660 MW Sipat Boiler
660 MW Sipat Boiler
660 MW Sipat Boiler
SUB CRITICAL & SUPER CRITICAL BOILER SIPAT BOILER DESIGN BOILER DESIGN PARAMETERS
BOILER CONTROL
BOILER LIGHT UP START UP CURVES
UNDERSTANDING SUB CRITICAL TECHNOLOGY Water when heated to sub critical pressure, Temperature increases until it starts boiling This temperature remain constant till all the water converted to steam When all liquid converted to steam than again temperature starts rising. Sub critical boiler typically have a mean ( Boiler Drum) to separate Steam And Water The mass of this boiler drum, which limits the rate at which the sub critical boiler responds to the load changes Too great a firing rate will result in high thermal stresses in the boiler drum
When Water is heated at constant pressure above the critical pressure, its temperature will never be constant No distinction between the Liquid and Gas, the mass density of the two phases remain same No Stage where the water exist as two phases and require separation : No Drum The actual location of the transition from liquid to steam in a once through super critical boiler is free to move with different condition : Sliding Pressure Operation
For changing boiler loads and pressure, the process is able to optimize the amount of liquid and gas regions for effective heat transfer.
No Religious Attitude
568C, 47 Ksc
FUR ROOF I/L HDR
SEPARATOR
S T O R A G E T A N K HPT
G
LPT
C O N D E N S E R
LPT
IPT
ECONOMISER
ECO I/L
BWRP
FEED WATER
FRS
Steam
Water Water
SEPARATOR TANK
PENTHOUSE
RH I/L hdr (R10) F28 Platen I/L hdr (S28) Div. Pan. I/L hdrs (S20) Back pass Roof i/l hdr Separator (F31) F8 S2 F28 Div. Pan. O/L hdrs (S24)
TYPE OF TUBE
Vertical Spiral
SPIRAL WATER WALL TUBING Advantage Disadvantage over Vertical water wall
Coal Analysis
Parameter High Heating Value Total Moisture Proximate Volatile Matter Analysis Fixed Carbon Ash Fuel Ratio (FC/VM) Combustibility Index Carbon Hydrogen Nitrogen Ultimate Analysis Oxygen Sulfur Ash Moisture Grindability ASTM Coal Classification Unit kcal/kg % % % % % % % % % % % HGI Design Coal 3,300 12.0 21.0 24.0 43.0 1.14 2,067 39.53 2.43 0.69 6.64 0.45 43.00 12.00 50 HiVol. C Bituminous Worst Coal 3,000 15.0 20.0 20.0 45.0 1.00 2,353 31.35 2.30 0.60 5.35 0.40 45.00 15.00 47 HiVol. C Bituminous Best Coal 3,750 11.0 24.0 29.0 36.0 1.21 2,476 40.24 2.68 0.83 8.65 0.60 36.00 11.00 52 HiVol. C Bituminous Young Hung #1,2(800MW) 6,020 10.0 23.20 52.89 13.92 2.28 2,781 63.03 3.60 1.53 7.20 0.72 13.92 10.00 45 Midium Vol. Bituminous Tangjin #5,6(500MW) 6,080 10.0 26.53 49.26 14.21 1.86 3,492 62.15 3.87 1.29 7.80 0.68 14.21 10.00 48 HiVol. C Bituminous
1.
High erosion potential for pulverizer and backpass tube is expected due to high ash content.
2. Combustibility Index is relatively low but combustion characteristic is good owing to high volatile content.
Ash Analysis
Parameter SiO2 Al2O3 Fe2O3 CaO Ash Analysis MgO Na2O K2O TiO2 P2O5 SO3 Others Ash Fusion Temp. (oC) (Reducing Atmos.) Ash Content Basic / Acid Initial Deformation Softening Hemispheric Flow Unit % % % % % % % % % % %
o o o o
Design Coal 61.85 27.36 5.18 1.47 1.00 0.08 0.63 1.84 0.54 0.05 1150 1400 1400 130.3 0.09
Worst Coal 62.40 27.31 4.96 1.42 1.03 0.08 0.32 1.88 0.55 0.05 1100 1280 1280 150.0 0.09
Best Coal 61.20 27.32 5.40 1.52 0.97 0.08 1.22 1.80 0.44 0.05 1250 1400 1400 96.0 0.10
Young Hung Tangjin #1,2(800MW) #5,6(500MW) 57.40 29.20 4.40 2.70 0.90 0.30 0.70 1.30 3.10 1200 57.40 29.20 4.40 2.70 0.90 0.30 0.70 1.30 3.10 1200
1.
Lower slagging potential is expected due to low ash fusion temp. and low basic / acid ratio.
C C C C
2. Lower fouling potential is expected due to low Na2O and CaO content.
kg/Gcal B/A
23.12 1.63
23.37 1.63
FLUE GAS PATH : No Of ESP Passes No Of Fields / Pass : : 6 Pass 18 1-7 fields 70 KV. 8&9 field 90 KV
No Of Hopper / Pass
Flue Gas Flow / Pass
:
:
36
1058 T/ Hr
M M
TO PULVERISER SYSTEM
PA FAN # A
PAPH # A
M
AIR MOTOR
AIR MOTOR
SAPH # A
FD FAN # A
M M M M
SAPH # B
M
AIR MOTOR
PAPH # B
M
PA FAN # B
FURNACE
FINAL SUPERHEATER DIVISIONAL PANEL FINAL REHEATER PLATEN COILS ECONOMISER BACK PASS LTRH
FD FAN # B
AIR MOTOR
AIR PATH
:
: : : :
30 %
2123 Kg / Hr 42.1 % 52.5 % 192 C
outlet
2. Blow down
4% (max.)b
13.8 m3
(H2O2)
This layer is much more dense and tight than Magnetite layer.
that of
39
40
DOSING POINTS
41
42
43
U#1
VENT HDR N2 FILL LINE
SAMPLE COOLER
WATER LINE N2 FILLING LINE VENT LINE DRAIN LINE SAMPLE COOLER LINE
SEPRATOR #1
SEPRATOR #2
2 VENT HDR
VENT HDR
FUR WW HDR
BRP
BACK PASS ECO I/L HDR BLR FILL PUMP FROM FEED WATER
TO DRAIN HDR
2.
CLEAN UP CYCLE
3.
4.
5.
This pump circulates feed water from the evaporator outlet back to the economizer inlet.
Located at the outlet of this pump is the UG valve which controls economizer inlet flow during the start-up phase of operation. Demand for this recirculation, control valve is established based on measured economizer inlet flow compared to a minimum boiler flow set point.
Boiler Clean-up
When the feedwater quality at the outlet of deaerator and separator is not within the specified limits, a feedwater clean-up recirculation via the boiler is necessary. During this time, constant feedwater flow of 10% TMCR ( 223 T/Hr) or more is maintained. Water flows through the economizer and evaporator, and discharges the boiler through the WR valve to the flash tank and via connecting pipe to the condenser. From the condenser, the water flows through the condensate polishing plant, which is in service to remove impurities ( Like Iron & its Oxide, Silica, Sodium and its salts ), then returns to the feed water tank. The recirculation is continued until the water quality is within the specified limits.
DRY MODE :
At 30 % TMCR Separator water level will become disappear and Boiler Operation mode will change to Dry BCP Will shut at this load Warm Up system for Boiler Start Up System will get armed
4. BFP Scoop
It measures value from Storage tank level Transmitter Maintain Separator Storage Tank Level
5. UG Valve
Maintain Minimum Economizer Inlet Flow ( 30 % TMCR = Approx 660 T/Hr) Maintain DP across the BRP ( Approx 4.0 Ksc) It Measures Flow Value from Economizer Inlet Flow Transmitter
6. WR / ZR Valve
Maintains Separator Storage Tank Level It Measures value from the Storage tank Level
1 No LL Level Transmitter has been provided At 1.1 Mtr level MFT will Act
2.
TRANSITION PHASE :- Changeover of FW Control valve (30 % to 100 % Control ) 100 % FW Flow valve will wide open During the transition phase system pressure fluctuates The system pressure fluctuation will be controlled by 30 % FW Valve. After stabilization of system 30 % CV Will become Full Close
3.
FEED WATER CONTROL It will be controlled in three steps Feed Water demand to maintain Unit Load Maintain Separator O/L Temperature Maintain acceptable Platen Spray Control Range
PLATEN SUPER HEATER SPRAY CONTROL Primary purpose is to keep the final super heaer spray control valve in the desired operating range Measures the final spray control station differential temperature It Compares this difference with Load dependent differential temperature setpoint Output of this is the required temperature entering the Platen Super Heater Section (Approx 450 C)
3.
FEED WATER DEMAND 1. FEED FORWARD DEMAND It is established by Boiler Master Demand. This Demand goes through Boiler Transfer Function where it is matched with the actual Evaporator Heat Transfer to minimize the temperature fluctuations FEED BACK DEMAND Work With two controller in cascade mode
2.
SECOND CONTROLLER Second Controller acts on the load dependent Separator Outlet Temperature adjusted by Platen spray differential temperature This controller adjust the feed water in response to firing disturbances to achieve the separator O/L Temperature
THE RESULTING DEMAND FROM THE COMBINED FEEDFORWARD AND FEEDBACK DEMANDSIGNAL DETERMINED THE SETPOINT TO THE FEED WATER MASTER CONTROL SETPOINT
2.
Output of the first controller is subjected to the second controller which monitors the Separator Storage tank level ( Since the system is in Wet Mode now)
The output of the second controller is the set point of Feed water master controller. The Feed back to this controller is the minimum value measured before the start up system and Economizer inlet.
3. 4.
BLR PATH ( WHEN WET MODE) Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH HP By-pass - Cold R/H Line - Primary R/H (Lower Temp R/H) - Final R/H - LP Bypass - Condenser BLR Path (When Dry Mode)
Primary Eco - Secondary Eco - Ring HDR - Spiral W/W - W/W Intermediate HDR Vertical W/W - Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH - HP TBN - Cold R/H Line - Primary R/H (Lower Temp R/H)- Final R/H - IP and LP TBN - Condenser
DIV SH
PLATEN SH
FINAL SH
406
451
486
480 DSH2 3%
540
BOILER LOAD CONDITION Constant Pressure Control Above 90% TMCR The MS Pressure remains constant at rated pressure
Sliding Pressure Control Boiler Operate at Sliding pressure between 30% and 90% TMCR The Steam Pressure And Flow rate is controlled by the load directly
ADVERSE AFFECT
As the pressure falls, the boiling temperature (boiling point) changes. The boiler is divided into zones in which the fluid is expected to be entirely water, mixed steam / water or dry steam. A change in the boiling point can change the conditions in each zone. The heat transfer coefficient in each zone depends upon the pressure. As the pressure falls, the heat transfer coefficient reduces. This means that the steam may not reach the correct temperature. Also, if heat is not carried away by the steam, the boiler tubes will run hotter and may suffer damage.
CHALLANGES The heat transfer coefficient also depends upon the velocity of the steam in the boiler tubes. Any change in pressure causes a change in steam density and so alters the steam velocities and heat transfer rate in each zone.
Pressure and temperature cause the boiler tubes to expand. If conditions change, the tubes will move. The tube supports must be capable of accommodating this movement. The expansion movements must not lead to adverse stresses.
The ability to use sliding pressure operation is determined by the boiler
As stated, in coal-fired plant, sliding pressure is normally restricted to a limited load range to reduce design difficulties. In this range, the boiler pressure is held at a value 5% to 10% above the turbine internal pressure. Consequently, the governor valves throttle slightly.
The offset is provided so that the unit can respond quickly to a sudden increase in load demand simply by pulling the valves wide open.
This produces a faster load response than raising the boiler firing rate alone.The step in load which can be achieved equals the specified margin ie 5% to 10%.
The throttling margin is agreed during the tendering phase and then fixed.
A margin of 5% to 10% is usually satisfactory because most customers rely upon gas turbines, hydroelectric or pumped storage units to meet large peak loads. The throttling margin means that the full potential gain of sliding pressure is not achieved. Nevertheless, most of the throttling losses which would otherwise occur are recovered.
ADVANTAGES
Temperature changes occur in the boiler and in the turbine during load changes. These can cause thermal stresses in thick walled components. These are especially high in the turbine during constant-pressure operation. They therefore limit the maximum load transient for the unit. By contrast, in sliding pressure operation, the temperature changes are in the evaporator section. However, the resulting thermal stresses are not limiting in the Once through boiler due to its thermo elastic design.
In fixed pressure operation , temperature change in the turbine when load changes, while in sliding-pressure operation ,they change in the boiler
The enthalpy increase in the boiler for preheating, evaporation and superheating changes with pressure. However, pressure is proportional to output in sliding pressure operation In a uniformly heated tube, the transitions from preheat to evaporation and from evaporation to superheat shift automatically with load such that the main steam temperature always remains constant.
Sliding Pressure
At loads over 25% of rated load, the water fed by a feed-water pump flows through the high pressure feed-water heater, economizer ,furnace water wall, steam-water separator, rear-wall tubes at the ceiling, and super heaters, The super heaters steam produced is supplied to the turbine. At rated and relatively high loads the boiler is operated as a purely once through type. At partial loads, however, the boiler is operated by sliding the pressure as a function of load.
25 20 15 10 5 0 0 25 50 75 100
Turbine load (%)
24.1 Mpa
9.0 Mpa
CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC Boiler Load % 20 +1 Efficiency Change % 0 -1 -2 -3 -4 Variable Pressure 40 60 80 100
Mode Basis
Stopped time SH Outlet Temp Separator Tank pr
Restart
Hot
6~12Hr 300 above 30120/
Warm
56Hr Within 100 above 30/ below
Cold
96Hr Above 100 below 0/
PURGE CONDITIONS
No Boiler Trip Condition Exists All System Power Supply Available Unit Air Flow > 30 % BMCR Nozzle Tilt Horizontal and Air Flow < 40 % Both PA Fans Off The Following Condition Exist At Oil Firing System The HOTV / LOTV Should Be Closed All Oil Nozzle Valve Closed The Following Condition Exists at Coal Firing System All Pulverisers are Off All Feeders are Off All Hot Air Gates Of Pulverisers are closed All Flame Scanner on all elevation shows no Flame Aux Air Damper At All Elevation should be modulating
MFT CONDITIONS
Both ID Fans Off
Both FD Fans Off Unit Air Flow < 30 % TMCR All Feed Water Pumps Are Off For More Than 40 Sec
2 / 3 Pressure Transmitter indicate the furnace pressure High / Low for more than 8 sec ( 150
mmwc / -180 mmwc)) 2 / 3 Pressure Transmitter indicate the furnace pressure High High / Low - Low ( 250 mmwc / - 250 mmwc) Loss Of Re-heater Protection EPB Pressed All SAPH Off Economizer Inlet Flow Low For More Than 10 Sec (223 T/Hr) Furnace Vertical Wall Temperature High For more than 3 Sec (479 C) SH Pressure High On Both Side (314 KSc) SH Temperature High For More Than 20 Sec ( 590 C) RH O/L Temperature High For More Than 20 Sec ( 590 C) Separator Level Low-Low During Wet Mode ( 1.1 M)
MFT Relay Tripped Loss Of Fuel Trip : It Arms when any oil burner proven. it occurs when all of the following satisfied All Feeders Are Off HOTV Not Open or all HONV Closed
Both Of The Following Condition Satisfied Less Than 2 / 4 Scanner Flame Shows Flame 2 / 4 Oil Valves not open at AB Elevation
Adjust fan and SADC to permit a purge air flow of atleast 30% of TMCR and furnace draft of approx. -12.7 mmWC.
When fans are started, SADC should modulate the aux. air dampers to maintain WB to furnace DP at 102 mmWC(g).
SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP FURNACE READINESS PRESSURE PARTS SCANNER AIR FAN BOTTOM ASH HOPPER READINESS FUEL FIRING SYSTEM START UP SYSTEM SEC AIR PATH READINESS FD FAN SAPH WIND BOX / SADC FLUE GAS SYSTEM ESP PASS A , B ID FAN
SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP CONDENSATE SYSTEM CONDENSER CEP CPU FEED WATER SYSTEM D/A MDBFP # A VACCUME SYSTEM SEAL STEAM SYSTEM TURBINE ON BARRING
Reduced number of evaporator wall tubes. Ensures minimum water wall flow.
Spiral wall