monthly maintenance
According to general maintenance plans, some equipments need monthly maintenance,
including resetting lub oil, oil feeding and surveying devices, as well as the checks and data
records; all equipments checks are more detailed than shift checks;
3.3 Periodical maintenance
Some parts need checks and/or maintenance every 6 month, every year or others. Details
on maintenance plans;
pressure with FDW pumps. Pay attention that the pressure can not be over running
pressure and then personnel can go into boiler to check whether pipes leak;
4.2 Operations while boiler on cold state and unloading
Into each layer casing, check whether there is corrosion caused by condensed acid in flue
gas. The phenomena are at coldest part of boiler, exactly in front of chimney;
Check fin pipes damage;
tanks, some personnel should accompany outside for sending alarm if some
problems happen.
6.1 Enter into blowdown flash tanks to check inner surface;
6.2 Enter into blowdown flash tanks to check whether there are cracks around pipes
connecting (suggest checking after 10 years);
6.3 Before close inspection doors for restarting boiler, ensure there is no one external
equipments in tanks;
While closing inspection doors, use new gaskets;
equipments vibrate;
Any problems about instruments (i.e.: indications between local instruments and
transmitters differ), operate as the following sequence:
8.1.1 Check intelligent transmitters parameters
8.1.2 Check the auxiliaries of transmitters: pressure leads, isolating valves and so on. Zero
position fault is often caused by incorrect erection, different height balancers, dirty
valves or dirty parts of survey elements;
8.1.3 Check transmitters. If necessary, regulate zero and adjustment scope (details on
manufacturers manuals). After zero regulated (based on transmitters erection), we
advise recording the transmitters zero value (close inlet and outlet valves, open balance
valves and at the same time feed water into balance pipes to condensing tanks height);
Above data will be used in future instruments recalibration, which is independent of
transmitters, just depend on water level in balance pipes;
8.2 Overhaul
8.2.1 Through opening drain valves, flush pressure pipes between equipments and
transmitters on cold and micropressure state (avoid steam and survey elements
contacting, otherwise the survey elements will be damaged)
8.2.2 In order to check fringe damage, the orifice boards must be removed. If the damage
over 0.4% of the diameter, they must be replaced; if they are in good, they can not be
removed in next maintenance;
8.2.3 Open drain valves to flush level meters. The drain valves must be closed at once after
opened. If open clod state level meters when HRSG on hot state, the glass of level
meters will be damaged by overstress;
8.3 Refeed water into pressure pipes
In order to refeed water into pressure pipes, take operations as following sequence:
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
Open positive pressure side inlet valves slowly to make water through balance valves
8.3.7
8.3.8
9.1.2.6 When close manholes, use new gaskets and before close inspection doors for
restarting boiler, ensure there is no one and external equipments in boiler;
Parameter
FDW
Boiler water
Appearance
1/shift
1/shift
PH
Periodical
1/shift
Rigidity
1/shift
1/shift
Oxygen
Periodical
1/shift
reducing agent
1/shift
Chloride
1/shift
1/shift
Phosphate or chemical
additives
1/shift
Silicon
Periodical
Periodical
Periodical
Periodical
Periodical
Periodical
Organic matters
Periodical
Periodical
Time
Shift Day Week Month
Half a
Year
year
#
#
#
Creep supervision
detection,
checks
Others Remarks
3 years
3 years
records
Superheaters
metallurgy detection
3 years
3 years
drums
NDE detection
Water chemical character
Continuous supervision
of main parameters
3 years
#
Chemical analysis
HP FDW 1
Vibration record
Check bearings
Vibration record
5000h
#
Check bearings
Vibration record
Lubricate bearing
Lubricate bearing
HP FDW 3
Lubricate bearing
HP FDW 2
5000h
#
#
#
#
#
Check bearings
5000h
LP FDW1
Vibration record
Lubricate bearing
Check bearings
5000h
LP FDW2
Vibration record
Check bearings
5000h
LP FDW3
Vibration record
Check bearings
5000h
of
Vibration record
Check bearings
pump
Lubricate bearing
Recirculation
PREH 2
Lubricate bearing
pump
Lubricate bearing
Recirculation
PREH 1
5000h
of
Vibration record
Lubricate bearing
#
#
Check bearings
5000h
Open/close valves
Running
stroke
valves,
full
Check tightness
Regulating valves
Check leakage: lining,
flange,
gaskets,
tightness
Full
stroke
running
valves, check position
correct
Actuator
Lubricating
running
Check fire-resistance
Full
stroke
actuator
running
Re-lubricate
(open/close valves)
6-8
years
Re-lubricate
(open/close valves)
2-3
years
Continuous
valves
blowdown
Open valves
while pressure
shortly
running
#
#
Check valve
(sound)
leakage
2 years
3 years
Filters
and
blowdown
#
#
3 years
#
Chimney
Check bolts
Climate dampers
Full
stroke
dampers
running
Muffles
Visual determination
#
#
Heat preservation
Visual determination
Transmitters
Recalibrate
Steel structure
Visual determination
Bolts
connection:
sliding phenomena
attachment strap:
sliding phenomena
no
Painting: no overstress
phenomena
Box
girder:
support good
Appearance:
bending
inner
no