OWNER:

JSW ENERGYVIJAYANAGAR LIMITED

OWNER CONSULTANT:

TATA CONSULTANCY ENGINEERS LIMITED

BTG PACKAGE FOR 2300 MW Coal Based Thermal Power Station at Toranagallu, Bellary
1015t/h SUBCRITICAL PRESSURE NATURAL CIRCULATION BOILER

INSTRUCTION FOR BOILER

DOCUMENT NO. 730-1-8601

CONTRACTOR:

Rev No. 0

SHANGHAI ELECTRIC GROUP CO., LTD.

SUBCONTRACTOR:

SHANGHAI BOILER WORKS,LTD.

SHANGHAI BOILER WORKS, LTD

1015t/h SUBCRITICAL PRESSURE NATURAL CIRCULATION BOILER

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL POWER STATION AT TORANAGALLU , BELLARY

SHANGHAI BOILER WORKS,LTD.

DOCUMENT CONTROL SHEET

PROJECT

BTG PACKAGE FOR 2300MW COAL BASED THERMAL POWER STATION at TORANAGALLU BELLARY JSW ENERGYVIJAYANAGAR LIMITED INSTRUCTION FOR BOILER 730-1-8601 0

CLIENT DOCUMENT TITLE DOCUMENT NO REV. NO.

ENDORSEMENTS

2008.11.04

REV. NO.

DATE

DESCRIPTION

PREP. BY SIGN.INITIAL

REVW. BY APPD . BY SIGN. INITIAL SIGN. INITIAL

. 2008.11.05

. 2008-11-5

DOCUMENT NO.: 730-1-8601

Page 1

of 1

Product Description

730-1-8601

INSTRUCTION FOR BOILER

MODEL OF PRODUCT NAME OF PRODUCT SERLES NO.

SG-1015/17.5-M730

1015t/h 1015t/h SUBCRITICAL PRESSURE NATURAL CIRCULATION BOILER 730-1-8601

PREPARED BY CHECKED BY

DATE DATE DATE DATE

2008.11.04
2008.11.04

REVIEWED BY APPROVED BY

2008.11.05
2008-11-5

SHANGHAI BOILER WORKS, LTD. 2008 11

Product Description

730-1-8601

Content
Foreword .............................................................................................................................................4

1 Boiler Design Condition and Technical Data.................................................... 7 1.1 Design Parameters of Boiler......................................................................... 7 1.2 Fuel .............................................................................................................. 7 1.3 The Steam and Water Quality Standard................................................... 10

1.4 Environmental Condition .............................................................................11 1.5 Boiler Operating Condition ......................................................................... 12 1.6. PERFORMANCE DATA (design coal) ....................................................... 13 2 Boiler General Arrangement and System ...................................................... 21 2.1 General....................................................................................................... 21 2.2 Steam & Water System .............................................................................. 25 2.3 Burning System .......................................................................................... 35 2.4 Flue Gas and Air System............................................................................ 38 2.5 Bottom Ash System .................................................................................... 38 2.6 Attamperation System ................................................................................ 39 2.7 Sootblowing System ................................................................................... 40 2.8 Pipeline System.......................................................................................... 42 2.9 Arrangement for Ports and Measuring Points ............................................. 45 3 Main Pressure Parts ...................................................................................... 46 3.1 Drum and Drum Internals ........................................................................... 46 3.2 Waterwall.................................................................................................... 55 3.3 Economizer ................................................................................................ 58 3.4 Superheater................................................................................................ 60 3.5 Reheater (RH) ............................................................................................ 64 3.6 SH and RH Control & Protection Maintenance........................................... 66 3.7 Desuperheater............................................................................................ 68
4 Others ................................................................................................................................69

4.1Steel Structure ............................................................................................. 69

2

Product Description

730-1-8601

4.2 Sealing and Insulation ................................................................................ 70 4.3 Air preheater (APH) .................................................................................... 70 5 Boiler Hydro Test ........................................................................................... 71 5.1 The Pressure of Hydro Test ........................................................................ 71 5.2 Water Quality.............................................................................................. 71 5.3 Notices ....................................................................................................... 71 5.4 Water Volume of Boiler Pressure Parts ...................................................... 72

Product Description

730-1-8601

Foreword 1015t/h subcritical pressure boilers in India BTG PACKAGE For 2300MW COAL BASED THERMAL POWER STATION at TORANAGALLU is optimized the design and manufactured by Shanghai Boiler Words Ltd.(SBWL). The design and manufacture is on the basis of 300MW subcritical pressure natural circulation boiler, following the principle of "Make excellent boiler, build famous brand". The close considerations in boiler design: (1) High available rate (2) High thermal efficiency and lesser air-heater leakage (3) Better control and regulating performance, flexible and reliable control, low steam temperature deviation as much as possible (4) Better flexibility with coal range, stable combustion within the regular change of fuel, safe and reliable (5) Better part load stable combustion performance and better start-up and peak load performance (6) Mature structure with increased universal parts and components. This instruction gives a detailed introduction of boiler performance, general arrangement, and other systems and main pressure parts. Except this, installation instruction, operation instruction and related equipment instruction are also offered. instruction list as follows: ITEM No. 1 SERIES No. 730-1-8301 DESCRIPTION DRUM STRENGTH CALCULATION SUMMARY 2 730-1-8302 HEADER STRENGTH CALCULATION SUMMARY 3 730-1-8401 SAFETY VALVE SET PRESS. & CAPACITY SUMMRY 4 730-1-8701 THERMAL CALCULATION SUMMARY 5 730-1-8702
4

Product Description

730-1-8601

ITEM No.

SERIES No.

DESCRIPTION TUBE & PIPING METAL TEMP. & STRENGTH CALCULATION SUMMARY

730-1-8703

STEAM & WATER PRESSURE DROP CALCULATION SUMMARY

730-1-8704

EVAPORATION CIRCULATION CALCULATION SUMMARY

730-1-8705

GAS & AIR PRESSURE DROP CALCULATION SUMMARY

730-1-8601

INSTRUCTION FOR BOILER

10

730-1-8602

INSTRUCTION FOR BOILER OPERATING

11

730-1-8603

INSTRUCTION FOR STEEL STRUCTURE

12

730-1-8604

PROTECTING LIMIT VALUE FOR BOILER

13

730-1-8607

INSTRUCTION FOR INSULATING

14

730-1-8608

INSTRUCTION FOR BOILER ERECTION

15

680197-1-8661

INSTRUCTION FOR COAL FIRING EQUPMENT

16

730-1-8609

INSTRUCTION FOR SAFETY VALVE

17

730-1-8610

INSTRUCTION FOR ERV

18

730-1-8611

INSTRUCTION FOR CONTROL VALVE

19

730-1-8612

INSTRUCTION FOR SHUT OFF & GATE VALVE

5

Product Description

730-1-8601

ITEM No. 20

SERIES No. 730-1-8613

DESCRIPTION INSTRUCTION FOR FURNACE FLAME TV MONITOR SYSTEM

21

730-1-8614

INSTRUCTION FOR DRUM WATER-LEVEL TV MONITOR SYSTEM

22

730-1-8615

INSTRUCTION FOR WATER LEVEL GAUGE

23

730-1-8616

INSTRUCTION FOR SOOTBLOWER

24

730-1-8617

INSTRUCTION FOR SOOTBLOWER PIPING SYSTEM

25

730-1-8618

INSTRUCTION FOR TEMP. PROBE

26

770059-2-7201

DOCUMENT LIST OF AIR PREHEATER FOR CUSTOMER

Product Description

730-1-8601

1 Boiler Design Condition and Technical Data The design coal and worst coal for the boiler are medium volatile bituminous coal. The boiler is subcritical pressure, single reheat, natural circulation, single furnace, balanced draft, tangential firing, corner arranged tilting burner, solid slag extraction, open air arrangement, all steel structure, monitor roof direct fired pulverized coal system with middle speed mill . 1.1 Design Parameters of Boiler Name SH steam flow Outlet pressure of SH Outlet temperature of SH steam RH flow Inlet steam pressure of RH Outlet steam pressure of RH Inlet steam temperature of RH Outlet steam temperature of RH Water temperature at ECON inlet 1.2 Fuel 1.2.1 Coal Quality Data Unit t/h MPa(g)
o

and

BMCR 1015 17.47 541 840.7 3.72 3.52 323 541 279

BECR 913.6 17.30 541 761.9 3.37 3.19 313 541 273

t/h MPa(g) MPa(g)

o

C C C

The coal quality analysis of design coal and worst coal

Product Description

730-1-8601

Sl.No Proximate Analysis Design coal 1 2 3 4 5 Fixed Carbon % Volatile Matter % Moisture % Ash % Higher Heating Value Kcal/Kg Ultimate Analysis Carbon % Hydrogen % Sulphur % Nitrogen % Oxygen % Moisture % Ash % Grindability index (HGI) Initial Deformation TEMP. C Hemispherical TEMP. Fluid Deg. C Crucibie swelling index (FSI) Bulk Density 54.82 23.02 11.04 11.12 6300 5977(LHV) Worst Coal 41.59 20.09 15.01 23.31 5000 4679(LHV)

1 2 3 4 5 6 7 8 9 10 11 12 13

64.64 4.75 0.30 2.24 5.94 11.04 11.12 53 1180 1240 1290 >1 0.91

49.19 4.24 0.46 1.39 6.40 15.00 23.32 45

<1400 <1400

Product Description

730-1-8601

Ash characteristics %/Wt

Design coal 1 2 3 4 5 6 7 8 9 10 11 Silico Alumina Ferric Oxide Calcium Oxide Magnesium Oxide Sodium Oxide Potassium Oxide Titanium Oxide Phosphate pent Oxide Sulphur Trioxide Undetermined 53.3 35.3 4.0 2.2 0.50 0.30 0.50 1.40 1.30 0.40 Worst coal 37.0 45.8 10.7 1.69 0.44 0.08 0.29 1.27 0.67 0.94 1.1

Sieve Analysis
+60 Mesh +120 Mesh +200 Mesh -200 Mesh Un-burnt % 02-0.4% 2.5-6.5% 8-11% 80-90% 4.0-18.0

1.2.2 Ignition and Combustion Supporting Oil LDO 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 ANALYSIS LIGHT DIESEL OIL (LDO) ANALYSIS AS PER IS 1460, 1995 Viscosity at 40 Cst 2.5 to 15.7 Density at 15 kg/m3 920 Flash point, Min 66 Pour point, Max. Water content, Max. Sediment, Max. Sulphur, Max. Ash content, Max. Gross calorific value (Approximate)
9

12 for Winter 21 for summer % vol. 0.25 % wt 0.05 % wt 1.8 % wt 0.02 Kcal/kg 9950

ANALYSIS OF HEAVY FUEL OIL (HFO)

Product Description

730-1-8601

Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 14. 15.0

Particulars Flash point Viscosity @ 150C Maxi. Pour point Ash content by weight Free Water content by volume Sediments by weight Total sulphur by weight Calcium Sodium Lead content Vanadium Carbon residence (Rams bottom) Approximate gross calorific value SP gravity at 15 Max.

Unit Deg. C min. Cst

Furnace Oil Grade MV2 (IS : 1593) 66 180 21 01 1.0 0.25 4.0 30.5 10 0.2 40.50 7.74 10,000 0.933

% max. % max. % max. % max. PPM PPM PPM PPM % wt Kcal/kg

1.3

The Steam and Water Quality Standard

1.3.1 The quality standard of feedwater To ensure steam quality, the boiler feedwater should be strictly controlled according to the following quality standard. Boiler feedwater quality should comply with quality standard.

(GB/T12145-1999 Quality criterion of water and steam for thermal generating unit and steam power equipment ) The quality of the feedwater in the operation should be higher than this standard. Rigidity Conductivity Oxygen Iron Cuprum Hydrazine PH value Oil ~0mol/L 0.30 S/cm 0.007mg/l 0.02mg/l 0.005mg/l 0.01~0.05mg/l 9.0~9.5 0.3 mg/l

10

Product Description

730-1-8601

1.3.2 The Ensure Quality of Boiler Steam The quality of boiler saturation steam and superheating steam should comply with quality standard. (GB/T12145-1999 Quality criterion of water and steam for thermal generating unit and steam power equipment ) 1.4 Environmental Condition 1.4.1 Meteorological data Annual average highest dry bulb temperature Annual average lowest dry bulb temperature Annual average highest wet bulb temperature Annual average lowest wet bulb temperature highest day average temperature Lowest day average temperature Ultimate highest temperature Ultimate lowest temperature Annual average rainfall Highest relative humidity Lowest relative humidity Highest and lowest annual average humidity Altitude Annual average wind speed Annual average highest wind speed Wind load Calculations for wind effect shall be in accordance with IS:875-1987(Part-3) taking into account the following: a) Basic wind speed = 39 m/sec b) Factor K1 = 1.07 c) Category of terrain = Category 2 d) K3 as per IS 875 32.9 22.2 38.1 17.4 31.1 17.6 40.8 14.6 500mm 73% 22% 73% 22% 478.375m 8.4km/hr 14.8km/hr

1.4.2 Earthquake The earthquake basic intensity at plant side, ZONE NO. II AS PER IS 893:2002.
11

Product Description

730-1-8601

1.5 Boiler Operating Condition a. Boiler supply a basic load, being capable of constant-sliding-constant pressure operation. b. Boiler minimum stable load without oil support is 30%BMCR. c. Boiler load continuous changing rates can reach following requirements Constant pressure operation 5% BMCR/min

Sliding pressure operation 3% BMCR /min Load jump 10% BMCR /min d. The time period required to start-up the unit shall not exceed the following duration, Cold Hot e. f. g. start-up start-up 6~8hours 3~4hours 1.5~2 hours Warm start-up Boiler ignition, HEA-LDO-HFO-coal . NOx emission at 100%TMCR with design coal is not higher than 650 mg/Nm3 . It is ensured that steam temperature (SH,RH steam outlet temperature) will reach design data within the load range from 60%BMCR to 100%BMCR. The temperature deviation is allowed to be +5/-10. h. Furnace is normal operating at pressure -37.3Pa (-3.8mmH2O column). Furnace water wall and buckstay are capable of withstanding transient furnace pressure. The limit values show in following, No. 1 2 3 4 Item Design furnace pressure Transient furnace pressure Furnace alarm pressure Main fuel trip pressure Unit Pa Pa Pa Pa value 5230 8720 996 +3240 -2490

12

Product Description

730-1-8601

1.6. PERFORMANCE DATA (design coal)

ITEM NO. 1 2 3 4 5 6 7 8 9 10 ITEM SH STEAM FLOW SH STEAM OUTLET PRESSURE SH STEAM OUTLET TEMP. RH STEAM FLOW RH STEAM INLET PRESSURE RH STEAM OUTLET PRESSURE RH STEAM INLET TEMP. RH STEAM OUTLET TEMP. FEEDWATER PRESSURE FEEDWATER TEMP.
o o o o

UNIT t/h Mpa(g) C

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS. 1014.954 17.47 541 840.7 3.72 3.52 322.9 541 19.24 279 913.624 17.30 541 761.9 3.37 3.19 312.8 541 18.78 273 796.851 17.13 541 778.0 3.51 3.32 320.6 541 18.32 177 717.218 17.02 541 606.5 2.67 2.53 294.9 541 18.03 258

SLIDING PRESS. 537.533 12.62 541 462.3 2.02 1.91 301.3 541 13.43 242 304.486 7.25 541 268.0 1.14 1.08 309.6 541 7.80 213

t/h Mpa(g) Mpa(g) C C

Mpa(g) C

13

Product Description

730-1-8601

ITEM NO. 11 12 13 14 15 16 17 18 19 20 21

ITEM SPRAY WATER TEMP. SH SPRAY WATER FLOWPrimary) SH SPRAY WATER FLOW(Secondary) RH SPRAY WATER FLOW DRUM PRESSURE DRUM TEMPERATURE EXIT GAS TEMP. UNCORRECT EXIT GAS TEMP. HEAT EFFICIENCY (GCV) FUEL CONSUMPTION CORRECT

UNIT o C t/h t/h t/h Mpa(g)

o

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS. 177 8.10 0 0.0 18.84 361.2 143.9 138.3 88.79 112.0 94.5 173 22.50 3 0.0 18.43 359.3 143.3 136.7 88.82 103.0 86.6 176 83.90 5 0.0 17.99 357.4 122.8 118.3 89.75 105.7 87.7 164 37.90 10 0.0 17.73 356.2 139.4 133.9 88.65 84.4 71.0

SLIDING PRESS. 153 32.40 5 0.0 13.17 332.4 131.1 124.4 88.97 65.4 54.0 133 19.00 3 0.0 7.57 292.0 122.2 112.8 88.78 39.4 31.8

C C C

% t/h
103Kcal/h 3 m

14

Product Description

730-1-8601

ITEM NO. 22

ITEM HEAT RELEASE RATE IN FURNACE VOLUME HEAT RELEASE SECTION HEAT RELEASE RATE IN BURNER AREA NET HEAT INPUT NUMBER OF NOZZLES IN SERVICE EXCESS AIR RH. WALL INLET STEAM TEMPERATURE RH. WALL OUTLET STEAM TEMPERATURE SH. DIV. PANEL INLET TEMPERATURE SH. DIV. PANEL OUTLET STEAM TEMPERATURE RATE IN FURNACE

UNIT
106Kcal/h m2

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS.

SLIDING PRESS.

4.21

3.86

3.91

3.17

2.41

1.42

23 24 25 26 27 28 29

106Kcal/h m2 106Kcal/h

1.30 729.8 4 1.20

1.19 668.8 4 1.20 313 378 407

1.21 677.1 4 1.20 321 381 395

0.98 548.1 4 1.29 295 369 402

0.74 417.1 3 1.20 301 381 382

0.44 246.0 2 1.20 310 402 355

C C C

323 383 412

STEAM
o

30 31

C C

455 455

454 454

442 442

455 455

447 447

443 443

15

Product Description

730-1-8601

ITEM NO. 32

ITEM SH. PLATEN INLET STEAM TEMPERATURE SH. PLATEN OUTLET TEMPERATURE RH PLATEN INLET STEAM TEMPERATURE RH PLATENOUTLET TEMPERATURE RH FINISH INLET STEAM TEMPERATURE RH FINISH OUTLET STEAM TEMPERATURE SH FINISH INLET STEAM TEMPERATURE SH FINISH OUTLET STEAM TEMPERATURE SHLT. PENDANT INLET TEMP. SHLT. PENDANT OUTLET TEMP. SHLT. HORIZ INLET STEAM

UNIT
o

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS.

SLIDING PRESS.

509

512

508

521

523

537

STEAM
o

33 34

C C

383 476

378 475

381 476

369 473

381 483

402 499

STEAM
o

35 36 37 38 39 40 41

C C C C C C C

476 541 509 541 406 416 364

475 540 509 541 408 419 363

476 540 502 541 436 452 364

473 540 508 541 417 430 362

483 539 513 541 408 423 342

499 541 525 541 394 412 309

16

Product Description

730-1-8601

ITEM NO. TEMPERATURE 42

ITEM SHLT HORIZ OUTLET TEMPERATURE ECONOMIZER INLET WATERTEMPERATURE ECONOMIZER TEMPERATURE FORNANCE OULTET GAS TEMP. SH. DVI. PANEL INLET GAS TEMPERATURE SH. DVI. PANEL TEMPERATURE SH. PLATEN INLET GAS TEMPERATURE SH. PLATEN OUTLET GAS TEMPERATURE RH PLATEN INLET GAS TEMPERATURE

UNIT
o

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS.

SLIDING PRESS.

406

408

436

417

408

394

STEAM
o

43 44

C C

279 303

273 298

177 237

258 289

242 273

213 246

OUTLET

WATER
o

45 46 47

C C C

1047 1326 1139

1031 1327 1127

1026 1313 1119

984 1299 1082

911 1243 1009

794 1140 893

OUTLET

GAS
o

48 49 50 51

C C C C

1139 1047 1047 934

1127 1031 1031 917

1119 1026 1026 914

1082 984 984 873

1009 911 911 801

893 794 794 693

17

Product Description

730-1-8601

ITEM NO. 51 52 53 54 55 56 57 58 59 60 61

ITEM RH PLATENOUTLET GAS TEMPERATURE RH FINISH INLET GAS TEMPERATURE RH FINISH OUTLET GAS TEMPERATURE SH FINISH INLET GAS TEMPERATURE SH FINISH OUTLET GAS TEMPERATURE SHLT. PENDANT INLET TEMP. SHLT. PENDANT OUTLET TEMP. SHLT. HORIZ INLET GAS TEMPERATURE SHLT HORIZ OUTLET GAS TEMPERATURE ECONOMIZER INLET GAS TEMPERATURE ECONOMIZER OUTLET GAS TEMPERATURE

UNIT
o

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS.

SLIDING PRESS.

C C C C C C C C C C C

924 842 811 742 735 698 669 430 424 343 343

906 826 794 727 721 684 655 424 419 336 336

904 824 794 727 721 688 656 431 422 288 288

863 788 757 698 691 660 630 418 412 322 322

790 723 691 644 637 607 576 387 382 296 296

682 634 602 578 571 542 508 345 339 256 256

18

Product Description

730-1-8601

ITEM NO. 62 63 64 65 66 67 68 69 70 71 72

ITEM AIR PREHEATER INLET GAS TEMP.

UNIT
o

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS.

SLIDING PRESS.

138 204534 884440 1264996 111465 135133 872646 1346190 42.8 37.8 304.4

137 191765 798004 1162941 119466 122818 786664 1243228 42.8 37.8 301.7

118 219862 823741 1193027 91344 152729 811494 1272407 42.8 37.8 256.7

134 149918 690626 1014780 121128 108640 667492 1079192 42.8 37.8 293.9

124 130203 484364 736445 83905 89832 462138 799042 42.8 37.8 276.1

113 105759 273446 442171 45798 67203 251674 502499 42.8 37.8 239.4

AIR PREHEATER OUTLET GAS TEMP. ENTERING PRIMARY AIR FLOW ENTERING SECONDARY AIR FLOW ENTERING GAS FLOW PRIMARY BY-PASSED AIR FLOW LEAVING PRIMARY AIR FLOW LEAVING SECONDARY AIR FLOW LEAVING GAS FLOW
PRIMARY AIR INLET TEMP.
o

T/h T/h T/h T/h T/h T/h T/h C C C

SECONDARY AIR INLET TEMP.

19

Product Description

730-1-8601

ITEM NO. 73

ITEM
PRIMARY AIR OUTLET TEMP.

UNIT
o

BMCR

TMCR

HPHO*

80%TMCR 60%TMCR

30%BMCR

CONSTANT PRESS.

SLIDING PRESS.

SECONDARY AIR OUTLET TEMP.

312.8

308.3

262.8

298.9

278.9

240.6

Note: *HPHO means all high pressure heater out of service. 74

SUPERHEATER STEAM PRESSURE DROP

kPa kPa kPa

1313 184 376

75 76

REHEATER STEAM PRESSURE DROP

ECONOMIZER WATER PRESSURE DROP

20

Product Description

730-1-8601

2 Boiler General Arrangement and System 2.1 General The boiler is a natural circulation subcritical pressure with single reheat, it is semi outdoor arranged and has a single furnace of reverse u-form arrangement and full pendant steel structure, dry bottom type water cooled, balance draft furnace and is designed with tangential firing arrangement of burners and

direct fired pulverized coal system. For general arrangement drawing of boiler, please refer to Figure 2.1. The furnace width is 14022mmdepth is 12350mmthe elevation of the top of the boiler is 59500mmthe elevation of the centerline of the drum is 64000mm the elevation of the girder at the furnace crown is 69750 mm. The furnace crown is a big hood of metal structure of full seal. The furnace is composed of outside diameter 60mm and thickness 7mm membrane water wall, and the angle of the dry bottom hopper is 55. The floor seal is water seal structure and the separating panel, superheater panel and platen, reheater platen are settled at the upside of the furnace. Radiation reheater is arranged at front wall and both side wall. The elevation of lower header of waterwall is 7340mm. The convection pass with the depth of 6278 mm is composed of the roof by pass superheater as the extended sidewall of furnace and extended sidewall of back pass. There are also final reheater and final superheater arranged in it . The depth of back pass is 10260 mm and low temperature superheater and economizer arranged in it. Positive pressure direct fired pulverization system is used for the boiler, with 6 HP863 medium speed coal pulverizers which is arranged in front of the boiler. At the four corners of the burner, tangential firing (totally 6 layers) is arranged. The center line elevation of the top burner nozzle is 28100 mm. The distance to the bottom of the compartition shield is 17800mm. The center line elevation of lowest burner nozzle is 20470mm. The distance to the corner of the cold ash bin is 4519 mm. Each corner burner bellow is equipped with 4 layers of startup & combustion supporting oil guns. The steel structure of the boiler is a full steel frame connected with high strength
21

Product Description

730-1-8601

bolts. For the whole boiler, totally 17 layers of platforms are provided, including 7 rigid platforms. To facilitate the operation, local platforms are provided for some places. Except for the deslagging bin device and the preheater, the whole weight of the boiler is suspended on the roof steel frame. For the steam temperature regulation of the superheater, mainly water spraying desuperheater is used. Two stages of water spraying desuperheaters are arranged in the superheater system. The first stage is arranged in the low temperature superheater outlet pipe, and the second stage is on the outlet pipe of the SH. Platen superheater. The steam temperature of the reheater will be controlled by tilting burners and excess air. One stage spray water attemperation in case of emergency condition. The emergency spraying desuperheater, which is arranged in the reheater inlet pipe. This boiler is provided with a startup drainage bypass with capacity of 5%BMCR at the lower header of the back pass. The boiler is provided with an expansion center. During the operation, the whole boiler expands with the expansion point as the origin. The expansion zero point of the boiler in the vertical direction is set at the top of the roof enclosure. The expansion points of the boiler in the depth and width directions are at the furnace center and boiler center. In the furnace height direction, three layers of guiding devices are provided to restrict the expansion direction of the boiler heating surface and to transmit the horizontal load of the boiler. The furnace and buckstays are provided with wire wound rigid beams around them to bear the pressure in both positive and negative directions. 20 layers of rigid beams are provided at the furnace part and 14 layers are at the back pass. There is water seal flash board device at the bottom of furnace ash hopper. 56 wall-type sootblowers are arranged in the lower furnace and 44 longretractable sootblower are arranged at the upper furnace and in the convection flue gas area. The air preheater is provided with 2 sootblowers altogether. All the sootblowers are controlled with program during the operation. The body of the boiler is provided with 10 spring safety valves, including 3 arranged on the boiler drum, 2 at the superheater outlet, 2 on the reheater inlet pipe, and 3 on the reheater outlet pipe. To minimize the tripping times of the safety valves, 2 dynamic relief valves are provided at the outlet of the
22

Product Description

730-1-8601

superheater. Flue gas temperature detection probes are provided at both the left and right sides of the furnace. During the startup, they can control the flue gas temperature at the furnace outlet. Furnace flame TV are provided at both the left and right sides of the furnace for observing the in-furnace combustion conditions. The boiler is equipped with boiler drum level gauge and water level gauge as well as the safety protection devices such as furnace safety & supervision system (FSSS).

23

Product Description

730-1-8601

Fig. 2.1 Boiler general drawing

24

Product Description

730-1-8601

2.2 Steam & Water System 2.2.1 Feedwater and Water Circulation System The feedwater flows along the route at the right side of the boiler, and enters the economizer inlet header after passing through the check valve and electric gate valve. It then flows through the economizer tube bank , intermediate connection header and suspension tube, and is collected in the economizer outlet header. Then it is led from the economizer outlet header to the boiler drum through three OD. 219mm boiler drum feedwater tubes. To ensure the safe and reliable operation of the economizer during the boiler startup, an economizer recirculation pipeline is provided between the boiler drum and the economizer inlet header. There is an electric shutoff valve in the pipeline. When certain feedwater quantity is established in the boiler, this valve can be closed. The capacity of the recirculation pipeline is designed on the basis of 5%BMCR The steam & water circulation system includes boiler drum (ID.1743mm), 4 large-diameter downcomers (OD. 558.8mm), furnace waterwall tube are rifled tube. The unboiled water coming from the economizer is injected into 4 large-diameter downcomer seats respectively in 4 routes from the feedwater distribution tubes arranged along the length of the boiler drum. The feedwater is mixed with the boiler water directly in the downcomers to avoid the contact of the feedwater with the drum wall. This can improve the stress conditions of the couplings and reduce the temperature difference between the internal/external walls and upper/lower walls of the boiler furnace, which is favorable for boiler startup and shutdown. A distributor is provided at the lower end of the 4 downcomers, and is connected with 96 waterwall connected tubes (80 OD.159mm and 16 OD.133mm). The connected tubes send the under-enthalpy water into the lower headers surrounding the waterwall. The waterwall is composed of 664 tubes with diameter of 60mm. According to the heating conditions and geometric shapes, they are divided into 51 circulation cycles. The waterwall tubes at the furnace corners are designed with chamfers to meet the corner tangential burning conditions. In addition, to improve the heating conditions of the corner waterwall circuits and to enhance the stability of the circulation circuits of this part, the chamfer tubes are designed as the
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Product Description

730-1-8601

water-cooling sleeves of the burner to protect the burner nozzle from being damaged. The working fluid is heated continuously while flowing upwards along the diaphragm waterwall, and a steam-water mixture is formed gradually. The steam-water mixture is led into the drum through 106 steam-water lead-out tubes (98 OD.159mm and 8 OD.133mm). In the boiler drum, the steam and water are separated properly with the axial flow cyclone separator and vertical bent plate. The separated water enters the downcomers again, and the dry steam is led by the 18 (OD.159mm) connection tubes to the roof superheater inlet header. The lower headers surrounding the waterwall are provided with neighbor boiler heating devices. Prior to the boiler ignition, the neighbor boiler heating steam enters the waterwall lower headers in 4 routes to accelerate the boiler startup speed. To ensure the safety and reliability of the circulation system, due attention is paid in the design to the abnormal work conditions that may occur during the operation. The parameters of the circulation system and the structural dimensions are selected under the principle of safety and reliability. For the middle part of the front and side waterwalls and almost all the rear waterwalls, internal thread tubes are used, improving greatly the safety margin for prevention of diaphragm-state boiling. The circulation magnification is reasonable, the circulation flow rate is relatively high, and the water circulation is stable and reliable. Due to the possibility of diaphragm-state boiling in the boiler chamber high-heat load area of the evaporation tube under subcritical pressure, how to avoid diaphragm-state boiling must be taken into consideration when the circulation system is designed. The circulation system of the waterwall of this boiler is designed reasonably. Even if smooth-tube waterwalls are used completely in this boiler, the actual steam content (mass) in the max. heat load area can keep a safety margin from the critical steam content. In this design, internal thread tubes of sufficient height are used, further improving the critical steam content in the max. heat load area. Therefore, no diaphragm-state boiling will occur under any load of the boiler. For the process, refer to Fig. 2.2-1 Feedwater & water circulation system diagram.

26

Product Description

730-1-8601

F20 F14 F1 F30 F2 F8 F13 F22 F9 F19

F24 F23

E-7

F18 E.6 F3 F21 E.4 E.5

F17 F7

F12

E.3

F16 F11 F5 F6 F4 F10 F15 E.1

E.2

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Product Description

730-1-8601

E.1 E.2 E.3 E.4 E.5 E.6 E.7 F.1 F.2

Economizer inlet tube Economizer inlet header Economizer Economizer suspension tube inlet header Economizer suspension tube Economizer suspension tube outlet header Economizer outlet connection tube Drum Downcomer seat

F.5 F.6 F.7 F.8 F.9 F.10 F.11 F.12 F.13

Front waterwall lead-in pipes Front waterwall lower header Front waterwall Front waterwall upper header Front waterwall lead-out pipes Left/right side waterwall lead-in pipes Left/right side waterwall lower header Left/right side waterwall Left/right side waterwall upper header

F.16 F.17 F.18 F.19 F.20 F.21 F.22 F.23 F.24

Rear water wall lower header Rear water wall Furn. rear wall hanger Furn. rear wall hanger outlet header Furn. rear wall hanger header lead-out tube Furn. corner Furn. Rear arch water wall Furn. Rear arch water wall outlet header Furn. Rear arch water wall outlet header lead-out pipe

F.3

Downcomer

F.14

Left/right side waterwall lead-out pipes

F.30

Connection tube from steam drum to downcomer

F.4

Downcomer distribution header

F.15

Rear waterwall lead-in pipes

Fig. 2.2-1 Feedwater & water circulation system diagram

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Product Description

730-1-8601

2.2.2 SH Steam System The saturated steam led out from the top of boiler drum enters the roof inlet header which is divided into two line. The steam of first line enters convection pass sidewall at RH finish through the bypass tube. Then, it enters the rear sidewall of back pass and continues into lower temperature SH inlet header through rear wall of back pass. The steam of second line enters sidewall upper header of back pass through front roof. The sidewall upper header of back pass is joined with back roof header. Then it enters into sidewall lower header through front sidewall of back pass. The steam of second line is divided into two line (A and B) at sidewall lower header. Steam of one line A enters backpass EXT. side wall at SH finish through connection pipe. In frontwall upper header of back pass it is mixed with steam of one line B which pass through front wall of backpass. The steam of second line continues into lower temperature SH inlet header and through rear roof and rear wall of back pass. Here it finally mixed with outlet header. After that, the steam is led to Stage-I desuperheater the steam of first line. Then It flows through the lower temperature superheater to its through the tee at the middle part of the header. After Stage-I desuperheater, the steam is re-divided into two routes and flows to the DIV panel SH. inlet header. It flows through the DIV panel SH. heating face tubes to the DIV panel SH. outlet header. From the DIV panel SH. outlet header, the steam is led to the SH. Platen Platen inlet header in two routes. Then it enters the SH. Platen outlet header through the SH. Platen heating face tube. Through the tee on the SH. outlet header, it converges into one route and flows into Stage-II water-spraying desuperheater so that the steam is mixed sufficiently. Finally, it enters the Final superheater and is heated to the required steam temperature. It then flows through the Final superheater to the last superheater outlet header, and then from the last superheater outlet header to the main steam pipe and to the turbine high-pressure cylinder. For the process, refer to Figure 2.2-2 Superheater system.

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Product Description

730-1-8601

S.33 S.1

S.49 S.45 S.48 S.32 S.23 S.22A S.5

I
S.34 S.35

I
S.31 S.30 S.6

S.7

S.39

S.44 S.43

S.6

S.38 S.2

S.40

S.42

S.46 S.22B S.17

S.3

S.16

S.21B S.21A S.36 S.4 S.37 S.52 S.47 S.15

S.8

S.9

S.18

S.29 S.28 S.41 S.20B S.26 S.20A S.50 S.51 S.19 S.25 S.24 S.27

S.14

S.12

I-I
S.40 S.38 S.39 S.42 S.46

S.13

S.10

S.10

S.11

S.48

S.30

S.44 S.34 S.35

S.33

S.32 S.31

Figure 2.2-2 Superheater system

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Product Description

730-1-8601

S.1 S.2 S.3

Steam drum outlet connection tube Roof inlet header Front roof tube

S.24 S.25 S.26

Low-temperature superheater inlet header Low-temperature superheater horizontal section lower tube bank Low-temperature superheater horizontal section middle lower tube bank

S.4

Convection pass extension side wall at final reheater inlet connection tube

S.27

Low-temperature superheater horizontal section middle tube bundle

S.5

Roof outlet header

S.28

Low-temperature superheater horizontal section upper tube bundle

S.6

Back pass side wall upper header left (right)

S.29

Low-temperature superheater horizontal section upper vertical tube bundle

S.7 S.8 S.9 S.10 S.11 S.12 S.13 S.14 S.15 S.16 S.17 S.18 S.19 S.20A S.20B S.21A S.21B S.22A

Convection pass extension side wall at final reheater outlet connection tube Back pass front side wall tube Back pass rear side wall tube Back pass left/right side wall lower header Back pass rearwall lower header Back pass rearwall lower tube Back pass frontwall lower header Back pass frontwall lower tube Back pass frontwall upper tube Back pass frontwall upper header Rear roof tube Back pass rearwall upper tube Back pass extension side wall at SH finish inlet connection pipe Final superheater extension side wall lower header Final reheater extension side wall lower header Final superheater extension side wall tube Final reheater extension side wall tube Final superheater extension side wall upper header 31

S.30 S.31 S.32 S.33 S.34 S.35 S.36 S.37 S.38 S.39 S.40 S.41 S.42 S.43 S.44 S.45 S.46 S.47

Low-temperature superheater outlet header Stage-I desuperheater inlet pipe Stage-I desuperheater Stage-I desuperheater outlet pipe DIV panel SH. inlet pipe DIV panel SH. inlet header DIV panel SH. (front) DIV panel SH. (rear) DIV panel SH. outlet header DIV panel SH. outlet pipe SH. Platen inlet header SH. Platen reheater SH. Platen outlet header Stage-II desuperheater inlet pipe Stage-II desuperheater Stage-II desuperheater outlet pipe Final superheater inlet header Final superheater

Product Description

730-1-8601

S.22B S.23

Final reheater extension side wall upper header Final superheater extension side wall outlet connection tube

S.48 S.49

Final superheater outlet header Final superheater outlet pipe

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Product Description

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2.2.3 RH Steam System The steam discharged from the turbine high-pressure cylinder is divided into two routes through the tee before the reheater inlet. It enters the wall radiation reheater inlet header and passes through the wall radiation reheater. Then it is led out from the upper outlet header and to the platen reheater inlet header through 4 connection tubes. After that, it passes through the platen reheater and Final reheater in turn, and then is led out of the top of the Final reheater outlet header to the reheater steam pipeline and enters the turbine medium-pressure cylinder. For the process, refer to Fig. 2.2-3 Reheater system. For the reheaters of all stages, large diameter pipes and tee connections are used to improved the conditions for sufficient mixing. Accidental water-spraying desuperheaters are arranged on the wall-type reheater inlet pipes. The left-right crossing is realized through connection pipes between the screen reheater and Final reheater. Desuperheater is mounted on the connection pipe to minimize the reheated steam temperature deviation caused by the flue gas temperature deviation between the left and right sides of the furnace.

33

Product Description

730-1-8601

R.1 6 R.8

II

R.4

R.1 2

R.1 5

II

R.9 R.7 R.1 1 R.1 3

R.6 R.3

R.1 0

R.1 4

R.1

I
R.2 R.5

I II-II
R.1 1

I-I

R.1 2 a R.1 0 R.1 2 b R.1 4 R.2

R.1

R.1 2 c R.4 R.5 R.7 R.9 R.1 1 R.1 3 R.1 5

R.1 R.2 R.3 R.4 R.5 R.6 R.7 R.8 R.9

Desuperheater Front-wall reheater inlet header Front-wall reheater Front-wall reheater outlet header Side-wall reheater inlet header Side-wall reheater

R.10 R.11 R.12a R.12b R.12c R.13

Side-wall reheater outlet R.14 header Platen reheater inlet R.15 Final reheater outlet connection pipeline header Platen reheater inlet R.16 Final reheater outlet header pipeline Fig. 2.2-3 Reheater system 34

Platen reheater Platen reheater outlet header Micro-spraying desuperheater inlet pipeline Micro-spraying desuperheater Micro-spraying desuperheater outlet pipeline Final reheater inlet header Final reheater

Product Description

730-1-8601

2.2.4 Bypass System Use 5%BMCR start-up bypass system as the method of controlling the pressure and temperature of the superheated steam when the boiler start-up to shorten the start-up time. 4 drain tubes are setted on the ring header that behind the boiler and below the back pass, 2 setted on the downside header. Each drain tube has 2 DN50 electric check valve. Four ducts converged to one duct connecting to the condenser, and the pressure reducer should be installed on it and the flow of the ducts is designed according to 5% maximum continuous load and rigidity design according to the rigidity design parameter of boiler. For cold start-up, the drain valve totally opened when the temperature of the medium in this system is the saturated temperature of 4.12 MPa . Increase the superheated steam temperature by the method of increase the burning rate. The drain valve should also be opened to drain the water in SH system. The temperature of the superheated steam when start-up is controlled by furnace burning rate, the pressure of the superheated steam is controlled by the drain valve, and this valve should be shut off when the steam turbine is synchronization.

2.3 Burning System The milling system is positive pressure and direct-fired with 6 HP863 type medium speed pulverizers and the burner is setted at four corner and firing at tangential mode. 2.3.1 Pulverized Coal Duct Pulverized coal pipes starts from pulverizing mill outlet until burner inlet, which is equipped with abrasion proof. For every pulverizing mill, there are 4 pulverized coal pipes connecting with coal burners arranged at four corners at the same level. 2.3.2 Burning Equipment The burner is arranged at the four corners, i.e. corner tangential DC burner.
35

Product Description

730-1-8601

a. Adopting vertical rich-lean primary air nozzle. When the coal powder flows through the burner inlet elbow, under the action of the centrifugal force, most of the coal particles enter the coal powder spraying tube closely along the external edge of the elbow. The partition board in the coal powder spraying tube divides the primary air into two parts, i.e. thick and thin parts. This can improve the coal powder concentration at the outlet of the primary air nozzle. In the primary air nozzle, a V-shaped bluff body is mounted so that the primary air can form a stable reflux zone in front of the V-shaped bluff body. This can suck the high-temperature flue gas and functions to stabilize the flame. b. The burner nozzles at the four corners have their respective oscillation link levers. They are driven by electric actuators through rocker devices and main link levers. The primary air nozzle can oscillate upwards and downwards for 20 respectively, while the secondary air nozzles for 30. The top manual secondary air nozzle can oscillate upwards for 30 and downwards for 6. During the boiler operation, the temperature of the reheater can be adjusted through the oscillation of the burner. The control of the burner nozzle oscillation can be connected to BMS system. If BMS system is not used or the oscillation control steps out of the BMS temporarily, to ensure the normal operation of the nozzle oscillation device, the nozzle should be operated manually to oscillate upwards & downwards for 1 or 2 times at appropriate time every day and then resume to the original position. c. The burner bellows are provided with 3 layers (totally 12 EA) of steam atomization stable-burning HFO guns. The total output of the oil guns is 30%BMCR. d. The burner bellows are provided with 1 layer (totally 4 EA) of mechanical atomization ignition & warming-up oil guns. The total output of the LDO guns is 10%BMCR. e. Each oil gun is provided with a set of 20J high-energy igniter, which is controlled with the forward/backward mechanism during the ignition.
36

Product Description

730-1-8601

f. To facilitate the field installation and to ensure the correct angle for the air flow to be injected into the furnace, the burner and the water-cooling jacket (burner area waterwall) should be assembled before being released from the factory. g. The burner housing is bolted to the water-cooling jacket. The 24 high-strength bolts at the center of the housing flange are used for securing, while the other bolts are not tightened completely to allow relative displacement between the housing and the waterwall and to absorb the expansion difference between the housing and the waterwall under various work conditions. For the detailed instructions concerning the burning equipments, refer to 680197-1-8661 Burning equipment instruction manual.

2.3.3 Ignition Equipment The burner is provided with 1 layer (4 EA) of forward/backward type air

atomization LDO guns used for boiler warming-up and pressure increasing,and also provided with 3 layers (12 EA) of forward/backward type steam atomization HFO guns used for ignition and burning stabilization. These oil guns can be used to ignite and stabilize the burning of the adjacent coal powder nozzles. The oil guns and forward/backward mechanisms are outsourced products. For the detailed requirements for the installation, operation and maintenance of the oil guns and forward/backward mechanisms, refer to the related documents provided by the oil gun manufacturer. Output of the oil guns is 1.75t/h. Boiler front oil system is composed of the pipelines, primary instruments,

valves, etc. It functions mainly to protect and supervise that the medium in the front oil system works under the normal pressure, flow rate and temperature, and to realize the requirements of FSSS and BMS (see Fig. 501730-E1-06 Rev. B).

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Product Description

730-1-8601

2.4 Flue Gas and Air System 2.4.1 Air System The primary air is used to transport and dry the pulverized coal. It is pumped from the atmosphere by fan to the primary chamber of the trisector air heater, and then goes into the pulverizer through the primary air duct after it is heated. Before goes into the air preheater, part of the cold air bypass the cold primary air duct and is mixed with the hot air at the inlet of the pulverizer, which is used as tempering air for the pulverizer. The function of the secondary air is to strengthen the combustion and control the quantity of NOx. The secondary air pumped by fan from the atmosphere to the secondary chamber of air preheater, and then goes into the wind box through the secondary air duct. SBWL design and supply the part of secondary air from air preheater outlet until wind box. 2.4.2 Flue Gas System The flue gas produced in the furnace flow from the back pass to the flue gas chamber of the air preheater through the flue gas duct. The primary air and secondary air is preheated in the air preheater by the residual heat of the flue gas. The flue gas goes out of the preheater and discharged to the chimney by the electrical precipitator and the induced-draft fan. Bargainor design and supply the parts and components until 1 meter outside the last column (M5 Column) of preheater outlet flue gas duct. 2.5 Bottom Ash System Mechanical deslagging is used for this boiler. The deslagging equipments are supplied by the buyer. The scope of design and supply of the seller is to the bottom sealing baffle device, which inserts into the upper-edge water sealing slot of the slag hopper annularly. It functions to seal the bottom of the furnace bottom.

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Product Description

730-1-8601

2.6 Attamperation System 2.6.1 Superheated Steam Attamperation Except for the influence of the tilting of the burner nozzles, the temperature of the superheated steam is mainly controled by water spray desuperheaters. This boiler is arranged with two stages of water-spray desuperheaters. Stage-I desuperheater is installed at the division panel superheater inlet piping to mainly control steam temperature. Stage-II desuperheater is installed at the final superheater inlet piping to regulate a small quantity of steam temperature. The spraying water comes from the feedwater pump outlet piping, and is divided into two routes at the water-spray header isolation valve, and then enters the desuperheater through Stage-I and Stage-II water-spray pipelines respectively. For the diagram of the water spray system, refer to Fig. 501730-E1-03 Steam-water system diagram. Electric gate valves (or electric shutoff valves) and pneumatic regulation valves are arranged in the piping. The pneumatic regulation valves are controlled by controlled panel. The electric cut-off valve before the regulation valve is interlocked with the regulation valve. During the operation of the boiler, normally the electric cut-off valve after the regulation valve is opened, and is only closed for isolation when the regulation valve is repaired in case of failure. The Maximum design water spraying quantity of the Stage-I desuperheater is 103t/h, and that of the Stage-II desuperheater is 15t/h. The nozzles of the desuperheaters are of perforated flute tube structure. The water spraying quantity (calculated) of the various stages of desuperheaters under different loads are as shown in the following table. BMCR Water-spraying volume of TMCR 80% TMCR
37.90

60% TMCR
32.40

30% BMCR
19.00

High plus tangential

83.90

Stage-I desuperheater t/h Water-spraying volume of

8.10

22.50

Stage-II desuperheater t/h Water spraying temperature

10

177

173

164

153

133

176

39

Product Description

730-1-8601

2.6.2 Reheat Steam Attemperation The reheated steam temperature is generally controlled by fuel nozzle tilts to change the height of the flame center and subsequently the furnace outlet flue gas temperature. The tilting angle of the nozzle is approximately 20 . As the reheater is arranged in the furnace outlet high-temperature flue gas area, it is quite sensitive to the temperature regulation of the tilting nozzles. When the load is lower than a certain value, the temperature can be regulated by excess air. In addition, two accidental water-spraying desuperheaters are provided at the reheater inlet. The nozzle is Monarch nozzle, which is used to control the steam temperature at the reheater steam under accidental condition. The desuperheaters are arranged in the wall radiant reheater inlet piping, with max. design water spray capacity of 42t/h. The spraying water comes from the feedwater pump middle tap, and is divided into two routes at the isolation valve. Then it passes through the pneumatic regulation valve and electric shut-off valve and enters the desuperheater. The regulation valve is controlled by controlled panel. The isolation valve and the regulation valve are interlocked. 2.7 Sootblowing System The boiler is equipped with sootblowing system to keep the heating surface clean and to achieve proper heat transfer effect. The whole sootblowing system is divided into two parts, i.e. boiler body heating surface sootblowing and preheater sootblowing. The boiler body part includes 56 boiler wall sootblowers arranged in the lower furnace and 44 long retractable sootblowers arranged at the upper furnace and the convection flue area. Each air preheater flue gas cold end is provided with a retractable sootblower. The sootblowing steam is connected from the platen superheater outlet header. Automatic drainage points are provided in the pipeline. Process control is realized in the whole sootblowing system of the boiler. Usually the system is designed considering that 2 long retractable and 2 furnace sootblowers and 2 air preheaters are put into service in the same time. One sootblower on each wall (side walls or front/rearwalls) relative to the long retractable and furnace sootblowers is put into service in the same time. It can also be set as per the requirements of the user. The design and manufacture of the whole set of sootblowing equipments for this boiler (including sootblower, pipeline and control equipment) is undertaken by
40

Product Description

730-1-8601

Shanghai Clyde Mechanical Co. Ltd. For the details, refer to 730-1-8616 Sootblower body instruction manual and 730-1-8617 Sootblowing pipeline system instruction manual. 2.7.1 Sootblowing System The sootblowing steam is led out of the DIV panel SH. outlet header. After the steam is subject to pressure reduction at the 2 pneumatic diaphragm reduction valve, the set value is 2.94MPa (30kgf/cm2) and the temperature is approx. 330. The optimal usage value depends on the various conditions after the sootblower is put into service, and this pressure value is regulated by the user according to the demand. A manual shut-off valve and an electric shut-off valve are arranged on the pipeline before the pressure reduction valve for closing the steam supply. A safety valve is arranged on the pipeline after the pressure reduction valve to avoid over-pressure of the sootblowing steam. Pressure measurement points are provided in the pipelines to monitor the outlet pressure of the pressure reduction valves. All the sootblower pipelines are provided with flow switches, and are connected with the program control. The set value of the flow switch contact is the minimum cooling flow rate necessary for keeping the sootblower. To ensure the appropriate dryness of the sootblowing medium, the sootblowing pipeline is provided with drainage system. The body sootblowing part has 4 drainage points, including 1 at the furnace sootblower and 3 at the long retractable sootblower. Each drainage pipeline is provided with an electric shut-off valve for temperature control and water drainage. The valve open/close set value is 300. To ensure the thorough drainage, all the horizontal pipelines should be sloped by at least 0.025m/m. 2.7.2 Air preheater Sootblowing System The air preheater sootblowing steam comes from the platen superheater outlet header, with steam temperature of 510 and pressure of 18.1MPa (g). After the pressure reduction at the 2 pneumatic diaphragm pressure reduction valve, the steam pressure becomes 2.94MPa (30kgf/cm2) and the temperature is approximately 330.

41

Product Description

730-1-8601

2.7.3 Main Design Parameters of the Sootblower Item Name Boiler sootblower Long retractable wall Type Steam temperature () ~315 Steam pressure (g) (MPa) ~2.45 Stroke (mm) 255

V04

sootblower Preheater sootblower

PS-SL

~315

~2.45

7000

PS-AT

~330

~2.45

970

2.7.4 Furnace flue gas temperature probes A retractable flue gas temperature probe is arranged at each side of the furnace outlet. On the boiler startup stage, the flue gas temperature probe extends into the furnace to monitor the furnace outlet flue gas temperature. The max. measurement temperature of the probe is 600. When the flue gas temperature arrives at 540, it will give an alarm and the probe retracts automatically. At such time, the fuel quantity should be reduced to prevent the wall-type reheater from being damaged due to excessive heat. The flue gas temperature probe is of TS-O type with stroke of 4700mm. For the details, refer to 730-1-8618 Flue gas temperature probe instruction manual.

2.8 Pipeline System 2.8.1 Drainage, Venting and Dosing Pipelines To ensure the safe and reliable operation of the boiler, drainage and venting points are provided at the necessary positions on the pressure parts. For the specific arrangement, refer to 820730-E1-01 Venting & drainage pipelines and 820730-E1-02 Drainage pipelines. The drainage pipelines below the four downcomer distributors are connected in parallel with four routes of regular blowdown pipelines. In addition, the economizer inlet header, roof inlet header and back pass lower annular header are all provided with drainage pipelines. In addition to the above normal drainage pipelines, the boiler is provided with an emergency accidental drainage pipeline, which is led from the lower front side
42

Product Description

730-1-8601

of the boiler drum to the 12.6m platform in front of the boiler. The pipeline is provided with two electric shut-off valves with inlet of DN100. When the boiler drum level is above +180mm, open this valve, when the normal water level is achieved, close this valve. Prior to the boiler ignition, the drainage valves and venting valves of the superheater and reheater systems must be opened to ensure the drainage of the pipelines in the systems. When steam is generated in the pipelines after drainage, close the venting valves in the superheated steam pipelines. The drainage valve on the back pass lower header should be closed as soon as the turbine is connected to the grid, and the reheater drainage valve and venting valve must be closed before vacuum is established in the condenser. The dosing pipe is provided on the boiler drum. To prevent from corrosion, the pipes and valves are made of stainless steel materials. 2.8.2 Blowdown Piping This boiler is provided with continuous and regular blowdown lines. The boiler blowdown is used to control the boiler water concentration and to remove the sediment. The blowdown quantity and blowdown times depend on the operation conditions of the boiler, such as water characteristics, water treatment nature, boiler load, etc. Under normal conditions, the continuous blowdown can meet the requirements. However, when excessive sediment forms due to high solid content or poor feedwater treatment causing carryover, regular blowdown is needed for the boiler through the regular blowdown pipeline. The continuous blowdown pipeline is led out of the lower part of the boiler drum end. Through the manual cut-off valve and regulation valve, it is led directly to the blowdown box. The specification of the regulation valve is 1, with max. flow rate of 10.15t/h and pressure difference of 9.09MPa. The drainage lines below the four downcomer distributors are connected in parallel with four routes of regular blowdown lines. Each pipeline is provided with a regular blowdown valve. In addition, each pipeline is connected in series with a high pressure difference regulation valve to reduce the inlet/outlet pressure difference of the regular blowdown valve, to improve the operation conditions and to prolong the service life. The pressure difference of the high pressure difference regulation valve is set at 10MPa. For the regulation, the flow rate and pressure difference necessary for the operation can be regulated
43

Product Description

730-1-8601

through the hand wheel. Each pipeline is also connected in series with a manual cut-off valve for isolating the regular blowdown valve for maintenance. These four regular blowdown lines eventually converge to a OD.133mm small header, which is equipped with a drainage valve. Prior to the blowdown, drainage should be carried out to prevent from water hammer. The steam / water quality during the boiler operation is normally guaranteed through continuous blowdown means. Only in case of a new boiler or during the startup after overhaul or when the continuous blowdown is not enough to ensure the steam / water quality should the regular blowdown system be started. For the regular blowdown system lines, it is necessary to design the hangers and supports properly, which can meet the expansion displacement requirements and the requirements that no vibration should occur when the regular blowdown is started. If it suffer severe vibration during the blowdown, the cause should be found immediately and should be resolved through improving the hangers and supports. 2.8.3 Sampling Piping The boiler is provided with saturated steam sampling points, boiler water sampling points, superheated steam sampling points and reheated steam sampling points. The saturated steam sample is taken from the steam lead-out tube from the boiler drum to the roof superheater inlet header. 6 points are arranged evenly along the length of the boiler drum. The boiler water sample is taken from the continuous blowdown tube. 1 steam sampling point is set at the superheater inlet main steam pipeline, and 2 points at the reheater outlet steam pipeline. Each sampling pipeline is arranged with two manual cut-off valves. 2.8.4 Safety Valve ,Venting Piping To ensure the safe operation of the boiler and to protect the pressure parts against excessive pressure, the boiler is provided with 10 safety valves, including 2 at the boiler drum, 2 at the superheater outlet main steam pipeline, 2 at the reheater inlet and 3 at the reheater outlet . In addition, to minimize the tripping times of the safety valve at the superheater outlet and subsequently to protect the safety valve, electric relief valve is arranged downstream the superheater outlet . For the setting pressures and discharge quantities of the safety valve and electric relief valve, refer to 730-1-8401 Summary of safety valve setting pressure and discharge quantity.
44

Product Description

730-1-8601

Each safety valve or electric relief valve is provided with a venting tube, which penetrates the large house roof starting from above the drainage dish on the safety valve venting elbow. There are sufficient gaps between the venting tube and the safety valve venting elbow and drainage dish to prevent the weight of the venting tube from being transferred to the end of the valve venting tube. The venting tubes of the boiler drum safety valve, reheater inlet/outlet safety valve, superheater outlet safety valve and electric relief valve are provided with silencersfirst jump safety valve.

2.9 Arrangement for Ports and Measuring Points 2.9.1 Arrangement for Ports The boiler is provided with holes for inspection, observation, sootblowing, instrumentation measurement, TV pickup, temperature probe, boiler tube leakage alarming device, etc. This is convenient for operation, maintenance and commissioning. All the holes are arranged at proper positions on the boiler as per the requirements. To prevent from flue gas leakage and to ensure the boiler sealing, all the holes that need elbows should be provided with sealing boxes. A 610mm760mm water cooling door is arranged on each side of the waterwall at the bottom of the furnace cold ash bin. During the operation, water circulates in it for cooling to prevent from burning damage. The parameters of the cooling water are as follows: inlet temperature 20, inlet pressure 0.29MPa, water volume 0.91m3/h, outlet temperature 54. For 420mm460mm maintenance doors, the holes should be blocked with refractory materials during the boiler operation to prevent the gas from damaging the maintenance doors. For the details of the ports, refer to 502730-E1-10 port arrangement drawing and 751730-D1-01 port sealing box arrangement drawing. 2.9.2 Measuring Points for Steam-Water System The steam-water system measurement points include the measurement points for working fluid temperature, pressure, flow rate and metal wall temperature, and are used for recording, control and test. Measurement points for working fluid temperature are provided at the economizer inlet/outlet pipelines, downcomers, inlets/outlets of Stage-I & -II desuperheaters of the superheaters, outlets of Final superheaters, inlets of reheater desuperheaters, inlets of
45

Product Description

730-1-8601

wall-type reheaters, inlets/outlets of screen-type reheaters, and outlets of Final reheater outlets. The measurement points for working fluid pressure are arranged at the economizer inlet, boiler drum, superheater outlet, reheater inlet/outlet, etc. The measurement points for metal wall temperature are classified under two types: one is for record and for control in the control room, and the other is for local test. For the measurement points used for record and control, the thermocouples are led directly to the control room; while for the measurement points for local test, the thermocouples are connected to the terminal boxes at the side of the roof large enclosure. (The thermocouples are not in the scope of supply of SBWL.) For the detailed arrangement of the measurement points, refer to 502730-E1-11 Steam-water system measurement point arrangement drawing. 2.9.3 Measuring Points for Gas-Air System The measurement points for the gas-air system include those for furnace pressure, flue gas temperature, pressure difference between furnace and various air ducts, tail flue gas pressure & temperature, etc. Some of these measurement points are needed for operation supervision, and some are for regulation and alarming required by FSSS and BMS control. For the details, refer to 502730-E1-12 Gas-air system measurement point arrangement drawing. 3 Main Pressure Parts 3.1 Drum and Drum Internals 3.1.1 Drum The length of the straight section of the boiler drum is 19662mm, and the total length (including heads) is ~22338mm. The internal diameter of the drum is 1743mm and the thickness is 192mm. It is composed of six (6) 3277mm long cylindrical sections made of SA-299. The heads at the two ends of the drum are spherical, with the material as same as that of the drum body. Four large diameter downcomer seats made of SA-299 plates are welded to the lower part of the boiler drum. 8 OD.133mm lead-in tube seats and 98 OD.159mm lead-out tube seats are arranged at the horizontal and vertical positions of the boiler drum respectively. 3 feedwater lead-in tube seats are
46

Product Description

730-1-8601

arranged evenly at the lower part of the boiler drum. The drum body is also provided with 2 economizer recycling tube seats, 1 accidental (emergency) drainage tube seat and 1 dosing tube seat. At each end of the lower part of the drum body, 1 downcomer connection tube is provided to eliminate the dead corner at the end of the boiler drum. 9 pairs of internal/external wall temperature measurement points are provided along the length of the boiler drum, which are arranged in 3 sections, i.e. upper, middle and lower. They are used for monitoring the boiler drum wall temperature difference during the startup and shutdown of the boiler. The auxiliary steam tube seat is located at the left end of the boiler drum. 3 safety valve tube seats are arranged at the upper parts of the left and right heads respectively (1 at left and 2 at right). 7 groups of level monitoring tube seats (2 dual-color level gauges, 3 single-chamber level balance vessels and 2 electrode level gauges) are arranged on the heads of the two sides respectively. The continuous drainage tube seats are located below the two ends of the boiler drum, and are gathered and then led out. The total weight of the boiler drum (including internal parts) is 217.5 tons. Two pairs of lifting lugs are welded at the upper part of the boiler drum for lifting of the boiler drum. The normal water level of the boiler drum is -50mm below its centerline. The water level control protection limits are as follows: Serial No. 1 Item Steam -50mm Normal water level +50mm Normal water level -50mm Normal water level +125mm Normal water level -200mm Normal water level +250mm Normal water level -350mm
47

Limits Drums center-line

Normal water level Normal water level range Max. Min.

2 3 4 5 6

High water level alarm Low water level alarm High water level trip Low water level trip

Product Description

730-1-8601

3.1.2 Drum Internals The boiler drum internal devices include axial-flow separator, corrugated dryer, blowdown tube, dosing tube, accident drainage tube and feedwater distribution tube. (See Fig. 3.1 Boiler drum internal devices.) The water feed mode of this boiler is direct injection type, i.e. the feedwater is injected into the inlet end of the downcomer directly. The purpose is to reduce the upper/lower and internal/external wall temperature difference of the boiler drum during the startup, sliding pressure operation and high plus tangential operation of the boiler. Especially, it can prevent from the temperature difference thermal stress of the downcomer tube seat under the above operation conditions, improving the service life of the boiler drum. The feedwater distribution tubes located at the bottom of the boiler drum have 4 feedwater injection tubes led from above the downcomer seats. The feedwater enters the center of the downcomer through the injection tube, avoiding the direct contact of the downcomer tube seat weld area and the feedwater and eliminating the possibility of excessive temperature difference stress at the weld area. Grid plates are provided at the inlet of the downcomer tube seat to avoid eddy. This prevents the downcomer from bringing in large quantity of steam and improves the water circulation safety. In the boiler drum, 94 axial-flow cyclone separators and 112 wave-shaped dryers are arranged. The steam-water mixture enters the cyclone separator through the steam-water lead-in tube and flows in a rotational way from the top to the bottom. The steam passes through the shutter at the upper part of the separators, and then to the dryers at the top. The water drops fall along the separator partition layers and the bottom of the dryers, and then enter the water space of the boiler drum. The separated dry steam is led from the top of the boiler drum to the superheater system through 18 OD.159mm steam guiding tubes. As a deal of axial flow cyclone separators and wave-shaped dryers are set in the boiler drum, the data of the separators such as steam load values are quite conservative (see the following table). Therefore, the quality of the steam can be guaranteed effectively even when the load varies. The steam-water space of the boiler drum is quite large. This is favorable for the stability of the water level.
48

Product Description

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Characteristics of axial-flow cyclone separators at 100% boiler load Separator size 254mm Separator quantity 94 Steam load of each Mean separator 10.80t/h mixture load of each

separator 40.2t/h

If the boiler drum internals are assembled with the drum in the factory, the cyclone separators and dryers should be removed before the pickling on site so that they would not participate in the pickling. This is to prevent the scraps from blocking the gaps and to protect the steel sheets from being corroded.

49

Product Description

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-+ Figure 3.1 Boiler drum internal devices

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Product Description

730-1-8601

3.1.3 Water Level Test To calibrate the local level gauges and the remote level indicators, the drums of all the large boilers (with design pressure 16.6MPa) are provided with water level measurement sampling devices to establish a real water level during the high-pressure operation. 1. Equipment The typical water level measurement sampling device is as shown in Fig. 3.2. Normally only 4 couplings are used on the sampling cylinder to connect with the test pipeline. All the other couplings are blocked with blind plates. Sufficient high-pressure sampling coolers should be prepared so that at least two connection tubes can be used for sampling and cooling in the same time. Each sampling pipeline should be provided with a conductivity gauge (0.1 setting). The conductivity value can be detected with portable instrument complete with switch boxes or with multiple-point recorder. Because the approximate conductivity is enough to differentiate the water and steam in the boiler drum, no temperature compensation is needed. However, all the sampling tubes should be cooled to approximately the same temperature for the measurement. The water level sampling barrel should not be arranged directly above the large-diameter downcomer inlet as the water level in such area is liable to the interference of vortex. Therefore, it is wrong and meaningless to measure the water level in such affected area. The level measurement should be limited to the position as shown in the figure. See 3.2 Water level measurement sampling device (typical arrangement) drawing. 2. Test Requirements To obtain the maximum reliable documents, the test group and operators are required to cooperate appropriately in the water level performance test. The max. deviation of the boiler drum level appears at the full load. Therefore, it is suggested that the test should be carried out under stable full-load work conditions. Load variation in process of the test can cause some additional factors and complicate the data processing. In addition, the water level must vary evenly while observing the reaction of the various level indicators and the relative position of the water level in the level sampling barrel. Sootblowing
51

Product Description

730-1-8601

should be avoided during the test as sootblowing can cause wrong water level. It is absolutely necessary to supply sufficient quantity of cooling water during the test. The normal necessity of each sampling cooler for cooling water is 0.5675m3/h (2.5 gallon/minute). As the test is carried out close to the boiler drum, the water delivery head of the cooling water for the power plant must meet the water level requirements. As the conductivity is the foundation for differentiating the steam phase and water phase, it is required that the boiler water should contain ideal electrolysis concentration. If the power plant uses volatile content or low solid content to control the boiler water, some sodium salt must be added into the boiler water to generate conductivity of at least 30 . 3. Test Procedure (1) The connection tube should allow the sampling barrel to take samples from the following four points: a) 51mm below the normal water level b) Normal water level c) 51mm above the normal water level d) 102mm above the normal water level (2) The samples taken by the two probes on the sampling barrel should condense in the same time, and the conductivity should be supervised. In the beginning, the cooler should be connected with the points at the normal water level and 51mm above the normal level. If such sampling probes are not satisfactory, the cooler can be connected with one of the other two points. (3) The water level in the boiler drum should decrease gradually until the conductivity of steam at all the sampling points is shown (less than 5). Keep it stable for 15 minutes and record the following data: a) Conductivity of the various sampling points b) Readout of the automatic level regulator c) Readout of the remote water level indicator d) Readout of the dual color level gauge e) Readout of the electrical terminal level gauge f) Time and load. (4) Increase the water level by 13mm according to the automatic level regulator and keep for 15 minutes. Repeat to record the data as described in Step (3).
52

Product Description

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(5) Repeat Step (4) until all the sampling points are immersed in the boiler water (with conductivity >30). If the test discloses that the real water level deviates greatly from the indicated level, consider compensating the external level indicator or regulating the pre-offset of the various level indicators.

53

Product Description

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Fig. 3.2 Water level measurement sampling device (typical arrangement) 54

Product Description

730-1-8601

3.2 Waterwall 3.2.1 Brief Introduction The boiler furnace is enclosed with a membrane wall, which is composed of 664 tubes with OD. 60mm, material of SA210-C and spacing of 76mm. The depth of the furnace is 12350mm and the width is 14022mm. The whole waterwall system is divided into 51 calculation circuits, i.e. 23 at the side walls, 12 at front wall and 16 at rear wall. The four corners of the waterwall are large chamfers. The chamfer at the lower part of the furnace is designed as burner water-cooling windbox, which leave factory integrally assembled to the burner . The front/rear waterwall forms a 55 angle with the horizontal level at the elevation of 15.951m, i.e. forming a furnace bottom. The front/rearwall of the furnace bottom inclines downwards to the elevation of 7790mm to form a 1.4m-deep deslagging opening, which is connected with the slag bin device as a flashboard water-sealing structure. At the elevation of 42200mm, the rearwall forms a 2.591m-deep diaphragm-type wall flame deflection corner, which is composed of tubes with diameter of 70mm and spacing of 91.2mm. At this elevation, 28 OD.76mm, SA213-T11 tubes penetrate evenly from the rearwall to form rearwall suspension tube or suspension tube No. I to support the entire weight of the rearwall of the boiler chamber. The flame deflection corner is at 30 angle to the horizontal direction, and extends upwards and backwards. At the Final reheater, it extents to the front end of the side wall to form the front bottom of the horizontal flue. Then, it extents upwards vertically to form the rearwall tube bundle. The fins of the waterwalls surrounding the boiler chamber are made of 166mm flat carbon steel. The fins of the flame deflection diaphragm wall is made of 21.26mm flat steel. They are connected with the tubes with submerged arc welding to form the diaphragm wall. The whole waterwall is divided into 4 sections along the furnace height direction, and is divided into 124 diaphragm screens (including 4 groups of water-cooling jackets) before being released out of the factory. At the middle and lower parts of the front and side waterwalls, sufficient quantity of internal thread tubes are arranged. The rear waterwall, starting from the cold ash bin corner to the flame deflection corner, is composed of almost all internal thread tubes. 3.2.2 Installation When waterwall is installed on site, the installation gaps among the various tube screens should be controlled strictly to meet the requirements in the drawings.
55

Product Description

730-1-8601

Repair welding of the flat steel due to excessive fitting gaps is not allowed in order to prevent from burning damage during the operation. When the bulk tubes at the 2#,3# upper corners and the bulk tubes at the boiler bottom corners are installed on site, the requirements in the drawings must be followed strictly so that the tubes in the boiler could be at the same level. The spacing should be even, and the gaps should be welded and sealed with flat steel or round steel to avoid leakage of flue gas or ash during the operation. In the roof tube penetration area at the upper part of the waterwall, all the gaps larger than 5mm must be welded and sealed with flat steel to prevent the sealing devices and expansion joints from over-burning. When the upper and lower tube screens are fitted, it is allowable to cut temporarily a section of flat steel at the middle of the tube (without damaging the tube wall) to convenience the fitting. After the fitting is completed, fill it up with round steel or flat steel and weld them. 3.2.3 Operation 1) Encrust in pipe Normally the heat transfer rate of furnace waterwall in design is very high, so only good feedwater treatment can prevent encrust and copper and iron oxide deposition. The insulation membrane made by deposed encrust on water side tube will increase the tube surface temperature and may cause superheating in local tubes. In high-pressure boiler, the iron oxide and copper oxide coming from feedwater may cause internal corrosion at deposition zone, even tube destruction. Under this condition, the water treatment of upstream steam drum system contains the control of corrosion. Before putting into operation, the acid wash for the boiler circulation loop is good to cleaning of boiler internals. After long time operation, it is necessary to acid wash the boiler, especially when the feedwater can easily cause encrust or oxide deposition. 2) Blow-down Boiler blow-down is a method to control the boiler water density (salt and alkaline) and eliminate the deposition. The quantity of blow-down is decided by the working condition online, such as water characteristics, water treatment characteristics, boiler design and the evaporative rate. For most cases, the continuous blow-down system can satisfy the requirements of controlling the boiler water density (salt and alkaline)
56

Product Description

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and eliminating the deposition. However, in case that the quantity of deposition is very large while the feedwater treatment is not very effective due to the high content of solid substance, the boiler shall adopt the drainage of downcomer to achieve periodic blow-down. 3) Ash deposition (slagging) The amount and speed of slag are largely decided by the fuel types. The furnace waterwall cannot thoroughly avoid slagging, but it should keep enough clean(refers to the note), and the proper use of sootblower devices can prevent severe local slagging. Note: at the early stage of operation, the steam temperature will be lower than the design value. The reason is the excessive cleanness of furnace waterwall causes the furnace heat absorption rate higher than normal condition. The period of set-up normal slagging is called as ageing, and it is universal for the coal-fired units, which use high ash content fuel, and some oil-fired units. The extension of ageing is up to change of the characteristics of the fuel (characteristics of ash content). At the stage of commercial operation, the furnace waterwall increasingly get fouling. And this will cause the increase of furnace outlet flue gas temperature and steam temperature, even exceeding the steam temperature control value. But the steam temperature can be controlled within the operation range by furnace sootblowers. 4) Water quenching of floor tube When directly contact with the comparatively cold water below the water-cooled hopper bottom, the waterwall tube of boiler floor can produce fatigue failure. Although the design of hopper and ash disposal system can meet with normal operation code, abnormal working condition will still cause water quenching of furnace waterwall. Therefore, the control to water level of water sealing of slag disposal is of key importance. 3.2.4 Maintenance 1) Inspection The routine inspection of furnace waterwall, steam drum and header are at every boiling out, first time acid wash, routine acid wash and every unit trip period. During the inspection, open the steam drum manhole and dismantle the handhole cap, then inspect the steam drum internals conditions and sampling inspect the tubes, inspect the internal encrust to the tube section, after all the fouling is
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Product Description

730-1-8601

diminished, use clean water to clean the headers, steam drum and pipes, and inspect the blister outside the furnace tube, overburning corrosion and fissure (the surrounding area of sootblower is easily eroded). For this purpose, the slag and ash deposition in all the furnace tubes at fireside surface should be cleared. The water-cooled hopper bottom should be inspected at the early stage of boiler operation. The installment and operation of slag removal system, and any observed conditions that may cause boiler floor water quenching (in normal or abnormal working conditions) should be corrected. All the inspections should be thoroughly proceeded in every detail, which shall be performed by those personnel who have certain capabilities and are familiar with boiler operation, maintenance, water treatment and so on. Every inspection record should be filed in the same manual, so as to check all the corrected results to the original condition. If the conditions of tube destruction or that may cause tube destruction is found, the inspection to the tubes should be more thoroughly. If the sources of the conditions are not clear or indefinite, then the inspection should include metallographic examination to the tube section, chemistry analysis to the encrust, etc. 2) Tube repairing The broken tube parts, which must be replaced because of severely destruction, under most circumstances, can be easily replaced. After diminishing the heat insulation material on furnace wall behind the destroyed parts of tubes, cut out the tubes at enough height along the vertical direction of the broken tube parts, then carefully cut out the fins on tubes groove preparation must be done. Note: installing new tubes, the cut out of pins along the pipe lengthways should extend to enough length near the tube vertical fracture, in order to allow thorough welding along the tubes circumferences. The fins between the tubes must be exchanged and sealed. 3.3 Economizer 3.3.1 General Description The functions of ECON are to preheat the feedwater before it comes into the steam drum, and recycle part of heat in the exhaust gas to make the boiler more economic.
58

both sides, (refers to the note) then take out the

tube section. Before welding with the new tube section and re-welding, good welding

Product Description

730-1-8601

ECON is located below the low temperature superheater of back pass. ECON is arranged in 2 banks. ECON adopts bare coil tubes with OD. 51mm, material of SA210 C. There are 116 rows of coil tubes all together in ECON. Each row of them is made up of 3 parallel coil sleeves, arranged in-line with horizontal spacing of 120mm and vertical spacing of 102mm. ECON is hung by hanger plate and pipe clip, which are hung to the bottoms of 3 ECON intermediate headers. They are hung in 3 rows. And the weight of each row is undertaken by 56 hanger tubes at ECON intermediate header. The outside diameter of the hanger tube there is 60mm, and material is SA210- A1. The cooling medium inside the hanger tube is from ECON. One DN300 check valve and one DN300 electric gate valve are set at the economizer inlet pipeline. An economizer recycling tube is provided between the furnace rear sewage bag and the economizer inlet pipeline. In order to assure that the flue gas is evenly distributed in the back pass, baffle plate are welded at both the rearwall enclosure tube of low temperature superheater inlet, and the frontwall and rearwall enclosure tubes. The purpose is to avoid the forming of flue gas passage, and local wear.

3.3.2 Operation At boilers star-up, 1 electric stop valves on ECON circulation piping must be open, in order to provide enough water flow to ECON, and prevent ECON from gasification. This valve can only be closed after a continuous water flow has been set up.

3.3.3 Maintenance a. At the time of unit trip and before operation, inspect the exterior of ECON. If necessary, do the cleanings. As to the new unit, careful inspection to ECON is needed. Pilling up and blocking of materials for assembling such as wood, heat insulation material, welding electrode is very normal. The big sundries should be eliminated by hand.,then water wash ECON. b. Inspection hole should be tightened closely. And check the closeness of Inspection hole at any time. 3) The usage times of sootblowers is up to the actual ash deposition in ECON. When the first time of operation for ECON, the sootblowers should be used for every shift. And the interval of sootblowing is decided by the changes of flue gas resistance observed between the 2 neighboring sootblowings. In most cases, it is found that
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Product Description

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once a day for operation of ECON sootblower or even less is suitable.

3.4 Superheater 3.4.1 Introduction The superheaters are designed in radiation and convection type. All the superheaters except for the low-temperature SH are arranged at the high flue gas temperature area with in-line position. Large piping and tees are used for connection so as to improve the mixing of steam. The superheater consists of 5 parts: roof and side wall superheater of back pass and convection pass, low temperature superheater division panel superheater platen superheater final superheater. 1) Roof and side wall superheater of back pass and convection pass The tube specification of roof and side wall superheater of back pass and convection pass show in table below .Item Front roof Sidewall of back pass Front wall of back pass Rear roof Upper rear wall of back pass Lower rear wall of back pass Convection pass EXT. side wall at RH. finish Back pass EXT. 516.5
60

Size mm 516 516

qty. 122 182

spacing mm 114 114

material SA210-A1 SA210-A1

456 456 456

92 117 117

152 120 120

SA210-A1 SA210-A1 SA210-A1

385.5

96

145

SA210-A1

456

72

94

SA210-A1

60

102

SA210-A1

Product Description

730-1-8601

sidewall at final SH.

2).

Low temperature SH

The low temperature SH is arranged above the ECON inside the back pass. There are 116 assemblies with transverse spacing 120 mm, longitudinal spacing 102 mm. Each tube assembly is made of four(4) parallel tubes of material OD.51mm, thickness 7\6.5\6 mm, SA213-T22, SA213-T11, SA210-A1 . Specification show in summary table 3.4.3. The low temperature SH tubes are hung by the ECON 3). Division panel SH Division panel SH is located at the upper furnace. There are 4 big assemblies arranged in the furnace width with transverse spacing of 2565\ 2736\3420mm. Each big assembly is composed of 6 small assembly. Each small assembly is composed of 9 parallel tubes, with OD of 51mm. The bottoms material of No.1~3 tube is SA213-T91, all the other is SA213-T11, T22. Specification show in summary table 3.4.3. The fixing between tubes adopts sliding junction made of heat-resisting stainless steel, which is composed of 1 protruding-shape junction and 2 concave-shape junctions. These 3 junctions are directly welded onto the tube. Their function is to connect tube one another, and to assure that each tube can freely expand in the vertical direction. The junctions are arranged at 4 locations along the tube height of division panel SH.. 4). Platen SH Platen SH is located behind the division panel SH. There are 23 assemblies in all. Each assemblies is composed of 13 parallel tubes, the exterior tube size is OD.60mm, while the other tubes size is OD.54mm. Their traverse spacing is 684mm. longitudinal spacing is 63 mm. The bottom of the exterior tube and the bottom of the interior tube is made of the material of stainless SA-213 TP347Hall the other tubes SA213 -T22T23SA-213 T91. Specification show in summary table 3.4.3. The fixing between the tubes of platen SH. is the same as that of the division panel SH., adopting movable junctions. The junctions are arranged at 5 locations along the
61

suspendant tubes.

Product Description

730-1-8601

height direction of rear platen SH.. The traverse fixing between the platen SH. assemblies adopt the locating tube of fluid cooled spacer tubes. The cooling steam is educed in 2 line from the inlet pipe of backpass EXT. side wall at SH finish, one is used for the traverse fixing of Platen SH, while the another one is used for the traverse fixing of Platen RH. 5). Final SH Final SH is arranged in the convection pass. There are 81 assemblies with transverse spacing 171 mm, longitudinal spacing 102 mm. Each tube assembly is made of four(4) parallel tubes of material OD.51mm, thickness 7\7.5mm, SA213-T23 . Specification is in summary table 3.4.3

3.4.2 Operation For the operation instruction for whole boiler, please refer to 730-1-8602 , Boiler Operation Instruction. For the operation instruction of vent and draining valves, please basically refer to following principle. (For the operation instruction of RH, please refer to the section of RH). Prior to ignition, draining valves on header and vent valves in the piping will be opened in order to fully drain the bypass SH and main steam piping (specially after hydro test). After draining, the vent valves in the piping will be closed immediately when boiler generate steam. The draining valves on the header of back pass will be closed when turbine is on line. The draining valves and vent valves in the main steam piping are used for exhausting the air during start-up, which will be opened before the turbine is operated in low load. These valves can be used for throttle when the pressure of steam drum increases. It ensures that the enough steam can flow through SH. The vent valves on heater and piping will keep to be open before steam drum pressure reach 172KPa(25Psig), which will be closed when the pressure of steam drum reaches 172KPa. The draining valve which is close to turbine will coordinate with the start-up vent valve during operation in order to provide more steam flow for draining and for heating main steam piping prior to turbine rolling.Specification of SH. heating surface is in summary table 3.4.3

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Product Description

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3.4.3 Specification of SH. Heating Surface

Item low temperature SH Vertical section 1#~4# Upper section1#~4# Medium section1#~4# Lower section 1#~4# Division panel SH 1# 2#~3# 4#~8# 9# Platen SH 1# 2#~3# 4#~6# 7#~12# 13# Final SH 1#~4# 81 4 171 102 20 13 684 63 607.5, 609 547, 547.5, 547,547.5 547,548 548 SA213-T23 SA213-T91 SA213-TP347 SA213-T23 SA213-T91 SA213-T23 SA213-T22 SA213-T23 SA213-T22 SA213-T23 SA213-T22 SA213-T23 SA213-TP347 24 9 2736 60 516,516.5 516,516.5 516.0,516.5,517.0 516.0,516.5,517.0 SA213-T91SA213-T22 SA213-T91SA213-T22 SA213-T11SA213-T22 SA213-T11SA213-T22 116 4 120 102 517 516.5 516 516 SA213-T22 SA213-T11 SA213-T11 SA210-A1 No. of assemblies No. of elements Transverse spacing mm Longitudinal spacing mm Tube specification mm material

547,517.5548

517,517.5

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Product Description

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3.5 Reheater (RH) 3.5.1 Description The temperature of RH steam is controled by burner nozzle tilting. RH is arranged at the high flue gas temperature area, with in-line position. RH is composed of radiation wall RH, platen RH and final RH. Each stage heating surfaces of RH is connected to each other by big pipes and Tee junctions. Radiation wall RH locate at the front wall and side wall of upper furnace. Radiation wall RH covers a portion of waterwall. There are 204 tubes all in the front wall and 119 tubes at each sidewall. These tubes are OD.54mm, thickness 5mm, material SA213-T22. The radiation wall RH tubes are fixed to the waterwall by the connecting plate and tie rod. The radiation wall RH and the waterwall can move comparatively, so as to avoid expanding stress. Platen RH is located above the arch nose, and behind the Platen SH. There are 30 assemblies in total with traverse spacing 456mm. Each assembly is composed of 14 parallel tubes. The tubes size OD.63mm, material the Platen SH. Final RH is located inside the convection pass in front of final SH. There are 60 assemblies in total with traverse spacing 228 mm. Each assembly is composed of 7 parallel tubes. The tubes size OD.63mm, material SA213-T22 and SA213-T91. The fixing between assemblies and longitudinal tubes of final RH are the same as that of the final stage SH. Specification of RH. heating surface is in summary table 3.5.2 A213-T22, T23 and SA213-T91. The fixing between assemblies and longitudinal tubes of platen RH are the same as that of

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Product Description

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3.5.2 Specification of RH. heating Surface

Item No. of assemblies No. of elements Transverse spacing mm Longitudinal spacing mm Tube specification mm material SA213-T22, T23 SA213-T91, TP304H SA213-T22, T23 SA213-T91, TP304H SA213-T22 SA213-T22 SA213-T22, T23 SA213-T91, TP304H SA213-T22 SA213-T22 SA213-T22 SA213-T22 SA213-T22 SA213-T22 SA213-T91 SA213-T91 SA213-T91 SA213-T91

Platen RH 1# 2#~6# 7#~12# 13#~14# Final RH 1# 2#~3# 4#~5# 6# 7# Radiant wall RH. 30 14 456 73

634.0, 634.5 634.0 634.0 634.0 635

634.0, 634.5 634.0, 634.5 634 636 634 634, 635.5 545

60

228

114

442

57

65

Product Description

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3.5.3 Operation Open all drain valves and vent valves before ignition, vent valve and drain valve which leads to the atmosphere shall be closed before the condenser become vacuum, drain valve which leads to condenser can be kept opened before the turbine carrying low load.

3.6 SH and RH Control & Protection Maintenance 3.6.1 Control & Protection Necessary control and protection must be provided to SH and RH during combustion, especially when the turbine has no need of steam, and its protection is more important at start-up and shutdown stage. In the meanwhile, there is no steam go through turbine, steam must go passing header live steam piping drainage and venting in order to assure enough flow in SH. During boiler initial firing, RH drainage and venting provide residual moisture evaporation for vertical RH piping. This boiler utilize header drainage under back pass steam enclosure as handy start-up bypass systemits capacity is 5%MCRpressure is 4.14MPa. During start-up drain valve is full-open, and furnace combustion rate is increased so as to improve and control the superheated steam temperature. During start-up, superheated steam temperature is controlled by combustion rate within furnace, superheated steam pressure is controlled by drain valve close it after the turbine synchronized, the drainage system directly goes to the condenser or drain flash tank. The use of 5%MCR handy start-up bypass system shortens start time and improves operating flexibility. Piping strength and matching valves for bypass drainage system shall be designed per full load design pressure. safety valve is another control and protecting measureand is essential. Safety valves, which installed on SH main steam line, set-pressure is a little lower than the one installed on steam drum, which assures adequate steam flow pass through SH. The set-pressure of safety valve arranged at RH outlet piping is a little lower than that of the safety valve arranged at RH inlet piping. Therefore, this also assures enough flow passing RH. PCV are installed on main steam lineits setting value is a little below the one
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for main steam line safety valve. PCV discharge amount is excluded from total safety valve release, which required in boiler regulations, PCV discharge amount is normally 10%MCR at least. And this PCV is accompanied with isolation valve for overhaul. During the whole process of start-up, the overheating of SH piping and RH piping should be avoided. Especially in case that the turbine bypass is not used, the furnace combustion rate should be controlled to maintain the flue gas temperature at furnace outlet lower than 540, and to protect the wall-type RH. Flue gas temperature probes are arranged at the panel bottom of the side wall of upper furnace, so as to monitor the gas temperature at furnace outlet. Thermocouples are installed on end tubes of roof SH and RH threading out roof, during initial stage and normal operation, this can be used to supervising metal tube wall temperature. Alarm temperature supervising set up on all levels of heating surface act as another protective measure. On the walls at the boiler furnace, horizontal flue and back pass roof enclosure, 30 boiler tube leakage automatic alarming devices are provided to detect any leakage or leakage pre-alarming at the tubes of the heating faces such as in-boiler waterwall, superheater, reheater and economizer in real time. For the specific arrangement of the measurement points, refer to Fig. 502730-E1-10 port arrangement drawing. 3.6.2 Maintenance SH and RH external and internal cleaning is related with reasonable structural arrangement, for instance: fly ash slagging leads to flue gas unevenineffective heat conduction and potential local overheating. Reasonable sootblower arrangement and appropriate periodicity sootblowing are major means to keep external surface clean. Periodic inspecting SH and RH appearance cleaning, reasonably use sootblower can minimize slagging, immediately remove severe slagging, local slag leads to tube local overheating and tube damage. in additionslag may blocking flue gas flow, cause uneven heat transfer and made operation difficulty. Reasonable water treatmentqualified steam and control of carrying are major factors to assure SH internal surface clean. overload in operation, load swing,
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high water level,high concentration and water foaming etc. would influence internal surface's cleanness, forming sedimentsediment collection in tubes leads to boiler accident. sospray attemperator installing shall made sure

condensate water used to avoid solids carry in SHRH and turbine. Regular checking SH and RH steam pressure drop under identical load. Markedly increased pressure drops means depositions exist. If tube element has trouble, it's best to inspect and analyses reason, also can discuss the overhaul procedure and accident prevention adequate measures with the manufacture. 3.6.3 Inspection In order to assure boiler long-term continuous operation, the customers shall observe normal maintenance and inspection manual. a. Check SH and RH when the boiler is shutdown. b. Check tubes regularity reeling and rugged evidence. Replace them or the one with other superheated evidence. c. check position and behavior of hanger and support clamp device and seal plate, timely repair and replace damaged pieces. d. check internal surface's cleanness (by pressure drop) or exam deposit in steam drum, if any, it must be removed.

3.7 Desuperheater 3.7.1 SH steam Desuperheater SH system is equipped with 2 stages of spray desuperheaters. The quantity of primary spray desuperheater is one. It is arranged at the connecting piping between low temperature SH and division panel SH. The spray nozzle of primary spray desuperheater adopts the flute-type tube structure with multiple pores. The flute-type tube is of OD.108mm, thickness 5mm, on which 135 pores of size OD.7.5mm are arranged. The primary spray desuperheater header adopts size of OD.610mm, thickness 65mm, material of SA335-P22. The quantity of secondary spray desuperheater is one too. It is arranged at connection pipe of final stage SH inlet. The spray nozzle of secondary spray desuperheater adopts the flute-type tube structure with multiple pores. The flute-type tube is of OD.76mm, thickness 7mm, on which 48 pores of size
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OD.5mm are arranged. The secondary spray desuperheater header adopts size of OD.610mm, thickness 90mm, material of SA335-P22. The spray direction of desuperheater is the same as the flow direction of steam. After spraying from the pores of flute-type tube in the form of fog, the sprayed water is mixed with the steam and then flow tighter with the steam inside the shell course of desuperheater to reduce the steam temperature. The amount of water spray is different at different working loads. The amount of water spray can be adjusted by using the adjusting valve of desuperheater system.

3.7.2 RH Desuperheater RH Emergency desuperheaters are arranged at the piping of RH cold end. That is to say, one RH emergency desuperheater is located on the left, while another one on the right. The spray of RH emergency desuperheater is not needed in the normal working condition. It is used only for the emergency. The header of RH emergency desuperheater adopts size of OD.559mm, thickness 26 mm material of SA106-B. The spray direction of RH emergency desuperheater is the same as the flow direction of steam. 3.7.3 Maintenance Each desuperheater is equipped with a replaceable liner, so as to avoid the alternating stress caused by the contact between spray water and the inner wall of shell course, and to prevent the wear caused by the spray water flow. In this way, the main shell of desuperheater is protected. If there is very loud noise coming from the inside of desuperheater, that means the liner has been worn. In that case or any abnormal case, the manufacturing plant shall be contacted, and the liner shall be replaced if necessary. 4 Others 4.1Steel Structure Boiler frame is stand-alone type. Load-bearing member is connected with high strength bolts. The diameter of high strength bolts are M22. The whole boiler frame can be divided into five installation layer, including: each vertical bracing, horizontal bracing, roof hanger and support, level, stairway, boiler roof, etc. Vertical bracing is composed of steel column and intercolumnar bridging, respectively disposed along boiler depth and width direction. Earthquake force and air force are transferred to boiler foundation through vertical bracing.
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Horizontal bracing is composed of five rigidity levels along boiler short transverse. It helps support and transfer horizontal loading, control boiler expansion, keep structural stable. Roof hanger and support level is composed of roof steel framepressure parts hanger and support level, roof support etc. boiler heating surface is suspended at pressure parts hanger and support level via hanger rod, roof steel frame is composed of main beam, secondary beam and level supportforming a rigidity level hanger and support level beam of pressure parts is connected to secondary beam with high strength bolt. The boiler main stairways are concentrately disposed at boiler both sides, near front furnace. Together with the platform, the boiler stairways form the passage system for boiler maintenance, oversee and overhaul. The roofing located at the top of the boiler adopts pestle structure. The roof surface adopts galvanized undulated plate, enclosure plate is setuped around the bottom of roof. Boiler steel frame has 6 main beams in total. The steel columns adopt H bars. The platform adopts galvanized grid. Among them, the biggest width is 1200mm. The inclined angle of main stairways is 42 digress.

4.2 Sealing and Insulation Boiler air membrane type heating surface sealing adopt internal casing and tightness, reliable expansion joint etc. Internal casing are disposed at roof, arch nose, furnace chamber bottom, back pass etc. Back pass, joint at front waterwall with roof use corrugated-type expansion joint. Use all-welded structure for expansion joint between roof tube and side wall, expansion cubicle is used at radiate RH threading out roof. Metal penthouse is arranged at the boiler roof, to centralize the heat preservation. It also ensures no flue gas and ash leakage. Boiler proper adopt high grade low-duty insulation material

outside is metal external casing, when ambient temperature is 27, furnace outer wall shall be not more than 50. For the details, refer to 730-1-8607 furnace wall and insulation manual. 4.3 Air preheater (APH) The boiler is equipped with two trisection rotary Air Preheaters. For the details,
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refer to 770059-2-7201APH technical document list for user 5 Boiler Hydro Test After installation, all the pressure parts of the boiler shall conduct a hydro test. The water circulation system, SH and ECON shall conduct the hydro test as an integrated individual. RH shall conduct the hydro test independently. 5.1 The Pressure of Hydro Test For the primary steam system, the pressure of hydro test shall be 24.74MPa, which is 1.25 times of the designed boiler pressure For the secondary steam system, the pressure of hydro test shall be 6.30MPa, which is 1.5 times of the designed boiler pressure 5.2 Water Quality The water shall be treated condensate water or de-mineralized water, added by 10PPm ammonia or 200PPm hydrazine treated filtering water. The PH value of the water shall be about 10, the solid contents of the water shall be no more than 1PPm, the organic matter density shall be about zero, the chlorine ion contents shall be no more than 25ppm, and the water temperature shall not be less than 35 5.3 Notices a. Solid-chemical treated water shall not be used, so as to avoid the solid matter deposit in SH or RH. b. The metal temperature of pressure parts shall be no less than 35 during hydro test. c. Ensure all foreign material in steam drum and header are removed before boiler filling. d. Before a hydrostatic test with pressure higher than the normal operation pressure is carried out, plugs and tightening devices should have been installed on all the safety valves as per the instruction manual of the manufacturer (730-1-8609 Safety valve instruction manual and 730-1-8610 Powered relief valve instruction manual). e. ECON recirculation pipeline valve shall be fully open if filling the boiler via economizer, which not only easy to do, but also reduce carried air as much as possible.

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5.4 Water Volume of Boiler Pressure Parts Water-circulation system SH system Economizer system RH system Total water volume 190m3 (wherein steam drum owns 50m3) 220m3 50m3 90m3 550m3

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