Presentation is loading. Please wait.

Presentation is loading. Please wait.

SIPAT SUPER THERMAL POWER PROJECT. SIPAT STAGE # 1 BOILER.

Similar presentations


Presentation on theme: "SIPAT SUPER THERMAL POWER PROJECT. SIPAT STAGE # 1 BOILER."— Presentation transcript:

1 SIPAT SUPER THERMAL POWER PROJECT

2 SIPAT STAGE # 1 BOILER

3 ECO. JUNTION HEADERS ECO I/L HDR ECONOMISER ECO O/L HDR ECO. O/L LINKS ECO. MIXING PIECE BOTTOM RING HEADER SPIRAL WALL INTERMITTENT HEADERS VERTICAL WALL OUTLET HEADERS ECONOMISER TO 1 ST PASS TOP HEADERS :

4 ECONOMISER : COUNTER FLOW 4 BANKS 163 ASSEMBLIES 4 JUNCTION HEADERS 224 HANGER TUBES ECO OUTLET HEADER SA 106 C ; SA 210 C SPIRAL AND VERTICAL WALLS : TOTAL SPIRAL TUBES : 440 (102X2 FRONT & REAR; 108X2 LEFT & RIGHT) SPIRAL TO VERTICAL RATIO = 1:3 FRONT VERTICAL TUBES: 336 SIDE WALL TUBES: 648 REAR SCREEN TUBES : 280 REAR HANGER TUBES : 56 TUBES : T22 HEADERS : P12

5 STORAGE TANK MIXING PIECE FLASH TANK CONDENSER BOILER FILL LINEFEED WATER LINE TO ECONOMISER BCP WRZR UG STORAGE TANK MIXING PIECE FLASH TANK CONDENSER BOILER FILL LINEFEED WATER LINE TO ECONOMISER BCP WRZR UG START UP SYSTEM : SEPERATOR TANKS 1 ST PASS ROOF O/L HEADERS SEPERATORS I/L LINKS

6 EXTENDED WALL : 2 ND PASS STEAM FLOW : BACK PASS BOTTOM RING HDR BACK PASS TOP LHS HDR BACK PASS TOP RHS HDR BACK PASS ROOF I/L HDR EXTENDED WALL HDR 1 ST PASS ROOF I/L HDR EXTENDED WALL

7 BACK PASS WALLS & HEADERS : FURNACE FRONT ROOF : 168 BACK PASS ROOF : 111 BACK PASS REAR WALL : 111 BACK PASS SIDE WALL : 328 BACK PASS FRONT WALL : 167 BACK PASS SCREEN : 167 TUBES : T12 HEADERS : P12 EXTENDED WALL : EXTENDED WALL FLOOR : 142 EXTENDED SIDE WALL : 142 TUBES : T12 HEADERS : P12 FLUID COOLED SPACER TUBES: 3 BACK PASS WALLS & HEADERS : LINK PIPES : P12 LINK PIPES : P12 SEPERATORS & STORAGE TANK : SA 302C STORAGE TANK : SA 302C START UP SYSTEM : LINK PIPES : P12 LINK PIPES : P12 SEPERATORS & STORAGE TANK : SA 302C STORAGE TANK : SA 302C

8 FROM II nd PASS BOTTOM RING LHS HDR FROM II nd PASS BOTTOM RING RHS HDR DIV. PANEL I/L HDR DIV. PANEL O/L HDR DIV. PANEL II ND PASS TOP RHS HDR II ND PASS TOP LHS HDR DIVISIONAL PANEL : SH DIV. PANEL TUBES : 480 TUBES : T23; T91 HEADERS : P12; P23 FLUID COOLED SPACER TUBES : 6

9 DIV. PANEL O/L HDR PLATEN I/L HDR PLATEN O/L HDR PLATEN COILS DIV. PANEL I/L HDR PLATEN TO FINAL SH LINK DIV. PANEL O/L HDR FINAL SH I/L HDR FINAL SH O/L HEADERS TO HP TURBINE FINAL SH COILS DIV. PANEL TO PLATEN LINK PLATEN AND FINAL SH : PLATEN ASSEMBLIES : 20 NO OF TUBES : 480 TUBES : T12; T23; T91 HEADERS : P12; P23 NO OF STAGES : 2 ASSMBLIES : 2X55 NO OF TUBES : 935 TUBES : T23; T91 HEADERS : P23; P91 COUNTER FLOW DIRECTION

10 LTRH O/L HDR FINAL RH I/L HDR FINAL RH O/L HDRS LTRH BANKS LTRH O/L TO FINAL RH I/L LINKS TO IPT FINAL RH LTRH I/L HDR FROM CRH REHEATERS : NO OF BANKS : 3 NO OF TUBES : 111 TUBES : SA 210C; T12; T23 HEADERS : SA 106C; P12 NO OF ASSEMBLIES : 41 NO OF TUBES : 615 TUBES : T23; T91; SUPER 304H HEADERS : P12; P91

11 HPT IPT LPT CONDENSERCONDENSER FEED WATER FRS STORAGE TANKSTORAGE TANK SEPARATOR BWRP Spiral water walls MS LINE HRH LINE VERTICAL WW ECO I/L ECO JUNCTION HDR ECO HGR O/L HDR FUR LOWER HDR FUR ROOF I/L HDR DIV PANELS SH PLATEN SH FINAL RH FINAL SH LTRH ECONOMISER 290°C, 302 KSC 411°C, 277Ksc 411°C, 275 Ksc 492°C, 260 Ksc 540°C, 255 Ksc 305°C, 49 Ksc 457°C, 49 Ksc 568°C, 47 Ksc G LPT

12 FEATURES OF SUPER CRITICAL BOILER : 1. ONCE THROUGH OPERATION : FEED WATER PUMP ECONOMISER WATER WALL/ EVAPORATOR SEPERATOR SUPERHEATER STORAGE TANK RECIRCULATION PUMP CONSTANT WATER WALL FLOW (below 30% load) FEED WATER PUMP ECONOMISER WATER WALL/ EVAPORATOR SEPERATOR SUPERHEATER ONCE THROUGH FLOW OPERATION (above 30% load)

13 2. CONSTANT PRESSURE OPERATION : Above 90% & below 30% Above 90% & below 30% 3. SLIDING PRESSURE OPERATION : B/W 30% & 90% B/W 30% & 90%

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

15 DESCRIPTIONUNIT 660 MW AT BMCR S/H STEAM FLOW S/H STEAM FLOWT/HR2225 SH STEAM PR SH STEAM PR KG/CM SH STEAM TEMP 0C0C0C0C540 RH STEAM FLOW T/HR1742 RH STEAM TEMP INLET 0C0C0C0C299 RH STEAM TEMP OUTLET 0C0C0C0C568 RH STEAM PRESS OUTLET KG/CM FEED WATER TEMP 0C0C0C0C SECONDARY AIR FLOW T/HR1732 PRIMARY AIR FLOW T/HR946 TOTAL COAL FLOW T/HR MW PARAMETERS :

16 FEATURES OF 660 MW- STEAM QUALITY PARAMETERS S.NO.PARAMETER STEAM QUALITY AT SG OUTLET DURING START UP DURING NORMAL OPERATION 1TDS202 2SILICA202 3SODIUM102 4CHLORIDES02 5COPPER201 6IRON105 7 CATION CONDUCTIVITY <0.2 to 0.25 micro siemens /cm <-0.2 micro siemens / cm 8PH6~8

17 COMMISSIONING NETWORK

18 ID FAN # 1A TRIAL RUN FD FAN # 1A TRIAL RUN SAPH # 1A TRIAL RUN BRP TRIAL RUN SACNNER AIR SYSTEM READINESS FURNACE READINESS FUEL OIL SYSTEM READINESS DDCMIS FSSS READINESS MFT CHECKING GATES, DAMPERS / VALVES TG : SG : SG ECW SYSTEM CW SYSTEM READINESS CHEMICAL CLEANING OF BOILER MS Line Welding Completion CRH Line Welding Completion HRH Line Welding Completion MS Line Hanger Erection Cold Setting CRH Line hangers Cold Setting HRH Line Hangers Cold Setting MS Line Insulation CRH Line InsulationHRH Line Insulation MS Line HT CRH Line HTHRH Line HT COMPRESSED AIR SYSTEM READINESS AUX PRDS READINESS ACW System Temporary Piping Completion Boiler Light Up & Steam Blowing MDBFP Trial CEP Trial TG ECW System HOT Well Readiness

19 LIST OF APPROVED PROCEDURES Boiler Commissioning is carried out based on the guide lines of Corporate commissionin groups. OS) These are the list of approved commissioning procedures which are followed in sipat commissioning activities Boiler Commissioning is carried out based on the guide lines of Corporate commissionin groups. OS) These are the list of approved commissioning procedures which are followed in sipat commissioning activities 1. BOILER HYDRO TEST 2. OIL FLUSHING OF ROTARY MACHINES 3. BOILER & DUCTS AIR TIGHTNESS TEST (ATT) 4. ESP AIR IN LEAK TEST 5. ESP GAS DISTRIBUTION (GD) TEST 6. BOILER CHEMICAL CLEANING 7. BOILER COLD AIR VELOCITY TEST 8. CLEAN AIR FLOW TEST 9. LDO & HFO SYSTEMS COMMISSIONING 10. BOILER & AUX LINES STEAM BLOWING

20 COMMISSIONING MILE STONES 1.BOILER HYDRO TEST : HP SYSTEM : Hydro test done on HP system hydro test is done at 410 KSC. HP system consists of Economiser, boiler 1 st & 2 nd pass, divisional panel, platen & final super heater upto boiler stop valves. MP SYSTEM : Hydro test done on MP system hydro test is done at 80.1 KSC. MP system consists of CRH isolator to LTRH, Final Reheater upto HRH isolators. 2. BURNER TILT, OIL GUNS & IGNITOR CHECKING : Checking is completed on Burner tilt checking is done from inside the boiler in which burner limits & angles adjusted. Oil guns & ignitors clearances are checked inside the boiler. 3. FD, ID & PA FANS COMMISSIONING : FD Fan # 1A trial run taken on ID Fan # 1A trial run taken PA Fan # 1A trial run taken

21 COMMISSIONING MILE STONES 3. FD, ID & PA FANS COMMISSIONING : FD Fan # 1B trial run taken on ID Fan # 1B trial run taken PA Fan # 1B trial run taken Fans commissioning involves following steps:  Lube oil flushing of lube oil skid, lube oil lines with flushing oil (32 grade) (bearings bypassed) (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)  Lube oil flushing through bearings (32 grade)  Lube oil flushing through bearings (68 grade oil)  Blade pitch commissioning & discharge gate commng.  Cooling water lines flushing & charging  Fan trial 4. AIR PREHEATERS COMMISSIONING : SAPH # 1A trial run taken on SAPH # 1B trial run taken on

22 4. AIR PREHEATERS COMMISSIONING : PAPH # 1A trial run taken on PAPH # 1B trial run taken on Air Preheaters commissioning involves following steps:  Lube oil motors & main motor no load trial  Lube oil flushing of Support & Guide bearings with 32 oil (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)  Lube oil flushing through bearings (32 grade)  Lube oil flushing through bearings (680 grade oil)  Air motor service air line blowing  Cooling water lines flushing & charging  Air preheater trial with air motor & electrical motor

23 4. BOILER & DUCT ATT : Secondary air duct ATT is completed on Primary air duct ATT is completed on Flue gas air duct ATT is completed on Furnace ATT completed on  ATT of boiler & ducts is done at 150 mm of water column.  Secondary air duct & boiler pressurisation is done by FD Fan.  Primary air duct pressurisation is done by PA fan.  Flue gas duct pressurisation is done by using temporary blowers 5. ESP COMMISSIONING : ESP Air In Leak test: All passes air in leak test completed on The test is done to prove that air in leak into ESP is with in guaranteed value of 1%of design gas flow rate. ESP Rapping system commng. : All passes rapping systems commng. completed on Each Pass has 18 nos. collecting electrodes rapping system, 18 nos emitting electrode rapping system & 2 nos. gas distribution plates rapping system.

24 5. ESP COMMISSIONING : ESP Fields charging ESP GD test completed on This is done to verify uniform flow distribution inside the ESP Chambers. 6. BOILER CAVT : CAVT (Cold Air Velocity Test) is completed on This test is done to check flue gas flow patterns inside the boiler. 7. AIR BALANCE TEST (ABT): 8. BOILER CHEMICAL CLEANING : Boiler Chemical cleaning is completed on Chemical cleaning involves following steps:  Flushing  Acid Cleaning  Rinsing  Pre Neutralization  Neutralization  Passivation

25  Main chemicals used are formic acid (10%), sorbic acid, coronil 200S  Boiler chemical cleaning is completed in 7 days. 9. BRP (Boiler Recirculation Pump) COMMISSIONING : BRP trial completed on BRP commissioning involves following steps:  Cavity filling line flushing (until Conductivity & Turbidity reaches required parameters)  Flushing through motor cavity & through cooler  ECW lines water flushing  Pump trial 10. BOILER LIGHT UP : Boiler is Lighted Up on Boiler is lighted up with LDO and all 4 corner oil guns were proven. 11. STEAM BLOWING : It has following steps PRE STEP1: Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Tailpipe to atmosphere Blowing is done from 40 KSC to 20 KSC

26 11. STEAM BLOWING : Steam blowing consists of following steps: PRE STEP 2: Separator Superheater Main Steam Line HP Bypass Valve Cold RH line backward flush through drain pot near RH inlet header Temporary Piping tailpipe to atmosphere Blowing is done from 40 KSC to 20 KSC MAIN STEP 1: Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Non-return Valve Cold Reheat Line Reheater Hot Reheat Line IPT Stop Valve Tailpipe to atmosphere Blowing is done from 80 KSC to 40 KSC MAIN STEP 2: Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Non-return Valve Cold Reheat Line Reheater Hot Reheat Line LP Bypass Valve Tailpipe to atmosphere Blowing is done from 80 KSC to 40 KSC

27 11.PF SYSTEM COMMISSIONING: (a) Seal air fan & its dampers (b) Mills commissioning:  Lube oil pumps load trial  Lube oil flushing of oil line with 32 oil bypassing gear box & bearings (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)  Lube oil flushing through bearings & gear box(32 grade)  Lube oil flushing through bearings (320 grade oil)  Cooling water lines flushing & charging  Roller & Bowl gap adjustment  Spring tension adjustment  P&I checks & Mill solo run.

28 11.PF SYSTEM COMMISSIONING: (C) RC Feeders  Motor checks  P&I checking  Feeder belt trial with clean out conveyor. (D)Commissioning of gates & dampers  Commng of HAD, CAD, HAG, CAG, BIG, MDV from remote (E) Clean air flow test of mills as per approved procedure

29 PROBLEMS & MODIFICATIONS

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

31 BOILER HEADERS REPLACEMENTS  Some of the super heater headers were replaced with higher grade materials.  5 nos. of headers & link pipes of Gr P23 were replaced with Gr P91.  This material replacement is done to avoid probable material failure in the pipes and fittings of the boiler subjected to very high temperature and pressures.

32

33


Download ppt "SIPAT SUPER THERMAL POWER PROJECT. SIPAT STAGE # 1 BOILER."

Similar presentations


Ads by Google