ThermalPowerPlant
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Notices
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Chapter5:BlowingofFuelGasPipingSystem....................................................85
5.1Introduction..........................................................................................................85
5.2DescriptionofFuelGasSystem..........................................................................90
5.3Precautions...........................................................................................................90
5.4Prerequisites.........................................................................................................92
5.4.1TypicalListofBillofMaterials.....................................................................93
5.4.2TypicalListofSafetyGadgets.......................................................................94
5.5PreparatoryArrangements...................................................................................94
5.6OperatingProcedure............................................................................................96
5.6.1NaturalGasBlowing.......................................................................................97
5.6.2CompressedAirBlowing................................................................................98
5.6.3CompressedNitrogenBlowing.......................................................................99
5.6.4SteamBlowing................................................................................................99
5.6.5WaterJetFlushing...........................................................................................99
5.6.6Pigging...........................................................................................................100
5.7Conclusion.........................................................................................................100
Chapter6:ChemicalCleaningofaSteamGenerator.........................................103
6.1Introduction........................................................................................................103
6.1.1Drum-TypeSteamGenerator........................................................................112
6.1.2Once-ThroughSteamGenerator...................................................................113
6.2Precautions.........................................................................................................114
6.3Prerequisites.......................................................................................................115
6.3.1TypicalListofApparatus..............................................................................117
6.3.2TypicalListofSafetyGadgets.....................................................................117
6.4PreparatoryArrangements.................................................................................118
6.5OperatingProcedure..........................................................................................119
6.5.1Drum-TypeSteamGenerators.......................................................................121
6.5.2Once-ThroughSteamGenerator...................................................................122
6.6EstimationofDMWaterandChemicals..........................................................126
6.6.1Water-HoldingCapacity................................................................................126
6.6.2EstimationofDMWaterRequirement.........................................................127
6.6.3EstimationofChemicalRequirement...........................................................128
6.7Conclusion.........................................................................................................129
7.1Introduction........................................................................................................132
7.1.1PurposeandTypeofLubrication..................................................................134
7.1.2OilCoolers.....................................................................................................135
7.1.3OilFilters.......................................................................................................136
7.1.4OilPumps......................................................................................................136
7.1.5CareandSupervisionofaLubricationSystem............................................137
7.2DescriptionoftheLubeOilSystem.................................................................137
7.2.1LubeOilSystemofSteamTurbine..............................................................137
7.2.2LubeOilSystemofGasTurbine..................................................................138
7.2.3LubeOilSystemofDieselEngine...............................................................139
7.3Precautions.........................................................................................................141
7.4Prerequisites.......................................................................................................142
7.4.1TypicalListofBillofMaterials...................................................................143
7.4.2TypicalListofApparatus..............................................................................143
7.4.3TypicalListofSafetyGadgets.....................................................................143 7.5PreparatoryArrangements.................................................................................144
7.5.1MechanicalCleaning.....................................................................................144
7.5.2ChemicalCleaning........................................................................................144
7.5.3WaterWashingofFactoryPickled(ChemicallyCleaned) LubeOilPipeLines......................................................................................146
7.5.4InstallationofFineMeshScreen..................................................................147
7.5.5BypassingAllVulnerableSystems...............................................................147
8.6OperatingProcedure..........................................................................................180
8.6.1SteamBlowing..............................................................................................180
8.6.2CompressedAirBlowing..............................................................................185
8.7EstimationofDMWater...................................................................................188
8.8EstimationofFuelOil.......................................................................................189 8.9Conclusion.........................................................................................................190
PART2ACTIVITIESTHATMAKECRITICALEQUIPMENT READYTOPUTTHEMINSERVICE193
Chapter9:HydraulicTestofSteamGenerator.................................................195 9.1Introduction........................................................................................................195
9.4.1TypicalListofBillofMaterials...................................................................198
9.4.2TypicalListofSafetyGadgets.....................................................................201 9.5PreparatoryArrangements.................................................................................201
9.6FillingofSteamGenerator................................................................................204
9.6.1Drum-TypeSteamGenerators.......................................................................204
9.6.2Once-ThroughSteamGenerators..................................................................206
9.8.1EstimationofDMWater...............................................................................208
9.8.2EstimationofChemicalRequirement...........................................................209
13.4.1TypicalListofApparatus/Instruments......................................................272
13.4.2TypicalListofSafetyGadgets.................................................................273
Preface
IworkedinthepremierengineeringconsultancyfirmofIndia,M/SDevelopmentConsultants PrivateLimited(DCPL),formorethanfourdecades.DuringthislongtenureIhadthe opportunitytoworkininnumerablethermalpowerplantsofvarioussizesandconfigurations. Themostimportantpartofthisassociationwasmyexposuretochronologicaldevelopmentin powerplanttechnology,bothwithinandoutsideIndia.Againstthisbackdrop,whenIwas executingvariousprojectsIobservedthatthereisadearthofpublishedbookswhereinvarious aspectsofpreoperationalactivitiesareconsolidated.Thiswasthestartingpointingetting motivatedtowritethisbook, ThermalPowerPlant PreoperationalActivities,inwhichItried myutmosttoincorporatethestate-of-the-arttechnologyapplicabletotheseactivities.
Designofathermalpowerplantisadesktopstudy,whileoperationoftheplantfallsexclusively withinthepurviewoffieldengineering.Inbetweendesignandoperationtherearecertainareas, generallyknownintheindustryaspreoperationalactivities.Theprocedureforexecutionof theseactivitiesisdevelopedduringdesktopstudy,butisexecutedinfieldonly.Sothese activitiesactasago-betweenfordesignandoperationtoensureunruffledpowergenerationas farastheenduserisconcerned.Thus,thisbookmaybeconstruedascomplementaltomy previousbook, ThermalPowerPlant DesignandOperation,publishedbyElsevier.
Thisbookaimstoaddresssomeoftheessentialpreoperationalactivitieswhichareextremely importanttocarryoutinlinewiththepracticefollowedintheindustryglobally.Smooth, trouble-free,andeconomicoperationofthermalpowerplantscanbeensuredifpreoperational activitiesarecarriedoutwiththeutmostcareinordertoestablishthatpriortothestart-upof varioussystems,equipment,and/ortheplantasawhole,theywouldbereadyinallrespectsin accordancewithmanufacturers’recommendations,andatthesametimefulfillallrequirements ofapplicablestatutoryguidelines.Themainpurposeofaddressingtheessentialfeaturesof preoperationalactivitiesistoensureeconomicgenerationfromaplant.Hence,theprimary focusofthisbookisonprofessionalengineers.
Thecontentsofthebookaresuchthatthebookshouldnotbetreatedasaconventionaltextbook usedintechnicalinstitutes.Fordesignengineers,thisbookwouldactasareferencetohelp themdevelopproject-specificprecommissioningmanualsofanewplant.Itwouldalsofulfill theneedsofcommissioningengineers,suppliers,andutilityoperatorsduringtheexecution
periodofnewplants.Whilesuccessfulcompletionofpreoperationalactivitiesisessentiallyto beaccomplishedandcertifiedpriortothestart-upofnewplants,areasaddressedinthiswork areapplicabletorunningplantsaswell.Inrunningplants,thisbookwouldbeatooltohelp operationandmaintenanceengineers/suppliers(contractors)executecleaning/testingactivities (eg,overhaul,criticalinspection,majorrepair)successfullytocomplywithregulatory requirements.
Degradationintheperformanceofmajorprime-movers—namelysteamturbines,gasturbines, anddieselengines—ofrunningunitsisacommonphenomenonintheindustry.Inordertoarrest theseverityofdegradation,itisgenerallyrecommendedtoundertakeamajoroverhaulofthese prime-moversfollowingaspecifiedperiodofoperatinghours.Inthecaseofsteamturbines,this periodisusually6years,whileforgasturbinesanddieselengines,permissibleoperatinghours thatareusuallyrecommendedbymanufacturersare48,000and8000,respectively.Steam generatorsaregenerallyinspectedafterabout12–24monthsofoperationtomeetthestatutory requirementsoftheboilerinspectorate.Anydefectobservedduringinspectionneedstobeattended tobeforetheboilerinspectorateextendspermissiontorestartthesteamgenerator.
Inmanycountriesinitiativeshavebeenundertakentoimprovetheefficiencyand environmentalperformanceoftheirexistingthermalpowerplantsthroughrefurbishment, upgradation,rehabilitation,andmodernizationactivities.Beforeputtingtheseoldplantsinto serviceoncompletionofroutineoverhauls,oncompletionofrenovationandmodernization, followingamajorrepair,orafterlongshutdownofcriticalequipmentoroftheplant,itis compulsorytocarryoutpreoperationalactivitiestomeetstatutoryrequirements;otherwise, theseplantswouldnotbeinapositiontosupplyuninterruptedpower.
Beforediscussingdetailsoftheseactivities,itisessentialthatreadersareconversantwithan outlineofathermalpowerplantorthatreaders’knowledgeofathermalpowerplantis refreshedfortheconvenienceofunderstandingvarioussystemsandequipment.Hence, Chapter1 addresses“GeneralDescriptionofThermalPowerPlants.”Inaddition,ageneric descriptionofsystemsandequipmentpertainingtospecifictypesofpreoperationalactivitiesor thermalpowerplantsisdiscussedsubstantiallyinvariouschapters.
Successfulcompletionofapreoperationalcleaningactivityoraprestart-upactivitydependson howconsciouslyeachactivityiscarriedout,suchthataplantdoesnotfaceanyuntoward incidentduringnormalrunning,lestgenerationgetsperturbed.Thisisensuredbyadheringto theguidelineslaiddownbyaninternationallyrecognizedqualitymanagementsystem(eg,ISO 9000).Fortheconvenienceofreaderstoadoptafoolproofqualitymanagementsystem, guidelineson“QualityAssurance(QA)andQualityControl(QC)(Applicableto PreoperationalActivities)”arediscussedin Chapter2.Priortoconductinganypreoperational activityitisextremelyessentialtoobservecertainprecautionarymeasures,andalsotoensure thatcertainactivities/itemsarecompletedbeforehand.Thesetwoaspectsareaddressedunder “Precautions”and“Prerequisites”in Chapters3–17.TheQAteammustberesponsiblefor
fulfillingtheseaspects.ThereaftertheQCteamtakesovertoensuresuccessfulcompletionof eachpreoperationalactivity,followingthestepsofdevelopingpreparatoryarrangements, operatingprocedurestobefollowed,availabilityofrequiredmaterials(chemicals/water/any specialgadgets),availabilityofsafetyequipment,andsoon.
Lookingtowardcommissioningofanewplantorrecommissioningofarunningplantfrom availabilityofelectricpowertocommercialoperation,theeffectiveorderofpreoperational activitiesthataregenerallyfollowedintheindustryarepresentedhere:
1.Hydraulictestofsteamgenerator
2.Airtightness/leakagetestofthefurnace,air,andfluegaspathsofsteamgenerator
3.Alkaliflushingofpreboilersystem
4.Flushingoffueloilpipingsystem
5.Blowingoffuelgaspipingsystem
6.Steamgeneratorinitialfiringanddryingoutofinsulation
7.Chemicalcleaningofsteamgenerator
8.Flushingoflubeoilpipingsystem
9.Steam/airblowingofmainsteam,coldreheat,hotreheat,andothersteampipelines
10.Floatingofsteamgeneratorsafetyvalves
11.Cleanairflowtestofpulverizers
12.Condenserfloodtestandvacuum-tightnesstest
13.Generatordryingoutandairtightnesstest
14.Fillingofgeneratorwithhydrogenandprotectionstabilitytestofgenerator
15.Completiontestofthepowerstation
Whilesomeoftheaforementionedactivitiespertaintothepreoperationalcleaningofpiping systems,theremainingactivitiesareconductedtoensuretheintegrityofcriticalequipment. Hence,preoperationalactivities,aslaiddowninthisbook,areaddressedunderPart1andPart2, ascategorizedhere:
Part1:PreoperationalCleaningofVariousSub-Systems
Preoperationalcleaningofvariouspipingsystemsofmodernthermalpowerplantsassumes considerableimportancebecauseofthehigh-qualitydemandofflowingfluid,beitsteam, water,oil,orgas,throughdifferentpipelines.Duringtheprocessofmanufacturing, transportation,storing,anderectionofvariouspipingsystems,inspiteoftakingthebest precautionarymeasures,acertainamountofdirt,millscale,oil,grease,andsoonfindsitsway intothesesystems.Theseunwantedconstituentsneedtobecleanedpriortoputtingintoservice “erectednewpiping”or“replacedoldpiping.”
Inrunningunits,depositsmaygrowinsidepipelinesduetoimproperwatertreatmentorfrom processcontamination.Corrosioninsidethepipelinesofoperatingunitsmaytakeplaceeither
fromanimproperlycontrolledpHofdemineralizedmakeupwaterorfromconcentrationof boilerwatersalts.
Inordertogetridoftheseundesirableelementsfromthepipingsystemsofbothnewunitsand runningunits,asfaraspracticable,preoperationalcleaningofpipingsystemsiscarriedout. Basedonthetypeofflowingfluidsthroughvariouspipingsystems,differenttypesofcleaning activities,asadoptedintheindustry,arediscussedinthefollowingchapters:
i. Chapter3:Alkaliflushingofpreboilersystem
ii. Chapter4:Flushingoffueloilpipingsystem
iii. Chapter5:Blowingoffuelgaspipingsystem
iv. Chapter6:Chemicalcleaningofboiler
v. Chapter7:Flushingoflubeoilpipingsystem
vi. Chapter8:Steam/airblowingofmainsteam,coldreheat,hotreheat,andothersteam pipelines
Part2:ActivitiesthatMakeCriticalEquipmentReadytoPutThemin Service
Thissectionaddressesactivitieswhicharecarriedouttomakecriticalequipmentreadypriorto puttingitinserviceandtoestablishtheintegrityofthisequipment,alongwithitsassociated systems.Activitiescoveredinthissectionare:
i. Chapter9:Hydraulictestofsteamgenerator
ii. Chapter10:Airtightness/leakagetestofthefurnace,air,andfluegaspathsofsteam generator
iii. Chapter11:Steamgeneratorinitialfiringanddryingoutofinsulation
iv. Chapter12:Floatingofsteamgeneratorsafetyvalves
v. Chapter13:Cleanairflowtestofpulverizers
vi. Chapter14:Condenserfloodtestandvacuum-tightnesstest
vii. Chapter15:Generatordryingoutandair-tightnesstest
viii. Chapter16:Fillingofgeneratorwithhydrogenandprotectionstabilitytestofgenerator ix. Chapter17:Completiontestofthepowerstation
Asaprequelto Chapter17,“BriefDescriptionofPerformanceGuaranteeTests”isaddressedin AppendixA.
Safetyisafundamentalnecessityforoperatinganyplant.Hence, AppendixB laysdown “GeneralSafetyGuidelines.”
Whenaplantisinoperation,undermaintenance,orkeptundermothballedcondition,certain valves/areas/systemspurposefullyneedtobekeptisolated.Anyattempttoviolatesuch
isolation,eveninadvertently,mayleadtoharm,injury,ormajordisasteroftheplantand personnel.Inordertoobviatesuchaninadvertentattemptofviolation,warningtagsofvarious typesareappliedonisolatedvalves/areas/systems.Typical“TaggingProcedures”delineating variouswarningcontentarethereforepresentedin AppendixC ofthisbook.
Inaccordancewithcurrentglobalpractice,SIunitshavebeenusedthroughoutthebook. Nevertheless,fortheconvenienceofreaders,conversionfactorsfromSIunitstothemetric systemofunitstotheimperialandUSsystemofunitsareaddressedin AppendixD.
Readersuggestionsfortheimprovementofthecontentsofthisbookarewelcome,andwould beacknowledgedgratefullybytheauthor.
DipakK.Sarkar June30,2016
Acknowledgments
TheoverwhelmingresponseIreceived frompowerengineersformybook ThermalPower Plant DesignandOperation promptedmetowritethisbook.Iamsincerelythankfulto thepowerengineeringcommunityformotivatingmeinthisregard.Ialsoamindebtedto mycolleaguesandfriendsintheindustryfortheiradviceonbridgingthegapbetweenthe designandoperationofathermalpowerplantintheformofabookonpreoperational activities.IamparticularlygratefultoMr. SamiranChakraboty,retiredchiefengineer, erstwhileM/SACCBabcockLimited(ABL), currentlyM/SAlstomIndiaLimited,who firmlyexpressedthenecessityofabookonpreoperationalactivitiesofathermalpower plantforthebenefitofmembersofstart-up,commissioning,andoperationengineering departments.
IalsoamindebtedtoM/SDevelopmentConsultantsPrivateLimited(DCPL)becausewhile workinginthisorganizationIreceivedexposuretoavarietyoftechnologieschosenbydifferent manufacturersadoptedindifferentcountries,thebenefitsofwhichwerereapedwhilewriting thisbook.
Mr.S.K.Saha,generalmanagerDCPL,anoutstandingoperationengineer,sharedhislong experiencethathelpedmeinpreparingthemanuscript.IgratefullyacknowledgeMr.Saha’s support.
WhileIwasinDCPLIlearntmanyaspectsofelectricalsystemandelectricalprotectionsystem frommythethencolleaguesMr.P.S.BhattacharyaandMr.S.K.Bhattacharya.Knowledge gatheredthuswassubsequentlyhonedatthefield. Chapters15 and 16 mightnothavebeen developedbymewithoutmyinteractionwithboththeBhattacharyas.Iamspeciallyindebted tothem.
Ithankmyson,Krishanu,daughter,Purbita,andson-in-law,Sudip,whowerethesourceof encouragementinwritingthisbook.MywifeAnita’sinspirationneedsspecialmention; withoutherceaselesssupportIcouldnothavefinishedthebookontime.
IamgratefultoElsevierforallowingmetoborrowmaterialsonsystemdescriptionfrom mypreviousbook, ThermalPowerPlant DesignandOperation .Ialsoamindebted tothepublishingandeditorialteamatElsevier—SarahHughes,JoeHayton,CariOwen, AlexWhite,LucyBeg,PoulouseJosephandVictoriaPearson—fortheirsupportand guidance.
May27,2016
ListofAcronyms/Abbreviations
μSMicrosiemens
a,absAbsolute
AAsh(contentincoal)/ampere
ABMAAmericanBoilerManufacturersAssociation
A/CAir/cloth
ACAlternatingcurrent/airconditioning
ACFActivatedcarbonfilter
ACWAuxiliarycoolingwater
adAirdried
AFBCAtmosphericfluidizedbedcombustion
AFRAir-fuelratio
AHAirheater
AHSAshhandlingsystem
a.k.a.Alsoknownas
ANSIAmericanNationalStandardsInstitute
APCAuxiliarypowerconsumption
APIAmericanPetroleumInstitute
APSAutomaticplantstart-upandshutdownsystem
AQCAirqualitycontrol(ESP/bagfilterandFGD)
arAsreceived
ASAuxiliarysteam
ASMEAmericanSocietyofMechanicalEngineers
ASTMAmericanSocietyforTesting&Materials
atmAtmosphere
AVRAutomaticvoltageregulator
AVTAllvolatiletreatment
AWWAAmericanWaterWorksAssociation
bBar
BBillion
BABottomash
xxivListofAcronyms/Abbreviations
B&WTheBabcock&WilcoxCompany
BDCBottomdeadcenter
BEIBritishElectricityInstitute
BFBasefactor
BFBCBubblingfluidizedbedcombustion
BFPBoilerfeedpump
BHRABritishHydraulicResearchAssociation
BISBureauofIndianStandards
BMCRBoilermaximumcontinuousrating
BMSBurnermanagementsystem
BOOSBurneroutofservice
BOPBalanceofplant
BPBoosterpump
BPVCBoilerandpressurevesselcode
BSIBritishStandardsInstitution
BtuBritishThermalUnit
BWRBoilingwaterreactor
CCarbon/celsius/centegrade
CaCalcium
CACompressedair/citricacid
CAACleanAirAct,U.S.A.
CAAACleanairactamendments
CBDContinuousblowdown
ccCubiccentimeter
CCCombinedcycle
CCCWClosedcyclecoolingwater
CCGTCombinedcyclegasturbine
CCPPCombinedcyclepowerplant
CECombustionEngineeringInc./collectingelectrode
CEACentralElectricityAuthority,India
CEGBCentralElectricityGeneratingBoard
CEN(ComiteEuropeendeNormalisation)-EuropeanCommitteefor Standardization
CEPCondensateextractionpump
CFBCCirculatingfluidizedbedcombustion
cfmCubicfeetperminute
CFRCleaningforceratio
CHFCriticalheatflux
CHPCombinedheatandpower
ListofAcronyms/Abbreviationsxxv
CHSCoalhandlingsystem
CICombustioninspectionofgasturbine
C.I.Compressionignition
cmCentimeter
COCarbonmonoxide
CO2 Carbondioxide
cPCentipoise
CPCBCentralPollutionControlBoard,India
CRCompressionratio
CR/CRHColdreheat
CSACanadianStandardsAssociation
CSBChemicalSafetyandHazardInvestigationBoard,U.S.A.
CVCalorificvalue/controlvalve
CWCirculating(condensercooling)water
cwtHundredweight
DDrain/diameter
D,dDay
DAFDryashfree
dBDecibel
DASDataacquisitionsystem
DCDirectcurrent
DCADraincoolerapproach
DCSDistributedcontrolsystem
DEDischargeelectrode
degDegree
DINDeutschesInstitutfurNormung
DMDe-mineralized
dmmfDrymineralmatterfree
DMWDe-mineralizedwater
DNBDeparturefromnucleateboiling
DODissolvedoxygen
DSIDuctsorbentinjection
EAExcessair
ECSEnvironmentalcontrolsystems
EDIElectricalde-ionizationunit
eff/EFFEfficiency
EHSEnvironmental,healthandsafety
EIAEnvironmentalimpactassessment
emfElectromotiveforce
