Boiler Operating Course

OPERATION OF BOILERS OPERATION OF BOILERS........................................................................................................................... 4 1.1 PREPARATION BEFORE OPERATION OF BOILERS ........................................................................... 4 1.1.
1 Boiler Hydrostatic Pressure Test ................................................ 4 1.1.2 Scope of Hydrostatic Test and Requirements on Water ............................ 4 1.1.3 During the hydrostatic test, water filled in different equipment is not the same: ........ 4 1.1.4 Preparations for Hydrostatic Test ............................................... 5 1.1.5 Procedures of Hydrostatic Test ................................................. 6 1.2 CHEMICAL CLEANING ................................................................................................................... 8 1.2.1 General ..................................................................... 8 1.2.2 Chemical cleaning scope ...................................................... 8 1.2.3 Chemical cleaning medium .................................................... 8 1.2.4 General steps of chemical cleaning ............................................. 9 1.3 BOILER STEAM PURGE ................................................................................................................ 10 1.3.1 Range of boiler steam purging ................................................ 10 1.3.2 Steam purge mode .......................................................... 11 1.3.3 Steam purge requirements ................................................... 11 1.3.4 Precautions for steam purge .................................................. 11 1.4 FEED WATER AND BOILER WATER TREATMENT .............................................................................11 1.5 DRUM BOILER STARTUP ............................................................................................................. 12 1.5.1 General Introduction for Boiler Startup .......................................... 12 1.5.2 Characteristics of Drum Boiler Startup .......................................... 12 1.5.3 Boiler startup state classification............................................... 13 1.5.4 Essential Conditions for Boiler Startup .......................................... 14 1.5.5 Necessary Conditions for Boiler Startup ........................................ 14 1.5.6 Cold State Startup of Boiler ................................................... 15 1.5.7 Warm State Startup (The Warm State Startup Curve Refers to Fig. 3.) .............. 19 1.5.8 Thermal State Startup (The Curve for Thermal State Startup Refers to Fig. 4.) ....... 20 1.5.9 Extremely Thermal State Startup (The Curve of Extremely Thermal State Startup Refers to Fig. 5) ............................................................... 20 1.5.10 Boiler Thermal State Startup ................................................. 20 1.6 BASIC OPERATION FOR WATER DRAINAGE AND STEAM EXHAUST ............................................. 21 1.6.1 Basic Principles ............................................................. 21 1.6.2 Operation for Drainage and Steam Exhaust Valves at Cold Startup ................. 22 1.6.3 Suggestions for the Operation of Drainage and Steam Exhaust Valves at Warm State startup. 23 1.6.4 Suggestions for the Operation of Drainage and Steam Exhaust Valves at Thermal State Startup ................................................................. 24 1.6.5 Suggestions for the Operation of Drainage and Steam Exhaust Valves at Extremely Thermal State Startup: ....................................................... 26 1.7 BOILER SOOT BLOWING ..................................................................................................................... 27 1.8 BOILER BLOWDOWN AND WATER DRAINAGE .................................................................................. 28 2. BOILER OPERATION ADJUSTMENT ................................................................................................. 29 2.1 CONTENT OF BOILER OPERATION ADJUSTMENT ................................................................................. 29
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2.2 THE INFLUENCE OF WORKING CONDITION CHANGES ON BOILER PARAMETERS ................................ 29 2.3 BOILER STEAM TEMPERATURE CONTROL AND ADJUSTMENT ............................................................. 30 2.3.1 The Influence of Steam Temperature on the Safe and Economic Operation of the Unit 30 2.3.2 Heat-Transfer Characteristics of Boiler Heating Surfaces ......................... 31 2.3.3 Drum Boiler SH Steam Temperature Control and Adjustment ...................... 32 2.4 CONTROL AND ADJUSTMENT OF REHEATED TEMPERATURE ............................................................... 33 2.4.1 The Characteristics of Reheated Temperature ................................... 34 2.4.2 Factors influencing the temperature variety of reheating ........................ 34 2.4.3 Adjusting method for reheated steam temperature ............................... 35 2.5 CONTROL AND ADJUSTMENT OF BOILER LOADING AND STEAM PRESSURE ....................................... 36 2.5.1 The Impact of Steam Pressure Swing .......................................... 36 2.5.2 The Reasons of Steam Pressure Variation ...................................... 36 Reasons for causing the steam pressure of boiler are plenty; mainly in two aspects: one is the external factor of the boiler; the other is the internal factor. ........................ 36 2.5.3 The Adjustment of Boiler Loading and Steam Pressure ......................... 37 2.5.4 Steam pressure adjustment ................................................... 38 2.6 THE CONTROL AND ADJUSTMENT OF DRUM LEVEL ........................................................................... 39 2.6.1 The Importance of Keeping Steam Drum Normal Level ........................... 39 2.6.2 The Main Factors for Impacting the Drum Level Swing ........................... 39 2.6.3 Control and Adjustment of Boiler Steam Drum Level ............................. 40 2.7 BOILER COMBUSTION ADJUSTMENT .................................................................................................. 41 2.7.1 Purpose and Target of Combustion Adjustment .................................. 41 2.7.2 The factor influencing the combustion and measures intensifying combustion........ 41 2.7.3 Adjustment of Burner ........................................................ 42 2.7.4 Principles of Combustion Control: ............................................. 43 3. SHUTDOWN OF BOILER....................................................................................................................... 46 3.1 THE SHUTDOWN MODE AND PREPARATION OF BOILER ........................................................................ 46 3.1.1 Shutdown mode of boiler ..................................................... 46 3.1.2 Preparation for the shutdown of boiler .......................................... 46 3.1.3 Shutdown of Nature Cycle Steam Drum Boiler................................... 47 3.2 MAINTENANCE AFTER SHUTDOWN ..................................................................................................... 51 3.2.1 Principle of storage .......................................................... 51 3.2.2 Maintenance method selection of shutdown ................................... 51 3.2.3 Method of boiler storage ..................................................... 51 3.2.4 Selection of storage method after boiler shutdown ............................... 52 4. SAFETY OPERATION OF BOILER ...................................................................................................... 54 4.1 THE ATTRITION AND ATTACK OF BOILER HEATING SURFACE................................................................ 54 4.1.1 Fly ash erosion of boiler heating surface ........................................ 54 4.1.2 Cold end corrosion of heating surface of boiler .................................. 54 4.1.3 Hot corrosion of heating surface of boiler ....................................... 54 4.1.4 Internal Corrosion of the Boiler ................................................ 55 4.2 SAFETY OPERATION OF HEATING SURFACE OF BOILER ...................................................................... 55 4.2.1 Safety operation of water cooling wall, coal economizer ......................... 55
4.2.2 Safety operation of superheater and reheater ................................... 58 4.2.3 Precaution measures on leakage and burst of boiler four pipes .................... 60 4.3 SAFETY OPERATION OF BOILER PRESSURE PARTS ........................................................................ 62 4.3.1 Safety devices for boiler super-pressure issues.................................. 62 4.3.2 Boiler hydrostatic test and Super-Hydraulic Test ................................. 62 4.3.3 Prevent pressure parts from being over-pressed during boiler operation ............ 63 4.4 PREVENT BOILER AND TUBES FROM WATER IMPACT ............................................................................ 63 4.4.1 Water impact caused by steam passing through steam tubes ...................... 63 4.4.2 Water impact caused by low-temperature water getting into steam ................. 64 4.4.3 Water impact caused by sudden drop of steam temperature ....................... 64 4.5 COUNTERMEASURE FOR EXPLOSION ON BOILER ......................................................................... 64 4.5.1 Principle on furnace explosion ................................................ 64 4.5.2 Preventive measures to furnace explosion ...................................... 64 4.6 SLAGGING IN FURNACE .............................................................................................................. 65 4.6.1 Principle of slagging ......................................................... 65 4.6.2 In accordance with factors that will result in slagging, preventive measures are described as follows: ................................................................. 66 APPENDIX VARIOUS START-UP CURVES AND OTHERS .................................................................. 66
Operation of Boilers
1.1 Preparation before Operation of Boilers
1.1.1 Boiler Hydrostatic Pressure Test Upon completion of erection or maintenance of the boiler steam and water system, an overall hydrostatic pressure test shall be performed in cold state to test the tightness of all pressure parts, to check them for residual deformation and to determine if they have sufficient strength. During the test, the pressure system is filled internally with pressurized water, the pressure of which may be evenly distributed to each location. In case of any tiny hole or gap on the pressure parts, or if weld, flange or valve plug is not well sealed, leakage will occur. If the weak points of pressure parts can not withstand high pressure during test, they will be subject to permanent deformation or even cracking. Therefore, measures are to be taken in a timely manner to correct the defects of leakage, deformation or damage found in the test. In this way the purpose for inspection of boiler pressure parts can be achieved.
1.1.2 Scope of Hydrostatic Test and Requirements on Water As a principle, the scope of hydrostatic test for boilers shall cover all the pressure parts in the heating surface system, i.e. all the pipes, valves, the drainage and discharge system, the attemperating water system, temperature and pressure measuring points as well as instruments and fittings from boiler feed water isolating valve to primary isolating valve at main steam outlet. The test scope for the reheating steam system shall be from the turbine HP cylinder steam exhaust to the low temperature reheater inlet, through the high temperature reheater outlet and then to the IP cylinder combined steam valve. As pressures are different, tests for primary steam system and reheating steam system are separately performed.
1.1.3 During the hydrostatic test, water filled in different equipment is not the same: l) For the drum and water wall, slightly treated water may be filled as they may
discharge completely. And it will certainly be better if demineralized water is used; 2) For the superheater system, demineralized water must be used to avoid
internal sedimentation and local corrosion; 3) For stainless steel parts, the water filled shall be removed from natrium,
kalium, chloride and sulphide, otherwise alloy pit corrosion, intergranular chemical corrosion and stress corrosion cracking will occur. For simplified operation, demineralized water obtained by addition of ammonia or hydrazine is often used for hydrostatic test: hydrazine at a concentration of 200pp, PH value at about 10. 4) Water temperature for hydrostatic test is usually determined by the following
factors: (1) The temperature shall be above dew point, otherwise it will be difficult to
tell the actual occurrence of leakage; (2) Excessively high temperature is likely to cause evaporation, which
would make it difficult to identify leakage; (3) The temperature of water for test of alloy steel parts shall be higher than
that of the fracture appearance transition temperature; (4) The temperature between water into drum and drum wall shall be no
more than 28. In summary, the water temperature for hydrostatic test is usually between 20C and 70C, and the metal temperature at heating surface should be no less than 20C. The ambient temperature shall be above 5 when performing test, otherwise anti-freezing measures must be in place.
1.1.4 Preparations for Hydrostatic Test l) All the joints and welds shall be exposed for inspection during the test. Close connection shall be maintained for the equipment subject to pressure test, while low pressure pipes and all other equipment requiring no pressure test shall be isolated by proper means. 2) Before filling water to drum, water wall and superheater, it shall be ensured that all the sundries, welding slag and contaminants in drum and header are cleaned, and that steam separator inside the drum is properly installed. 3) The drainage and discharge pipes, air valves and steam exhaust pipes shall be free. The valves shall be easily operated with good seals. Due pressure gauges, instrument pipes and relevant valve fittings are installed in the hydrostatic test system. Electrically operated valves and regulation valves shall be calibrated and the power supply shall be energized. 4) During the test, at least two certified calibrated pressure gauges shall be provided on the boiler for cross reference during boosting operation. The test
pressure read from the pressure gauge at outlet header of drum or superheater shall prevail. 5) Before water pressure is increased above rated operating pressure, hydrostatic test plugs shall be installed for all the safety valves according to instructions of manufacturers. If the test pressure is equal to or below the rated operating pressure, it is only required to shut off the safety valves. 6) Chemical water in sufficient quantity shall be prepared for hydrostatic test.
1.1.5 Procedures of Hydrostatic Test Hydrostatic test for boiler is classified into two types: operating pressure test and excess operating pressure test. The former is usually performed after minor repair, overhaul of boiler or maintenance of pressure parts, while the latter is usually performed after erection of new boilers. The test pressures are given in Table 8-1:
Operating System pressure test (MPa) Primary steam system Secondary steam system 3.98 5.97 18.87 23.59 Excess operating pressure test (MPa)
Table 8-1: Pressures in regular pressure test and excess pressure test
In general, the procedures of hydrostatic are as follows: 1) Before filling water to the boiler, all the air valves shall be open and all the secondary valves in drainage and discharge systems as well as in the scope of boiler proper shall be turned off. 2) Start the feed water pumps or the pumps specially provided for hydrostatic test, and slightly open the boiler water inlet valves to allow slow inflow. Check frequently for air leakage at the drum air valve during this process until three to five minutes after water starts to leak without air bubble. Take water samples from the air valve for chemical analysis, and close all the air valves if the impurity content in water is compliant with relevant requirements. 3) Fill the reheater in the same way as used for superheater (for which special
joint shall be installed) and take water samples for chemical analysis when water spills from the reheater air valve. Close the air valves when the water is compliant. 4) As the water is filled, raise the pressure at a rate of 0.2-0.3MPa/min to 10% of the maximum allowable operating pressure. Hold for a while to perform initial inspection. Continue the boosting procedure if no leakage is found. 5) When the pressure is increased to 80% of the minimum setting pressure of safety valve, halt the process and maintain at a stable pressure. Press the safety valves of drum, superheater and reheater, and then continue to increase the pressure to regular pressure. Close the water inlet valves and record the pressure fall after five minutes. Maintain the pressure for overall inspection, and record the discovered defects and problems. 6) If the inspection results of regular pressure test allows for excess pressure test, increase the pressure to the intended test value at a rate below 0.1MPa/min after disconnecting water levels and evacuating all workers. Then stop the process, observing that the pressure shall at least maintain for 10 minutes. It shall be noted that the excess pressure may not be over 6% of the regular test pressure. 7) Reduce to the rated operating pressure and continue the overall inspection of both internal and external pipes of the boiler. During this period the pressure shall be able to maintain stable with the metal temperature not exceeding 49C. 8) Reduce the pressure at a rate of 0.3-0.5MPa/min by means of continuous blowdown or drainage valves. Open the air valves and drainage valves to drain water after the pressure is reduced to 0MPa, when the devices pressing safety valves are to be removed. 9) If the boiler is to be put into operation after the hydrostatic test and the water is eligible, the drum may be fed to ignition level, however, the water in superheater, main steam pipe and reheater shall be discharged. If the boiler is not to be in operation in short term, reliable maintenance measures shall be taken. 10) Eligibility Criteria for Hydrostatic Test 1) Within five minutes after closure of inlet valves, the pressure drop of primary steam shall be no more than 0.5MPa and of secondary steam shall be no more than 0.25MPa;
2)
The external metal wall and welds of pressure parts shall be free of any water drop and moisture signs;
3)
After excess pressure test, the pressure parts are identified free of obvious residual deformation by visual check.
Boiler water volumem3 State Economizer system 101 101 Drum Water system cooling SH system RH system Total
Hydrostatic test Normal operation
66 33
197 197
372 /
333 /
1069 331
1.2
Chemical cleaning
1.2.1 General Boiler chemical cleaning is a necessary measure to upgrade water quality of power plant, preventing heating surfaces from scaling and being eroded. The chemical cleaning method generally includes alkali cleaning and acid cleaning. The former is mainly used to remove dirt which has been brought into boiler during fabrication and installation, such as lubricant, oil, rust etc. The latter is mainly used to remove dirt, sediment, oxidation scale and corrosive product which arise from the contact between heating surface and water. It is necessary to prevent the cleaned heating surface from being eroded again. The specific cleaning steps shall follow the GUIDELINE FOR THERMAL POWER PLANT BOILER CHEMICAL CLEANING (JB/T794-2001).
1.2.2 Chemical cleaning scope Chemical cleaning shall be performed for economizer, drum and water wall prior to putting them into operation and after them operating for certain period. Superheater and reheater systems generally only need to be water washed.
1.2.3 Chemical cleaning medium Chemical cleaning medium shall be selected according to the scale composition, boiler structure style, metal material, cleaning effect, corrosion inhibit effect and requirements of
economical efficiency and environmental protection. Hydrochloric acid, citric acid, hydrofluoric acid or EDTA (Ethylene Diamine Tetraacetic Acid) can be selected as resolvent. Meanwhile an appropriate corrosion inhibitor shall be selected to protect tube wall against corrosion.
1.2.4 General steps of chemical cleaning System chemical cleaning process: water flushing-alkaliine boilout-water flushing after alkaliine boilout-acid cleaning-water flushing after acid cleaning-rinsing-passivation.
1.2.4.1. Preparation before chemical cleaning Before feeding the dose, all glass instruments easy to be eroded shall be separated. Saline water or condensed water shall be fed into the system before chemical cleaning to prevent superheater from being contaminated by cleaning liquid. 1.2.4.2. Alkaline boilout The selected dose is suggested to be mixed with water in order to keep the even concentration of alkali solution in the whole boiler. The time span of boilout depends on the amount of oil and grease inside. The boiler shall be cooled down slowly and drained after boilout, rinsing out residues, and then the cleanliness is checked up. Acid cleaning shall be conducted after this boilout is acceptable.
1.2.4.3. Acid cleaning Acid cleaning for boiler shall be conducted as per the stipulated procedure. Acid liquid temperature shall be strictly controlled, or cannot be exceeding to avoid corrosion inhibitor being damaged. Acid liquid shall be squeezed out by injecting nitrogen gas to prevent metal surface from secondary corrosion, and then water flushing shall be performed. Twice rinsing shall be generally enough. There is possibility that the superheater is corroded by cleaning liquid since it is close to drum. If the superheater has been contaminated, cleaning process shall be suspended, and water flushing shall be performed to get rid of contamination. The boiler shall be never ignited prior to removing contamination completely.
1.2.4.4. Passivation After the completion of rinse, alkaline solution such as ammonia water shall be fed into the boiler to neutralize the residuary cleaning medium. After that, passivator shall be ejected to passivate metal surfaces so as to prevent them from being rusted. Solution in the system shall be drained after deactivation. Nitrogen gas may be fed into the system if necessary.
1.2.4.5. Precautions for chemical cleaning: 1) The temperature, flow rate, concentration of the acid alkaline liquor shall be strictly controlled during the entire chemical cleaning process. For the release of cleaning liquor, proper measures shall be taken to avoid the occurrence of environmental pollution. 2) Combustion input cannot be increased before the acid solution is not removed from the system, otherwise the passivator may be damaged. 3) During rinsing process, the water in superheater which might contain acid alkaline solution shall be replaced or cleaned by demineralized water or condensed water. 4) Boiler chemical cleaning shall be performed nearly before steam purging stage. If the interval between chemical cleaning and boiler steam purging is too long, heating surfaces may be eroded again. 5) The drainage time of cleaning liquor shall be controlled within certain scope to prevent dirt from attaching to the lower header again. 1.3 Boiler steam purge Boiler purge is an indispensable stage before the startup of the whole unit, it is a way to remove impurities by using steam. Since dirt is easily accumulated in the lower ends of U-type superheater or reheater pipes during acid cleaning to cause blockage. Besides, acid cleaning has corrosion effect on alloy metal material, so steam purge is generally performed for superheater and reheater.
1.3.1 Range of boiler steam purging SH and RH systems, desuperheating water pipelines, water drainage pipelines and final steam exhaust pipelines of boiler SH and RH systems etc.
1.3.2 Steam purge mode Steam generated from boiler ignition may be used as purging medium. Decompression purging method shall be done for SH, RH and their steam pipelinesMain steam system may be purged separately or main steam system and RH system are purged in series.Steam parameter of purge could be decided by calculation in advance.
1.3.3 Steam purge requirements During purge process, it shall be guaranteed that the steam kinetic energy in the pipeline is higher than the steam kinetic energy under BMCR condition. Take a section of heating surface as an example, the pressure drop of heating surface inlet and outlet during purge shall be higher than that of heating surface inlet and outlet under full load, i.e. purge coefficient K1 (K=P blowpipe /PBMCR 1). In this way it is possible to guarantee the cleanness inside the SH and RH pipelines.
1.3.4 Precautions for steam purge Boiler various heating surfaces and pipelines (particularly thick wall component) will be affected by intensive thermal impact during steam purge, so boiler purge times shall be reduced provided the purge quality is guaranteed. The design parameter of provisional purge pipeline shall guarantee there is no overheating or overpressure during the boiler purge process. During purge under the ignition of boiler oil guns, furnace outlet gas temperature shall not be over 540 to prevent the occurrence of SH/RH dry combustion. During steam purge, water level fluctuation of boiler drum may be great. When the temporary purge gate is opened, the water level will rise quickly with the descent of pressure, but it will soon fall below the low level. Therefore, once the temporary purge gate is opened, feed water amount shall be increased to insure that the drum water level will not be too low. During each purge, the pressure drop value of drum shall be strictly controlled, and the saturated temperature drop value shall not be over 42. 1.4 Feed water and boiler water treatment Feed water and boiler water shall be chemically examined to meet certain water quality requirements. Feed water quality shall meet relevant stipulations of DL /T561-95 STEAM
WATER CHEMICAL TEST GUIDE RULE FOR POWER PLANT AND GB /T12145-1999 STEAM WATER QUALITY STANDARD FOR POWER PLANT UNIT AND STEAM GENERATING EQUIPMENT. 1.5 Drum Boiler Startup
1.5.1 General Introduction for Boiler Startup The modular unit is generally started up in a mode of combining boiler with turbine, which means that, the boiler and turbine shall be started up simultaneously. During startup, the steam whose temperature increases gradually with the rising boiler parameters will warm pipes, start up and warm turbines under load. Therefore, this mode of startup is also known as startup with variable parameters which improves the startup condition of turbines, shortens the time for startup and increases the flexibility of grid dispatching. Currently, the startup with variable parameters of 600MW units is usually pressure startup with variable parameters.
1.5.2 Characteristics of Drum Boiler Startup 1 Thermal Stress Problem
The startup process is a heating process for every part of the boiler, but the heating process is uneven. Therefore, large temperature differences exist among boiler parts, which may cause thermal stress to damage the equipment. When other conditions are identical, the greater wall thickness of the parts to be heated, the larger temperature differences between the inner wall and the outer wall, and accordingly, the greater the thermal stress. The drum, header, main steam pipes and some valves of drum boilers are thick-wall parts. Starting up these parts may cause their thermal stress to reach a dangerous degree if no control measures for temperature rising rate is adopted during startup.
2Metal Over-temperature Problem During startup, the working medium inside heating surfaces cannot flow normally, with little or even no flow in some heating surfaces, resulting in insufficient cooling of the heating surfaces. In such condition, overheating will make the metal wall temperature become excessively higher than its tolerance limit and thus be damaged. These heating surfaces includes partial water wall before water circulation is established, SH tubes when
steam flow is very small, RH tubes when steam flow is very small or no steam at all, and economizer tubes when boiler water feeding is stopped temporarily.
3) Bad Fire Conditions When the boiler is ignited, the furnace temperature is very low. During this period of time after ignition, in order to keep temperature rise rate and temperature differences of all parts in a stipulated scope, the increase of fuel shall be slow, so the furnace temperature is still not high. Besides, the temperature of combustion air at this moment is also very low. Under these conditions, furnace flameout will easily happen or furnace deflagration will happen accordingly if no proper combustion controlling measures is taken.
4Great Heat Losses The fuel burned in the process of boiler startup is not only used to warm working medium and boiler parts but also used to exhaust steam and drain water. The energy spent for steam exhaust and water drainage accounts for a significant portion but cannot be recycled. For combustion under low load, the furnace excess air coefficient is relatively larger, resulting in increase of flue gas heat loss. The low furnace temperature will decrease fuel economy and thus increase losses. As such, the boiler startup method shall be optimized to shorten startup time, minimize various heat losses and improve boiler efficiency.
1.5.3 Boiler startup state classification The determination of boiler startup state for is based on the metal temperature of the upper inner wall at the regulating stage of high pressure inner cylinder when steam turbine is latched. Boiler startup state may be divided into the following 5 types: Startup state Time after boiler shutdownh Boiler startup pressure P(Mpa .g) Metal temperature of the upper inner wall at regulating stage of high pressure inner cylinder T
Extremely startup
cold
state
t72
P0.5
T150
Cold state startup Warm state startup Thermal state startup Extremely thermal state startup
48t72 8t48 2t8 t<2
P0.5 0.5P9.0 9.0P14.0 P14.0
T150 150T300 300T400 T400
1.5.4 Essential Conditions for Boiler Startup In order to ensure all equipment of boiler unit are in good condition, the boiler shall be successfully started up at the first time upon completion of installation and major/minor repair of boiler unit. For equipment after maintenance, it shall be checked and accepted according to the items and standards stipulated in Acceptance System. In addition, trial run shall be conducted for auxiliary boilers in accordance with the stipulations and rules, so as to further check the installation & maintenance quality, and determine the working performance of the equipment & system. After major/minor repair of boiler units, any equipment change shall have a Change Report for future reference for maintenance, operation and other relevant personnel. The operating personnel shall personally take part in the acceptance and trial run work. During acceptance and trial run process, the operating personnel shall closely check the equipment, timely record any found problem or equipment defection on relevant log, and must eliminate these problems and defections before equipment is put into service. 1.5.4.1 Overall Inspection after Boiler Maintenance 1.5.4.2 Calibration of Boiler s electric control valves, Regulating valves and Gas Control Devices 1.5.4.3 Trial Run of Auxiliary Boilers 1.5.5 Necessary Conditions for Boiler Startup 1.5.5.1 Prior to boiler unit startup, installation and maintenance of equipment have been finished, the thermal & electric work tickets have been accomplished, all boiler equipment have passed the check and acceptance, and all rotary machine run normally through trial test. Before boiler startup, the following calibrating and testing work shall be finished and proved up to requirements: 1) Boiler Hydro-test (overpressure test);
2) Dynamic balance calibration for air fans; 3) Resistance adjustment test for boiler coal pipes; 4) Dynamic field test for air inside boilers; 5) Air leakage test in cold state for air preheaters; 6) No-load step-up test for electrostatic precipitator; 7) Protection check for electric interlock and thermal machine of auxiliary boilers. 1.5.5.2 The following boiler equipment have all been electrified: all auxiliary boilers and accessories, all instruments and instrument panels, electric control valves & regulating valves, solenoid valves, moving blades and stationary blades conditioning devices of air fans, air door dampers, all automatic devices, sequencers, data loggers, computer systems, boiler protective systems, alarm signals and related boiler lightings. 1.5.5.3 Boilers steam/water systems, attemperating water systems, water drainage systems, flame detecting cooling air systems, turbine bypass systems and the valve positions of thermodynamic instruments have met the requirements prior to startup. 1.5.5.4 The sight holes, access doors and inspection doors of boiler combustion chamber and air & gas duct have been closed with seals being complete. All soot blowers have been withdrawn. 1.5.5.5 Boiler cooling water systems, compressed air systems, fuel atomization steam systems have been put into operation; hopper heating systems of electrostatic precipitators and air heating systems are already in hot standby status. 1.5.5.6 Boiler fuel oil and coal reserves can meet the requirements; light oil and heavy oil have formed a circulation; and the fuel system with hot steam has operated normally. 1.5.5.7 Ash handling systems, deslagging systems, ash sluice water systems, shaft sealing water systems and electrostatic precipitators, pre-heaters, air fans, pulverizing systems and their ancillary equipment are all ready for operation. 1.5.5.8 Various boiler interlocks and protective devices have satisfied the startup requirements; DCS systems have met the operation requirements; steam turbines and generators have been qualified for startup; and relevant systems and equipment such as fuel and chemicals have satisfied the requirements of startup. Except for meeting the above requirements, it is required that the operating personnel have already known change situations and startup measures of the equipment. The operating personnel on duty shall have been orderly arranged with clear division so as to conduct the startup smoothly.
1.5.6 Cold State Startup of Boiler Cold state startup of the modular unit can be classified into four stages with the
following main characteristics: boiler ignition, turbine startup, grid integration of power generators and unit load rising. During these stages, turbine startup and generator synchronization require less boiler operation, while the other two stages require much more boiler operation. As such, the main working of natural circulation drum boilers during startup can be subdivided into the following five stages: boiler water filling, furnace purge, boiler ignition, boiler heating-up and pressure boosting-up, unit startup and synchronization and boiler load rising to rated value.
1.5.6.1 Boiler Water Filling 1) After completion of all inspections and tests required by boiler startup, the boiler can then be filled with water in accord with the following requirements: u u The water shall pass the examination before water filling: PH: 9.0-9.5; hardness5.0moL/L; dissolved oxygen30g/L; hydrazine: 1050g/L Inlet water temperature shall be from 20 to 70; temperature differences between feeding water and lower drum wall shall be less than 28; and the metal temperature of heating surfaces shall be no less than 20. The average temperature differences of drum s upper-lower wall shall be no more than 56. Time for water filling: no less than 2 hours for summer and 3 to 4 hours for winter
u u
When water was seen in the local water level gauge,, it is necessary to reduce the inlet water flow and fill water until the drum water level is kept within -300mm. Then stop water filling by closing electric control valves and regulating valves for main feedwater and open the recirculating valves of economizers.
2) When boiler water filling is completed, chemical test of boiler water quality is required. If verified to be unqualified, the boiler water shall be fully released and refill water till the water quality is proved up to standards.
3) Why natural circulation drum boilers have relatively strict requirements for filling water lies in that the drums are large pressure parts. During water filling, the warm water will heat the inner wall of the drum by contacting its walls, which leads to temperature differences between the inner/outer walls and upper/lower walls of the drum. Thermal stress caused by temperature differences will affect the service life of the drum. Therefore, when water filled to drum boilers, the water filling temperature and time shall be strictly controlled. When water filling is finished, it is required to record every 30 minute the wall temperature and temperature differences at all points of the drum. 4) After water filling, it is required to heat from the bottom of the boiler:
The bottom of the boiler shall be heated slowly; the temperature rise rate of boiler water saturation temperature shall be equal to or less than 28/h; the upper-lower wall temperature differences of the drum shall be less than 56. During the heating process, when the drum water level is +100mm higher than normal water level, it is required to open the emergency water drainage valves and close them after it dropping to +50mm. Detected by thermocouples, when the wall temperature at downcomers is higher than 95 or when the drum pressure is greater than 0.125MPa, the heating work for the boiler bottom can be stopped.
1.5.6.2 Furnace Purge Furnace purge is generally performed by FSSS system. Furnace purge asks for a series of conditions and only when all conditions are satisfied at the same time, can the purge control system send a signal of purge allowed. Shall any unsatisfied condition be found, the signal will not be sent. The boiler requires for the following 15 conditions in general: 1) No conditions exist for MFT( losses of all flame are excluded); 2) DCS has no power failure; 3) The pressure of instrument gas source shall be normal, namely, within 0.5 0.8MPa; 4) At least one FD fan shall be running and its corresponding baffles be opened; 5) At least one ID fan shall be running and its corresponding baffles be opened; 6) The pressure inside furnace is normal; 7) The two air preheaters shall be running; 8) 25%40%BMCR air flow of the furnace shall be maintained; 9) The front quick open-and-close valves of furnace inlet oil main tubes, return oil main tubes and all oil guns shall be closed; 10) All primary air fans, mills and coal pulverizers have tripped; 11) All primary air doors on coal pipes have been closed; 12) The drum water level is normal; 13) No signal of flame existence in furnaces; 14) All air door dampers of burners are in adjustable status and at the position of purge; 15) The leak test has been accomplished.
1.5.6.3 Boiler Ignition
1)
Before cold state start up, all drainage valves, steam exhaust valves and dampers shall be at the position of boiler ignition.
2) 3)
After the oil guns have been ignited, at least 30% BMCR air flow shall be maintained. Drainage valves and steam exhaust valves shall be adjusted according to relevant requirements from boiler ignition to synchronization (being incorporated into the grid).
4)
The oil guns corresponding to the first row of burners (on the lower layer of front wall) shall be ignited. It is recommended that full load ignition of the oil guns shall be performed.
5)
If necessary, the secondary row of burners (on the lower layer of rear wall) shall be started up and their input heat may be adjusted according to boiler load requirement.
1.5.6.4 Boiler Heating-Up and Pressure Boosting-Up After the boiler has been ignited normally, the temperature of all heating surfaces will increase gradually; the boiler water temperature and steam pressure will increase accordingly; and the saturated water and steam will coexist in the drum. Because of one-to-one relationship between temperature and pressure in saturated state, boiler heating-up will be accompanied by pressure boosting-up, that is, temperature heating up and pressure boosting up will happen simultaneously. In order to avoid greater thermal stress resulted from fast rate of temperature rise and large temperature differences, it is usually to control the temperature rise rate by controlling pressure rise rate. Generally, the temperature difference between the drum s upper and lower wall shall be not more than 56 ; the boiler water temperature rise rate shall be 28 /h before boiler pressure rising; after pressure rising, it is necessary to control the temperature rise rate by controlling pressure rise rate (Fig. 8-2):
Drum Temperature () 100184 184265 265312 >312
Pressure rise rate (MPa/min) 0.0150.020 0.0600.080 0.160.18 0.20
The setting of drainage valves shall be adjusted according to boiler startup mode. The steam discharging valve and bypass system at the main steam safety valve pipe section shall be adjusted to make the boiler steam parameters meet the requirements for turbine startup.
Air fans of combustion system are started up in sequence. When the warming-up time and rotation speed of turbine reach the stipulated requirements, the turbine can be incorporate into the grid, with certain load exerted. The mill system is started up. In cold condition start up, the mills corresponding to the lower row, the medium row and the upper row of burners shall be started in sequence (from the front wall to the rear wall). Mill shutdown sequence shall be based on boiler shutdown mode and in combination with operation experience. For boiler warm, thermal and extremely thermal state startup, the startup sequence of mills shall be based on actual operation requirements. The first mill is started up and the secondary air door damper is manually adjusted. More mills are started up continually according to boiler load rising requirement. Before mill startup, it is necessary to confirm that the oil guns of burners corresponding to that mill are ignited in advance. Subsequently, mill outlet air temperature, secondary air door, coal feeder may be switched to automatic control mode until all of the five mills have entered into automatic control mode. For the combustion of check fuel, all of the six mills must be put into service to reach full load. OFA air door damper shall be in manual mode and in closing position. OFA air door damper may be switched to automatic operation mode when boiler reaches proper load. The adjustment of oxygen amount may be switched to automatic operation mode after two mills have been put into service. The adjustment of superheated steam temperature and reheated temperature may be switched to automatic operation mode at proper load. Boiler master control system may be switched to automatic operation mode, and corresponding operation mode shall be selected (such as constant pressure operation or variable load operation). The following parameters shall be monitored closely during the whole boiler startup process such as boiler combustion condition, boiler pressure rising speed, temperature difference of drum and temperature difference of RH/SH wall.
1.5.7 Warm State Startup (The Warm State Startup Curve Refers to Fig. 3.) 1) Before warm state startup, boiler drum water level shall reach the preset position namely150mm below normal water level.
2)
The boiler shall be started up as per the same sequence as cold state startup mode.
3)
During warm startup mode, drainage valves and steam exhaust valves shall be operated according to corresponding sequence.
1.5.8 Thermal State Startup (The Curve for Thermal State Startup Refers to Fig. 4.) 1) Before thermal state startup, drum water level shall reach the preset position, i.e. drum normal water level. 2) The boiler shall be started up as per the same sequence as cold state startup mode, but generally the medium row of burners shall be ignited first. 3) For thermal state startup, water drainage valves and steam exhaust valves shall be operated in the same sequence as that of thermal state startup.
1.5.9 Extremely Thermal State Startup (The Curve of Extremely Thermal State Startup Refers to Fig. 5) 1) Before extremely state startup, drum water level shall reach the preset position, i.e. drum normal water level. 2) The boiler shall be started up as per the same sequence as that of cold state startup, but generally the medium row of burners shall be ignited first. 3) For extremely thermal state startup, water drainage and steam exhaust valve shall be operated as per the same sequence as that of thermal state startup.
1.5.10 Boiler Thermal State Startup 1) Extremely thermal state startup (The curve of extremely thermal state startup refers to Fig. 5) 2) Before extremely state startup, drum water level shall reach the preset position, i.e. drum normal water level. 3) The boiler shall be started up as per the same sequence as that of cold state startup, but generally the medium row of burners shall be ignited first. 4) For extremely thermal state startup, water drainage and steam exhaust valve shall be operated as per the same sequence as that of thermal state startup.
1.6 Basic Operation for Water Drainage and Steam Exhaust
1.6.1 Basic Principles 1) It is necessary to confirm that condensed water in the back pass (BP) lower circular header and convection SH inlet header (partition wall outlet header) is drained when they are started up, 2) When the boiler is started up or its load is decreased under constant pressure condition, condensed water may form inside BP lower circular header and convection SH inlet header. If such water has not been drained before ignition or under relatively lower pressure (less than 5 MPa) after ignition, this condensed water will baffle steam flow in heating surface tubes, thus resulting in uneven heating of enclosure wall, partition wall and convection SH. The condensed water may also be carried in other heating surface pipes to block steam flow there. Consequently, the tube temperature at the steam blockage area is too low while its downstream tube temperature is too high. This will results in large temperature difference of membrane walls, thus causing tube leakage or tube rupture. 3) The condensed water in platen SH and finishing SH shall be fully evaporated before being taken away. 4) Because heating surfaces of platen SH and finishing SH are not fully of drainable configuration, during boiler shutdown, condensed water will deposit in the tube bundles. (For example: after hydraulic test, the tubes are full of water, while at extremely thermal state startup little water deposits in the tubes.) Cooling of these suspended heating surfaces starts from the bottom of tube platen to the platen header. Before boiler startup, the wall temperature of platen bottom will be the lowest (150~200lower than the header connected with the tube platen) and the wall temperature of the header will be the highest (close to the temperature of normal operation before thermal state startup). Hence, during boiler startup, the introduction of condensed water into the outlet header will result in abrupt cooling of the nozzles and shell of header to cause the occurrence of crack at the joint between the header and its nozzles. More condensed water is brought away by steam, greater the cooling degree of steam is. And it is possible that the steam temperature before turbine main steam valve cannot reach the required value, thus causing the temperature difference of valve. 5) We could deduce gas temperature based on the platen heating surface metal
wall temperature detected by thermocouples. When the metal wall temperature reaches the preset value, we affirm the condensed water in the tubes has been vaporized. The condensed water in the platen heating surface tubes will generate steam during heating process. This heating process may be detected by thermocouples. When the vaporization of condensed water begins, the metal wall temperature detected by thermocouples dropswhen the vaporization of condensed water decreases or stops, the metal wall temperature rises again. 6) It is necessary to guarantee the acquisition of appropriate steam temperature and steam pressure during boiler startup process. 7) To guaranteed the acquisition of appropriate steam temperature and steam pressure during boiler startup process, it shall be confirmed which row of burners are firstly put into service besides water drainage and steam exhaust by operating relevant valves to process . For cold state startup, the lower row of burners shall be put into service at first so as to supply heat to the lower furnace, thus raising pressure and maintaining relatively lower steam temperature. For thermal state startup, the medium row of burners shall be ignited at first to maintain steam temperature. 8) It is necessary to guarantee combustion input is stably increased during boiler startup process. During boiler startup, either maintaining combustion input or decreasing combustion input will lead continual descent of steam temperature. If the steam flow through heating surface is increased continually without combustion input increased, the steam temperature will drop. The steam temperature cannot be maintained unless combustion input is increased before increasing boiler steam flow. Therefore, during boiler startup process, especially when starting up turbine and incorporating it into the grid, the steam temperature must be monitored closely to prevent the abrupt drop of temperature of the steam entering into turbine, which may lead the cooling and shrinkage of high, medium and low rotors, thus resulting in turbine failure and its shortening of service life. 1.6.2 Operation for Drainage and Steam Exhaust Valves at Cold Startup Operation Mode
Sequence
Description Enclosure wall circular header drainage valve, (partition wall lower header) convection superheater inlet header drainage valve, main steam outlet release valve shall be all opened.
Initial Position
2 Manual
5 oil guns corresponding to the lower row of burners on the front wall and rear wall are ignited respectively, with approximately 5%BMCR heat inputted. When the pressure rises up to 1.0MPa.a, enclosure wall circular header drainage valve shall be closed; the drainage valve shall be opened for 30 seconds every other 30 minutes before the pressure rises up to 5.0MPa.a. When the pressure rises up to 1.2MPa.a, LT SH inlet header drainage valve shall be closed; the drainage valve shall be opened for 30 seconds every other 20 minutes before the pressure rises up to 5.0MPa.a. When the pressure rises up to 1.6MPa.a, main steam outlet steam exhaust valve shall be closed. The automatic mode of bypass is selected. Ignite more oilguns corresponding to the lower row and the middle row of burners on the front & rear wall until the boiler heat input reaches 15%BMCR, and steam parameter meets the requirements of steam turbine (pressure: 6.0MPa.a ).
Automatic
Automatic
Automatic
Manual/ 6 automatic
1.6.3 Suggestions for the Operation of Drainage and Steam Exhaust Valves at Warm State startup. Sequence Operation Mode 1 Initial Position Description
Rear enclosure wall circular header drainage valve, (division wall lower header) convection superheater inlet header drainage valve, main steam outlet exhaust valve shall be all closed. Ignite oil guns corresponding to the lower row and the middle row of burners on the front & rear wall until the boiler heat input reaches 15%BMCR, and steam parameter meets the requirements of steam turbine.
2 Manual
Sequence
Operation Mode 3 Automatic
Description
Lower enclosure wall circular header drainage valve, convection superheater inlet header drainage valve, main steam outlet exhaust valve shall are opened. When the initial pressure is lower than 4.5MPa.a: When the pressure reaches the value of initial pressure plus 0.5MPa, close rear enclosure wall circular header drainage valve, then open it for 30 seconds every 15 minutes until the pressure reaches 5MPa.a. When the pressure reaches the value of initial pressure plus 0.7MPa, close LT SH inlet drainage valve, then open it for 30 seconds every other 10 minutes until the pressure reaches 5MPa.a.
4 Automatic
When the initial pressure is higher than 4.5MPa.a: When the pressure reaches the value of initial pressure plus 0.5MPa, enclosure wall circular header drainage valve shall be closed. When the pressure reaches the value of initial pressure plus 0.7MPa, LT SH inlet header drainage valve shall be closed; 5 Automatic When the pressure reaches the value of initial pressure plus 1.0MPa, main steam outlet steam exhaust valve shall be closed.
6 Manual/
Bypass is switched to automatic mode. Adjust the boiler combustion input to make steam parameters meet the automatic requirement of steam turbine.
1.6.4 Suggestions for the Operation of Drainage and Steam Exhaust Valves at Thermal State Startup Operation Mode
Sequence
Description
Sequence
Operation Mode
Description Rear enclosure wall circular header drainage valve, (division wall lower header) LT SH inlet header drainage valve, main steam outlet steam exhaust valve shall be all closed. Ignite oil guns corresponding to the upper row and the middle row of burners on the front & rear wall until the boiler heat input reaches 15%BMCR, and steam parameter meets the requirements of steam turbine. Note: The higher superheater outlet parameter is required at thermal state startup, which is fulfilled by igniting the oil guns corresponding to the upper row and the middle row of burners on the front & rear wall (if necessary). After the first oil gun has been ignited for a certain time(about 3 minutes), enclosure wall circular header and LT SH inlet header drainage valves shall be opened (100% opened). Note: When Item 4 and 5 are performed, the temperature measured by thermocouples on platen SH outlet and HT SH outlet tube panels (measured by thermocouples) shall not decline, otherwise the operation shall be stopped, and not be continued until the measured wall temperature rises up to the original level. The drop of HT SH outlet steam temperature will cause the drop of main steam pipe temperature, and delay turbine operation.
1 Initial Position
2 Manual
3 Automatic
4 Manual
Gradually close drainage valve of enclosure wall circular header. Gradually close drainage valve of LT SH inlet header. Note: Item 6 and 7 shall be performed in sequence.
5 Manual
6 Automatic 7 Automatic
Open high pressure bypass inlet stop valve and main steam pipe lower point drainage valve. The warming valve on main steam pipeline is opened. Note: Item 6, 7 and 8 shall be performed synchronously.
Sequence
Operation Mode Manual/ 8
Description
Bypass is switched to automatic mode (The pressure value shall be 10Mpa.a for high pressure bypass, and automatic 0.7Mpa.a for low pressure bypass.) Combustion input shall be regulated to insure that turbine startup parameter is met. Bypass flux, pressure and temperature shall be verified to meet the requirement for main steam parameter.
9 Manual
1.6.5 Suggestions for the Operation of Drainage and Steam Exhaust Valves at Extremely Thermal State Startup: Sequence Operation Mode Description Rear enclosure wall circular header drainage valve, (division wall lower header) LT SH inlet header drainage valve, main steam outlet steam exhaust valve shall be all closed. Ignite oil guns corresponding to the upper row and the middle row of burners on the front & rear wall until the boiler heat input reaches 15%BMCR, and steam parameter meets the requirements of steam turbine. Note: The higher superheater outlet parameter is required at extremely thermal state startup, which is fulfilled by igniting the oil guns corresponding to the upper row and the middle row of burners on the front & rear wall (if necessary). Note: Item 3, 4, 5, 6 and 7 shall be performed in sequence. LT SH inlet header drainage valve shall be immediately closed after opening the enclosure circular header drainage valve. Open the high pressure bypass drainage valve.
1 Initial Position
2 Manual
3 Automatic
4 Automatic
5 Automatic
Open the main steam pipeline low drainage valve. Open the main steam pipeline electric warming valve. Bypass is switched to automatic mode (The pressure value shall be 14.5Mpa.a for high pressure bypass, and 0.7Mpa.a for low pressure bypass.) Combustion input shall be regulated to insure that turbine startup parameter is met. Bypass flux, pressure and temperature shall be verified to meet the requirement for main steam parameter.
6 Automatic
Manual 7 automatic
8 Manual
1.7 Boiler Soot Blowing 1.7.1 Periodic soot blowing shall be conducted for the heating surfaces of the new unit put into operation so as to keep the outer walls of heating surfaces clean and prevent the occurrence of slagging and insure good heat transfer performance and low gas emission temperature. Only by this means could boiler economic operation be guaranteed. 1.7.2 The soot blowing system of the unit is designed, fabricated and provided by Daimengde Electric Power Machinery (Hubei) Co., Ltd. The company shall also provide site service during installation. Relative commissioning requirements and operation instruction shall be strictly followed. 1.7.3 Before soot blowing, the soot blower shall be drained and warmed. The water drainage valve could be closed only after the medium temperature has reached the setting value. After soot blowing, steam feeding shall be stopped and water drainage valves shall be opened to prevent the formation of condensed water in the piping system. 1.7.4 Soot blowing shall not be conducted at low load or unstable combustion condition. Generally, soot blowers shall be out of service when boiler load is lower than 50%. Soot blowing shall be performed before boiler shutdown. 1.7.5 Boiler soot blowing shall start from the furnace to the rear part along flue gas flow direction. Soot blowers are symmetrically arranged and shall be put into operation at the same time. 1.7.6 During boiler startup or low load operation, the steam source for soot blower of air preheater may be substituted by steam out of the auxiliary steam system.
1.7.7 Any soot blower that failed shall be immediately repaired to keep it in good condition. The soot blower shall not be out of service for long time. 1.7.8 The soot blowing procedure shall be optimized according to slagging conditions of each boiler part during operation to improve soot blowing efficiency and prevent the occurrence of damage caused by soot blowing. During low load operation, soot blowing frequency for the rear part of boiler shall be increased to prevent ash deposition. 1.8 Boiler Blowdown and Water Drainage 1.8.1 To make the steam/water quality meet the requirements and stipulations in Quality criterion of water and steam for thermal power plant and steam power equipment, boiler blowdown shall be conducted. This boiler is designed with the periodic blowdown system and the continuous blowdown system. The periodic blowdown starts from boiler waterwall lower header while the continuous blowdown starts from boiler drum. The blowdown pipeline shall be warmed to prevent the occurance of water impact before blowdown. Drum water level shall be properly increased before periodic blowdown, and blowdown shall be performed one loop after another. Two or more points blowdown cannot be performed at the same time to keep the stability of drum water level and safety of water circulation. Periodic blowdown shall be conducted as fast as possible under stable load. 1.8.2 During boiler normal operation, the open degree of continuous blowdown control valve and blowdown time shall be properly adjusted according to steam/water quality control requirements and results of their tests. Periodic blowdown is mainly used to control boiler water and steam quality in short term. Continuous blowdown can be used to control boiler water and steam quality in both long term and short term. 1.8.3 When boiler operation is abnormal or accident occurs (except excessive high water level) or the blowdown system fails, blowdown shall be stopped. 1.8.4 The water drainage and steam exhaust system of boiler proper are mainly used for drainage and pressure/temperature control during boiler startup or shutdown. The water drainage of convection SH inlet header and BP circular header are mainly used for drainage of accumulated condensed water during boiler startup or shutdown. 1.8.5 Steam discharge valve at SH outlet is mainly used for steam temperature/pressure control when safety valve rejects motion.
2. Boiler Operation Adjustment

2.1 Content of Boiler Operation Adjustment 1) Make the boiler parameters reach the rated values and meet the requirements of unit loading. 2) Keep stable and normal steam temperature and pressure. 3) Balance water feeding and maintain the normal drum water level. 4) Keep qualified boiler water and steam. 5) Keep good combustion, reduce heat losses and improve boiler efficiency. 6) Adjust boiler operation conditions in time to ensure the unit runs safely and economically under the best operation conditions. 7) Reduce the emission of NOx. 2.2 The Influence of Working Condition Changes on Boiler Parameters 2.2.1.1 Boiler Parameters The boiler conditions, namely, its operating conditions, are reflected by a series of relevant operating parameters. These reflection parameters are as follows: evaporation capacity reflecting boiler capacity, pressure and temperature reflecting steam quality, and fuel flow rate, air flow, oxygen content, drum water level, flue gas pressure & temperature etc. Among these parameters, some are used as governing objects; some are used to reflect the conditions of various matters entering boilers; and some are to reflect the economy and safety of boilers. 2.2.1.2 The Influence of Working Condition Changes on Boiler Parameters By the dynamic characteristics of the boiler, we can see that the stability of boiler s main operating parameters depends mostly on the following two balances: balance between turbine power and boiler evaporation capacity, and balance between fuel and feedwater of once-through boiler, or between evaporation capacity and feedwater flow of drum boiler. To maintain the first balance will be able to guarantee the stability of boiler steam pressure, while to maintain the second can keep superheated steam temperature of the once-through boiler or water level of the drum boiler. When changes happen to working conditions, the balance will be disturbed and will cause changes in operating parameters, if not adjusted timely. Whether the disturbance is internal or external, it will lead to changes in the boiler conditions, which ultimately manifested as changes in operating parameters. Whats worse, a change factor will usually cause changes in a number of relevant parameters at the same time.
2.2.1.3 Boiler Operation Economy Continuously improving the economy of boiler operation is an important part of boiler operation adjustment. For the modular unit, the boiler operation adjustment is not only to improve the boiler thermal efficiency, but also to improve the thermal efficiency of the whole unit. According to the relevant introduction, when 600MW units boiler is working at rated conditions, changes of some of the major parameters have the following influence on coal consumption for power generation of the whole unit as shown in the following table: Affecting Coal Consumption of the Parameters Main Steam Temperature Main Steam Pressure Reheat Temperature Flue gas temperature 1 0.17 Steam Unit MPa Variation 1 0.1 1 Generating Unit (g/kWh) 0.19 0.24 0.16
The contents of boiler operation adjustment can generally be classified into three aspectsi.e. combustion adjustment, parameter adjustment and operation modes. In terms of enhancing the operation economy, the purpose of combustion adjustment is to reduce the losses of a variety of incomplete combustion in the furnace; the purpose of parameter adjustment is to reduce the boiler flue gas heat losses and improve the thermodynamic cycle efficiency of the whole unit; the purpose of operation mode adjustment is to optimize the combination of auxiliaries, and reduce their power consumption and auxiliary water & steam consumption. In order to improve the thermal efficiency of the boiler and the whole unit, the following shall be followed: a relatively high steam temperature and pressure shall be generally maintained during normal operation; rational air distribution shall be ensured; the combination of burners shall be optimized; low oxygen combustion mode shall be adopted; appropriate fineness of pulverized coal shall be maintained; "The leakage of seven substance phenomena" shall be eliminated; the valve throttling losses and RH attemperating water supply shall be minimized; air leakage in all parts of the boiler shall be reduced; regular sootblowing of the heating surfaces according to the requirements shall be conducted and variable-pressure operation mode shall be adopted.
2.3 Boiler Steam Temperature Control and Adjustment 2.3.1 The Influence of Steam Temperature on the Safe and Economic Operation of
the Unit The SH and RH steam temperature of this boiler are 541 . When the steam temperature is too high, it will cause superheaters, reheaters, steam pipes and metals on steam turbine cylinders, valves and rotors to weaken in strength, resulting in shortened service life of equipment, or even serious equipment trouble accidents. When the steam temperature is too low, it will cause several turbine blades of the final class to increase in humidity, and even cause serious water hammer to rupture the turbine blades. In addition, it will also cause the turbine rotors to suffer from increased axial thrust. All the above consequences will seriously threaten the safe operation of the steam turbine. If significant changes happen to SH and RH steam temperatures, except for the greater thermal stress and fatigue of the boiler tubes and related components, they will also result in differential expansion between turbine cylinders and rotors, or even serious dynamic and static friction between turbine blades and diaphragms, causing a strong vibration of steam turbine. When the steam temperature difference on the turbines both sides is too large, it will lead to uneven heating and uneven thermal expansion on the sides, threatening the safe operation of the unit.
2.3.2 Heat-Transfer Characteristics of Boiler Heating Surfaces According to mode of heat transfer, boiler heating surfaces can generally be classified into three types, namely, radiation heating surfaces, semi-radiation heating surfaces and convection heating surfaces. The water wall evaporating surface, the front platen and the wall enclosure tube heating surface, etc. belong generally to the radiation heating surface in that the radiant heat accounts for the major proportion. The rear platen superheater belongs to semi-radiation heating surfaces for the following reasons: on the one hand, it absorbs the convection heat transfer of flue gas; on the other hand, it absorbs the radiation heat transfer of flue gas in furnace and tubes. Heating surfaces of economizers, and SH/RH in the convection pass belong generally to the convection heating surface on the ground that the convective heat constitutes the major proportion. With the changes in boiler load, the furnace radiant heat and convective heat distribution ratio will change accordingly. When the boiler load increases, the heat transfer share of the convection heating surface will increase, and the heat transfer share of the radiation heating surface will decrease comparatively while the semi-radiation heating surface will be less affected. Refer to Figure 4-2-1.
Figure4-2-1 Relation curve between boiler load and the amount of heat absorbed for each heating surface Q-The amount of heat absorbed per unit of working medium D-Boiler load -Radiation heating surface -Semi-radiation heating surface
-Convection heating surface
2.3.3 Drum Boiler SH Steam Temperature Control and Adjustment 2.3.3.1 Influence Factors for Drum Boiler SH Steam Temperature Changes: 1) Changes in the nature of the fuel 2) Changes in air flow and its distribution ratio 3) Changes in burner operation modes 4) Temperature changes in feedwater 5) Changes in cleanliness of heating surfaces 6) Changes in boiler load 7) Changes in saturated steam temperature and attemperating water flux
2.3.3.2 Natural Circulation Drum Boiler SH Steam Temperature Control and Adjustment. This drum boiler adopts the primary attemperation installed at the inlet of platen SH as the chief means for regulating SH steam temperature. In case of emergency, the secondary attemperation at the outlet of platen SH can be used to adjust SH steam temperature. The attemperating water flux for original design coal and various working conditions is shown in the following table:
Item Unit B-MCR TRL THA
70%TRL 50%TRL 30%BMCR
The
SH
primary t/h
19.50
21.69
16.49
54.94
66.07
51.93
attemperating water flux
The
SH
secondary
t/h
13.00
14.46
10.99
36.63
44.06
34.62
attemperating water flux a. Under Constant pressure operation (60 ~ 100 % B-MCR), rated temperatures of superheated steam and reheated steam shall be kept, and under sliding pressure operation (45~100% B-MCR) rated temperatures of superheated steam and reheated steam shall be kept, 5 temperature difference permitted. b. Two-stage spray attemperation shall be adopted to adjust superheated steam temperature. The primary attemperation shall be arranged at the inlet of platen SH for coarse adjustment, while the secondary attemperation shall be arranged at the inlet of finishing SH for fine adjustment. When the high pressure heaters are out of service, large amount of spray water must be fed via the primary attemperator to protect the platen SH and finishing SH from being overheating. c. For The secondary attemperation, temperature drop value may be set as 7. In order to prevent the occurrence of steam condensation and water forming after attemperation, the steam temperature after the primary attemperation shall not be under the saturation temperature plus one degree (margin) under operation pressure D. When the pressure is less than 12.1Mpa, D shall be at least 28. When the pressure is more than 17.6Mpa, D shall be at least 14. Under intermediate pressure, D value may be calculated by linearity difference. In case the primary attemperation could not meet the steam temperature requirement, then the desuperheating extent of the secondary attemperation may be enlarged. d. Under 20%BMCR, the primary attemeration shall be out of service, and under 10%BMCR, the secondary attemperation shall be out of service.
In short, during the regulation of steam temperature, it shall be firstly adjusted by combustion, seeking for non-deflection flame and avoiding partial coking, and then by fine adjustment of SH steam temperature. Within the limits of all levels of wall temperature, when attemperating water flux become inefficient for stable adjustment of steam temperature, combustion adjustment shall be considered as the measures and methods for steam temperature adjustment.
2.4 Control and Adjustment of Reheated Temperature Reheated temperature of this boiler reached 541, steam pressure is 3.9MPa.
2.4.1 The Characteristics of Reheated Temperature Because of the characteristics of construction and lay out of SH, the characters of steam temperature are: 1) Capacity of SH is big enough, so flow velocity of working medium is relatively low, and the location of SH is in smoke low temperature area, so there has low temperature differences of heat transfer. Therefore, when the condition changes, reheat temperature will take relatively long retarded time to change. 2) Because of the low reheated steam pressure and specific heat, when unit working medium changes at the same caloric receptivity, the variation of reheat temperature will be larger than that of superheated steam temperature. Convection section of RH is located in relatively low gas temperature area, because of the heat transfer characteristic of convective heating surface and low specific heat of reheated steam, so there is a smaller effect to reheated temperature. 3) Reheated temperature is sensitive to heat deviation. Because of its low pressure and specific heat, under the same heat deviation condition, derivation of reheated temperature will be larger than superheated steam temperature. 4) Operating condition of RH suffer not only from the operating condition of boiler, but also from operating condition of steam. Flow rate of reheat steam changes with unit load, class one and two extraction flow of turbine and open/close status of boiler safety valve and steam discharging valve. While unit working in constant pressure modes, turbine HP cylinder s exhaust temperature (cold RH input temperature) will have substantially change as unit load is change. So change of RH input temperature and working medium flow rate will change reheat temperature.
2.4.2
Factors influencing the temperature variety of reheating
For the characteristics of the structure and layout of RH, there are various factors for influencing the temperature variety of reheating. Mainly as the followings: 1) Impact of high pressure cylinder steam exhausting temperature variation 2) Impact of RH heat absorption capacity variation 3) Impact of reheated steam flow variation 4) Impact of reheated desuperheater water flow variation
2.4.3 Adjusting method for reheated steam temperature Flue gas side adjustment is the main adjusting method for the reheated steam of this furnace (to adopt fuel gas damper adjusting, changing the height of center flame of furnace), then operate with desuperheater water adjusting mode. a. Adjustment of Flue Gas Temperature Adjusting Damper The open degree of the rear flue gas adjusting damper changes with the loading swing of boiler; and the recommended open degree of the damper of SH and RH see drawing 7. Shut down one side flue gas damper, when adjustment of flue gas damper towards to the stop is needed, dont simultaneously close the flue gas adjustment damper of SH and RH.
The open degree of back pass gas damper shall be adjusted according to boiler load fluctuation. The recommended open degree is shown in Fig. 7. b. When RH steam temperature is low, the flue gas damper at convection RH side shall be adjusted toward open side, meanwhile the flue gas damper at convection SH side shall be adjusted toward close side. When RH steam temperature is high, the flue gas damper at convection RH side shall be adjusted toward close side, meanwhile the flue gas damper at convection SH side shall be adjusted toward open side. c. RH spray attemperator outlet steam temperature shall not be less than the saturation temperature plus 14 under operation pressure. When the boiler load is lower than 40%BMCR, RH spray attemperator shall not be put into service. d. The heat absorption ratio of radiation and convection surface can be modified via altering the central height of furnace flame to fulfill the temperature
adjustment of reheating steam. Factors that influencing the furnace flame central height are plenty; the furnace flame central height can be decreased by lowering the loading of upper burner and adding the loading of lower burner, properly decreasing furnace pressure and increasing the secondary wind of the upper and reduce the secondary wind of the lower etc; for the convection RH, the reheating steam temperature will be lower when the furnace flame center dropping. Otherwise, the reheating steam temperature will be upper when the furnace flame center rising. 2.5 Control and Adjustment of Boiler Loading and Steam Pressure The work of boiler loading and steam pressure adjustment is actually maintaining the balance between boiler duty and quantity of steam that steam turbine required while sustaining the outer electrical loading. Under normal operation (rated working condition), SH outlet steam pressure shall be 17.40.2Mpa.g.
2.5.1 The Impact of Steam Pressure Swing High economic benefits of the units will be realized by a high sustaining degree of the boiler main steam pressure within the allowable variation scope. However, the steam pressure over the allowable range will severely harm the body and equipment. If the steam pressure fluctuated frequently, it will cause the metal of the boiler heating surface under the action of repeated stress, in addition to other factors such as temperature stress; finally the heating surface metal will have fatigue damage. For the drum boiler, when the temperature dropping, the water volume inside of the drum boiler will expand; and the drum level will rise. Otherwise, when steam pressure rising, the water volume shrinking; the drum level will go down. This untrue water level will cause water level accidents such as full water level or water shortage in the violent steam pressure variation. Additionally, suddenly steam pressure dropping or rising will also cause the vaporization of down pipe inlet working medium or lowering the circulation ratio to impact the water cycle safety of boiler.
2.5.2 The Reasons of Steam Pressure Variation Reasons for causing the steam pressure of boiler are plenty; mainly in two aspects: one is the external factor of the boiler; the other is the internal factor.
1)
External factor: boiler external factor is also called external disturbance,
means the disturbance caused by the equipment or operation outside of the boiler. 2) Loading swing of the outside: High pressure heater suddenly out of operation for fault The quality changing of fuel: Internal factor: Internal factor of boiler is also called internal disturbance, usually means the disturbances caused by the equipment and operation of the boiler itself. a) The alteration of combustion conditions: b) Equipment fault:
2.5.3
The Adjustment of Boiler Loading and Steam Pressure
1Adjusting method for boiler loading and steam pressure The modular unit with rated pressure operation, the adjusting method for loading and steam pressure normally could be classified by three modes; they are boiler following mode (also called Lugenji mode), turbine following mode (called Jigenlu mode) and coordinating mode. a. Boiler following mode In the boiler following adjustment system, pressure set is drawing upon the boiler main control, manually adjust the opening degree to fulfill the loading; the main control of the boiler adjusts the main steam pressure. b. Turbine following mode In the turbine following adjustment system, pressure set works on the turbine. The control valve of the turbine will be set in compliance with the pressure to fulfill the pressure set. c. Coordinating mode Coordinating mode boiler main control mainly controls steam pressure, steam turbine main control mainly control loading. Through the co-working and effect, the set requirement of the loading and steam pressure can be fulfilled.
2.5.4 Steam pressure adjustment a. Main steam pressure shall be adjusted by increasing or decreasing fule on the premise that the stable combustion cannot be affected . Safety valve and steam exhaust shall not be used to decrease the steam pressure under non-accident working condition. Under superpressure operation, the electric discharge valve shall be first opened to release pressure due to its low setting pressure. b. If the steam pressure reaches the action value of safety valve, the safety valve still rejects action while the pressure keeps on rising, emergency measures shall be taken to release pressure, namely partial burners are out of service, and steam exhaust valve is opened. c. All kinds of pressure gauges shall be rectified from time to time to prevent the occurrence of measurement error. d. Boiler drum wall temperature control No matter which kind of operation mode is used, the drum wall temperature shall be controlled during boiler startup and shutdown to insure that the differences between the upper and lower wall temperatures and between the internal and external wall temperatures are kept with the permissible value. The maximum permissible temperature differences are shown in Fig. 9. When boiler drum pressure is below 0.1MPa.g during boiler startupdrum temperature change rate shall be less than 1.1/min. When boiler drum pressure is below 6.0MPa.gdrum temperature change rate shall be less than 1.5/m in. e. Under sliding pressure operation condition, if boiler pressure change rate is more than 1.0Mpa/min and lasts for 5 seconds, the first electric discharge valve shall be opened and the second electric discharge valve shall be opened in 5 seconds following the first one. When the pressure change rate is less than 1.0Mpa/min, the electric discharge valves shall be closed. The electric discharge valves shall be opened at least 5 seconds before they are closed. 2Features of Drum Boiler Steam Pressure Swing and Adjustment The adjustment of drum boiler steam pressure depends on the variation of combustion ratio, when the steam pressure dropping, only rising the heat release inside of the furnace, could raise the high steam pressure. Otherwise, only fall off
the combustion, lower the heat release inside of the furnace could drop the steam temperature; there is no direct connection between adjustment processing and water allowance. 2.6 The Control and Adjustment of Drum Level
2.6.1 The Importance of Keeping Steam Drum Normal Level Sustaining the normal water level of steam drum is the key to guarantee the safe operation of boiler and turbine, drum level over high, steam space shrinking will increase carryover, make the quality of steam deteriorate to make the salification and over-temperature of SH and the scale formation of flow parts of turbine easily. Drum level in severely high or full water level, the steam with water greatly, makes the main steam temperature drop suddenly, there is serious water impact inside of the steam pipe and inner turbine, and even it may damage the blade of turbine. The lower water level of drum may damage the boiler water cycle; make the cooling wall pipe overtemperature overheat; severely water shortage and improper handling may cause the large boiler pipe blasting. As the boiler capacity increasing, the relative capacity of drum is decreasing; therefore, the variation rate of the drum level of large capacity boiler is quick. With calculation, 600MW modular unit, the nature cycle drum boiler, which drum level with 200mm alteration may take 6 to 8 seconds.
2.6.2 The Main Factors for Impacting the Drum Level Swing In normal operation of boiler, the water level swing frequently. The main reasons are: 1) Boiler loading swing 2) Combustion condition swing 3) Feed pressure swing 4) Size of the relative capacity of steam drum Condition Economizer system Drum Water cooling system In water 95 66 197 372 333 1063 SH system RH system Total
pressure testing In normal operation 5) Impacts by equipment leakage or fault 95 33 197 / / 325
2.6.3 Control and Adjustment of Boiler Steam Drum Level 1) Boiler water level adjustment and control shall be based on the measured value of single chamber balancing vessel. 2) Boiler water level shall be controlled within the 50mm range of normal water level (51mm above drum center line) at normal operation. 3) Water level protective values are: +100 mm -100 mm High alarm level +150 mm -250 mm
High level alarm
High level trip
+200 mm
Low level alarm
Low level alarm
Low level trip
-365 mm
4) Automatic feed water adjustment shall be adopted for normal operation. Boiler water level changes shall be closely noticed in the case of load change, combustion adjustment, periodic blowdown and water pump switching. 5) Feed water control The system is design with single-impulse water level control (only for drum water level) and three-impulse water level control for the flux of boiler water fed into drum and the flux of steam separated from drum shall be adopted for the system. During load rising, when the feedwater flux is lower than 25%BMCR, the single-impulse water level control shall be adopted for drum. When the flux approaches to 25%BMCR, the water level control mode shall be switched to three-impulse control mode. During load decreasing, when the load approaches to 20%BMCR, the water level control mode shall be switched to single-impulse control mode. To sum up, the factors that impact the steam drum level are plenty, water level variation
is the co-working of each factor. So, careful inspect each parameter and conditions changing in normal operation shall be conducted, and timely have related adjusting, make sure all the adjustment is prior to the alteration of water level, once the water level changed, find out the reasons that cause the water level changing, analyze the trend of variation and make some necessary handling to ensure the steam drum level operate normally. 2.7 Boiler Combustion Adjustment
2.7.1 Purpose and Target of Combustion Adjustment The condition of boiler combustion condition can directly affect the operation and parameter variation of the boiler itself, and have great impact on the economic operation and safe operation of the modular unit, therefore, no matter normal operation or ON/OFF processing, reasonable combustion shall be organized to ensure the combustion condition stable and good. The tasks of boiler combustion adjustment are: 1) Ensure the parameter of the boiler in the required range and fulfill creating the adequate qualified steam to meet the needs of external loading; 2) 3) Ensure the boiler operation stable and reliable; Minimize the incomplete combustion loss to enhance the economic efficiency
of boiler operation; 4) Make the NOxSOx and each of the exhaust indexes of the boiler in the allowable range.
2.7.2 The factor influencing the combustion and measures intensifying combustion 2.7.2.1 Factors influencing combustion 1) The fuel quality 2) Coal fineness 3) Air flow rate, wind speed, wind temperature of primary wind 4) Characters of burner 5) Boiler loading 6) Passage air index
7) The coordinating of primary air and secondary air 8) Combustion time
2.7.2.2 Requirements of Good Combustion a) Supply the air amount of complete combustion b) Maintain a proper furnace temperature; c) Good mixture for the air and fuel; d) Adequate combustion time
2.7.2.3 Measures for intensifying coal dust combustion a) Raise the hot wind temperature b) Maintain a proper air amount; control the primary air amount according to the coal type reasonably c) Select a proper air flow rate to ensure a proper ignition point; d) According to the combustion processing development, timely supply secondary wind to make the combustion with adequate oxygen and sustainable flame temperature; e) Maintain ignition area in high temperature; intensify the entrainment of high temperature fuel gas in the air flow f) Select coal dust with proper fineness; g) Maintain the flame tail that has distance with the burner in an adequate high temperature to intensify the combustion degree of burning out.
2.7.3 Adjustment of Burner Burner shall be maintained with proper primary and secondary air proportion and outlet rate, which is necessary to build a good furnace condition to make the air and coal dust mix equally and ensure the fuel ignition and combustion normally. Normally, the turbulent burner is equipped with secondary air amount damper and wind speed damper (liguliform damper), and the primary air damper is mounted on primary air pipe. The primary wind speed of this burner can be only controlled by adjusting the primary air amount. When primary air amount is rising (opening up the
primary air damper), its wind speed and air amount will increase proportionally. Secondary wind speed adjustment is accomplished by changing the secondary air amount. The tangential velocity of outlet air flow of burner can be controlled by wind speed damper to alter the disperse state of outlet air flow of burner. The adjustment of secondary wind speed damper in operation shall be in accordance with fuel volatile component variation and boiler loading state. For low volatile coal, ignition is difficult, so the wind speed damper shall be turned down properly to make the spread angle increase, the hot reflux enhanced, thereby hoist the temperature of flame root to improve the ignition of combustion; for high volatile coal, ignition is easy, shall turn up the wind speed damper, increase the axial velocity of outlet air flow of burner, to decrease the spread angle and improve the range to protect the burner and restrain scorification. In high loading, for the furnace temperature is high, coal fineness ignition condition is good, the combustion is stable, so the secondary air spread angle could be smaller, i.e. the opening of the secondary air wind speed damper could be larger; while in lower loading, for the lower furnace temperature, the combustion is not stable, the air damper opening degree could be smaller, i.e. the secondary air spread angle shall be larger to intensify the hot reflux of high temperature fuel gas and improve the ignition and combustion of coal fineness. After adjusted the air speed damper, the secondary wind speed changed as well as the secondary air s air amount, therefore air amount damper adjustment is necessary. If the wind speed damper is turned down, for maintaining the wind speed, the air amount damper shall be turned up. For the adaption of different kinds of coal and conditions, the matching control for primary, secondary air and turbulent strength shall be conducted. Normally the adjustment of tangential wind speed of burner shall be coordinated with air amount swing, however, when necessary, monomial adjustment is feasible.
2.7.4 Principles of Combustion Control: a. The air rate, air speed, air temperature of burner shall meet the requirements of design. Please see the details in 59N-3SM BURNING EQUIPMENT INSTRUCTION. b. Combustion in furnace shall be stable during normal operation, with flame looking luminant golden, otherwise the opening of each burner damper shall be adjusted in time.
c. When boiler load changes, air flowrate, coal feeding rate shall be adjusted in time to keep steam temperature and steam pressure stable. During load rising, increase the air flowrate is increased and then the coal feeding rate is increased. In case of load decreasing, the coal feeding rate is decreased and then the air flowrate is decreased. In case that the requirement cannot be met by coal feeding rate adjustment during great changes of load, the requirement shall be met by starting up or shutting down the coal pulverizer. d. During normal operation, the front and rear wall burners at the same elevation shall be operated as simultaneously as possible. It is prohibited to operate single wall burners on two or more layers. e. -10050pa furnace outlet negative pressure shall be kept. Air delivery rate and induced draft rate shall be regulated in time in case of overpressure or excessive low pressure. The furnace pressure protective values shall be as follows:
Low alarm High alarm
980Pa 980Pa
Low fuel trip High fuel trip
2500Pa 2500Pa
f. All furnace doors/holes shall be tightly closed during boiler operation. g. The core air, which is taken from the air before the secondary air adjustment damper. The core air is fed in to prevent the reflux of thermal flue gas and provide oil guns with certain proportion of combustion air. h. Overfire air (OFA) is mainly used for the reduction of NOx emission during operation. i. In case of BMCR load, approximate 2.6% of secondary air shall be used as cooling air, which is used to cool the burners which are not put into operation. j. In case of boiler load changes, furnace outlet excess air coefficient shall be adjusted accordingly. The relation curve between load and excess air coefficient is shown in Diagram 6. k. Coal pulverizer outlet air temperature shall be 70. Coal pulverizer outlet air temperature shall be controlled by adjusting coal pulverizer air damper.
3. Shutdown of Boiler
3.1 The shutdown mode and preparation of boiler
3.1.1 Shutdown mode of boiler Shutdown of boiler normally can be classified in two types; they are normal shutdown and boiler emergency shutdown
3.1.2 Preparation for the shutdown of boiler Shutdown shall be in accordance with the traffic order; and prior to the preparation, the reason, time and mode of shutdown shall be clarified. l) Before boiler is shutdown, operators of each post shall have a full check of the modular unit, take a detailed record for the found equipment deficiency so as to check and handle. 2) Normally, the standby period or downtime of shutdown shall be over 7 days; the run coal bin and residual coal shall be burnt out to avoid the scorification and self-ignition. If all the run coal bins are clear; the processing shall be operated gradually. When shoveling, all staff shall particularly pay attention to the flame stability to prevent the boiler flameout. 3) Before the shutdown, all operation bills shall be filled and the heat surfaces of boiler shall have full soot blowing. The on-site water gauge of the boiler shall be flashed, and check the index of upper and lower water gauge. When deviation is found, send the heat engineer to handle. 4) Steam escape testing of steam drum, SH, RH relief vale and magnetic relief valve and switch on/off testing of accident discharge electrical gate shall be conducted prior to shutdown, deficiencies shall be treated timely to ensure the shutdown goes well. 5) Normal cycle of heavy oil system and atomization steam system, oil temperature, pressure, atomization steam pressure shall be qualified to ensure the oil gun can be available anytime in shutdown to maintain the combustion and prevent flameout.
3.1.3 Shutdown of Nature Cycle Steam Drum Boiler 3.1.3.1 Normal shutdown of Units a. Boiler scheduled shutdown shall be performed according to the shutdown curve (adverse to the startup curve) and steam turbine requirements. b. Before boiler shutdown, an overall inspection shall be required, and any problem found shall be recorded and eliminated after boiler shutdown. c. Normal boiler shutdown sequence 1) 2) Load is decreased and soot blowing is performed before boiler shutdown. Before decreasing load, firstly ignite the oil guns of the burners
corresponding to the mill to be shut down, and then shut down the mill and its corresponding oil guns after decreasing the mill load to minimum load. 3) When the boiler load drops to around the minimum load (45%BMCR for design coal) under which boiler stable combustion is insured, without oil injected, the oil guns of burners corresponding to the mill in operation shall be ignited. 4) Boiler load drop rate shall be controlled within 1%/min, the temperature
drop rate of saturated steam shall be controlled within 1/min, the pressure drop rate shall be controlled 0.098MPa/min, and the temperature difference between thermal couples at random two points on the drum shall be controlled within 32. When boiler load drops to 30%, boiler load drop rate shall be controlled within 0.5%/min, the temperature drop rate of main steam shall be controlled within 1~2/min, and the pressure drop rate shall be controlled 0.098MPa/min. 5) 6) Inspect and keep boiler drum water at normal level. Air preheater soot blowing is performed.
1) After the last mill is shut down, the primary air fans and sealing air fans of mills are shut down. 8) When boiler load drops to lower than 20% load, the drum water level control shall be switched to single impulse control mode. 9) The lower water drainage valves of main pipelines and water drainage valve
of pipeline warming system are opened according to the requirement of steam turbine.
10) 11)
Shut down all oil guns. After flameout, the final setting positions of air regulators and dampers of
furnace windbox shall be kept and ID /FD fans shall go on operating for at least 5 minutes to sweep combustible matters inside the flue gas duct. 12) If the drum pressure needs to be kept after boiler shutdown, the air fans
shall be out of service after boiler purge. When boiler drum load drops to lower than the minimum setting pressure of finishing SH safety valve, and also there is not enough heat left in the boiler to activate the safety valve action, the steam exhaust valve at SH outlet header shall be closed. The water drainage valves and steam exhaust valves shall be closed during boiler flameout. The feedwater system shall keep on operating as long as steam is generated in the unit. Meanwhile, the drum visible water level shall be close to the normally indicated water level of the drum water level gauge. 13) If the boiler pressure needs to be relieved, all the drainage valves and
steam exhaust valves of SH system could be adjusted to relieve the drum pressure at the allowable rate (0.1MPa/min). The unit could be cooled by air fans after purge. The boiler shall be cooled evenly. Because steam is continually generated due to the heat accumulation inside the boiler walls and boiler components at the initial stage of boiler shut down, the boiler drum water level shall be kept above the visible scope of water level gauge. 14) Air preheater shall keep on operating until the air preheater inlet gas
temperature is less than 120. After that it could be shut down. 15) When the drum pressure drops to 0.17MPa.g, the boiler water drainage is conducted by opening all the steam exhaust valves and water drainage valves. The boiler water shall not be over 90 during water drainage. The boiler water drainage shall be performed while the tiny pressure is kept in the drum because the residual heat is helpful to dry the internal surface of boiler components. 16) The water drainage valve and steam exhaust valve of SH header shall be
kept open during boiler short term shutdown. 17) The boiler shall not be partially filled with water for a long term after boiler
shutdown, but it shall be filled with hydrazine deoxidized alkaline water to protect the boiler from corrosion. If the boiler shutdown term lasts several weeks or months, or
the climate does not allow the boiler to be filled with water, then the boiler shall be drained and dried. Several thin plates with certain amount of silica gel may be placed inside the drum to absorb the water and keep its internal surface dry. If the shutdown term only lasts several days or a little longer, the boiler accumulated ash shall be cleaned to prevent the occurrence of corrosion. It is suggested that soot blowing shall be performed before boiler shutdown. However no soot blowing shall be allowed for the warm furnace after flameout. 9.2. 2 Shutdown notes: 1) During the shutdown, inspect and adjust temperature drop rate of the
main steam temperature, reheating temperature and metal to control heat stress in the allowable range, main steam temperature drop<1.5min, reheating steam temperature drop<1.5min, metal temperature drop within 1<1.5 min. 2) In the shutdown, the temperature range at any two points shall be
strictly controlled and make sure it in the required limit. 3) After the shutdown, if as the hot standby, all holes, air doors and gas
wind damper of boiler shall be closed tightly, minimize the steam pressure drop as much as possible. 4) After the shutdown, keep going on the inspecting of the steam drum
level to prevent the steam drum overflowing into SH. 5) For shutdown in winter, attention shall be paid to the frost protection
measures to avoid equipment frost damage.
3.1.3.2 Boiler emergency shutdown Boiler emergency shutdown shall be performed under any of the following emergent situations: 1) 2) Boiler rejects motion under trip condition. Boiler water level is excessive high or boiler is lack of water, as is beyond the
stipulated range. 3) All boiler water level gauges are damaged.
4) Tube leakage happens to main feedwater piping, superheated steam piping or reheated steam piping.
5) 6)
Boiler tube rupture, which is dangerous for personal and equipment safety. Safety valve rejects motion when the boiler pressure has risen to its action
value, and steam exhaust valve cant be opened. 7) 8) 9) All FD fans and ID fans or rotary air preheaters stop. Boiler flameout. Deflagration which happened in furnace or flue gas duct, causes the
damage of main equipment or secondary combustion occurs in the back pass. 10) Supply failure happens to boiler thermal control instruments, resulting in surveillance or adjustment of boiler main operation parameters could not be realized. 11) Reheated steam abruptly halts. 12) Furnace negative pressure reaches 2500Pa.
3.1.3.3 Shutdown application Any of the following conditions occurs, boiler shutdown application may be made. 1) Boiler water or steam quality deteriorates badly and they are still
unqualified after treated. 2) Tube leakage occurs to pressure part and can not be eliminated during
operation. 3) 4) Boiler local water level gauge is damaged. Severe slagging and ash deposit happen to boiler, resulting in boiler
cannot run normally. 5) 6) solved. 7) Hanger and support of main equipment are deformed or ruptured. Safety valve has defect and cant normally act. Overheating happens to heating surface tube wall and can not be
3.2 Maintenance after shutdown
3.3.1 Principle of storage The main purpose of boiler storage is to prevent the boiler from corrosion, and the main principles of storage are as follows 1) Prevent air from entering boiler steam/water system. 2) Keep the metal surfaces of boiler steam/water system dry after boiler shutdown. 3) Form anti-corrosion film on the metal surfaces to isolate air. 4) Soak metal in water solution which contains deoxidant or other protecting agent.
3.3.2 Maintenance method selection of shutdown The boiler storage method during shutdown shall be selected according to the shutdown time, maintenance and local circumstance condition. For boiler shutdown in winter, proper antifreezing requirements shall also be considered. The storage of boiler during shutdown shall be considered based on the personnel safety and environment protection. Harmful storage method should not be selected. During shutdown, anti-erosion measures shall be taken not only for the inside of heating surface tube but also for the exterior of heating surface. 3.3.3 Method of boiler storage The boiler storage methods include wet protection and dry protection in general. 1) For wet protection, the boiler steam/water system shall be totally isolated, and
the heating surfaces shall be filled with protective water solution to prevent oxygen from entering boiler. For dry protection, the boiler internal surfaces shall be kept dry to realize the corrosion protection. 2) Wet protection includes ammonia-hydrazine protection and nitrogen pressure protection etc. 3) Dry protection includes nitrogen blanketting, waste heat drying protection,
passivation heating drainage protection / dried air purging protection etc.
3.4.4 Selection of storage method after boiler shutdown For the selection of after boiler shutdown various conditions shall be considered such as duration of boiler shutdown, maintenance of pressure parts during the shutdown term, local natural circumstance situations and climate etc. Normally, wet way protection may be adopted for a standby boiler, which shall be quickly started up by request of the electric grid. Dry way protection may be adopted for boiler scheduled shutdown which gives enough preparation time for boiler startup. The selection of storage method shall follow the stipulations in Fig. 9 and 10.
Maintenance after shutdown of 600Mw nature cycle steam drum boiler, normally as the methods listed in table 53---l. Method for anti-corrosion Operation condition Temporary Afterheat drying method Anti-corrosion technical requirement Adequate afterheat in furnace, <1 week No seeper Outage period Remark
repair, minor system tight, no deficiency on repair discharge gate and air door. Adequate afterheat in furnace
Sub-pressure afterheat drying method Dryer dampness eliminating method Heavy repair, minor repair
equipped with air suction system <1 quarter system tight Relative air moisture in furnace >7080 With some tightness With nitrogen charging system, >1 quarter No seeper
Cold stand by dead storage
Nitrogen flushing method
Cold standby nitrogen purity as the requirement, >1 quarter system tight standby dead
Ammonia water
storage
with feeding system
<1month
Hydrazine and ammonia solution method Steam pressure method
Cold standby dead storage Boiler Hot standby With feeding system and effluent disposal devices >1 quarter
with
some
residual
pressure Boiler with some pressure, and
Feed pressure method
Cold, hot standby
the dissolved oxygen shall meet the <1 week feed water standard
4. Safety Operation of Boiler

4.1 The attrition and attack of boiler heating surface
4.1.1 Fly ash erosion of boiler heating surface The fly ash erosion of coal burning boiler heating surface will cause the heating surface replacing frequently growing the cost of generating and leading to heating surface leakage or tube blasting. The fly ash erosion of heating surface normal has local character, in the zone of high speed flue gas passage and high density ash fineness, normally the erosion is serious; judging from the fray tube, the attrition rate is uneven.
4.1.2 Cold end corrosion of heating surface of boiler Cold end corrosion mainly happens to the cold end of the air preheater. The sulfur content will be produced into SO2 after combustion, some of the SO2 oxidized further into SO3, and SO3 reacted with the water steam in the flue gas forming the H2SO4 steam. When the heating surface metal wall temperature is lower than the dew point temperature of sulfuric acid, the sulfuric steam in the flue gas will condense on the heating surface and rust the metal. To the air preheater of revolution, metal temperature of cold end heat transfer element could be approximately calculated with the (34) empirical formula:
In the formula tbmetal temperature of heat transfer pyflue gas temperature t,kg-- inlet air temperature of air preheater Judging from the formula (34), the temperature raising of flue gas temperature of boiler or air preheater inlet air temperature will correspondingly increase the metal temperature of air preheater cold end heat transfer element.
4.1.3 Hot corrosion of heating surface of boiler External corrosion of water cooling wall, SH, RH tube and suspending parts of
boiler is called hot corrosion. Normally there are two types for high temperature corrosion of the coal burning boiler: (1) sulfide hot corrosion, (2) sulfate hot corrosion.
4.1.3.1 Measures and methods to avoid and minimize the hot corrosion (1) Improve combustion, restrain the over-thick coal fineness, and ensure the flue burning out in the furnace. Prevent the flame directly flushing the water cooling wall and platen superheater. (2) Handle the wall temperature properly to avoid scaling in tube. Partially hot loading over high shall be restrained. Reasonably arrange the heating surface and lower the wall temperature via operation adjustment. (3) Maintain the oxidation ambient, reasonably distribute air, and restrain the reducibility gas around the wall surface, the excess air coefficient shall maintain on a proper degree. (4) Adopt anti corrosion steel material To improve the anti-corrosive power of metal, adopt high alloy anti corrosion steel, e.g. adopt aluminized steel tube, lay carbonized silicon paint outside of the tube.
4.1.4 Internal Corrosion of the Boiler Internal corrosion means the corrosion in the steam water passage of boiler, normally there are steam water corrosion, gas corrosion, scaling corrosion and corrosion by the co-working of electrochemistry and mechanical action. 4.2 Safety operation of heating surface of boiler
4.2.1 Safety operation of water cooling wall, coal economizer Water cooling wall of steam drum is working under the high temperature flame, the stably and reliably operation are determined by the wall temperature of tube. If the tube wall working temperature is beyond the limit of the allowable temperature of metal material of tube, tube will be damaged. If there are cyclical changes for the wall temperature of tube, even the max temperature is lower than the limit temperature; the tube will also be affected by the swing temperature stress and damaged. In a certain hot loading, the temperature of outer wall mainly depends on the heat emission factor and flow rate of working medium. As the heat emission factor is large in boiling, and the wall temperature in normal state is just a little bit higher than the saturation
temperature of working medium, so the wall temperature will never be out of limit. When the working medium of diphase in the tube moving and heat transfer worsening, the water film in the inner wall of the tube will be damaged, the heat transfer coefficient will drop dramatically and the metal of the tube will overheat. The flux situation of water and steam mixture in the tube is related to water flow speed, the volumetric rate of steam in the 2 phases, pressure of working medium and thermal load and so on. To ensure the safety of water cooled wall under various conditions, full consideration for the water cooled wall circulation characteristics has been integrated into the boiler designation, and after the boiler is put into service, comprehensive characteristics test shall be performed for the water cooled wall system, including boiler startup characteristics, load characteristics, water level characteristics, pressure characteristics and effect on boiler water circulation system by means of modification to feed water temperature and intermittent blowdown. During normal operation, the following two measures shall be usually taken to improve reliability of water circulation of boiler water cooled wall, to further guarantee the operation safety of the water cooled wall. 1) Reduce uneven heating of parallel tube bank
Because the uneven distribution of furnace temperature from depth and width, the amount of heating absorb varies on various part of the water cooled wall, as thermal load in the burner area is heavy, and work medium would absorb more heat. To reduce uneven heating phenomenon occurring among the parallel tube bank during operation, the general method should begin with appropriate combustion, to reduce deflection of furnace flame, to eliminate slagging in combustion chamber, to maintain the furnace flame fullness, to keep steam temperature and pressure stable, and perform sootblowing and removing slag timely to keep the heating surface clean.
When the boiler is operated under low load condition, as few burners are put into service and lower furnace flame fullness, the uneven heating on the water cooled wall will increase accordingly. At this time, much attention should be paid on the operation situation of the burners to keep combustion stable. The input to the burners should be kept as symmetrical as possible, and ensure the flame is in good position, and increase flame fullness to improve heating conditions. 2) Prevent steam from being mixed in the downcomer To prevent the steam from being mixed in the downcomer, the normal drum water level shall be kept during operation to prevent the sudden change occurred in pressure and drum. If the water level is too low, steam mixed in downcomer will happen; the sudden change to pressure and load will result in working medium evaporation at the downcomer inlet. Therefore, more attention should be paid for controlling and maintaining these parameters such as water level, steam pressure and steam temperature at a stable condition. For the natural circulation steam drum boiler, there is recirculating pipe connected between drum and economizer inlet, which is shown in Figure. 3-2-l.During normal operation, the boiler shall be fed continuously, and valve A shall be kept open, and valve B shall be kept close. Under boiler startup or accident conditions, feeding water to the economizer must be stopped, which means the closure of valve A. However, the heat transferred from furnace gas may result in working medium evaporation in the economizer and cause pipe mental overheat. To ensure safe operation of the economizer, valve B shall be kept open. Drum working medium shall be constituted into a set of water circulation through valve B to economizer to protect economizer by
means of density difference between heated working medium in the economizer and drum working medium, as well as height difference between economizer and drum. Note: under normal operation, valve B must be kept tightly closed to prevent water from getting into drum by shortcut valve B, which may damage the economizer due to lack of water.
4.2.2 Safety operation of superheater and reheater Superheater and reheater are mainly heating surfaces of the boiler. During startup and shutdown or operation under varying duty conditions, much attention shall be paid to safety operation of heating surface of superheater and reheater. During operation two conditions shall be meet: superheated steam temperature and reheated steam temperature shall meet the requirements for rolling, acceleration,parallelizing and loading of the turbine; secondly, during startup and shutdown of superheater and reheater as well as operation under varying load conditions, the temperature on the wall shall not be more than the allowable temperature of the materials, and the excessive cyclical stress shall not be occurred on the headers and pipes for the sake of their service lives.
4.2.2.1 The safety operation of superheater During boiler startup, the superheater heating surface cooling shall be implemented by means of fluctuation of steam itself. Meanwhile the excessive heat deviation should result in getting overheated on the superheater wall mental parts. Generally, the water accumulated in vertical superheater could not be completely drained by drainage door. The vertical superheater shall be full filled when startup after boiler water pressure test; When the boiler starts up after shutdown, there would be some water condensed on the internal parts of the superheater. Although drainage devices have been equipped for various superheaters, water block would be taken place, which may interfere with the flux of steam after boiler startup. Due to some arrangement issues, water accumulated in each parallel pipe is often distributed unevenly, under which the less water-accumulated pipe should be cleaned with steam, and heavy water-accumulated pipe should still be in water blockage state, all of this leads to different working medium flux in various pipes, which would cause heat deviation occurred among the parallel pipes. For wall superheater, water blockage may occurs due to shrouded superheater and insufficient drainage for lower header. During boiler operation, the uneven distribution of gas flow and temperature at flue gas duct side caused by insufficient
combustion and partially heavy ash deposited on the flue gas duct should result in heat deviation. The general methods to eliminate heat deviation are described as follows: (1) During boiler startup and prior to complement of drainage, the increment of boiler pressure shall be limited, and water drainage shall be sufficiently conducted under lower pressure conditions, and water shall be spontaneously evaporated in the coil pipe, by these means, the amount of water accumulated should be reduced and the pipes should be cooled by water evaporation. To accelerate evaporation of water accumulated on the heating surface, the utilization of turbine pumped vacuum system shall be performed for the boiler during startup, which is a usual way for this. (2) For embracing superheater, lower header drain door shall be kept open fully to facilitate drainage process during boiler startup. When the main steam pressure raises up to 0.5MPa, the drain door may be turned down a little. All drain doors shall be turned off prior to the startup of the turbine. (3) To facilitate to drainage for the superheater drainage and pipeline warming, superheater outlet header drainage valves shall be kept fully open. After SH bypass being put into service, SH header drainage shall be turned down appropriately. Upon startup of turbine main stop valve front drainage, SH header drainage shall be closed. The main steam pipeline shall be drained and warmed by turbine main stop valve front drainage system. (4) Adjustment to combustion condition in furnace. During boiler startup, according to requirements, the gas temperature deviation between left side and right side at furnace outlet shall not be more than 30, and 50 shall be the maximum limit. During adjustment to combustion, the temperature at both sides may be balanced by usual means of modification to load of ID, FD fans of both sides or adjustment to burner position and operating method.
4.2.2.2 Safety operation of reheater During operation of reheater, the pressure in the reheater has not been established yet and the reheater would operate out of service until the startup of bypass system. Meanwhile, to protect the wall being overheated, gas temperature at furnace outlet shall be strictly controlled below 540. Working state and safety operation procedures of reheater will be identical to those of SH.
4.2.2.3 Safety operation of SH and reheater heating surface To prevent overheating on wall, firstly, adjustment measures facing reduction of deviation between SH and RH shall be taken, and avoid flame flushing over the wall or reburning of combustible materials at rear flue gas duct; establish and complete soot blowing requirements to prevent the occurrence of uneven heating due to dust deposited or slagging. Measures to improve quality of steam shall be taken to reduce slagging on heating surface. Steam temperature shall be strictly controlled to prevent accident caused by over-limited temperature. When accident occurs, measures should be implemented swiftly and resolutely according to relevant requirements to reduce risk on damage on heating surface of SH or reheater due to mistreatment or failure to treat it in time.
4.2.3 Precaution measures on leakage and burst of boiler four pipes Those accidents regarding to the four pipe (economizer, water cooled wall, SH and RH) have accounted for approximately 30% of all boiler accidents, even reached 50 70 in some unit. Therefore, precaution for boiler leakage and burst shall be taken carefully, which is significant for reducing unit unscheduled shutdown and improvement to equipment health. There are many reasons that could result in leakage and rupture occurred on boiler four pipes. common reasons including: material defects or ageing pipe materials, poor welding, stuck by foreign substance or sediment in pipe, wall get more thinner due to erosion or flushed by high temperature gas and steam or dust abrasion, being sudden overheated in short term or overheated for a long term, unreasonable designation or arrangement for heating surface, inappropriate operation and so on. To prevent boiler four pipelines being leaked or ruptured frequently, inspection, monitoring, analysis and statistics works shall be taken, and for those suspected issues and leakage or rupture reasons, feasible preventive measures shall be made. Additionally, the following work shall be implemented according to the operation: 1) The boiler parameters and temperature of various heating surface shall be strictly controlled within the allowable range, and any accidents regarding to over-temperature, over-pressure, over-filled water, water shortage shall be prevented. The boiler startup and shutdown parameters shall be strictly controlled according to startup and shutdown curve. Surveillance and adjustment shall be strengthened under varied conditions to avoid
occurrence of apparent change on parameters and overheating on boiler tubes 2) After boiler startup or the cooling after shutdown, inspection and record shall be performed for various headers and expansion indicators according to
relevant requirements. Expansion or shrinkage states of various parts shall be monitored to ensure they are under normal conditions. 3) Surveillance of boiler water and steam shall be strengthened to ensure qualified water and steam. Water quality issues shall be reported to
operator timely and be submitted higher authorities. Meanwhile, the reasons shall be figured out and be resolved as soon as possible. When steam and water quality would become worse and dangerous to facility operation, emergency measures shall be taken up to shutdown. 4) Adjustment to combustion shall be strengthened to avoid flame to being deflected, stick to wall and sweep the heat surface. The amount of air shall be controlled appropriately to avoid occurrence of over-amount air or starved-air-combustion. Burner startup and shutdown shall be arranged symmetrically and evenly, by which the heat deviation would be decreased as much as possible and the occurrence of overheating on heating surface would be avoided. 5) Boiler slag shall be timely purged and cleaned to prevent water wall tubes of water-cooled hopper bottom from being crushed by accumulated bigger blocks 6) Management on soot blowing shall be strengthened. Appropriate measures about soot blowing procedures, parameters and soot blowing cycle shall be made to prevent heating surface from being damaged due to misoperation or defects on soot blower. 7) .Surveillance for heating surface temperature and working medium temperature of water wall tubes, SH and reheater and etc shall be strengthened. Over-limit issues shall be found and analyzed timely. Recovery shall be implemented as soon as possible by adjustment to operation and relevant record shall be made carefully. 8) Equipment inspection and surveillance mechanism shall be seriously implemented. Once heating surface leakage is found, maintenance staff and relevant personnel shall be noticed in time and measures shall be performed according to related requirements.
9)
For those burst faults or accidents regarding to heating surface leakage due to misoperation, cause shall be found out and liability shall be identified to work out an effective method to respond to such accidents.
4.3 Safety operation of boiler pressure parts
4.3.1 Safety devices for boiler super-pressure issues (1) Boiler Safety valve (2) Air relief valve (3) Turbine bypass valve
4.3.2 Boiler hydrostatic test and Super-Hydraulic Test Boiler hydrostatic test and super-hydraulic test shall be strictly performed according to manufacture code or requirements for supervision code for boiler of the power industry. Usually, after major or minor maintenance or partial heating surface maintenance, hydrostatic test for the boiler shall be performed at rated working pressure; super-hydraulic test shall be performed every six years. Super-hydraulic test shall be performed at rated pressure required by the boiler manufacture, or at 1.25 times drum pressure on boiler proper, and 1.5 times inlet pressure on reheater. During Boiler hydrostatic test and super-hydraulic test, speed of pressure increment or drop shall be kept slow. On super-hydraulic test, when water pressure reaches working pressure, increment of pressure shall be suspended. Super-hydraulic test should be continued once there is no more water leakage or other abnormal case. Pressure shall be maintained at as same as Super-hydraulic test required for 5 minutes and returned to working pressure level and then inspection shall be performed again. During inspection, pressure shall be kept stable without any variation. After Super-hydraulic test, macroscopic inspection shall be carried out for residual deformation of various pressure parts. During boiler hydrostatic test, designated personnel shall be responsible for surveillance and adjustment to pressure, which shall implement relevant measures to lower the pressure when abnormal pressure increment occurs. After hydrostatic test, usually, water accumulated in boiler and pipelines shall be drained completely when there is no special requirement. During hydrostatic test, circumstance temperature shall be no less than 5, otherwise specific measures against freezing problems must be made. Water temperature of hydrostatic test shall be controlled according to values required by
manufacture. Normal temperature shall be 3070 to avoid water impact resulted from steam due to overheated water. Furthermore, steam would be leaked from leakage point due to overheated water during hydrostatic test. Therefore, it will be difficult to find out those leakage points, and the overheated water is not safe for those maintenance personnel who get inside the boiler for leakage inspection.
4.3.3 Prevent pressure parts from being over-pressed during boiler operation During boiler operation, the integrity and function of various pressure meters shall be maintained. Periodic maintenance and inspection shall be performed to ensure surveillance for various pressure parts would be exact during boiler operation. During pressure variation on press parts, pressure velocity shall be strictly performed according to manufacture requirements. Due to pressure variation velocity, either safety operation of boiler pressure parts, or boiler operation conditions and parameter variation should be affected. It is important to pay attention to this issue. During normal operation, surveillance and adjustment shall be performed for various pressure parts. Abnormal cases shall be analyzed and dealt with timely. Over-pressure operation for press parts shall be strictly prohibited. Pressure parts would be damaged when the pressure has overpassed the metal strength limits. Measures shall be conducted according to related accidental requirements in case of boiler pressure jump due to unit accidents, and boiler pressure shall be recovered within normal pressure value. 4.4 Prevent boiler and tubes from water impact Violent variation on fluid speed and pressure in pressure parts and pressure tubes, can result in sudden or cyclical vibration of equipments or tubes, which is called water impact. Reasons causing water impact and vibration are many, such like pressure of tube working medium, violent flow change. However, for the water impact happened in boiler and its tubes, it is usually caused by existence of two-phase fluid inside pressure parts or internal working medium violent change. The characteristic of water impact is described as follows:
4.4.1 Water impact caused by steam passing through steam tubes If warming steamtube procedure is conducted insufficiently prior to service, or water is not completely drained or too much fast drainage operation, water impact will happen. Because there is some water remained in cool tubes prior to the entry of steam and the steam will condense into water when contacting with cool tube
While insufficient drainage or too fast operating occurssteam with high temperature will condensed immediately when contacting with supercooled condensate water which will result in cavity due to Abrupt drop of partial pressure. Under Medium around cavity will fill it quickly due to pressure difference, which can cause sudden change on flow speed and pressure and then the formation of water impact which is responsible for serious tube vibration.
4.4.2 Water impact caused by low-temperature water getting into steam When certain amount of water moves into tubes or heating surface in which the working medium is in gaseous state, water impact will happen due to working medium rapidly flowing to cavitation caused by sudden condensed vapor which will result in partial pressure drop.
4.4.3 Water impact caused by sudden drop of steam temperature Opening the valve while steam temperature falls or temperature difference before and after the valve is huge, can result in tube water impact. The main reason would be that working medium flushes to lower pressure area which is formed by sudden pressure drop of partial steam when getting into the tube with temperature sudden drop. 4.5 Countermeasure for explosion on boiler
4.5.1 Principle on furnace explosion When some burners get extinguished or the whole boiler flameout occurs, furnace explosion may happen if fuel for extinguished burner is not cut off timely,
4.5.2 Preventive measures to furnace explosion In accordance to analysis to furnace explosion, combustible mixture must not be produced and accumulated in furnace. In general, the following requirements shall be met: 1) Stable boiler combustion conditions shall be maintained to ensure fuel could be combusted swiftly and completely. 2) 3) Fuel must not be put into furnace when flameout Any factor that may cause combustion shall be eliminated when a certain amount of combustible substance left in furnace, and in this case ventilation and purge shall be
performed appropriately to lower the combustible concentration. 4) Making good use of protection system for furnace safety Microprocessor based logical program control equipment and safety interlock device have been adopted by protection system for boiler furnace safety to eliminate and prevent against occurrence of boiler explosion. Therefore full utilization of protection system for large boiler furnace safety shall be necessary. Protection system for furnace safety shall be carefully commissioned, operated and maintained to constantly improve healthy operation, and ensure precision and reliability for service and motion. 5) BMS includes the following requirements All oil guns of a group of burners, which are corresponding to a mill, must be put into service before pulverized coal feeding. Each oil gun shall be deployed with one oil flame detector, and each fuel burner shall be deployed with one coal flame detector. There are 30 coal flame detectors and 30 oil flame detectors in total, with cooling air supplied. During normal shutdown of a mill, it is necessary to confirm that the oil guns of relative burners are in work condition, namely before shutting down a mill, oil guns of its corresponding burners shall be ignited. If one of main auxiliary facilities (air fan, air preheater, and soot remover) fails, the unit load shall drop to target load (50%). If a mill fails, the oil guns of its corresponding burners shall be put into service when this mill is cut off. The shutdown of oil guns shall be manually performed separately.. 4.6 Slagging in furnace
4.6.1 Principle of slagging Slagging means those melting adhesive ash particles mixed with high temperature flue gas collide on the furnace wall or heating surface and stick together as slag layer. Slagging is very common among those coal boilers.
Slagging effect on boiler operation: 1) Slagging can cause increment of steam temperature, even result in explosion 2) Slagging can cause flameout and damage the heating surface and personnel safety 3) Slagging can result in drop of boiler output, even shutdown when it becomes
worse 4) High temperature erosion will happen on the heating surface. 5) Boiler economics will be affected.
4.6.2 In accordance with factors that will result in slagging, preventive measures are described as follows: 1) The smaller heat load shall be chosen to avoid heating surface being flushed. Meanwhile, temperature of the whole furnace will be lowered down and possibility of slagging will be decreased. 2) Equivalence ratio of combustion areas chemical reaction shall be chosen reasonably. Not only a low NOx exhausting outlet shall be ensured, but also possibility of slagging shall be reduced to the lowest level. 3) Appropriate temperature of gas exhausted from furnace may be chosen for eliminating any possibility of slagging on convective heating surface. 4) Membrane secondary and final superheater shall be adopted to prevent part tube from being out of array and deformed and occurrence of slagging 5) Soot blower across pendant superheater shall be integrated with membrane designation plane to ensure efficiency of soot blowing 6) Water-cooled wall bent tube shall be placed around the throat of burner and in conjunction with silicon carbide bricks with high heat conductivity, which may decrease the surface temperature around burner throat to avoid slagging at burner area efficiently. 7) Lower flame maximum temperature shall be produced by low NOx burner in burner area. 8) The distribution of burner fuel and air shall be controlled to ensure even combustion within furnace width and avoid formation of reducing zone. 9) Fineness and evenness of pulverized coal shall be kept at an appropriate level 10) Soot blowers shall be arranged at those areas where slagging may often occurs.
Appendix Various Start-up Curves and Others

Boiler Operating Course

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OPERATION OF BOILERS OPERATION OF BOILERS........................................................................................................................... 4 1.1 PREPARATION BEFORE OPERATION OF BOILERS ........................................................................... 4 1.1.

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Hydrostatic test Normal operation

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1.5.2 Characteristics of Drum Boiler Startup 1 Thermal Stress Problem

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48t72 8t48 2t8 t<2

P0.5 0.5P9.0 9.0P14.0 P14.0

T150 150T300 300T400 T400

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1.5.6.3 Boiler Ignition

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Drum Temperature () 100184 184265 265312 >312

Pressure rise rate (MPa/min) 0.0150.020 0.0600.080 0.160.18 0.20

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1.6 Basic Operation for Water Drainage and Steam Exhaust

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Operation Mode 3 Automatic

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Operation Mode Manual/ 8

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2. Boiler Operation Adjustment

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-Convection heating surface

attemperating water flux

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Factors influencing the temperature variety of reheating

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External factor: boiler external factor is also called external disturbance,

The Adjustment of Boiler Loading and Steam Pressure

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High level alarm

High level trip

Low level alarm

Low level alarm

Low level trip

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