Beruflich Dokumente
Kultur Dokumente
A type
Description
Problem on
turbine side
Turbine trip
Problem on
boiler side
Fire extinguishing
of boiler
B type
Generator trip
Problem on generator
side
Generator trip
Problem on turbine
side
Turbine trip
Fig. 35
C type
Fire extinguishing of
boiler
Generator trip
Problem on turbine
side
Turbine trip
Fire extinguishing of
boiler
Description
If a problem occurs in any of the
boiler, turbine, or generator,
mutual interlock is activated to
trip the unit completely.
This interlock where the turbine
is tripped immediately if a
problem occurs in the boiler is a
characteristic feature, which
cannot be seen in the A type or B
type.
Description
Problem on generator
side
Generator trip
Problem on turbine
side
Turbine trip
Fire extinguishing of
boiler
Turbine
driven feed
pump
Seal oil
equipment
Contents of test
Twice/week
The valves are manually opened or closed one by one from the central control
room to check the valve operation and open/closed indication lamp operation.
Twice/week
The valves of each system are manually opened or closed from the central
control room to check the valve operation and open/closed indication lamp
operation.
Once/week
Twice/week
After the operation of the emergency shutdown device has been removed, the
test handle is operated to check the operation of the oil trip mechanism.
After the operation of the thrust failure protection device has been removed,
the test handle is operated to check the operation of the thrust bearing wear
trip mechanism.
Valves are manually opened or closed with the test handle or switch to check
the valve operation and open/closed indication lamp operation.
Once/week
Once/week
The indication rod of the oil gauge is moved up or down to check the alarm
operation.
Valve test
Once/week
The high-pressure and low-pressure steam stop valves are opened or closed
manually to check the operation of the valve and open/close unit.
Once/month
After the trip circuit has been removed, the RPM is increased in the simulated
mode to check the overspeed trip set hydraulic pressure level.
After the trip circuit has been removed, the bearing oil pressure is decreased
in the simulated mode to check the trip set hydraulic pressure level.
After the trip circuit has been removed, the thrust position is moved in the
simulated mode to check the trip set hydraulic pressure level.
The hydraulic pressure is decreased using the testing equipment in the
simulated mode to check the automatic startup at the set hydraulic pressure
levels of the extra main oil pump and emergency oil pump.
The pump is manually started at the work site, and a load is applied to check
the operation of the auxiliary oil pump and minimum flow recirculating valve.
The discharge pressure and differential pressure of the seal oil are decreased
using the testing equipment in the simulated mode to check the alarm
operation and auto startup at the set hydraulic pressure level.
Once/week
Once/month
Once/month
Once/month
Once/month
Once/week
Once/month
The vacuum level is decreased using the testing equipment in the simulated
mode to check the alarm operation.
13
I.
14
If the AH differential pressure becomes excessively large (normally, the reference level is the
planned value multiplied by 1.5) or if the ventilating equipment capacity reaches its limit, it must
be investigated whether to water wash the AH.
For the pressure loss of the water and steam systems (particularly pressure loss of the furnace),
the increased speed caused by the secular change is grasped and it is used as a factor to judge the
chemical washing timing, etc.
2.1.2.3 Others
It is important to strictly control the water quality during boiler operation including startup
according to the standard for water treatment.
2.1.3 Auxiliary units of the boiler
Generally, the auxiliary units of the boiler are the feed water, ventilation, and fuel systems.
This section describes the ventilating equipment, air preheater, and coal pulverizer of the coal-fired
boiler plant.
15
I.
Boiler
Boiler
Gas
Secondary
air
Mill
Primary air
Mill
Fig. 10
A-air pre-heater
startup
B-air pre-heater
startup
A-induction fan
startup
60s
Moving vane of
A-induction fan fully
closed
B-induction fan
startup
60s
Auto operation of
moving vane of
A-induction fan
Auto operation of
moving vane of
A-forced draft fan
Moving vane of
A-induction fan fully
closed
Moving vane of
B-induction fan fully
closed
60s
Ventilation system
startup completion
Auto operation of
moving vane of
B-forced draft fan
Auto operation of
moving vane of
B-induction fan
Moving vane of
B-forced draft fan
fully closed
Fig. 11
Moving vane of
A-induction fan fully
closed
A-induction
fan stop
Moving vane of
A-forced draft fan
fully closed
30s
Fig. 12
Moving vane of
B-induction fan fully
closed
B-induction
fan stop
Moving vane of
B-forced draft fan
fully closed
Ventilation system
stop completion
The primary air also has the purpose of drying raw coal to allow easy pulverizing of raw coal to be
loaded into the coal-pulverizing machine in addition to the purpose of transferring the pulverized
coal.
The primary air temperature at the inlet of the coal-pulverizing machine is 180C to 250C. The
fan installation places and the number of fans to be installed in the cold primary air system are
different from those of the hot primary air system.
In the cold primary air system, one or two fans are installed on the upstream side of the air
pre-heater regardless of the number of coal-pulverizing machines. This fan is intended to control
the primary air duct pressure. On the other hand, in the hot primary air system, one fan specific
to one coal-pulverizing machine is installed on the downstream side of the air pre-heater. This fan
16
Center section on
high-temperature side
Primary air outlet
Guide bearing
Soot blower on
high-temperature side
Main pedestal
Side pedestal
Connecting duct
Rotor
Pin rack
Gas
outlet
Center section on low-temperature side
Rotor post
Fig.13
Primary air
inlet
Secondary air
inlet
Support bearing
Gas inlet
Primary air outlet
Collar seal
Soot blower
Sealing frame
Secondary air
inlet
Fig. 14
Rotation unit
In the regenerative air pre-heater, air leaking to the gas side cannot be avoided due to its structure.
17
I.
18
Coal
feed
port
Rotary classifier
Housing
Reject chute
Coal feed pipe
Roller pressurizing unit
Roller
Table segment
Primary air port
Table
Primary air inlet
Motor
Speed reducer
Fig. 15
Coal feed
pipe
Motor
Mill drum
Fig. 16
If the mill is stopped in case of an emergency, the above steps cannot be performed correctly. Pulverized
coal and raw coal exist inside the mill in relatively high-temperature status. Therefore, great caution shall
be taken since nature conservation or mill explosion may occur. This risk increases as the volatile
components included in the raw coal are large.
To prevent a fire inside the mill or to extinguish a fire, inert gas (inert steam) injection equipment or
fire-extinguishing water injection equipment are often installed. It is necessary to establish procedures if
the mill is stopped in case of an emergency.
2) Mill motor overload
When using coal (coal with low HGI) with poor grindability in the roller mill, the mill motor may be
19
I.
Pilot ignition
burner ignition
Mill purge
Mill motor startup
Coal supply
volume above
specified value
Mill outlet
temperature above
specified value
Fig. 17
Fig. 18
Since the combustion volume rather than the primary air volume is controlled in the horizontal mill, the
auxiliary air damper is opened to keep the minimum flow velocity inside the pipe if the flow velocity
decreases.
6) Coal feed volume and coal consumption volume
When the mill is operated at a constant load, a relationship is established in which the coal feed volume is
equivalent to the coal consumption volume (combustion volume). However, this relationship is not
established when the mill is started or stopped or when the mill load varies.
Precise grasping of the combustion volume is an essential condition for boiler control. In particular, it is
20
absolutely necessary to control the steam temperature in the once-through boiler. Generally, the
combustion volume is measured by the coal supply machine. However, when the mill is started up, the
coal supply start does not meet the coal consumption start.
In the control system, when the mill is started up or stopped, the simulated coal consumption signal is used
as combustion volume in order to adjust the coal consumption close to the coal consumption characteristics
suitable for actual conditions. The coal consumption characteristics may vary depending on the type of
coal. Changes in steam temperature and exhaust gas O2 may occur when the mill is started up or stopped.
Therefore, these points must be taken into consideration.
7) Mill pyrite
Rocks or other foreign objects other than the raw coal supplied to the mill are discharged to the outside of
the mill without being pulverized. These discharged foreign objects are called pyrites. In the
horizontal mill, such foreign objects are not discharged to the outside and they are accumulated as materials
for pulverizing. In the vertical mill, pyrites are snapped from the primary air port inside the mill to the
primary air chamber, and then they are discharged to the outside. If this processing unit malfunctions,
pyrites and coal are accumulated in the primary air chamber. As a result, a fire may occur by the hot
primary air. Therefore, it is important to check that the pyrite-processing unit functions correctly.
According to the circumstances, the mill needs to be stopped.
Figures 17 and 18 show examples of the vertical mill startup sequence and stop sequence.
21
Run-off-river
hydraulic power
Peak
Pumping-up
hydraulic
power
(Energy)
Adjustable
hydraulic
power
Nuclear power
Coal fired
power
Base
(Electric power)
(Time)
Fig. 27
Example of daily load curves and combination of power generation methods by time zone
lowest price.
Delay
Curve AB:
Curve BC:
Curve CC:
Advance
Fig. 29
24
Main steam
temperature
Start
Parallel
Ignition
Parallel-off
Main steam
pressure
Fig. 3
Start
Parallel
Ignition
Parallel
-off
Main steam
pressure
(This thermal stress is caused by differences in temperature between the steam and turbine rotor when the unit
is started. Normally, this temperature difference is called mismatch temperature.) According to the low cycle
fatigue index (LCFI) of the turbine rotor, the number of yearly start and stop cycles is limited to take measures
against this problem. In the second case, the start and stop time is short and the operation reliability needs to be
kept at a high level.
To solve these problems, it is necessary to take appropriate measures, such as improvement of the unit
reliability, omission of operation steps, and/or review of standards.
(4) Quick start
This quick start is used to restart the unit after it has been stopped for a short time (about less than 6 hrs.) due to
system problems or power control. Normally, the quick start is called very hot start.
In this case, the thermal stress of the turbine requires special attention.
The metal temperature of each part meets the steam temperature immediately before the trip. However, since
the boiler and piping after restarting are cooled as the stop time elapses, the steam temperature is mismatched with
the metal temperature due to decrease of the steam temperature and throttle of the control valve. Therefore, it is
preferable that the steam temperature is increased to a high temperature level and the speed is increased rapidly,
and the parallel and load are increased.
Main steam
pressure
RPM
Parallel/
output
increase 1
Fig. 4
Output
increase II
26
Power supply
distribution
Wet/dry change-over
Voltage transformation start
Coal single fuel firing
Preparations for
parallel
Turbine start/speed up
Temperature increase/
pressure increase
Boiler ignition
High-pressure cleanup
Low-pressure cleanup
Output
increase III
Table 1
Start type
Item
Unit
Warm 2 start
(Stopped for 32 hrs.)
Warm 1 start
(Stopped for 56 hrs.)
Cold start
(Stopped for 150
hrs.)
- 230
8.5
400
200
C
MPa
C
C
460 8.5
510
505
390 460
8.5
470
480
340 390
8.5
410
377
230 340
8.5
410
289
438
391
315
315
301
494
453
368
326
216
C
rpm/min.
min.
min.
%
min.
-56
300
0
0
3
0
-62
300
0
0
3
0
-53
150
0
0
3
15
-11
150
0
0
3
15
+85
100
20
55
3
60
The boiler start mode is determined by the fluid temperature at the inlet of the water separator, and it is then
used for the fuel program for start or start by-pass valve control.
(2) Preparations for unit start
Inspect and check each part so that the work during unit stop is completed and there is no obstacle hindering the
start.
Confirm that units related to common facilities are being operated correctly or that they are ready for operation.
Confirm that the interlock, alarm device, and monitoring instrument function correctly, and that the fuel and
demineralized water necessary to start are maintained.
(3) Pre-boiler cleanup
In the once-through boiler, it is necessary to supply high purity water from the start.
Therefore, cleanup is carried out to remove impurities (particularly, iron content) from each system prior to the
ignition.
In the pre-boiler cleanup, the vacuum in the condenser is increased, and then the condenser system,
low-pressure supply water system, and high-pressure supply water system are cleaned up from the upstream side
in order.
In each system, the circulation operation is carried out through the condensate demineralizer so that the water
quality becomes the standard value or less after the standard to pass the water to the condensate demineralizer has
been satisfied using the blow outside the system.
Additionally, the turning operation of the turbine is performed to prevent deflection of the turbine rotor before
increasing the vacuum.
(4) Boiler cold cleanup
When the water quality in the pre-boiler satisfies the boiler passing water standard, the water is fed to the boiler
to perform the cleanup at a normal temperature. Table 2 shows the water quality standard when the once-through
boiler is started.
After the boiler has been filled with water (this work is not needed when the boiler filled with water has been
stored), the blow outside the system is performed through the drain system of the water separator. After the
water quality of the blow water has satisfied the standard for the water passed to the condensate demineralizer, the
circulation operation is performed until the water quality is the standard value or less through the condensate
demineralizer.
(5) Preparations for boiler ignition
The supply water system is changed from the cleanup status to the boiler ignition status.
The ventilation system is started to purge the furnace. The remaining unburnt gas is purged at a specified air
flow rate for a specified period of time in order to prevent explosion in the boiler furnace. (Example, 30% MCR
flow rate for 5 min.)
The fuel system for start (oil or gas) is started up to check the system for leak.
Generally, light oil is used for the start.
(Note) Cleanup is essential for a cold start. The cleanup is usually omitted for the WSS or DSS start. The operation often
enters the ignition preparations from the low-pressure cleanup circulation status during unit stop.
temperature. If the water quality becomes the standard value or less, the temperature increase is restarted.
(7) Temperature increase and pressure increase
The temperature increase and pressure increase of the boiler are performed to achieve the steam conditions at
turbine start determined by the turbine start mode. By adjusting the fuel charging volume, the start bypass valve
and drain valve in the steam system, the temperature increase and pressure increase are completed within the
target time.
The feed water flow rate and air flow rate are controlled to their minimum flow rates. At this time, the
re-heater protection (prevention of burning) and the thick wall part protection (relaxing of thermal stress) exist as
limitation items when started. The former is limited by the gas temperature at the outlet of the furnace, as well
as the fuel charging volume. The latter is limited by the temperature increase ratio at the inlet of the water
separator and the outlet of the super heater.
(8) Preparations for turbine start
In the cold start, the metal temperature of each turbine part decreases to a level close to room temperature.
When starting the turbine in this status, thermal stress occurs as a result of the difference in temperature when
compared to the steam.
Class
Table 2
Temperature increase/pressure
increase circulation
(Boiler hot cleanup)
Greater than
Greater than
15 and 20 or
20
less
8.5 9.6 (19)
9.0 9.6
0.1 or less
0.1 or less
100 or less
100 or less
10 or less
10 or less
100 or less
50 or less
20 or less
10 or less
20 or more
20 or more
30 or less
30 or less
0.1 or less
0.1 or less
100 or less
100 or less
200 or less (40)
100 or less (41)
Load operation
[1/2MCR (42) or less]
Greater than
Greater than
Greater than
Greater than
15 and 20 or
15 and 20 or
20
20
less
less
8.5 9.6 (19)
Economizer
9.0 9.6
8.5 9.6 (19)
9.0 9.6
pH (at 25C)
inlet
0.1 or less
0.1 or less
0.1 or less
0.1 or less
Electric conductivity (mS/m) (11)(19) (at 25C)
11 19
100 or less
100 or less
100 or less
100 or less
(S/m) ( )( ) (at 25C)
36
38
40
or
less
(
)
20
or
less
(
)
7
or
less
7 or less
Dissolved oxygen (gO/l)
200 or less
100 or less
30 or less
30 or less
Iron (gFe/l)
20 or less
20 or less
5 or less
5 or less
Copper (gCl/l)
20 or more (38)
20 or more (38)
10 or more
10 or more
Hydrazine (gN2H4/l)
30 or less
30 or less
30 or less
30 or less
Silica (gSiO2/l)
Furnace
0.1 or less
0.1 or less
Electric conductivity (mS/m) (11)(19) (at 25C)
11 19
water wall
100 or less
100 or less
(S/m) ( )( ) (at 25C)
outlet
300 or less
300 or less
Iron (gFe/l)
(38)
Note
This value becomes the target according to the boiler shape.
(39)
When starting the unit after it has been stopped for a long period of time, it is preferable to adjust the hydrazine concentration to a higher level in order to promote forming
of a protective coat inside the system.
At this time, the hydrazine is dissociated in the water and it exists as the hydrazinium ion (N2H5+).
(40)
The target concentration of the iron is 100gFe/l or less.
(41)
The target concentration of the iron is 50gFe/l or less.
(42)
This shows an abbreviation of the maximum continuous rating that means the maximum continuous load.
Feed water
To reduce this thermal stress, the warming of the casing and control valve must be carried out before starting
the turbine.
Additionally, it is important to check for faulty parts, such as the shaft position or eccentricity using the turbine
monitor instruments before starting the turbine through turning.
(9) Turbine start and speed up
Items to be considered most at turbine start are thermal stress and vibration problems.
Therefore, the warming (heat soak) is performed until the rotor temperature reaches the transition temperature
[temperature, at which the mechanical properties of the material lower rapidly (becomes fragile)] to prevent the
fragility of the turbine rotor from being broken or to reduce the thermal stress of the rotor surface and the stress at
the center of the rotor.
This heat soak is classified into two groups. The first group is the low-speed heat soak in which the turbine is
started with low-speed RPM kept in order to prevent the turbine rotor from being broken. The second group is
the high-speed heat soak in which the turbine is started at a rated RPM to prevent excessive thermal stress of the
rotor as the parallel and output increase.
As described above, the heat soak time and speed up rate are determined by considering the thermal stress in
order to control the service life of the rotor.
Additionally, it is necessary to determine a start schedule most suitable for the turbine so that vibration is
minimized.
To determine this turbine start schedule, the start load operation chart (mismatch chart) is provided. The heat
soak time and speed up rate are usually determined by the metal temperature at the first stage, as well as the main
steam temperature and pressure when the turbine is started up.
Table 1 shows examples of the speed up rate and heat soak time in each start mode. It is important that the
turbine is started according to the schedule created based on this chart and the operation is performed while
carefully checking the steam temperature so that the difference in temperature between the internal and external
28
metal surfaces of each turbine part and the steam temperature change ratio do not exceed their limit values.
The vibration and expansion difference are monitored during increasing of the turbine RPM.
Great care should be taken as the amplitude tends to be large at a speed close to the critical speed of the rotor.
In the boiler, as the turbine speed increases, the fuel charging volume is adjusted to keep the necessary steam
volume. For a cold start, the fuel charging volume is minimized before starting the turbine in order to reduce the
thermal stress applied to the turbine. It is also necessary to prevent excessive increase of the main steam
temperature by suppressing the increase of the fuel charging volume during speed up to the minimally required
level.
(10) Preparations for parallel
If heavy oil facilities are provided, light oil is changed to heavy oil before starting parallel output. Variations
in main steam temperature and main steam pressure are checked when changing light oil to heavy oil.
It must be checked that the ash processing facility, desulfurization facility, and denitration facility have been
started and they are in standby mode before charging the coal after parallel output has been started.
If the coal on the belt of each coal supply machine is discharged, each coal supply machine needs to be put in
coal on status.
(11) Parallel, output increase 1
When the turbine reaches the rated RPM, the generator voltage is increased to its rating, and then the turbine is
synchronized with the system to put in parallel status.
After the initial output is kept using the initial output volume corresponding to the turbine start mode, the
output increases to 20%ECR.
In the output increase process, the turbine valve is changed, the low-pressure/high-pressure feed water heater is
started, and the coal burner at the first stage is started.
Variations in main steam pressure in the process utilizing the bleed air and in the coal charging process are
checked carefully while the output is increasing. Additionally, it is also necessary to carefully check the NOx
and SOx control after the coal has been charged.
After the output has reached approx. 20%ECR, the boiler supply water pump is changed from the electric drive
(M-BFP) to the turbine drive (T-BFP). After that, the power at the station is changed (start transformation
station transformation).
(12) Output increase II
The output increases to 50%ECR. The wet/dry of the boiler is changed at an output of approx. 25%ECR (the
boiler status is changed from recirculation to once-through status and the control system is also changed to
once-through control). By changing the wet/dry of the boiler, the boiler circulation pump (BCP) is stopped.
According to the voltage transformation mode, the main steam pressure starts increasing at an output of approx.
30%ECR. This operation is controlled by the boiler input command. However, in the output and main steam
pressure increase process after the wet/dry has been changed to dry, it is necessary to carefully check the
balance between the feed water flow rate and fuel flow rate, as well as variations in the steam temperature of each
part.
As the output increases, the coal burners are ignited in order and the oil burners are turned off to burn only coal.
Additionally, the second T-BPP unit is put in the service in status.
After the output has reached 50%ECR, the stable operation of the unit is checked and the water quality of each
part is checked. When the water quality satisfies the standard value, the drain is collected from the high/low
pressure supply water heater.
(13) Output increase III
The output increases to 100%ECR. As the output increases, the coal burners are ignited in order.
After the output has reached 100%, the operation status of the unit is checked and the patrol inspection is
performed at the work field to check that no errors exist. After that, load dispatching ferry is done.
Output drop I
Output drop II
Boiler off
Parallel-off
Turbine trip
BFPT/M change-over
Coal single fuel firing
Dry/wet change-over
Starting of preparations
for unit stop
Output
Output
drop III
Fig. 5
30
Vacuum
retention
Vacuum
break
Pressure
Load
Temperature
Load
Main steam
pressure
RPM
1%/min.
RPM
0.5%/min.
Time
Load drop start
Parallel-off.
360 min
Fig. 6
Example of turbine forced cooling stop
Additionally, the preparations for auxiliary steam supply from another boiler or a boiler in the plant are
performed.
(2) Output drop I
The output drops to 50%ECR.
When the output is approximately 95%ECR, the main steam pressure starts dropping according to the voltage
transformation mode. According to the output drop, the coal burners are turned off sequentially.
(3) Output drop II
The output drops to 20%ECR.
According to the output drop, the oil burners are ignited and coal burners are turned off.
Additionally, the first T-BFP unit is put in the service out status.
The drain tank level of the water separator increases when the output is approximately 25%
ECR. The BCP is started to change-over the dry/wet.
After the M-BFP has been put in the service in status, the second T-BFP is put in the service out status.
The output reaches 20%ECR. The transition to heavy oil single fuel firing is completed and the power
change-over in the plant (station transformation start transformation) is completed.
(4) Output drop III, parallel-off
The output is dropped to the parallel-off target value (5%ECR).
The high-pressure/low-pressure supply water heater is stopped according to the output drop.
Additionally, oil burners are turned off in order.
When the output reaches the parallel-off target value, the parallel-off is performed.
(5) Turbine trip, boiler off
After completion of parallel-off, the turbine is tripped. After checking that the auxiliary steam is changed to
another boiler or a boiler in the plant, all oil burners are turned off.
When the burner purge is completed after the final burner has been turned off, the MFT is then operated to
check that all fuels are shut off completely.
After the MFT has been operated, the furnace purge is performed for 5 min.
cooling stop.
The above stop methods are carried out according to the schedules even though there is a difference between
the plan stop and work stop. In addition to the above stop methods, there is a stop method by the MFT operation
during unit operation.
(1) Normal stop
When the unit stop schedule is determined, heavy oil warming or SAH is started according to the output drop
schedule time. The preparations are made so that the auxiliary steam can be supplied from another boiler or a
boiler in the plant.
When the output drop is started, the coal burners are turned off in order according to the decrease of the fuel
flow rate. When the output is approximately 95%ECR, the main steam pressure also drops according to the
voltage transformation program.
In particular, the balance among the supply water, fuel, and air (boiler input command, water-fuel ratio, air-fuel
ratio) should be checked carefully.
The heavy oil burners are ignited in order when the output becomes 50% or less. If the preparations for
ignition of the heavy oil burners are not in time, the output is kept at 50%ECR.
When the output becomes approximately 25%ECR, the drain tank level of the water separator increases. As
the BCP is started, the dry/wet is changed over.
The output reaches 20%ECR. Check that the transition to heavy oil single fuel firing is completed and the
power change-over in the plant (station transformation start transformation) is completed. After checking the
above, the output drops to the parallel-off target value (5%ECR).
After the output has reached the parallel-off target value, the parallel-off is performed, and then the turbine is
tripped.
After checking that the auxiliary steam is changed to another boiler or a boiler in the plant, all oil burners are
turned off.
When the burner purge is completed after the final burner has been turned off, the MFT is then operated to
check that all fuels are shut off completely. After the MFT has been operated, the furnace purge (after purge) is
performed for 5 min.
(2) Stopping of boiler hot bank
After the MFT has been operated and the furnace purge has been completed, the ventilation system and
water/steam system are sealed to minimize the heat loss of the boiler as preparations for restart.
The contents of the stop operation are described in clause 1.3-(5).
The result data of the boiler pressure drop rate and steam temperature drop rate during hot bank is grasped. If
the drop rate is excessively fast, check whether any leak comes from the start bypass valve, or the main
steam/super-heater drain valve.
Heat or pressure remains in the boiler during hot bank. As a rule, the operation and adjustment of the boiler
system valve, and the inspection and work of the equipment leading to the boiler system valve, and the opening of
the manhole must not be performed.
(3) Boiler forced cooling stop
Before conducting the inspection work or periodic inspection work related to the boiler, forcibly cool the boiler
to stop it in order to enable safe work on the turbine side.
The contents of the stop operation are described in clause 1.3-(6).
After forced cooling has been completed, the boiler storage status may vary depending on the stop purpose.
Table 6 shows examples of storage methods (except for plant that the oxygen process applies to the water
process).
Actually, water filled status or nitrogen disused status often occurs. In this case, the boiler water is blown
completely after the forced cooling has been completed, and then the boiler is stored in the dry status.
(4) Measures for MFT operation
The operators must understand the causes of the MFT operations fully. If MFT occurs, check that the
protection interlock functions properly. Additionally, the boiler must not be restarted until the cause of the MFT
has been located and corrective action has been taken.
The following describes the measures to be taken after the MFT has been activated when the operation of the
auxiliary machine in the ventilation system is continued.
1) Check items after MFT
x The fuel shut-off valve, burner valve, and SH/RH spray valve are closed.
x The auxiliary machines are tripped. (Mill, coal supply machine, PAF, and RFP, etc.)
32
1
48 hrs. or less
48 hrs. to 1 week
1 month or more
Hot banking
(Valve is closed with
normal operation kept.)
Same as above.
Same as left.
If the auxiliary machine in the ventilation system is tripped, the furnace must be purged after the damper in the
gas duct has been put in the natural ventilation status. Additionally, when all power supplies are lost, it is
checked that the fuel is shut-off and the back-up operation of the AH is performed by the air motor and that the
damper in the gas duct is put in the natural ventilation status.
(5) Operation of Soot Blower When Unit Is Not Used Boiler clinker removal
When working inside the furnace during the suspension of boiler operation, it is necessary to conduct clinker
removal before paralleling off in order to ensure safety against clinker fall.
2.3.5 Concept of turbine start
Thermal power generation facilities in Japan were originally positioned for adjustment of the load. However,
thermal power generation actually comprises approximately 60% of all capacity, and this output will continue to
be important in the future. Additionally, thermal power generation facilities are considered increasingly
important for stable energy supply.
Thermal power generation facilities are classified into two groups, combined power generation facilities having
high efficiency and excellent operability, and conventional power generation facilities utilizing various fuels and
having rich operation results. Continuing the operation of conventional power generation facilities is important
in order to maintain a range of energy sources, and there are plans worldwide to construct thermal power
generation plants mainly using coal. Since coal is dispersed worldwide and its deposits are abundant,
conventional thermal power generation plants are being constructed.
It is desirable to increase the capacity of conventional power generation facilities and to improve their
efficiency levels in order to reduce greenhouse gas emissions. In 2000, commercial operation started of
Tachibana Bay Plant, controlled by Electric Power Development Co., Ltd. This state-of-the-art large capacity
plant (1,050MW) has a main steam pressure level of 25MPa and a temperature of 600 C, and utilizing high steam
conditions with a re-heating steam temperature of 610 C.
However, the turbine has many small gaps and is rotated at high speed and high temperature. Therefore,
rubbing or excessive thermal stress occurs, causing damage to the unit.
For this reason, utilization of the proper operation method and monitoring method is more important by
considering extension of the periodic inspection, which has been utilized recently.
As the number of new plant being constructed in Japan is decreasing rapidly, and the construction and
maintenance of power generation plants are shifting overseas, the remote monitoring service business is started.
33
The following items can be monitored by the manufacturers in their own country.
Hot start
Stop time
Stopped for up to 4 hrs. from
immediately after turbine trip.
Stopped for 8 to 11 hrs.
Warm start I
Warm start II
Cold start
Remarks
Load: 100%
Vacuum degree
(Parallel-in (initial
load holding))
(Turbine start)
(M/T change-over)
(Rub check)
(Low-speed heat soak)
(2nd T-BFP turn ON)
(Speed up start)
(Low-pressure cleanup)
(High-pressure cleanup)
(Boiler cold cleanup)
(Boiler hot cleanup)
Fig. 19
As described above, the natural cooling is started and the rotor temperature is changed according to the turbine
stop time. The typical start mode is classified into various typical classes because the operation mode is
classified into patterns by operation style. To relax the thermal stress that occurs as a result of the difference in
temperature between the main steam and rotor, it is necessary to adjust the start method.
As described above, since the time needed for the start is different from the stop time, it is important to grasp
the start time for the power supply plan.
Figure 19 shows the events in the typical cold start processes. The following introduces the main monitoring
items in the start process.
(1) Pre-warming
In the cold start in which the turbine is started from almost room temperature, warming of the high-pressure
turbine is needed to reduce the thermal stress. The metal temperature after the first stage is controlled. This
pre-warming is intended to reduce the brittleness of the rotor even though it depends on the material.
(2) All-around flow operation
To reduce the thermal stress of the construction, casing close to the nozzle at the first stage or nozzle during
ventilation, the all-around flow operation (full-arc operation) is performed. When using the machine control
method (MHC), the sub-valve of the MSV is opened to perform.
When using the individual oil tube method using the electric control method (EHC), all control valves are opened
slightly to perform this method. At approximately 7% of the load after starting, the partial insertion operation is
started. Figure 20 shows the relationship between the opening of the control valves and load during this partial
34
Control valves
opening
Main steam
pressure
Fully opened.
4th valve
1st to 3rd
valve
Load
Fig. 20
Example of pressure and control valves opening during voltage transformation operation
Shaft
3000rpm/3600rpm
1500rpm/1800rpm
Bearing
3000rpm/3600rpm
1500rpm/1800rpm
12.5
17.5
6.2
8.7
15
21
7.5
10.5
25
35
12.5
17.5
Alarm value
Stop value
Remarks
Rated speed or
more
Less than rated
speed
35
Oil temperature
Start
Continuous
turning
RPM of
Turning
disengagement rating
Rated
RPM
Control valve
change-over
Oil temperature
Stop
Continuous turning
Fig. 21
Turbine
trip
RPM of
rating
Turning
start
36
Vacuum degree
Fig. 22
Allowable time
Under the operation conditions, the motion that comes and goes between the wet area and dry area is called
dry and wet alternation. However, it is important that coming and going between the wet area and dry area are
eliminated at the final stage or L-1 (stage one before the final stage). Impurities in the steam may accumulate in
the nozzle and on the vane due to dry and wet alternation, causing corrosion to occur.
Frequency
Fig. 23
37
High
pressure
Thrust bearing
Low pressure B
Low pressure A
Medium
pressure
Low pressure B
casing
Low pressure A
casing
Fig. 24
Orange
band
Red band
Fig. 25
Red band
Green
mark
Red
mark
That is, even though the rotor does not enter the red band on the long side during operation, it is extended as it
is released from the centrifugal force in the stop process.
As a result, the rotor may enter the red band area.
On the contrary, when the rotor is started in a status close to the short side before the RPM is increased, it may
advance toward the rotor short side as the RPM is further increased.
This width shows the portion between the red mark and the first alarm point, and the orange band.
38
2. 4
Performance Management
2.4.1
Grasping of performance
In the performance control of thermal power plants, the constant, accurate grasping of unit operation, and
working to improve thermal efficiency are most important.
As a method to grasp performance, the deviation from the desired value which can be expected as long as the
equipment is operated normally including the acceptance performance test results etc., and also initial design
values at the start of operations are controlled. This desired value comprises operation status values such as the
temperature and pressure of each part, and performance values such as unit efficiency and boiler efficiency. The
latter performance values change by external conditions and therefore revision of the same conditions is necessary
for making comparisons. Setting of coefficients for revision may be performed by theoretical calculation or by
testing.
Next, in order to reasonably maintain facility performance in thermal power plants, in general, daily control is
made so that appropriate measures may be taken by monitoring the operation status. By monitoring the necessary
control items by instruments, daily operation log, calculators, etc., abnormal conditions are detected early and by
conducting operation and maintenance properly, efforts are made to perform reference value operations.
On the other hand, every day operation conditions are grasped from operation records and typical items which
affect performance (condenser vacuum degree deviation, exhaust gas temperature, exhaust gas O2) are plotted by
day, ten days, month in graphs, and the trend controlled. Especially, in regard to power plants with coal energy and
such where coal quantity, quality cannot be grasped in real time, the plant situation is grasped by trend control.
Also, to evaluate performance and thermal efficiency improvement measures at the time of regular inspection,
performance test items (high pressure turbine internal efficiency, air preheater efficiency, feed water heaters, etc.)
were grasped and simultaneous records taken on the overall unit for detailed control.
2.4.2 Grasping of equipment performance
To control performance changes of the unit, unit performance tests were conducted regularly, and efficient
operation, maintenance and improvement of facilities are being undertaken.
In general, performance tests were conducted with minimum output, 2/4 output, 3/4 output and rated output and
items such as plant thermal efficiency are being measured.
2.4.2.1
An example of fuel, electric output, and various losses of a thermal power plant is shown in Fig. 2.4.2.1. The major part
of fuel consumed in boiler combustion is used for the generating of steam. This steam is sent to the turbine but a
little over ten percent of the heat quantity are discarded into the atmosphere as exhaust gas. Steam that flows into
the turbine expands inside the turbine and works to rotate the generator to generate electric power. During this
time, a part of the work becomes mechanical loss such as by bearings, etc. and also becomes generator loss. The
steam which has expanded with the turbine exhaust pressure flows into the condenser where it is cooled to
become condensed water while the heat quantity possessed by the steam is discharged into the cooling water of
the condenser.
Boiler fuel
(A)
Mechanical
Generator
loss
In-station
loss
motive
power
Turbine end
output (D)
(F)
Heat discharge
loss (G) to
condenser
Boiler auxiliary
steam (C)
39
Fig.2.4.2.1
With oil fired thermal power use boilers, furnaces into which air is forced drafted by a force draft fan are widely
adopted. With this system, operation is performed with the pressure inside of the furnace or flue higher than the
atmospheric pressure and therefore caution must be exercised on leakage of gas and measures taken. Also, in the
case of coal fired boilers, blast furnace gas or coke oven gas burning boilers, a balanced draft system in which the
gas pressure inside the furnace is maintained slightly lower than the atmospheric pressure by an induced draft fan
is mainly adopted.
The reason for this is that with coal fired boilers, consideration is made for ash leakage and with blast furnace
gas and coke oven gas fired boilers, the fuel gas containing a large amount of CO is hazardous and the supplied
pressure of fuel gas is low.
With boiler capacity becoming greater, the consumed motive power of force draft fans and induced draft fans also
becomes greater and therefore it becomes necessary to restrain the draft loss of the convective heat transfer
surface to a suitable value. Table 2.4.2.1 shows an example of draft loss of respective parts of a large capacity
boiler of the coal fired balanced draft system.
Table 2.4.2 .1Example of draft loss of a boiler (Calculated values at maximum continuous load)
Draft loss
kPa
Items
Air (secondary) side pressure loss
Forced draft fan inlet air duct and silencer
Forced draft fan outlet air duct
Air preheater
Air preheater outlet - Burner wind box inlet air duct
Burner wind box
0.54
0.43
1.37
0.59
1.47
Total
4.40
1.37
1.03
1.52
1.59
0.84
1.06
Total
7.41
11.81
40
2.4.2.2 Boiler
When calculating boiler efficiency, it is necessary to clarify whether the standard of the fuel calorific value is of
a high level calorific value containing latent heat of vaporization at the time the moisture from hydrogen in the
fuel becomes steam or whether it is of a low level calorific value in which latent heat of vaporization is deducted
from the high level calorific value.
In this chapter, explanation is provided with high level calorific value as the standard.
As a method to obtain boiler efficiency, the quantity of heat which is transferred to the feed water in the boiler
and used to generate steam is compared with the heat quantity which should be generated by the combustion of
the fuel fed to the furnace. This is called the heat input output method and is expressed by the following
equation.
Boiler efficiency =
Ws (h0 - hl)
100% (1)
Gf Hh
Where WS is the boiler steam quantity kg/h, h0, h1 is the generated steam and feed water enthalpy kJ/kg, Gf is
the fuel consumed quantity kg/h, and Hh is the high level calorific value of fuel kJ/kg.
As another method, the boiler heat loss is calculated from the exhaust gas temperature and the exhaust gas
amount after passing the entire generating surface of the boiler, (the outlet if there is an air preheater) and by
deducting this from 100%, the boiler efficiency is obtained. This is called the heat loss method and is calculated
by the formula mentioned later. The heat loss becomes less as the exhaust gas temperature is lowered and boiler
efficiency rises but for this a larger air preheater generating surface is required and facility expenses increase.
Additionally, in the case where fuel containing sulfuric
content is used, the problem of low temperature corrosion (sulfuric corrosion) occurs and therefore it is important
to select a suitable exhaust gas temperature in planning the boiler. In current boilers, the exhaust gas temperature
is set at 130 - 150C with coal and heavy oil (crude oil) fuel, at 165C with high sulfuric content heavy oil, etc,
and around
100C with gas fuel but with certain fuels, normally an environment preserving device (Electric dust collector,
desulfurizing equipment) is installed for the back wash and therefore it is necessary to optimize the exhaust gas
temperature in the entire facility including this.
(1) Dry exhaust gas loss L1
Out of the heat loss by the exhaust gas discharged from the outlet of the boiler (air preheater), when the portion
by latent heat of dry gas is assumed to be:
Gdry : Dry gas amount per 1 kg of fuel kg/kg
: Average specific heat of dry gas .0 kJ/kgC
Cg
tg
: Air preheater outlet exhaust gas temperature C
: Boiler efficiency standard temperature C
to
L1 =
L2 =
Mf (hR + Cm - ts - Cw - ts)
100% (3)
Hh
41
L3 =
L5 =
23,700 C
(CO)
100% (5)
Hh
(CO 2) + (CO)
Where;
23,700
L6 =
33,900 C'
100% (6)
Hh
Where
33,900
: Combusted heat amount KJ/Kg of carbon
C
: Unburned carbon amount KJ/Kg per 1 kg of fuel
This heat loss in liquid and gaseous fuel is negligible.
(7) Other loss L7
Besides the above, there are small losses such as by carrying out of combusted ash or steam atomizing or heat
losses which cannot be measured or for which the cause is unknown and these are treated as other losses. Errors
of measuring instruments may be included in this loss.
From the above heat losses, boiler efficiency may be expressed by the following equation
7
Table 2.4.2.2 shows examples of boiler efficiency and heat loss of commercial use boilers for exclusive firing
of heavy (crude) oil, of natural gas and of coal.
With natural gas, the hydrogen content during combustion is approximately double that of heavy (crude) oil and
therefore the loss by hydrogen moisture content during combustion is great. Since the exhaust gas temperature is
low, dry exhaust gas loss is small but boiler efficiency becomes approximately 2% lower compared with heavy
(crude) oil. Also with coal, the hydrogen content during combustion is even less than that of heavy (crude) oil and
therefore even when loss by unburned carbon is considered, boiler efficiency tends to become the highest among
the three fuels. However, coal characteristics will differ greatly by origin and caution must be exercised in the
evaluation of its efficiency.
42
Table 2.4.2.2 Examples of heat loss by boiler efficiency (Calculated values by rated loads)
Natural gas
exclusive boiler
99
Coal exclusive
boiler
135
1.14
1.16
1.20
%
%
4.33
6.53
2.70
10.19
4.31
4.03
%
%
%
%
%
%
%
0.07
0.17
0.00
0.00
1.00
12.10
87.90
0.05
0.17
0.00
0.00
1.00
14.11
85.89
0.09
0.17
0.00
0.52
1.50
10.62
89.38
43
HR =
HR =
Turbine
LP turbine
Boiler
HP turbine
Boiler auxiliary
steam etc.
Condens
er
#1 Heater
2 Heater
#3 Heater
Deaerator
#5 Heater
#6 Heater
Condenser pump
44
Q
(3)
Ls
Q
Net Heat Rate =
(4)
Ls LBFP
Q
(5)
Ls + LBFP
Q
(6)
Ls
t=
3,600
100% (7)
HR
t=
(E)
100% (8)
( B) (C )
Moreover, the following definitions are used to express efficiency of the generation plant.
(E)
100% (9)
( A)
(F )
100% (10)
( A)
The two factors which affect turbine heat rate and thermal efficiency are steam conditions of boiler steam
production, condenser vacuum degree, feed water temperature and feed water heating steps, etc. namely the heat
cycle conditions are the performance of the turbine itself. Fig.2.4.2.3-2 shows the trends of unit capacity and
thermal efficiency of commercial use reheating turbines.
16.6 MPa
class
Output (MW)
45
i = Hg / Ho 100 % (11)
Figure 2.4.2.3-35 shows the steam condition (Pressure, enthalpy functions) in the case of the reheating turbine
and the internal efficiency of the high pressure turbine, medium pressure turbine and low pressure turbine are
expressed by the following quotation.
Pressure:
Px: Turbine main steam check valve inlet
P0: 1st step nozzle inlet
P1: High pressure turbine outlet
Pr: Before medium pressure turbine reheat
stop valve
P2: Medium pressure 1st step inlet
P3: Medium pressure turbine outlet
P4: Low pressure turbine inlet
P5: Low pressure exhaust (Condenser inlet)
EL: Exhaust loss
Saturation line
IH =
H eH i s ir'
=
(12)
H o H i s i1
It =
H el ir i4
=
(13)
H o l i r i3
IL =
H eL i4 i6
=
(14)
H o L i 4 i5
Turbine efficiency is the ratio between theoretical work and effective work, and is the product of internal
efficiency and mechanical efficiency. The relation between the turbine efficiency r of a back pressure turbine or
a simple condenser turbine and the steam specific consumption SR (Kg/kWh) is as follows:
SR =
3,600
GS
=
(15)
PS Hets
Where:
GS : Inflow steam quantity (Kg/h)
Pg : Generator output (KW)
Ho : Adiabatic heat drop inside turbine (KJ/kg)
g : Generator efficiency
46
Boiler
High
pressure
turbine
Low pressure
turbine (A)
Medium
pressure turbine
Low pressure
turbine (B)
Condenser
Make up water
Condenser
pump
BFP turbine
Grand steam
condenser
Condensate
booster pump
Fig. 2.4.2.3-4
Drain pump
(1) Piping pressure drop from the turbine extraction point to the feed water heater is normally maintained at
around 5% of the pressure (2.5 - 12%).
(2) Temperature inside the feed water heater becomes the saturation temperature of the extraction pressure.
(3) The feed water heater outlet feed water temperature is selected to be 2.5 to 5C lower than the saturation
temperature inside the heater and feed water heater to be designed. (In the case of a direct contact type such
as a deaerator, the outlet feed water temperature is to be the same as the saturation temperature and also in
the case where the extraction temperature is fairly higher than the saturation temperature in reheating steam
turbines, etc., this temperature may be utilized with a superheat reducing section provided inside the feed
water heater with the feed water selected to be 0 - 3C higher than the saturation temperature. (Refer to
Chapter 2, Clause 3.4)
(4) When a drain cooler is provided in the water feed heater, the drain outlet temperature is designed to be 5 to
10C higher than the water feed temperature.
(5) Taking the No. 5 heater in Fig. 2 as an example, the extraction amount necessary for the water feed heater
is obtained by the following procedure. (However, the heat discharge loss is to be neglected.)
Gx (ix-i14) = Gw(i12-i11)-Gd(i13-i14)
Where:
Gx : Extraction quantity (Heated steam quantity)
: Extraction enthalpy
ix
Gw : Feed water quantity
i11 : Feed water heater inlet feed water enthalpy
i12 : Feed water heater outlet feed water enthalpy
Gd : Inflow drain quantity
i13 : Inflow drain enthalpy
i14 : Outflow drain enthalpy
47
Leading phase
Lagging phase
2.4.2.4 generator
(1) Available output curve
Figure 2.4.2.4-1 shows an example of available generation output curve. This curve is divided into parts (A),
(B), and (C).
Output (MVA)
Terminal
voltage=Rated Voltage
48
10
226
208
30
154
146
60
130
125
120
116
112
Continuous unbalanced
load
I2(%)
10
8
6
5
1. Core loss
If the used material is assumed to be the same, core loss relates to magnetic flux density, frequency, and stator
core weight, and with their increase, core loss increases.
2. Mechanical loss
Mechanical loss consists of bearing friction loss and windage loss. Since windage loss is proportional to gas
density, the windage loss of hydrogen cooling machines is extremely smaller than that of air cooling machines.
This is one of the advantages of the hydrogen cooling machine. Bearing friction loss increases in an exponential
function manner with increases in revolutions and journal diameter.
3. Stator I2R loss and stray load loss
Stator I2R loss is proportional to the square of the stator current and stator coil average length/coil cross
sectional area. In addition, surface loss is affected by void length and winding pitch, becoming smallest with a
5/6 winding pitch and loss decreases as void length increases.
4. Field I2R R Loss
Field I2R Loss is proportional to the square of the field current and field resistance but as shown in the V curve
of Fig. 36, more field current becomes necessary with the same output as the power factor becomes lower and loss
increases.
Figure 2.4.2.4-3 shows the generator efficiency and changes in efficiency by partial load of a typical capacity
generator. As shown in this figure, in general, in the case of standard specification generators, efficiency tends to
become better with larger capacity. Also, in regard to partial load, core loss and mechanical loss are constant and
therefore efficiency rapidly worsens with low load but in the case of hydrogen cooling machines, lowering of gas
pressure inside the machine and operating at low load is possible and as a result, windage loss decreases and
normally, the maximum efficiency rate is displayed at 70 - 80% load.
Load (%)
Vacuum
degree
from decreasing to increasing and since there is a risk of problem occurrence in the facilities, the vacuum degree
is controlled so that it does not exceed the efficiency limit vacuum degree.
(2) Facility control
By the frequency of operation and data measurements of the respective facilities, difference control of the
desired value of the vacuum degree is being conducted.
The following shows the general control items.
x Operation control of the ball cleaning device
x Control of electrolytic protection device
x Measuring of vacuum pump extraction quantity
x Control of instrumentations
x Tubing brushing cleaning
x Cleaning of the inlet channel and circulating pump chamber
(3) Disposition to adopt when deviation is seen from the desired value of the vacuum degree
First, check to see if there is any abnormal condition of instrumentation and when confirming, pay attention to
the following points.
x Drain accumulation in the detection piping
x Temperature compensation if the standard temperature differs between the mercury vacuum gauge and
the atmospheric pressure gauge.
x Difference between the atmospheric pressure compensated vacuum degree and the transmitter side.
x Whether there is any abnormal condition in the correlation between the atmospheric compensation value
of the mercury vacuum degree gauge and the respective temperatures of the exhaust room and hotwell.
x Any abnormal condition of the mercury vacuum degree and atmospheric temperature gauge at the time
of periodic checking.
Upper limit of
vacuum degree
Vacuum degree
desired value
Lower limit of
vacuum degree
Fig. 2.4.2.4-4
(4) Investigation method of cause for deviation of vacuum degree from the desired value
When a deviation seen from the vacuum desired value is found with measuring instruments in a normal state, in
general, investigate the following.
1.Increase in leak in quantity of air
The lowering of the vacuum degree occurs when leak in exceeds the extraction capacity of the vacuum pump.
2.Lowering of cleanliness of tubing
With no increase in the leak in air amount and with the vacuum pump found to be normal, the cause of lowering
of the vacuum degree is often caused by the lowering of cleanliness of the tubing.
3.Lowering of the cooling water volume
When the cooling water volume drops, an increase of difference in the cooling water inlet, outlet temperature
(UT), increase of CWP discharge pressure, and lowering of the condenser water chamber level occurs, and an
abnormality of the condenser side (tubing clogging, siphon cut-off, etc.), abnormality of the CWP side CWP
51
performance lowering, CWP chamber water level lowering, check washing valve seat leak, etc. are conceivable.
4.Abnormality of the vacuum pump
When an abnormality of the vacuum pump is seen, conduct changeover testing with a spare machine and
compare the respective air extraction amount and vacuum degree.
Also, since the seal water relations of the vacuum pump greatly affect the vacuum degree, pay attention to the
following points.
a. Increase in seal water temperature by contamination of the seal water cooler, increase of bearing
cooling water temperature.
b. Shortage of seal water by abnormality of the seal water pump, clogging of the discharge strainer of
the pump, etc.
c. Lowering of water level by malfunctioning of float valve for seal water tank water level adjustment
5.Increase of condenser heat load
The desired value of the vacuum degree is calculated from the design heat load, cooling water amount, and
heating surface, etc. and if the heat load increases above the design value, even if the cooling water volume and
others are in accordance with designed values, the vacuum degree decreases. Especially, with the once-through
boiler unit, leakage of the respective bypass valves from the start-up bypass system to the condenser causes
lowering of thermal efficiency and care should be exercised.
(5) Performance curve
The vacuum degree of the condenser is affected by the condenser load, cooling water inlet temperature, and
cooling water volume. Condenser pressure is obtained from saturation steam temperature ts.
t s = t1 +
Where
p=
Q
1
Gc c p (1 p )
e
= t1 +
t 2 t1
1
1 p
e
(1)
A K
Gc c p
(2)
Figure shows an example of the condenser performance curve. The condenser pressure change at the time of
changes in condenser heat load and cooling water inlet temperature when the cooling water volume is constant is
shown. When the condenser pressure is recorded by the elapse of time in this curve, the contamination coefficient,
etc. of the cooling pipe may be assumed. This curve is a straight line at the time of no load to a certain load. When
the condenser load is small or the inner pressure is low, the condenser pressure is restricted by the performance of
the air extraction device and there are cases where the pressure to be obtained by equation (1) cannot be obtained.
52
Fig. 2.4.2.4-5
desirable to raise the temperature evenly with heaters of less than the reheating point in the one step reheating
cycle. From the aspect of performance, it is optimal to plan to increase the average temperature rise at the low
pressure feed water heater rather than to increase the temperature of the feed water reheater by extraction from the
reheating pump.
This temperature rise is restricted by the thermal stress, etc. of the water chamber and normally, the increase is
suppressed to around 20 to 75C.
(2) Effect by terminal temperature difference (T.D.) change
To obtain the effect on turbine heat rate by T.D. changes, the extraction quantity changes to the respective water
heat heater T.D. change are calculated, and with the turbine inlet steam quantity kept constant, the heat rate may
be obtained from the extraction quantity change and output quantity change. The following shows an example of
calculation in regard to a high pressure feed water heater.
a. Trial calculation data
Subject unit 600MW
At rated output, when T.D. is +3C
b. Trial calculation results
x Decrease of extraction quantity by T.D. increase
EXT
x Turbine room input heat increase by reheated steam quantity increase by extraction quantity decrease by
T.D increase
x Output heat decrease from the turbine room by feed water temperature decreasing
UQ
54
Condenser
G:
T:
I:
CRH, HRH :
EXT :
EXH :
FW :
I, O :
COND :
Flow rate
kg/h
Temperature
C
Enthalpy
kcal/kg
Low, high temperature
reheated steam
Extraction
Exhaust
Water feed
Inlet, outlet
Condensed water
x Output change
(increase)
x Turbine room thermal efficiency HR
Reference heat
consumption
Reference output
Reference specific heat
consumption (HR)
Reference
output
Reference output
acid dew point measurement etc. as a reference and upon confirming the corrosion situation of the AH element,
etc. staged lowering is attempted. It is desirable to set the average temperature control value at the maximum
point of sulfuric acid condensation quantity in accordance with the sulfur contents of the used fuel but reduction
should not be made in one stroke but in stages with consideration of the following points and confirming that
there are no problems.
x Deviation of the theoretical value and actual record value of the sulfuric acid dew point
x The relation between the sulfur contents in the fuel and produced SO3 density.
x Local metal temperature drop by unbalance of gas temperature distribution
(2) Exhaust gas temperature control
The AH outlet exhaust gas temperature differs greatly by boiler according to the boiler and AH structure, and
the kind of fuel and since it fluctuates greatly by factors such as load and atmospheric temperature and air leakage
of AH, it is difficult to set a standard but it is set upon executing of countermeasures on temperature decrease of
exhaust gas by each boiler, conducting an actual machine test with the AH element in the best condition, with the
air leakage in the minimum condition and based on these results, with exhaust gas control data as a reference and
with the atmospheric pressure as the parameter. The deviating trend to the control value is grasped and when the
deviation is large and continuous, the following deviation factors are analyzed and appropriate measures are to be
taken.
x Lowering of exhaust gas temperature by increase in AH air leakage amount
x Aging deterioration by corrosion, wear of AH, and rising of exhaust gas temperature by lowering of AH
performance by staining of the heating surface, etc.
x Increase of exhaust gas temperature incident to dry gas quantity increase by Combustion gas O2 (Excess
air factor)
x Those by characteristic changes of the fuel.
(3) Control of exhaust gas O2
The Eco outlet combustion gas O2 differs by each boiler, depending on the boiler, combustion method, and type
of fuel. Therefore, a combustion test is to be made after improvement of combustion facility or after periodic
inspection as required, O2 distribution is to be measured, abnormality of instruments, inappropriateness of
detection point, faulty combustion, etc., deviation factors from control values are to be analyzed, and if a large
deviation situation continues, the O2 meter, burner tip, and body, and damper are to be checked for combustion air
or exhaust gas O2 distribution is to be measured and suitable measures taken.
(4) AH air leakage ratio
The temperature of the gas which passes the boiler will differ depending on the boiler condition (cold boiler hot
boiler, etc.) which in turn effects changes in the amount of heat deformation. Therefore, to prevent leakage of
AH air, the setting of respective seals is calculated in advance and the gap value is set in a cold boiler condition so
that the clearance becomes minimum in rated load operation but a certain amount of leakage is unavoidable.
However, with the new type AH, with the improvement of the seal plate supporting method and additions to the
seal section, direct leakage from the seal gap has been improved compared with the old type. Furthermore, to
reduce leakage from the high temperature side radial seal which was the greatest leakage factor during operation,
a sensor drive system of the high temperature side sector plate has been developed. With this system, the rotor
shaft side that controls the gap between the sector plate and seal to a minimum under any boiler operation
condition is structured so that it constantly follows the contraction-expansion of the rotor, and control is conducted
so that only the gap of the rotor periphery and sector plate outer end section gap becomes minimum.
56
2.5 Example of Operation Control and Performance Management (Hokkaido Electric Power Co., Inc)
2.5.1 Overview of Hokkaido Electric Power Co., Inc.
Hokkaido Electric Power Co. Inc. was established in May 1951 to supply electricity in the Hokkaido region.
With an area of about 83,500km2 and a population of 5.7 million, Hokkaido is flourishing in agriculture, fishery and
tourism. The capital city, Sapporo, with a population of 1.7 million, located at 45 degrees at north latitude, once hosted
the winter Olympics in 1972, and has held Sapporo Snow Festival every February visited by numerous visitors
including those from foreign countries.
Hokkaido Electric Power Co., Inc., established on May 1, 1951, has the headquarters in Sapporo and has been
engaged in electric power generation, transmission and distribution by about 5,800 employees. Table 2.5.1-1shows the
electric energy sale, the supply facilities and transmission and distribution facilities.
Electric energy demand
Year 2005
Supply facilities
Total
Electric light
Electric power
Specific scale
Total
Hydro-electric power station
Thermal power station
Nuclear power station
Transmission distance
Transforming station
Distribution line distance
66 places
53 places
12 places
1 place
369 places
Table 2.5.1-1
The company has 12 thermal power stations. The breakdown is shown in Table 2.5.2.
Steam power station
Gas turbine power station
Internal combustion power station
Geothermal power station
6 places
1 places
4 places
1 places
3,900 MW
148 MW
17.4 MW
50 MW
Table 2.5.1-2
Fig. 2.5.1 Thermal Power Stations of Hokkaido Electric Power Co. Inc.
Okhotsk Sea
Japan Sea
Sunagawa
power station
Sapporo
Pacific Ocean
Shiriuti power station
57
30,833 GWh
11,540 GWh
2,218 GWh
17,075 GWh
6,505 MW
1,231 MW
4,115 MW
1,158 MW
8,230 km
19,300 MVA
66,753 km
Authorized
output
Date
MW
No.1 unit
No.2 unit
Oct., 1980
Oct., 1985
350
600
No.4 unit
Jun., 2002
700
No.1 unit
No.2 unit
No.3 unit
No.4 unit
May, 1968
Feb., 1970
Jun., 1977
May, 1982
175
175
125
125
Name
Tomatouatsuma
Naie
Sunagawa
Main steam
Fuel
Foreign
coal
Domestic
coal
Reheat steam
Pressure
(MPa)
16.6
24.1
Temperature
()
566
538
Temperature
()
538
566
25.0
600
600
16.6
16.6
12.5
17.7
566
566
538
538
538
538
538
538
Boiler type
Natural circulation
Supercritical once-through
Ultra supercritical
once-through
Natural circulation
Natural circulation
Natural circulation
Subcritical once-through
Boiler
efficiency
Turbine
Unit
efficiency efficiency
87.28
87.91
45.03
47.70
39.41
41.93
88.73
49.83
44.21
87.08
87.08
85.72
86.27
45.14
45.55
43.63
45.40
39.26
39.40
37.41
39.16
Table 2.5.2
58
Station manager
Deputy manager
Generation Div.
Business staff
Management staff
Operation staff
Environment
Engineering Div.
Environment
Engineering Staff
Environment
Facility Staff
Machinery staff
Maintenance
Div.
Electrical
Measurement staff
59
Administration
deputy manager
+
7 personnel
Control of BTG
generation facilities
Environment
engineering manager
5 groups
Operators (8
Engineering assistant
manager
+
4 personnel
Operation
management of
environmental facilities
Operation management of
environmental facilities
+
6 personnel
people)
Operation of BTG
generation facilities
Centralized management
room (operation is
outsourced to affiliated
companies)
Daytime shift (11
personnel)
+
Team
leader + 8
4 groups
operators
Operation of
environmental facilities
Fig. 2.5.3-2
Table 2.5.4-1
Operation time
Unit
Hrs/min.
Generated energy
MWh
Generator output
Main stop valve steam
pressure
Main stop valve steam
temperature
Reheat stop valve steam
pressure
Reheat stop valve steam
temperature
MW
MPa
C
MPa
C
Measure
values
Daily and
monthly
totals
Daily and
monthly
totals
Max value
Max value
Max value
Max value
Max value
Max value
t/h
mmHg
t
kl
kl
t
kl
1/100mm
Fuel
Consumption
Condenser vacuum
Coal (humidity)
Crude oil
Heavy oil
Orimulsion
Diesel oil
Min value
Monthly
total
Measure location
Control values
under normal
operation
Recorder
+
of
or
Record frequency
Indicator
office
Rated output
24 hours
Rated output
Rated value
1.05
Rated value
8C
Rated value
1.05
Rated value
8C
Smaller one
the MCR
turbine intake
Min operation
Site
JEAC3717
caution value*
1/
month
1/
year
61
For generation
Remarks
As
needed
Max value
1/
day
Bearing
No.
Amplitude
*
Shaft
Bearing
Over rated
Under 12.5
Under 6.25
Measure
values
Unit
gSiO2/l
Average
value
Control values
under normal
operation
Measure location
Recoder
Record frequency
Indicator
office
Site
1/
day
Water
quality
standard value
1/
month
gSiO2/l
{
{
S/cm
mg/l
ASTM
%
mm
MPa
t/h
t/h
MPa
C
MPa
C
MPa
As
needed
Remarks
According to thermal power station water
management manual
{
{
S/cm
gO/l
minute
mgKOH/g
mg/100ml
mm2/s
1/
year
{
-
Calculate
value
Highest,
lowest
Maximum
Maximum
Maximum
Maximum
Maximum
Minimum
Maximum
Minimum
Over 70 mins.
Under 0.3
Under 10
(New
oil
standard) 10%
Under 500
Under 4
{
{
{
{
{
{
{
Warning value
Rated 1.05
Max operation
Max operation
Rated 1.05
Rated + 8C
Warning value
Warning value
Warning value
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
62
{
{
{
{
{
{
{
{
Unit
Measure
values
Control values
under normal
operation
%
mm
Maximum
Maximum
Max operation
mm
mm
Maximum
Maximum
Warning value
rpm
Maximum
Rated 1.05
Measure location
Recorder
Record frequency
Indicator
office
1/
day
1/
month
1/
year
As
needed
Remarks
Site
{
63
Table 2.5.4-2
Setting Standard for Control and Permissible Values for Trial Operation
(Boiler)
Items
Generator load
MW
Pressure
MPa
Temperature
Unit
Main steam
Feed water
Superheater spray
Reheater spray
Drum water level
Economizer gas oxygen
concentration
Furnace
Forced fan outlet pressure
Pulverizer inner pressure (For vertical
mill, pressure difference of primary
fan)
t/h
Combustion gas C
Draft
Flow rate
mm
%
kPa
Remarks
<
<
Warning value
Fan rated value
Minimum flow speed (For
vertical mill, mill pressure
difference corresponding to
min. flow speed)
Tube mill: Warning value
or
MCR
A
C
Wind box
64
C
t/h
MPa
MPa
MPa
rpm
t/h
MPa
MPa
C
Coal
t/h
MPa
C
t/h
MPa
Items
Heavy/cru
de oil
Fuel
Fuel pump
consumption
Burner pressure
Temperature
Flow rate
Unit
65
Remarks
<
(Turbine)
MPa
Items
Generator load
Pressure
Main steam
Unit
MW
Temperature
Main steam
High-pressure turbine
Reheat steam
Exhaust room
Oil
Control oil
Bearing oil
Control valve operness (cum angle)
Condenser vacuum
Difference expansion
Thrust bearing
MPa
% (deg)
kPa
mm
C
Radial bearing
Air bleed
Pressure
Temperature
Remarks
<
<
<
Warning value
Warning value
Warning value
1/100
mm
MPa
C
66
Fig 2.5.4-3
Appendix 3-2
Schematic of Thermal Performance / Heat Management System
Calculation Center
Head Office
Power Station
Unit calculator
Temperature sensor
Pressure sensor
Lsw, etc
Performance
Performance
management system
management system
Heat management
statistic data
Business transaction
automation calculators
Large computers
Data
transmission
Business terminal
Performance management
terminal
Display current
output of each
generator
67
Output various
monthly reports
Distribution
Submit to government
agencies
(Specified formats)
Table 2.5.4-4
68
69
70
71
72
Monthly Report (Table 2.5.4-5)..Boiler and Turbine Maintenance Log, Month-end Generation Record, etc
73
April, 2004
This month
Hr Min
Generation time
720 00
MWh
Generated output
Startup times
447,775
0
times
Fuel
Coal (w)
Consumption
Diesel oil
Gross efficiency
Net efficiency
t
kl
%
%
Items
144,001
16.3
42.64
40.70
Main steam
hours min
hours min
hours min
hours min
0 - 00
0 - 00
0 - 00
0 - 00
0 - 00
0 - 00
0 - 00
Control value
CWT
operation
AVT
operation
pH (25C)
Silica
gSiO2/l
Electric
conductivity
S/cm
Dissolved
oxygen
gO/l
CWT
operation
AVT
operation
CWT
operation
AVT
operation
Measured value
8.5 9.0
8.82
9.3 9.5
20
0.2
0.05
0.3
20 200
7
18821 - 02
12,348,254
34
This month
Reheat steam
Cumulative total
100.0
-
74
0- 01
0- 01
0- 00
0- 00
0- 00
0- 00
0- 00
0- 00
(B)
(T)
(B)
(T)
(B)
(T)
0- 00
0- 00
0- 00
0- 00
0- 00
0- 00
8:00
16:00
Shift 1
Patrol
Specific patrol
S
U
22:00
Shift 2
Shift 3
S
75
Main
piping
Furnace
Inside furnace
Main
rotating
machine
(excluding
steam
turbine)
Main
valves
Steam turbine
Main heat
exchanger
Generator
Relays
Breaker
Hydrogen
seal
oil
equipment
Armature
cooling
equipment
Main
transformer
Frequency
1 / day
3 / day
Items
Method
Remarks
Leakage
Tentacle,
hearing
Defects in hangers
Vibration
Leakage
Combustion
condition
Situations inside
Vibration, unusual
sound
Temperature rise,
oil surface, oil
leakage
{
{
{
Visual
Tentacle, hearing
Visual, hearing
Leakage
gland part
from
Vibration, unusual
sound from valve
Steam leak from
valve gland
Abnormality
in
working
Vibration unusual
sound, temperature
Steam leak from
casing
Oil drain from
bearing
Loosening of nut,
bolt
Leakage
Water level
Usual sound,
vibration,
smell
Usual sound,
smell
Usual sound,
smell
Usual sound,
vibration,
smell,
leaking
Usual sound,
vibration,
smell
Usual sound,
vibration,
smell,
leaking
visual,
Visual
Visual, hearing
Tentacle, hearing
Tentacle,
visual
Visual
smell,
Tentacle, hearing
Visual, hearing
Tentacle, hearing
{
Visual, hearing
Visual
Visual, tentacle
{
{
Visual, hearing
Visual
{
Visual, hearing,
tentacle, smell
Table 2.5.4-6
76
Visual, hearing,
tentacle, smell
Visual, hearing,
tentacle, smell
Visual, hearing, smell
d. Performance Management
(2) Frequency
Before periodical inspection
100% load
77
Table 2.5.5-1
78
79
80
81
82
Director
Deputy
Director
Manager
Maintenance Division
Deputy Manager
Steam
Computer
Equipment
Steam
Drum
Manager
Manager
Utilization Previous
factor
fiscal year
under survey
Thermal
efficiency
(thermal efficiency)
upper limit
38.65
average value 37.88
lower limit
37.10
Low
coefficient
use
Thermal efficiency
variation
efficiency (month)
38.28
Beginning
38.03
Middle
38.61
End
38.19
of
(amount of change)
upper limit
0.95
average value 0.96
Year
No. 2 Unit
Utilization Previous
factor
fiscal year
Thermal efficiency
efficiency (month)
40.74
Beginning
41.68
Middle
40.63
End
39.96
coefficient of
use
Thermal efficiency
variation
(thermal efficiency)
upper limit
41.19
average value 40.43
lower limit
39.68
(amount of change)
upper limit
0.93
average value 0.28
Year
No. 4 Unit
Utilization Previous
factor
fiscal year
(thermal efficiency)
upper limit
43.78
average value 42.98
lower limit
42.18
Thermal efficiency
Year
Table 2.5.5-2
83
efficiency (month)
43.73
Beginning
43.60
Middle
43.90
End
43.70
periodical check
(amount of change)
upper limit
0.98
average value 0.30
Appendix 2.5-1
Q-1-7
Steam Power Stations Performance Test Manual
April 1, 1995
Revised June 1, 2004 (First revision)
(Jurisdiction) Thermal Power Department
(Contents)
I. General
1. Objective of Performance Test
2. Implementation of Performance Test
II. Methods for Performance Test
1. Operational Condition for Testing
2. Measurement of Test Data
3. Measuring Equipment
4. Measurement Data and Calculation Methods
. Analysis of Test Data
1. Calculation Processing and Control charts
2. Preparation of charts
Attachment
1. Steam Power Generation Steam Schematic
2. Thermal Efficiency Calculation Equations
3. Performance Test Results (Actual)
84
Q-1-7
Steam Power Stations Performance Test Manual
This manual is to introduce standardized procedure for performance test methods for steam power stations based on
"Thermal Power Station Operation and Maintenance Regulations."
I. General
(1) Objective of Performance Test
The objective of performance test is to grasp the performance of each steam power station, to use such information in
daily operation and maintenance and to improve the energy efficiency in heat and electricity generated.
4/4 load
One time
One time
One time
Note: Periodic inspection means regular maintenance company inspection and intermediate inspection.
Test name
(Primary)
Boiler room
efficiency
Heavy/crude oil
Bituminous mix
PFBC
Heat
input/output
method standard
Heat input/output
method
Loss method
standard
Loss method
Coal-fired
thermal power
Turbine room
efficiency
Heat
input/output
method
Plant efficiency
Heat input/output
method
(Boiler room
efficiency)
(Turbine room
efficiency)
Data" is to be referred to. For measuring equipment largely affecting the test results, required precision needs to be
ensured. (Confer II Methods for Performance Test;3.Measuring Equipment)
(7) Sampling of exhaust gas is to be done at Eco outlet and designated point of AH outlet for analysis by Orsat
method or corresponding methods.
For PFBC unit, analysis is conducted between boiler outlet and gas turbine inlet.
(8) Items for Specimen Analysis are as follows;
Analysis of specimen is based on Fuel Quality Test Manual.
Type of fuel
Coal
Density
Humidity
Moisture
Ash content
Fuel
Calorific value
High standard
Industrial analysis
Hydrogen
Nitrogen
Combustive sulfur
CO2
CO
O2
AH outlet O2
Boiler outlet O2
Furnace clinker
EP ash
MC ash
PC ash
Analysis
Exhausted gas analysis
Remarks
Carbon
Eco
Outlet
Bituminous mix
crude oil
Analysis items
(Note)
Heavy
c : Items to be analyzed
U : Items analyzed when loss method is applied
: Items analyzed as necessary
: Items not analyzed
87
Elemental analysis
PFBC Unit
Test Procedure
Time
1H
2H
3H
4H
5H
6H
Test load
Record
Coal sampling
Fuel consumption record
Heavy/crude oil, ash sample
Gas analysis
3. Measurement Equipment
(1) Precision of Meters
Measuring equipment shall be arranged according to the table, grasping its precision.
value (min. meter
position
tolerance
Remarks
No water base
Hydrogen
0.01%
0.15%
Nitrogen
0.01%
0.06%
(Central
1C
0.5C
0.03%
0.01%
reading)
Precision /
Unit
Carbon
Boiler
Fuel analysis
Measurement items
Input minimum
Measuring
0.01Mpa (1atg)*
control)
(0.5atg)*
0.005Mpa
(Central
1C
0.5C
(Central
*The brackets show the minimum reading values of equipment for power stations requiring meter reading.
Reheat steam
control)
Temp.
Main steam
MPa
Reheat steam
Turbine
Main steam
Pressure
control)
In order to obtain control values, test needs to be conducted a few times, and the estimated value from the
results can be used.
89
90
QG
(Generator output)
QO (Output heat)
B = (1 -
QO + QBS - QEX
QBL
)=
Qf
Qf
Loss method
T = (1
QTL
QG
)=
QO - QTS
QO - QTS
Loss method
91
Unit thermal efficiency is the product of boiler room efficiency multiplied by turbine room efficiency.
Unit thermal efficiency
P = B T =
QO + QBS - QEX
QT
Qf
QO - QTS
QG QO + QBS - QEX
Qf
QO - QTS
(1)
(Note) Conventionally, Unit thermal efficiency by heat input-output method has been calculated as
P =
QG
Qf
However, the steam generated in the unit system is used outside, the heat value of such steam must be incorporated
into the calculation. Therefore, Equation (1) can represent the heat input-output method unit thermal efficiency.
Theoretically, heat input-output method and loss method should compute out the same results.
Boiler system
WMS x iMS
WEj x iEj
WSS x iSS
SH
WSD x iSD
WHR x iHR
WRS x iRS
WLR x iLR
Qf x QEX
RH
Heat loss
Heavy oil
Drain
Heavy oil
heater
WFW x iFW
WSAH x iSAH
WSAH x iSAHD
WSC x iSC
WSC x iSCD
AH
Atomize
steam
Exhaust gas
Combusted air
SAH
Heater
SC
(qsc)
92
Bi =
QO + QBS - QEX
100[%]
Qf
Qf = Hf Mf
Qf
[kJ/h]
QEX
[kJ/h]
QO
QBS
Hf
[kJ/h]
Mf
:Fuel consumption
[kg/h]
QO=WMS
iMS+WHR
WEj
(Heating, etc)
iEjWSS
[kJ/h]
iSSWRS
iRSWLR
iLRWFW
iFWWSAH(iSAHiSAHD)WSC(iSCiSCD)QEX
WMS
iMS
WHR
iHR
WEj
iEj
WSS
iSS
WRS
iRS
WLR
iLR
WFW
iFW
WSAH
iSAH
iSAHD
[kJ/kg]
WSC
[kg/h]
iSC
iSCD
: SC drain enthalpy
enthalpy
[kg/h]
[kJ/kg]
[kg/h]
enthalpy
[kJ/kg]
[kg/h]
enthalpy
[kJ/kg]
[kg/h]
enthalpy
[kJ/kg]
[kg/h]
enthalpy
[kJ/kg]
[kg/h]
enthalpy
[kJ/kg]
enthalpy
[kg/h]
[kJ/kg]
[kg/h]
enthalpy
[kJ/kg]
enthalpy
[kJ/kg]
[kJ/kg]
93
[kJ/h]
(Note)
( iSC - iSCD )
(Note) WSAH and WSC show steam flow from other units, own unit being 0.
Main Stop Valve Inlet Steam Flow Rate (WMS)
1
WCL
2
WCL
[kg/h]
WBD
[kg/h]
WMU
: Make-up water
[kg/h]
[kg/h]
WHi
[kg/h]
94
B1 = 1
Q BL
L CL L BD L AT L EX
Qf
[kJ/kg fuel]
Li = L g + L w + L as + L ASH + L co + L Rd + L UB + L AH
a.
L g = C g {M gt + (m 1)M at }(t g t a )
Cg
[kJ/kg fuel]
1.38
[m3N/kg fuel]
[kJ/m3N K]
[C]
ta
[C]
L w = (Ww + Wh )(i g t a )
[kJ/kg fuel]
[kg/kg fuel]
[kg/kg fuel]
ig
[kJ/kg]
: Air temperature [C] (same value as water enthalpy [kJ/kg]=ta)
ta
c.
L as = 1.29Z m M at (t g t a )
[kJ/kg fuel]
: Absolute humidity
[kg/kg]
Cs
1.88
95
[kJ/kg K]
L ASH = C ASH
(
)
A PBOT
(800 t a ) + 100 PBOT (t g t a )
100 100
100
1.05
[kJ/kg fuel]
[kJ/kg K]
[%]
[%]
e.
L co = H co {M gt + (m 1)M at }
[CO]
[kJ/kg fuel]
100
[kJ/m3N]
[%]
f.
(According to A.M.B.A. Standard Radiation Loss Chart in ASME Power Test Code)
L UB = Hc
A
u
100 100 u
[kJ/kg fuel]
Hc
33,900
[kJ/kg]
[%]
L AH = C a (1 + 1.61Z )
100
{M gt + (m 1)M at }(t g t a )
Ca
1.30
96
[kJ/kg fuel]
[kJ/m3N K]
[%]
i.
L CL =
1 WCL ( iFW t a )
2
Qf
j.
[kg/h]
[kJ/kg]
L BD =
WBD ( iFW t a )
Qf
[kg/h]
enthalpy
[kJ/kg]
L AT =
WAT ( iFW t a )
Qf
[kg/h]
Mat =
Mat
1
o
(100 W1 )
c = c
100
h = h
o = o
s = s
(100 W1 )
100
(100 W1 )
100
(100 W1 )
100
u
100 u
[m3N/kg fuel]
[%]
100A
o = 100 c + h + n +
100 W1
[%]
[%]
[%]
[%]
97
: Carbon
: Hydrogen
: Nitrogen
: Combustive sulfur
: Oxygen
[%]
W1
[%]
[%]
m=
21
(O ) 0.5(CO )
21 79 2
(N 2 )
(CO2)
(CO)
(N2)
1
o
M gt =
n = n
[m3N/kg fuel]
(100 W1 )
100
Wh =
9h
100
WW =
W2
W1
100
[kg/kg fuel]
W2
[kg/kg fuel]
100 W2
[%]
98
Absolute Humidity Z
Z = 0.622
Ps
Pa Ps
Ps = PW 0.0008 Pa (Td T W )
[kg/kg]
Pa
: Atmosphere pressure
[kPa]
Ps
: Steam pressure
[kPa]
PW
[kPa]
Td
[C]
TW
: Wet-bulb temperature
[C]
[%]
[%]
[%]
QG
100
Q O Q TS
T =
QG
PG
[%]
[kJ/h]
[kWh]
[kJ/h]
Pi =
K
K=
QG
K 100
Qf
[%]
Q O + Q BS Q EX
Q O Q TS
P1 = B1 T / 100
[%]
99
PGH +
PG
PCM
PG
100
PG
[%]
[kWh]
[kWh]
[kWh]
(Note) Auxiliary power consists of the common auxiliary power proportionately divided by each units generator
output added by house transformer power.
P = P 1
100
[%]
100
8. AH Air Leakage
According to the boiler boundary in Diagram 2, exhaust gas analysis is done at AH outlet, but in reality, to
eliminate the influence of combustion air leaking in, it is done at Eco outlet.
Along with this, AH air leakage ratio is measured to obtain the heat loss due to AH air leakage.
101
9. Calculation Method of High Pressure Turbine First-Stage Pressure Standard Steam Flow Rate by
Regression Line
(1) Preparation Procedure
a. At each generator output, high-pressure turbine firs-stage pressure (P) and feed water flowmeter standard main
steam flow rate (WMS) are measured.
(Note 1) High-pressure turbine firs-stage pressure is measured with meters capable of reading minute fluctuations
such as expanded pressure meter, transmitter output voltage.
(Note 2) Main steam flow rate is calculated after density correction of each flow rate.
b. Regression line for high-pressure turbine firs-stage pressure (P) and feed water flowmeter standard main steam flow
rate (WMS) are calculated.
This regression line is applied to performance tests conducted from this point on, calculating main steam flow
rate.
SH spray
(WSS)
High-pressure
Main steam
output
turbine
firs-stage
[t/h]
pressure Pi
[MPa]
WMS=WFWWSS
MCR
13.0
580.470
4/4
11.4
514.760
3/4
8.4
370.680
2/4
5.8
242.880
Minimum
3.5
152.810
Calculation procedure
a. Calculate S1= Pi2( Pi)2/n.
2
S1=60.928
2
S2=128,557.61
S3=2,796.953
d. Calculate P= Pi/n.
P = 8.42
WMS=372.32
f. From above,
WMS =
S3
S1
S
P + WMS 3
S1
WMS=45.9059P14.2074
S 2
= 3
S1 S 2
=0.9994
102
Group
I. Anthracite coal
1.
2.
3.
1.
2.
3.
4.
5.
III. Sub-bituminous
coal
1. A Sub-bituminous
coal
2. B Sub-bituminous
coal
3. C Sub-bituminous
coal
1. A. Brown coal
2. B. Brown coal
Range of fixed
carbon
(dry coal/no-mineral
base %)
98
92 / <98
86 / <92
78 / <86
Range of volatile
matter
(dry coal/no-mineral
base %)
2
2</8
8 < / 14
14 < / 22
69 / 78
22 < / 31
< 69
31 <
7,780
7,220 / <7,780
Exist
Not exist
103
Agglomeration
characteristic
Not exist
Generally, exist
Not exist
Anthracite refers to coal with non-agglomeration characteristics, low volatile matter, and a fuel ratio of more
than 6, and it is poor in ignitability and combustibility. Sub-bituminous coal and brown coal, whose fuel ratio is
less than 1, are excellent in ignitability and combustibility, but poor in mill grindability (explained later) and have
slagging/fouling characteristics. Therefore, bituminous coal, whose fuel ratio is intermediate, is generally used in
pulverized coal burning boilers. The bituminous coal is classified into five types as below, and the higher the rank
the poorer in ignitability and combustibility.
(1) Low volatile matter bituminous coal (the fuel ratio is approx. 4)
(2) Medium volatile matter bituminous coal (the fuel ratio is approx. 2.8)
(3) A high volatile matter bituminous coal (the fuel ratio is approx. 1.5)
(4) B high volatile matter bituminous coal (the fuel ratio is approx. 1.2)
(5) C high volatile matter bituminous coal (the fuel ratio is approx 1.1)
(2) Volatile Matter and Calorific Value
Ignitability evaluation of coal itself is generally performed in accordance with the volatile matter amount and
the calorific value contained in coal. In general, when the volatile matter amount is less than 20%, it is necessary
to consider some methods to stabilize the ignitability. The following expression has traditionally been used as the
ignitability index:
Ignitability index =
The ignitability index, which can be used as a judgment criterion of the ignition difficulty of coal with much
surface moisture, indicates discharged moisture and a calorific value of volatile matter. When the ignitability
index is 35 or less, it is said some measures for ignitability improvement should be taken.
(3) Adherence and Agglomeration Characteristics
Coal adherence means a property of the cake-like expansion of coal when it is heated, and is usually judged by
a button index. Coal with a high button index requires special attention because fuel-fines adhere to or clog in a
burner nozzle or unburned hydrocarbon increases due to fuel-fines blended in the process of combustion. For coal
with a button index of 6-7 or more, it is necessary to consider special designs to prevent these problems.
The large ash alkaline ratio means an increased slagging characteristic because low-melting oxides and
compound salt are easily generated. It is generally said that the slagging characteristic is small if the ash alkaline
ratio is 0.5 or less.
This is also identified by the color of ash: much SiO2 and Al3O3 show white, much CaO shows yellow, much
Fe2O3 shows red, and much Fe2O3 and CaO show pink to purple. That is to say, as the ash color changes from
white to reddish, the ash slagging characteristic becomes stronger.
(4) Fe2O3/CaO Ratio and S-content in Coal
When the ratio of Fe2O3 to CaO in ash is approx. 0.3-3, low-melting compounds tend to be generated. This fact
can become a supplementary judgment criterion of the ash alkaline ratio.
Also, when the S-content in ash is large, Fe generates basicity components and low-melting sulfuric acid complex
salt, increasing the slagging characteristic. The S-content in ash is preferably 2% or less for preventing slagging
problems.
105
Ash + unburned
hydrocarbon
Ash
Volatile matter
discharge
Supplementary air
compartment
(Volatile matter
burning area)
Combustion
completion
NOx generation
characteristic
Ignitability
Burnout
characteristic
106
Mora
Newlands
Daido
Warkworth
Drayton
Mirror blend
Optimum
Miike
The
Pacific
Ocean
Symbol
Brand
Pulverized coal
(200/mesh passes)
Amount of coal
supply
1. Air temperature
Normal
temperature
H coal
When the surface temperature of the grains in a coal grain assemblage exceeds the coal radiant ignition
temperature, they are ignited, and this position is called the ignition distance from the burner. Because the smaller
the grain intervals in the coal grain assemblage (the grains density is high), the larger the radiant heat from other
burning coal grains, and the smaller the air heat capacity around the coal grains, so the coal grain temperature is
apt to rise and the ignition distance becomes shorter. On the other hand, if the intervals among coal grains are too
small (the coal grains density is too high), it is difficult for the radiant heat from other heat sources to penetrate the
core, and because the oxygen consumption of the grain assemblage exceeds the oxygen amount supplied in the
primary air, it is difficult for the combustion to continue. So the ignition distance, on the contrary, becomes larger.
Thus, the pulverized coal assemblage in the primary air flow has the optimum ignition point for the coal grain
density (the inverse number of primary air/coal ratio).
Also, as you understand easily, pulverized coal ignition is strongly affected by ambient temperature.
As shown in Fig.3, the ignition distance of coal with lower volatile matter drastically increases along with the
ambient temperature drop, compared with that of coal with high volatile matter.
This ignition distance increases due to the ambient temperature drop coinciding with the fact that the lower the
load on the pulverized coal burning boiler, the worse the ignition stability.
G coal
A coal
D coal
B coal
Ambient gas temperature = 1,200C
Ambient oxygen density = 0.04 ala
K* =
(Wo WE )
(1)
nDo 2T
Because, in actual pulverized coal burning boilers, the gas/coal grain temperature and oxygen density change
when coal moves from the burner exit to the furnace exit, and the combustion is largely rate-controlled by
diffusion resistance in the higher temperature area, as well as by chemical reaction resistance in the lower
temperature area. So it is not appropriate to use the burning velocity coefficient K*, which has been measured
under a certain condition, for the calculation of the burnout in the boiler furnace.
The combustion of pulverized coal grains in the furnace is as per the following expression, where the grain size
is Dp:
d ro
3
2
DP = DP K P (2)
d 6
1
1
1
=
+
(3)
K KO K f
Where, the signs are as follows:
K: general combustion velocity coefficient (g/cm2xs)
Kf: combustion velocity coefficient when the oxygen diffusion density in
the gas film is dominant (g/cm2xs)
Kc: combustion velocity coefficient when the chemical reaction rate of
the grain surface is dominant (g/cm2xs)
P: oxygen pressure (atm)
Dp: coal grain size (cm)
ro: specific gravity of coal grain (g/cm3)
: burning time (s)
The general burning velocity coefficient K varies depending on the coal properties in addition to the grain size
and burning area gas temperature. Therefore, in order to lower unburned losses in a pulverized coal burning boiler,
we must know the characteristics of pulverized coal grains K, coal grain size Dp (coal fineness), in-furnace
retention time , and gas temperature distribution and oxygen density distribution in the furnace, and then
determine the furnace dimensions or pulverized coal facilities.
Figure 5 shows the trajectory of the flame axis obtained by simulations of heat-transfer flow in the furnace
using the aforementioned expressions (2) and (3), and the calculation results of the unburned hydrocarbon by
applying the calculation of the gas & oxygen density distribution. The combustion rapidly proceeds in the area
approx. five meters high above the burner toward the furnace exit, but it becomes slower in the area approx. 10
meters high, and the combustion reaction almost does not proceed in the area exceeding 20 meters high due to the
gas temperature drop. Therefore, this suggests that in order to improve the burning efficiency of pulverized coal, it
is more effective to reduce the coal grain size by increasing the coal fineness rather than to lengthen the retention
time in the furnace.
109
Fuel ratio
Air
temperature
Coal fineness
(200 mesh pass / 100 mesh
residuum)
Molecular
symbol
C
H2
S
O2
N2
H2O
SO2
CO2
Molecular weight
Approx.
Exact value
value
12
12.011
2
2.016
32
32.064
32
31.999
28
28.013
18
18.015
64
64.053
29
28.964
44
44.010
Specific weight
kg/Nm3
Specific constitution
Nm3kg
0.08997
1.42897
1.25041
0.80374
2.92659
1.29298
1.97682
11.12698
0.69980
0.79974
1.24419
0.34169
0.77341
0.50586
The following expressions are typical examples of calorific value calculation in the ultimate analysis and
proximate analysis of coal.
1. Dulongs expression (from the result of the ultimate analysis of coal)
HHV = 81C + 342.5(H-O/8) + 22.5S (kcal/kg)
Where, C, H, O and S show the wt% of carbon, hydrogen, oxygen and sulfur, respectively.
2. Kosakas expression (from the result of proximate analysis of coal)
HHV = 81Cf + (96 - y W) y (Vm + W) (kcal/kg)
Where, Cf, W and Vm show the wt% of fixed carbon, moisture, and volatile matter, respectively, and is
the coefficient of moisture and is used as the following values:
110
When W<5.0
When W5.0
= 6.5
= 5.0
(2) Combustion Air Flow Rate and Combustion Gas Flow Rate
In order to burn fuel completely, it is necessary to supply necessary and adequate air (oxygen) for combustion.
In actual combustion, air and fuel are not mixed ideally and it is difficult to burn fuel completely by the
theoretically necessary combustion air flow rate alone, hence a proper combustion air flow rate is supplied as an
excess air flow rate depending on the fuel in addition to this theoretical combustion air flow rate. Especially, for
pulverized coal burning, a more excessive air flow rate is needed (for bituminous coal with high volatile matter, it
is approx. 1.2-1.25 in the air ratio) because the combustion characteristic is poorer than that of heavy oil or gas
due to the larger-sized, solid grains with the slow combustion velocity.
Though the major components of coal consist of carbon (C), hydrogen (H), oxygen (O), nitrogen (N), sulfur (S)
etc., the combustible components are carbon, hydrogen and sulfur, each of which is completely burned to become
carbon dioxide (CO2), water vapor (H2O), and sulfur dioxide (SO2), respectively. The entire oxygen in coal is
considered to become water (water vapor) by combining with hydrogen during the combustion.
Table 3 List of Component Combustion Values
Theoretical dry air flow rate
Component
O2
N2
Air
Upper row: kg/kg
Carbon
Hydrogen H2
Oxygen
O2
Sulfur
Nitrogen
N2
Moisture
Theoretical
dry gas flow
rate
Lower row Nm3/kg
Combustion
product
(CO2)
2.67
1.87
8.83
7.02
11.50
8.89
3.67
1.87
8.00
5.60
-1.00
-0.70
26.48
21.06
-3.31
-2.63
34.48
26.66
-4.31
-3.33
9.00
11.19
-
1.00
0.70
-
3.31
2.63
-
4.31
3.33
-
2.00
0.69
-
(H2O)
(SO2)
Moisture
amount
12.50
8.89
26.48
21.06
-3.31
-2.63
9.00
11.19
-
5.31
3.33
1.00
0.80
-
1.00
1.24
1. Calculation expressions of combustion air- and gas-flow rates in the ultimate analysis of coal
The combustion air flow rate needed for coal combustion and the generating combustion gas flow rate can
be calculated by the ultimate analysis using the list of component combustion values shown in Table 2. The
calculation results of component combustion are summarized in Table 3.
In this case, it is assumed that air consists of oxygen and nitrogen in a weight ratio of approx. 23.2% and
76.8% each and in a volume ratio of approx. 21% and 79% each.
The following shows the calculation process of the combustion air- and gas- flow rates regarding carbon
in the list, as well as regarding other components.
1 mol C + 1mol O2 = 1mol CO2
12 kgC + 32 kgO2 = 44 kgCO2
Necessary O2 for C 1kg is:
32
2.667
= 2.667 kg or
= 1.867 Nm 3
12
1.429
CO2 generation by combustion of C 1kg is:
44
3.667
= 3.667 kg or
= 1.867 Nm 3
12
1.977
The theoretical dry air flow rate of C 1kg is:
100
= 11.496 or
23.2
100
= 8.891Nm 3
1.867
21
2.667
76.8
= 8.829 or
23.2
79
1.867
= 7.024 Nm 3
21
2.667
(kg/kg)
(Nm3/kg)
Likewise, the theoretical dry gas flow rate (Gdo) is obtained by the following expression:
(kg/kg)
or,
(Nm3/kg)
Supposing that the moisture included in the burning air is Xa (absolute temperature, kg/kg and dry air),
the water vapor flow rate (Wa) is represented in the following expression:
Wa =Xa y Ado (kg/kg)
or
Wa = 1.61Xa y Ado (Nm3/kg)
The generating water vapor flow rate (Wf) by the combustion of moisture and hydrogen during burning is
represented in the following expression:
Wf = 9H + W (kg/kg)
or
Wf = 11.19H + 1.244W (Nm3/kg)
The theoretical wet gas flow rate (Gwo) by which the theoretical dry gas flow rate and the entire water
vapor flow rate are added up is obtained from the following expression:
Gwo = Gdo + W + Wa (kg/kg)
or
Gwo = Gdo + Wf + Wa (Nm3/kg)
Supposing that the aforementioned air ratio (actual combustion air flow rate plus excess air/theoretical air
ratio) is m, the actual wet air flow rate (Aw) is represented in the following expression:
Aw = m(1 + Xa)Ao (kg/kg)
or
Aw = m(1+1.61Xa)Ao (Nm3/kg)
The actual dry gas flow rate (Gd) and wet gas flow rate (Gw) are obtained from the following expression:
Gd = Gdo + (m-1) y Ado (kg/kg)
or
Gd = Gdo + (m-1) y Ado (Nm3/kg)
Gw = Gd + Wf + m y Wa (kg/kg)
or
Gw = Gd + Wf m y Wa (Nm3/kg)
2. Exhaust gas component
As aforementioned, if O2 1mol is supplied to C 1mol, CO2 1mol is generated. However, if air is supplied,
exhaust gas consisting of 21% of CO2 and 79% of N2 generates if C is completely burned because the air
consists of 21% of O2 and 79% of N2 (volume ratio). Thus, if the fuel is C alone, the upper limit of CO2 in
the exhaust gas becomes 21% theoretically.
However, in fuel combustion, the exhaust gas component increases while the ratio of CO2 is relatively
smaller due to the other components (S, N, etc) or the excess air flow rate (O2, N2). In this case, the
theoretical CO2 content ratio (CO2max) and the actual CO2 content ratio are obtained by the following
expression. Here, CO is 0, and also what has been taken into account in the actual gas analysis (liquid
absorption method) is that SO2 gas is absorbed together with CO2 and quantified.
(dry vol%)
CO2max = (1.867C + 0.69S)/Gdo 100
(dry vol%)
CO2 = (1.867C + 0.69S)/Gdo 100
Also, the other composition in the actual burning gas is obtained from the following expression:
(dry vol%)
O2 = 21(m-1)Ado/Gd
(dry vol%)
N2 = (0.8N + 0.79m y Ado)/Gd100
112
H2O = (Gw-Gd)/Gw100
(wet vol%)
Australian G
coal
Japanese A
coal
Chinese D coal
Raw
coal
Fig. 6 Relation between the residual nitrogen content in chars and the primary reactor temperature
Symbol
Base condition
Coal
South African
coal
O1.56%N
Japanese B
coal
1.1%N
Japanese A
coal
1.09%N
Chinese D
coal
Australian
0.85%N
C coal
1.59%N
113
Canadian F
coal
1.03%N
Fig. 9 Relation between Nox generation amount and primary reactor temperature
Thus, the NOx generation characteristic of coal fuel, which includes much organic nitrogen, has an extremely
complex reaction pattern compared with conventional gas or oil fuel. In this section, we will consider the NOx
generation mechanism of fundamental pulverized-coal in the reactor pipe.
First, Fig. 6 shows the volatile matter of organic nitrogen included in coal and its content ratio to char.
According to this Fig., the organic nitrogen ratio included in carbonized char is almost the same as that in raw
coal. This means that both the volatile matter in coal and the char include organic nitrogen almost evenly. Also,
the following shows the investigation result of NOx generation characteristics when pulverized coal is burned in
the primary- and secondary combustion areas separately with two electric-heating-type magnetic reactive pipes
connected by a quartz joint.
Figure 7 shows the comparison of NOx generation amounts in these areas by using (Ar+O2) and (N2+O2) as
combustion carrier gas.
This difference in both areas can be considered to be Thermal NOx (Prompt NOx is included). From the figure,
it is considered that almost all generation is accounted for by Fuel NOx when the reactor temperature is below
1400C while 25-30% is accounted for by Thermal NOx when the reactor temperature is 1600C.
Figure 8 shows the comparison of NOx generation amounts when the type of coal is changed under the
primary- and secondary reactors temperature of 1350C.
The relation between the type of coal and the NOx generation amount cannot be determined by the organic
nitrogen content alone in coal. Rather, it seems to be more understandable by the fuel ratio.
Figure 9 shows the relation between the primary reactor temperature and the NOx generation amount, where
the primary reactor air ratio is set to 0.41.
According to this figure, in the volatile matter burning area of the primary reactor, the higher the reactor
temperature, the lower the NOx generation amount. This phenomenon is seen only in an air-short reductive
atmosphere. Because, generally, the higher the temperature, the greater the volatile amount of carbon hydride and
organic nitrogen in coal, it is considered that when the actual air ratio in the burning area of the primary reactor
further decreases, the NOx generation amount will be lowered.
Japanese A coal
Residual O2 = 3%
Secondary reactor temperature =
1,350C
Air ratio in the primary reactor =
0.41
Fig. 10 Relation between Nox generation amount and retention time in primary reactor
114
Symbo
l
Coal
Japanese A
coal
Char
Residual O2 = 3%
Reactor temperature = 1,350C
(Lateral side)
(4) Vertical
firing
(Surface side)
(Front side)
(Lateral side)
called an opposed firing method. In these methods, circling motions are given to combustion air to shorten
flames and the fuel and air are circulated and mixed, thereby forming high temperature flames.
2. Tangential corner firing
In this method, burners are placed at the four corners of the furnace, from which pulverized coal and air
are injected tangentially into a virtual circle in the center of the furnace. Each burner independently forms a
flame while the entire flame is swirling slowly in the furnace to form a single flame (fireball), featuring a
long flame trajectory and slow combustion.
Stack
Desulfurization
equipment
Regenerative
preheater
Bunker
Secondary air
Stoker
Primary draft fan
Coal
pulverizer
Coal pulverizer
Seal air fan
Primary air
gases is adjusted so that they reach the necessary temperature at the mill entrance.
The gas-mixed pulverized coal from the mill is separated into pulverized coal and exhaust gas when it
passes through the cyclone (primary) and the bag filter (secondary). The pulverized coal captured here is
stored in the bin while the exhaust gas is returned to the air preheater exit by the exhaust fan.
The pulverized coal is transferred by the pulverized-coal stoker from the bin to the burner entrance, where
it is blended with the primary air and fed into the burner.
2. Operability
In the direct combustion method, the mill operation and burner operation are directly interlocked, and the
load operation is restricted both by the mill operation (the minimum mill load and the dynamics including
mill startup) and by the combustibility at the burner.
Bag filter
Bunker
Stoker
Exhaust fan
Screw conveyor
Desulfurization
equipment
Cyclone
Stack
Induced draft
fan
Coal
pulverizer
Regenerative
air preheater
Pulverized-coal
bin
Stoker
Electric dust
collector
Distributor
Secondary air
Primary air
In the bin system, coal grinding and drying in the mill and combustion at the burner can be separated, so
there is no operation restriction by the mill in terms of the load operation, but the combustion alone at the
burner is restricted. This is a little more advantageous than the direct combustion method.
3. Combustibility
In the direct combustion method, when a mill load is low, the air/fuel ratio becomes larger as the load is
lowered, thereby combustibility is apt to worsen.
In the bin system, as aforementioned, grinding and drying in the mill and the pulverized coal input to the
burner can be independently operated (however, within the bins capacity), and the coal moisture
evaporated in the mill is discharged outside the system. Therefore, the burner can ensure the optimal, dried
primary air/ratio with high to low load. This is especially much better for combustibility with a low load
than in the direct combustion method. However, the direct combustion method can also maintain
combustibility equivalent to that in the bin system by employing a high turndown burner (where an
air-pulverized coal mixture is separated into thick and thin types to burn).
4. Maintainability
In the direct combustion method, the greater the number of mills, the more frequent the maintenance and
services of the mills, but it is possible to schedule the intervals of maintenance and services by installing
backup mills.
In the bin system, the mills maintenance and services become easier because the number of mills can be
reduced. And mills can be halted for a short time (depending on the bin capacity), during which
maintenance is possible. However, the frequency of maintenance and services for other devices (a cyclone,
bag filter, exhaust fan, etc) increases.
5. Safety
In the direct combustion method, special safety measures are not needed because there is no pulverized
117
coal storage, whereas in the bin system, strict safety measures (sealing the bin by inert gas, installing
electrostatic, explosion-proof-type explosion doors, enhancing monitor systems, arranging fire
extinguishing equipment, etc.) are required in order to prevent pulverized coal in the bin from sparking and
exploding.
2.6.3.2 Furnace
Furnaces must fulfill certain functions: to convert the chemical energy of fuel into thermal energy effectively,
that is to say, to have combustion equipment (a chamber) to burn fuel completely; and to let the internal can-water
absorb generated heat through the surrounding water pipes. For these purposes, furnaces must be equipped with
the proper type and quantity of burners according to the fuel, and have the appropriate shape and space to
completely burn fuel, as well as the structure to withstand the thermal load.
Typical
bituminous coal
Heavy oil
Gas
118
Brown coal
with low Na
Brown coal
with medium
Na
Brown coal
with High Na
Electrode
In the pulverized coal burner, a premixed airflow of both the pulverized coal ground by the pulverizer and the
primary air is injected into the furnace through a boxy or cylindrical nozzle, and from the vicinity of this nozzle,
the secondary air heated by the air preheater is blown in. The pulverized coal, which has been injected together
with the primary air, diffuses rapidly while slowing the speed after coming out of the nozzle, and is ignited and
burned while mixing with the secondary air from the outside by receiving radiant heat from the high-temperature
furnace wall and flames. The flow rate of the mixed gas of pulverized coal and primary air is set by taking into
account the flame velocity and the pulverized coal settling velocity.
Figures 17-19 show the structures of typical pulverized coal burners. The burners in Figs. 17 and 18 have been
designed so that the rotating device gives rotating motions to the mixed gas of pulverized coal and primary air.
The pulverized coal burner in Fig. 19, called a tangential tilting burner, has been designed so that the nozzle of
the burner tip moves up and down each at the angle of approx. 30 degrees to adjust steam temperature.
Either burner is usually equipped with an ignition burner in the center or the side.
The pulverized coal burner requires maintenance because the tip is especially apt to be deformed and damaged
by receiving radiant heat in the furnace and vulnerable to abrasion by pulverized coal. Therefore, recently new
techniques have been developed for durability improvement, such as lining the burner with material (made into a
tile form) - ceramic etc. with high heat and abrasion resistance -, or flame-spray coating the surface. Some of them
have been practically used.
Air adjustment handle
Ignition burner
Air cylinder
Pulverized coal
burner
Impeller
Transformer
Air cylinder
Pulverized coal
entrance
Air register (circular type)
Inspection window
Pulverized-coal
outer casing
Pulverized-coal
combustion liner
Oil burner
Tertiary damper
Front
plate
Tertiary air pipe
Vane support
plate
Vane
Secondary air
(heavy oil burner)
Pulverized coal +
primary air
Secondary air
(heavy oil burner)
mixtures. Though with common burners, the pulverized coal density becomes lower and the ignition stability
worsens when the burner load is lower, this high-turndown burner maintains better ignition stability with this thick
mixture even when the burner load is low.
Primary air + pulverized coal
Combustion liner
driving device
Heavy oil entrance
Pitot tube
Combustion
liner
Flow divider
Secondary-air vane
opening/closing device
Inner-vane
Furnace front
wall and furnace
wall pipe
Secondary-air vane
Secondary air
Pilot torch
Flame stabilizing
ring
(with ceramic parts)
Guide sleeve
Pulverized coal +
primary air
Inner-periphery
combustion air
Outer-periphery
combustion air
Fig. 21 NR burner
121
Fig. 22
Pulverized coal PM
burner
Burner front side
Variable separator
No kicker
block
122
(3)
(6)
(5)
(4)
(7)
(9)
(8)
Tertiary air
Secondary air
Classifier
Oil pressure
load equipment
Separator body
Separator
Body liner
Roll
Pull ring
segment
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Hot air
entrance
124
Coal
entrance
Primary air
inlet
Supply
and drain
water
Mill upper
housing
Coarse grain
separator
(classifier)
Upper-housing
disassembling
support leg
Loading rod
seal
Pressure frame
Grinding
-roller
ring seat
cover
Loading rod
Grinding ring
Spring frame
Spring
Mill intermediate
housing
Throat ring
Lower housing
Ring seat
Pyrite
blow
Yoke
Pyrite box
Yoke
seal air
Gear box
Pressure
cylinder
Fig. 28
Nowadays, coal burning boilers have often employed pressure mills whose abrasive exhausters need not be
repaired. For these mills, seal air is supplied to prevent pulverized coal leak. Also as a measure to prevent coal
blockage in the stoker pipe, a rotary-type pipe is mounted.
125
Raw coal
Stoker pipe
Classifier driving
equipment
Outlet port
Hydraulic
loading device
Hot-air inlet
duct
Pull ring
segment
Bowl
126
Pulverizer housing
Pulverizer wheel
Coal pulverizer
gate mill gage
Abrasion-resistant
plate
Primary grinder
2.6.3.5 Stoker
The stoker is equipment which plays an essential role to determine the combustion rate corresponding to the
load variation and maintain the optimum air/fuel ratio in the coal combustion system.
The most important point when selecting a stoker is that it feeds the correct amount of coal into the pulverizer
from the bunker or silo smoothly and uniformly according to the fuel demand signals.
The following are the types and characteristics of stokers commonly used for pulverized coal boilers.
(1) Belt-type volumetric feeder
This stoker, using rubber belts, has a stable feeding capacity because coal is cut out equally in width and height.
With little interruption of coal feeding and good maintainability, this is generally used for pulverized coal
combustion equipment. Since this is a volume-control type, the coal weight sometimes varies according to the
coal density variation.
127
Entrance door
Coal entrance
(from bunker)
End plate
Downspout
Dresser coupling
Entrance gate
(fixed type)
Measuring span
Exit door
Cleaning conveyor
Seal air manifold
Belt take-up adjust screw
Cell preening
take-up pulley
Cleaning conveyor
chain take-up
Support roller
Tension pulley
Coal exit
(to mill)
Belt scraper
Cleaning-conveyor
chain sprocket
3. Operation power
Cold PAF method
Mill
Control
damper
Secondary air
Combustion
gas
Primary hot
air
Combustion
gas
Secondary air
Control
damper
Separate type
Tri-sector type
System
From boiler
To mill
To boiler
To boiler
Outer
Inner
periphery periphery
From
PAF
From FDF
From boiler
From boiler
To
To boiler mill
From
FDF
From
PAF
From IDF
From IDF
Three-
From
FDF
To
mill
way
From
PAF
split
From IDF
Secondary air
Secondary air
Gas
Gas
Gas
Gas
Gas
Primary air
Gas
Primary air
Primary air
temperature
control
Duct work
Secondary
Gas
air
Primary air
alone is possible
Slightly complex
Relatively simple
Relatively simple
Almost same
5. Economic efficiency
As for equipment cost, AH is higher and PAF is lower in the Cold PAF method than in the Hot PAF method, but
these cannot simply be compared because, as a matter of fact, they largely vary with equipment arrangement, duct
work, etc. As for operation power, the efficiency is reversed depending on the operation load area, as
aforementioned, so it is necessary to estimate the economic effect comprehensively, including operation patterns,
to decide the path to be taken.
Generally speaking, high-capacity, exclusive coal-combustion boilers often employ the Cold PAF method while
small-capacity boilers with fewer mills or co-combustion boilers often employ the Hot PAF method.
(2) PAF placement and type
In the Cold PAF method, there are two ways to place PAF: in series with FDF or in parallel with FDF. The
comparison between them is shown in Table 4.
Regarding the PAF types, a centrifugal type has traditionally been used because the air pressure required by
PAF is high and flat across the entire area as shown in Fig. 36 and because the conventional axial-flow fans could
not be enlarged or improved in performance to prevent surging.
Nowadays, the axial-flow fans have been improved against surging characteristics, and some of them have been
provided with a casing treatment suitable for the rotating-blade tips to enhance the fan efficiency.
2.6.3.7 Bunker
The design of bunkers must be fully considered so that they do not cause coal retention or blockage because
such bunker problems are crucial issues causing a load decrease or unit trip in the power stations.
(1) Design of bunker
1. Capacity
The bunker capacity is determined by the following expressions:
The coal amount stored within an available feeding time is:
Vc =
QT
Vc
( / 100)
System structure
Boiler
Fundamental characteristics
Selection criterion
Mill
Boiler
Mill
FDF air flow rate is larger but PAF air FDF air flow rate decreases by the
pressure decreases by the amount of
amount of PAF air flow rate compared
FDF discharged air pressure compared with the method described at left.
with the method described at right.
The method with a higher economic effect should be employed by taking into
account the characteristics of primary- and secondary air flow rates and air
pressure required by the pulverized coal combustion equipment as well as the
characteristics of fans (varies with the types).
130
2. Bunker shape
Generally, there are two types of bunkers: a conical shape and a pyramidal shape. They are almost the same in
flow characteristics in a bunker, but the conical shape is excellent in the space-occupation rate while the pyramidal
shape is excellent in strength.
3. Inclination angle of hopper wall face
In order for coal to assume an arch shape and not to cause blockage in the bunker, the arch bending moment
must be large. Because the arch bending moment is proportional to the squared distance between the fulcrums and
to the load applied to the arch, the cross-sectional area of the exit and the inclination angle of the wall face must
be more or less large. Generally, an angle of more than 70 degrees has been employed.
Characteristic of
conventional type PAF
(large type)
(With casing
treatment)
Improved
type
4. Bunker exit
Though the bunker exit is restricted by the diameter of the downspout or the stoker, the larger the bunker exit,
the better blockage prevention. There is a method to enlarge the cross-sectional area of the main bunker exit by
installing a sub-bunker under the bunker.
5. Material
Almost all bunkers are made of steel plates. The bunker exit, where blockage is most apt to occur, is usually
provided with a lining of high corrosion resistant stainless steel or polymeric synthetic resin. Also, Gunite is
sometimes used as a lining material on the vertical section by taking into account the resistance to abrasion.
Adhesive coal
Non adhesive
coal
Plug flow
(core flow)
Mass flow
Therefore, the mass flow does not retain coal for a long time in the bunker, but the plug flow always retains
coal in the lower position in the bunker.
The flow form is mainly determined by the following factors:
1. Type of coal
Adhesive coal is apt to take the plug flow pattern, causing blockage.
2. Inclination angle of hopper wall face
It is confirmed by the experiments that if the inclination angle of the wall face exceeds 65-70 degrees, the
flow separates into a mass flow and a plug flow.
3. Material for bunker inner face
When corrosion-prone material, such as steel plates, is used for a bunker inner face, corroded portions cause
an adherence phenomenon, resulting in the retention or blockage of coal. Hence, corrosion resistant material is
usually used: the inner face is often provided with a lining of high corrosion resistant stainless steel or
polymeric synthetic resin to prevent corrosion.
(3) Coal properties and blockage
1. Repose angle
Moisture (%)
Repose angle
(degree)
The larger the coal grains the more often blockage occurs. The coal flow is affected by grain size distribution,
ash and clay contents and moisture as mentioned below (Fig. 38).
132
Superheater
Turbine
Reheater
WW3 level
WW2 level
Generator
WW1 level
Condenser
Low temperature
reheated steam pipe
Boiler
Soot blower
Water feed
pump
133
Swivel tube
Motor
Steam
Steam
valve
Ash (deposits)
Furnace
Ash (deposits)
Lance tube
Steam valve
Type
Furnace soot
blower
Furnace (WW)
Superheater (SH)
Reheater (RH)
Rear thermal
transmission part
Air preheater
Total
Long soot
blower
R.P.M.
Steam
consumption
290(mm)
1.0(rpm)
35.5(kg/pc.)
7,950(mm)
16.9(rpm)
656.5(kg/pc.)
2,540(mm)
7,300(kg/pc.)
24,240(kg)
54
16
10
8
2
90
134
Soot blowing
Increase of metal
surface temperature
Increase of coal
consumption
Decrease of thermal
transmission
performance
Attachment of ash
to the thermal
transmission surfaces
Combustion of coal
Figures 4, 5 and 6 show the process of operating a soot blower, rotation mode and the relationship between
the stain indicator and the soot blower respectively. In the high electric load range (250 MW or above), the
stain indicator is calculated to express the condition of ash deposited onto the thermal transfer surface, to
automatically operate the soot blower to the ash deposit areas only. However, in the low electric load range
(less than 250 MW), the stain indicator calculation is unreliable, necessitating operation of all soot blowers,
otherwise ash cannot be removed completely from all the areas of the thermal transmission area, causing
temperature surge of the metal surfaces and widened difference in the internal wall temperature of the
furnace.
"Operation Mode"
Sequence Control
All units
Automatic
Combustion Control
In the electric load range shown in Fig. 7, the thermal collection performance of the furnace is not balanced.
If a soot blower is used, the boiler is subject to a disturbance and hence, the areas for which soot blowing is
prohibited are designated. If the low electric load condition continues for 8 hours or more after all soot
blowers are operated before decreasing the electric load to the low electric load area, the thermal
transmission surface is stained with uneven distribution of ash deposits. Thus, the duration of 2 hours and
45 minutes is set during which the low electric load condition is maintained, and, after 2 hours and 45
minutes, soot blowing is conducted using all soot blowers. (See Fig. 8)
135
Starts all
soot blowers
Starts all
soot blowers
8 hours or more
2 hours and
45 minutes
3. Progress of Actions
(1) Organization
At Tsuruga Thermal Power Plant, decreasing the power generation cost and enhancing the reliability of the
power generation facilities prioritized. In line with this policy, a series of actions was implemented to
further decrease the power generation cost.
SH and RH sides
SH/RH side
Standard coal
Low combustible coal
High
Low
Furnace side
4. Measures Taken
(1) Selection of Soot Blower Group
After considering the coal categories and combustibility shown in Table 2, a soot blower operation test was
conducted to two patterns as shown in Fig. 9 and 10.
[Pattern 1]
[Pattern 2]
? WW3 level
WW3 level
WW2 level
WW2 level
WW1 level
WW1 level
The coal shown in Table 3 was used as the representative coal categorized by the combustion ratio and the
test was conducted on Test Group 1, 2 and 3 to determine the response of automatic control of the boiler
against a change in the electric load. In addition, refer to a Fig. 11 about Test Process.
136
Prima Coal
Country of origin: Indonesia
Combustion ratio: 1.21
All soot blowers are started at the electric load of 250 MW or above before decreasing it.
After decreasing the electric load, the electric load of 250 MW or below is maintained for at least 8 hours,
and then the electric load of 125 MW is maintained for at least 4 hours.
Soot blowing of either Pattern 1 or 2.
The electric load is uplifted up to 360 MW.
- To reduce the electric load
retention time
- To reproduce stain condition of
the thermal transmission surface
under the low electric load range
Starts all
soot blowers
(3) Criteria for Determining the Response of the Automatic Control of Boilers to the Shift of the Load
The temperature of the main steam must not deviate greatly from the set values along with the increase in
electric load.
The reheated steam temperature of which set values are subject to change along with the shift of the electric
load must not deviate greatly from the set values.
The difference of the internal wall temperature of the furnace must be within the controlled temperature of
150.
137
Shift to the
furnace in low
electric load zone
Furnace
(5) Results
Table 4 indicates the results of the test for highly combustible coal, standard coal and low combustible coal.
Test group
1
2
3
Side View
Fine
powder
coal
Front View
Burner angle
Lower limit: 30
Fig. 13
Before change
After change
Load (MW)
a. Test Group 1
(a)
138
b.
(6) Assessment of the Response of Automatic Control of Boiler to the Load Shift
As a representative of all coal categories, the response to the electric load shift for main steam temperature
(MST) and reheated steam temperature (RST) when all soot blowers are operated for highly combustible coal
are shown in Table 6, 7 and 8. For Test Group 3, the soot blower of the furnace was operated only.
Though the decrease in main steam and reheated steam temperature just after starting the soot blower was
slightly larger than that when all soot blowers were turned on, the difference was narrowed gradually as the
electric load went up. The performance was favorable with no adverse effects on the increase of the electric
load.
Soot blower
group
All
(A)(B)(C)
Table 6: MST and RST before and after the Operation of Soot Blowers
Set temperature
Temperature before
Temperature after starting
()
starting a soot blower ()
a soot blower ()
MST/RST
MST/RST
MST/RST
566 (constant)/
552/525
529/495
varies depending on
559/521
519/476
electric load
40/45
Temperature
decrease ()
MST/RST
23/30
139
Temperature Difference on
the Surface ()
Decreased by 22,323 kg
All
Test
Group 1
Test
Group 2
Test
Group 3
For all coal categories, it was confirmed that the response of automatic control of boiler against the electric
load shift was good when all soot blowers of the furnace were used only.
As to the temperature difference on the surface, the values were all within the controlled limit and good
results were obtained.
Blowing time
Response of the main
steam temperature
Response of the reheated
steam temperature
Steam consumption
Results
Curtailed by 2 hours
No problems
No problems
No problems
No problems
24,240
1,917
Reduced by 92%
(kl/time)
(Calculation Conditions)
Enthalpy of the sot blower steam source: 3,140 (kJ/kg)
Calorific power of crude oil: 38.2106 (kJ/kl)
Boiler efficiency: 90%
Number of times of changing the electric load: Once in two days or 65 times a year (except for summer
and winter time)
140
6. Summary
For all coal categories, use of furnace soot blowers in low electric load conditions only in low electric load
conditions did not reveal any problems in increasing the electric load, and the automatic control of boilers
functioned well. We were successful in reduction of soot blower steam consumption in response to the
change of operation mode of the coal thermal power generation system.
7. Future Plans
To anticipate future diversification in coal procurement, we will attempt to achieve a stable power supply and
reduce costs through energy saving after examining all operating conditions. At the same time, we will
raise the mind toward energy saving and address measures against it.
141