TPRI

Contract number: TPRI/TR-CA-047-2016A

Measures number: TPRI -A034-01-GL002
 

 
 
 
China Shandong Ruyi Sahiwal of Pakistan
2×660MW
Coal-fired power station project 1 boiler,
set to start the debugger steps
 

 
 
 
 
 
 
 XI ' an thermal power
Research Institute company
limited              
The year November 2016
 
  

 
Series Write: Bull Pei

Nuclear: Liu gang

Subject: Zhao Jing Tao

 
 
 
 
RECORDING
 
 

       
1 The purpose
Unit is set to start the debugger sets a major process of trial operation,
started trial operation of whole units, such as safety, quality, is a
comprehensive inspection of the performance of the unit, but also on the early
commissioning of the unit a comprehensive inspection, test. Try to guide the
boiler set to start the debugger work, ensure the safe and normal operation of
the unit, this measure is enacted.
Measures according to the situation on site commissioning phase of startup
programs, requirements, test conditions, methods and considerations, and
approved before implementation.
2 Prepared based on
2.1 Thermal power construction project started trial operation and acceptance
of the Statute of the Office ( DL/T 5437-2009 )
2.2 The construction technical specification of boiler articles ( DL/T5190.2-
2012 )
2.3 Commissioning the construction of coal-fired power generation engineering
quality acceptance and assessment Regulation ( DL/T 5295-2013 )
2.4 The steam pipe blowing scheme of thermal power construction project unit
guidelines ( DL/T 1269-2013 )
2.5 The steam boiler safety technology supervisory regulations ( TSG G0001-2012
)
2.6 Of the thermal power plant construction project commissioning specification
( DL/T 5294-2013 )
2.7 The boiler starts debugging guidelines ( DL/T 852-2004 )
2.8 Of the people's Republic of China engineering construction compulsory
article (electric power engineering) ( 2011 Year Edition)
2.9 Specification for safety operation of electric power construction (part of
thermal power plant) ( DL 5009.1-2014 )
2.10 Design drawings, specifications and equipment description
2.11 25 key requirements for the prevention of accidents of electric power
production (National Energy Board 2014 Year Edition)
2.12 The Shandong Huaneng Sahiwal of Pakistan 2 × 660MW Coal-fired power
station project 1 Outline of unit commissioning
3 Debugging quality objectives
In accordance with the commissioning of thermal power construction
engineering quality acceptance and assessment Regulation ( DL/T5295-2013 )
Unit complete with load in the commissioning phase of the quality standard,
and all tests pass rate 100% To meet unit package are required.
4 System introduction
China Shandong Ruyi Pakistan 2 × 660MW Coal-fired power plant boiler
design of Harbin boiler company limited 660MW Parameters of supercritical
once-through boilers, boiler models HG-2118/25.4-HM16 , П-type arrangement,
furnace, balanced ventilation, solid slag, steel frame, suspension structure,
boiler open layout, MPM Burners with separate burning wind ( SOFA ) The
combination of low NOX Air combustion system, corner tangential firing mode.
Boiler start-up system using built-in boot system without a Recirculation
pump, equipped with 6 -speed Coal mill consisting of Taichung direct firing
pulverizing system, when the burning coals 5 run, maximum continuous rating of
the boiler operating mode (B-MCR) for the design parameters. Synchronization
of the project construction of flue gas desulphurization facilities, reserved
and denitrification facilities (chimneys and steel frame construction). Spiral
of middle and lower part of furnace water wall tubes of boiler, the upper
vertical tube water wall once rose, with excessive header between the two
connections. Overheating steam thermostat way to coal water than regulation
mainly, while set two level four points spray water reduction temperature;
again hot steam thermostat main used shaft separated smoke road thermostat
bezel thermostat, while burning device of swing on again hot steam temperature
also has must regulation role, and in low temperature again hot device and
high temperature again hot device connection pipeline Shang also set has
accident spray water reduction temperature device.
Boiler mill uses heavy machinery plant in Shanghai HP1063/Dyn Mills,
positive pressure direct blowing pulverizing system uses medium speed mill
system, each furnace 6 Mills, B-MCR Work conditions 5 Running, 1 The reserve.
Each grinding for a total of 4 burners, burning a total of 24 groups, arranged
for furnace water wall 4 corners, forming a small circle cutters, burning, the
use of corner tangential firing large bellows structure, main burner using low
horizontal bias NO X Pulverized coal burner. Fineness of coal powder mill
exports R90=22%. Boiler is equipped with 2 capacity for 50% a fan, blower,
induced draft fan, merged with the buf in desulfurization of induced draft fan
settings. Blower in boiler primary air fan by the Shanghai factory production
of moving blade adjusted axial-flow fan and blower model PAF18.5-13.3-2. By
Shanghai boiler fan blower works limited production of moving blade adjusted
axial-flow fan and blower model FAF25.5-15-1. By Shanghai boiler induced draft
fan blower works limited production of moving blade adjusted axial-flow fan
and blower model SAF35-22.4-2. Configure two of the boiler air preheater for
three-ljunstoem structure of Rotary air preheater. For this project, using
micro-oil ignition of the boiler system, configured with three layers 12
mechanical atomizing type oil guns, guns the total heat input of light oil
boiler 15%B-MCR design, only design output for 1700kg/h. Coal and ash
characteristics are shown in table 1, ignition help fuel characteristics are
shown in table 2.
Table 1 And ash composition of coal quality characteristic analysis

Project Symbol Work unit Designed coal Checked coal

1. technical analysis        

ARB total moisture Mt ％ 18.2 25.1

Air dry basis moisture M ad ％ 11.53 10.04

ARB ash A ar ％ 8.15 9.28

Dry ash-free volatile V daf ％ 44.69 41.72

Receive low calorific value Q net , var MJ/kg 20.20 18.08

2. Harrington mill index HGI   52 51

3. erosion-wear index Ke   1.4 1.2

4. elemental analysis        

Receive carbon C ar ％ 55.14 49.90

ARB hydrogen H ar ％ 3.40 3.05

ARB oxygen O ar ％ 13.79 11.45

Receive-n N ar ％ 0.92 0.88

Total sulphur S t , ar ％ 0.4 0.34

5. ash melting temperature        

Ash temperature DT(T1) ℃ 1140 1180

 Project Symbol Work unit Designed coal Checked coal

Ash softening temperature ST(T2) ℃ 1170 1210

Ash hemispheric temperature HT(T2) ℃ 1190 1220

Ash melting temperature FT(T3) ℃ 1210 1240

6. ash analysis        

Silicon dioxide SiO2 ％ 44. 99 46.70

Aluminium oxide Al2O3 ％ 19.11 24.10

Ferric oxide Fe2O3 ％ 13.24 10.01

Calcium oxide CaO ％ 11.55 9.69

Magnesium oxide MgO ％ 1.2 1.07

Titanium dioxide TiO2 ％ 0.52 0.64

Sodium oxide Na2O ％ 0.42 0.39

Potassium oxide K2O ％ 0.87 0.9

Manganese dioxide MnO2 ％ 1.12 1.02

Sulfur trioxide SO3 ％ 7.45 5.75

 
Table 2 Ignition characteristic analysis of oil
Serial
Species Class 0# diesel oil
number
Kinematic mm2/s
1 3.0~8.0
viscosity
2 Ash % ≤ 0.01
3 Sulfur content % ≤ 0.035
4 Water   Mark
Closed cup flash
5 C 55
point
6 Freezing point C ≤0℃
The proportion t/m 3
0.8
7
of
Net calorific kJ/kg
8 ~41800
value
 
Boiler flue gas from furnace export to boiler tail, flue gas followed by
flows through Shang furnace of separated screen overheating device, and late
level overheating device, and level smoke road in the of high temperature
again hot device, then to tail double smoke road in the flue gas points two
road, way flows through Qian Department smoke road in the of vertical and
level low temperature again hot device, way flows through Hou Department smoke
road of a level overheating device, and province coal device, last into below
of two Taiwan Rotary type air Preheat device.
Boiler steam and water flow is bounded by built-in steam separator design
double process, imports from cold ash all the way to the Middle mixed spiral
between the header wall, connected to the furnace water wall at the top of the
vertical tube and rear hanging tubes of water wall, then drop into the furnace
arch and horizontal flue side walls, into the separator. Steam from the
separator into the ceiling and wall systems, then go for low temperature
superheater, and then flows through the last stage superheater platen
superheater and separated. Reheater is divided into low-temperature reheater
and the two-stage layout of high temperature reheater, located in the tail of
low temperature reheater of double flues flues in the front, last stage
reheater counterflow heat exchanger arranged in horizontal flue.
Boiler start-up system without a Recirculation pump system, four vertical
built-in startup separator located above the front of the boiler, media from
the horizontal flue outlet header 6 the next 15 ° tangential pipe separator
is introduced. At the bottom of the separator in the axial arrangement of
exports has a catheter will be separated out of the water to the storage tank;
at the top of the separator of axial layout 1 export of catheters, steam to
the entrance of a roof superheater header. Storage tank only, also for
vertical cylinder, on the lower part there are 4 two-layer radial catheter
into the four separator drain. The water in the storage tank consists of two
water level control valve into the drain capacity in order to ensure the
minimum flow of water wall in the 25%B-MCR. Boiler in 25%B-MCR loads more run
time, separator is running dry, and only as a circulation element separator
according to the full pressure of the boiler design. Water in the storage tank
to the condenser, can recycle refrigerants during the boot process.
Boiler slag in wet ash plant, boiler main parameters are shown in table
3。
Table 3 boiler main parameters
 Checked
Designed coal
  Work coal
The name unit 75 % 50 % 40 %
BMCR TRL THA BMCR
THA THA THA
The main steam t/h 2118 2017 1934.0 1403.0 923.0 748.0 2118
flow
Steam t/h 1752.0 1668.6 1610.8 1197.5 806.9 660.2 1752.0
Economizer t/h 1991 1896 1818 1319 868 703 1991
inlet flow
Superheater
level spraying t/h 63.54 60.51 58.02 42.09 27.69 22.44 63.54
water
Superheater
secondary t/h 63.54 60.51 58.02 42.09 27.69 22.44 63.54
spray water
Thermal water t/h / / / / / / /
spray
Main steam
outlet Mpa.g 25.4 25.3 24.8 18.4 12.3 10.3 25.40
pressure
Reheat steam Mpa.g 5.626 5.353 5.172 3.844 2.574 2.094 5.626
inlet pressure
Reheat steam
outlet Mpa.g 5.426 5.163 4.989 3.706 2.480 2.016 5.426
pressure
Separator Mpa.g 26.9 26.7 26.1 19.3 12.9 10.8 26.90
pressure
Water supply Mpa.g 29.00 28.59 27.90 20.62 13.76 11.50 29.00
pressure
Main steam
outlet ℃ 571 571 571 571 571 571 571
temperature
Feed water 300.5 296.9 294.4 275.5 252.0 240.8 300.5
℃
temperature
Inlet
temperature of ℃ 345.0 336.5 333.6 338.5 344.3 345.8 345.0
reheat steam
Reheat steam 569 569 569 569 569 543 569
℃
temperature
Superheater
spray   29.00 28.59 27.90 20.62 13.76 11.50 29.00
desuperheating
water pressure
Overheating
cooling water   300.5 296.9 294.4 275.5 252.0 240.8 300.5
temperature
Reheater
desuperheating ℃ ~13.0            
water pressure
Temperature of ℃ 190.1 187.5 181.2 174.5 158.0 148.8 190.1
reheater
 Checked
Designed coal
  Work coal
The name unit 75 % 50 % 40 %
BMCR TRL THA BMCR
THA THA THA
desuperheating
water
Total amount t/h 278.694 268.804 260.174 199.143 138.821 116.186 312.2
of coal-fired
The total air t/h 2232.6 2153.4 2084.2 1612.2 1204.7 1046.3 2265.6
volume
Furnace cross- Mw/
section heat 4.282 4.130 3.997 3.050 2.122 1.772 4.285
㎡
load
Furnace volume Kw/
68.85 66.41 64.28 49.05 34.12 28.50 68.90
heat loads ㎡
Efficiency
(low heat ％ 94.50 94.52 94.54 94.03 93.91 94.06 94.10
value)
Furnace exit
of excess air / 1.200 1.200 1.200 1.215 1.304 1.355 1.200
coefficient
Furnace exit
flue gas ℃ 970 960 951 884 809 778 972
temperature
Flue gas
temperature ℃ 124 123 123 117.2 112 109 123.3
(amended)
 
5 Debugging stage
5.1 Start preparation and ignition phase
Before this stage is the start of a comprehensive inspection and
commissioning stage.
 Valve check damper, soft drinks;
 Auxiliary equipment and station interlocking, protection;
 Air heater, fan, blower, fan partial commissioning; ESP, sealed air and
fire inspection fan, slag, ash removal system commissioning of the
system;
 Boilers cold ventilation test;
 Soot blowing systems commissioning;
 Commissioning of desulfurization system;
 Fuel system;
 Ignition of the boiler inspection;
 Boiler cold and hot water;
 Try putting the layer of grease gun.
5.2 No load phase
This phase A Milling system.
 MFT Interlock of static tests, unit tests;
 Cooperate in the turbine turning, fixed speed and turbine test;
 Steam turbines, electrical tests, with initial load;
 Speed test;
5.3 Loading phase
 Unit connected, according to the operating conditions to start other
system;
 Boiler conversion work-load during dry and wet;
 Coal, ash, slag and other satellite system with load-check;
 Combined with thermal control specialty in thermal power unit load 50%
~ 70% Throw when an automatic control device or system;
 Air tightness test of steam;
 , Reheater safety valve setting;
 Preliminary adjustment of combustion in boiler;
 Ash blowing hot throw games;
 Low temperature economizer operation test;
 According to the unit load and combustion oil stable combustion in low
load test was carried out.
5.4 168 Hour trial operation phase
At this stage, in accordance with the Thermal power construction project
started trial operation and acceptance procedures ( DL/T 5437-2009 ) And the
Thermal power plant construction project commissioning specification ( DL/T
5294-2013 ) 168 Working hours test run. 168 hours after the completion of the
transfer.
6 Boiler package before the start of the conditions of
6.1 The conditions of the locomotive
6.1.1 Boiler: the end of the installation, insulation, boiler pressure, wind
pressure test is over. Scaffolding dismantling within the furnace, flue gas
ducts, garbage, debris clean up, withdrawal of all staff, each hole, hole
closed.
6.1.2 Air/gas system: the end of the installation, insulation, air preheater
and draft, sending wind, a wind machine, sealing machine 8 Hour partial
commissioning, acceptance, visa.
6.1.3 Steam-water system: installation, insulation work is over, all, perfect
hanger, spring hanger pins removed, qualified acceptance.
6.1.4 Fuel system: installation work of oil pump 8 Hour partial commissioning
qualified. Oil line sweeping, the qualified. Purge the steam system water
pressure, the sweeping, the qualified. Oil-fuel system before the cycle has
been completed.
6.1.5 Coal handling system: the end of the installation process, all ancillary
equipment 8 Hours end of the partial test, acceptance, and end of the coal
bunker installation, storage conditions and transport coal system belt
transfer is released, can at any time to the coal bunker.
6.1.6 Milling system: installation, insulation work is over, mills, coal and
related ancillary equipment 8 Hour partial commissioning qualified.
6.1.7 ESP system: installation, insulation work is over, ESP booster, end of
the vibration test, acceptance. Coal ash bucket, clean up the dust inside the
hopper at all levels, can be put into operation at any time.
6.1.8 Ash-slag disposal system: the end of the installation, insulation, and
affiliated facilities 8 Hours end of the partial test, acceptance.
6.1.9 Flame cooling air system: the end of the installation process, check fan
the fire 8 Hour partial commissioning qualified.
6.1.10 Soot blower system for boiler: the end of the installation, insulation,
pipes by steam blowing. Soot cold commissioning qualified.
6.1.11 End of the micro-oil ignition system installation, commissioning, oil
gun control start/stop static test, condition of micro-oil ignition system is
put into operation.
6.1.12 Low-temperature economizer system: the end of the installation,
insulation, flush with pipe, cryogenic economizer booster pump installation is
complete, the 8 Hours try turning qualified, low-temperature economizer system
passes the debugging of soot.
6.1.13 System installation is complete, test-individual equipment turned over,
conditions of desulfurization system put into operation.
6.1.14 Start the furnace: end of the installation, insulation, drain the pump
through 8 Hour partial commissioning qualified, have used condition.
6.1.15 Steam and water sampling, drain water, air, nitrogen and other systems
installed end of the insulation.
6.1.16 End of pickling and flushing of boiler pipe work, temporary system has
been restored.
6.1.17 End of the furnace cold air test. The primary air leveling, air flow
calibration is complete.
6.1.18 Boiler expansion: the expansion indicators are installed according to
the design, the inflation indicator to adjust the "0" Bits. Check all parts
where no impediment to expansion.
6.2 The conditions of electrical and thermal control
6.2.1 Electric, pneumatic valves, smoke windshield panels finished debugging,
remote operation, flexible, right direction.
6.2.2 The static sound and light alarm system commissioning is completed, the
alarm window display correctly.
6.2.3 Buttons of various rotating machinery accident intact, circuit is
correct. Simulation operation reliable.
6.2.4 Auxiliary machines control system ( SCS ) Finished debugging, Cheng Qi,
Cheng stopped logically correct, reliable equipment.
 The wind oil station in the launch conditions;
 Pump linkage relationship;
 , Air, a fan of start and stop conditions and relationship;
 The damper, damper linkage relationship;
 Fan Cheng Qi, Cheng stopped testing;
6.2.5 Safety monitoring and control system of the boiler FSSS ( BMS ) Static
commissioning is completed. Logic is correct, reliable action.
 Purge the furnace conditions;
 Furnace MFT ( OFT ) Conditions, MFT ( OFT ) After the relationship;
 Oil ignition conditions;
 Oil gun Cheng Qi, Cheng stopped;
 Oil guns tripping conditions;
 Coal firing conditions;
 Conditions, coal grinding machine started;
 The mill started, stop the program.
6.2.6 Data acquisition system for boiler ( DAS ) Static calibration is
completed, parameter name is correct, shows.
6.2.7 Industrial television static, flame detection system adjustment is
completed, can invest at any time.
6.2.8 Coal feeder in automatic weighing system adjustment is completed,
accurate measurement and display correctly.
6.2.9 End of the infrared temperature measuring device calibration and
commissioning of the furnace, and displayed correctly.
6.2.10 Soot-qualified programmable static debugging, simulation, the right
order, reliable action.
6.2.11 Air preheater sealing automatic clearance adjusting device for static
debugging, fire alarm devices.
6.2.12 Coal, ash, slag boiler ancillary systems, such as logical correlation
is correct, reliable action.
6.2.13 Machines, furnaces, electrical ( BTG ) Interlocked simulation is
complete, correct and reliable action.
6.2.14 End of unit security power supply installation and commissioning,
acceptance, conditions of operation.
6.3 The conditions of construction
6.3.1 Commissioning on-site access adequate lighting, emergency illumination
and reliable.
6.3.2 Scene of the test equipment is available, and equipped with adequate
fire-fighting equipment.
6.4 The conditions of the other
6.4.1 Chemical water system, able to provide qualified demineralized water.
6.4.2 Compressed air system, able to provide qualified compressed air.
6.4.3 Auxiliary power system, according to test requirements at any time, the
transmission.
6.4.4 Before starting to prepare enough fuel, coal, chemicals.     
6.4.5 Central air conditioning systems, boilers, elevators, lifting equipment,
commissioning, can use at any time.
7 Debug steps
7.1 Cold and hot wash and ignition
7.1.1 Boiler water
On water supply operation front drain pipe drainage Fe<200 μ g/l Shi, boiler
began in Sheung Shui.
 Proposed water time: usually the winter not less than 4 Hours, summer is
not less than 2 Hours.
 While the boiler feed water temperature 20 — 50 ℃ Or so.
 Water process water, check all parts whether leak, expansion of the
heating surfaces is normal, if anomalies are found, should be
identified, be eliminated.
  Sheung Shui to separators and the air outlet of the furnace body, from
low to high by closing the air gate, completed in Sheung Shui.
 Start separator temperature difference between inner and outer walls <50
℃ 。
7.1.2 Cold water washing
Sheung Shui economizers, water wall, steam separators, storage tanks into
the hydrophobic Flash tanks, water level control in the relief valve control
open flush. Furnace body washing include cold and hot flush. Cold washing can
be divided into open-type flush and straight flush in two stages. Tank
drainage Fe>500μg/l Shi, unit drain Flash tank flush flushing of water tanks
or circulating water system without recovery; in tank drainage Fe<500μg/l, 200
~ 300 μ g/l Before it goes into the condenser when cycling. When you start
separating iron content in the outlet water to less than 200μg/l, the cold
water washing over it.
7.1.3 Boiler ignition preparation
Boiler After the end of cold flushing, Maintenance of stable operation of
boiler start system, establishing the water cycle. Ignition received command
before running the code requirements for fire preparation.
 Starting in coal handling system A Raw coal silo transport sufficient coal-
fired;
 Contact electrical turn to be put into operation, electric damper
transmission;
 Compressed air system, cooling system, contact the long values to the
auxiliary steam for steam header;
 Establishment of boiler cool ash bucket of water into the slag , ash removal
system;
 Established fuel cycle;
 Check to make sure air duct and flue opening all baffle plate in the correct
position;
 Launch two air preheater, into the interlock switch;
 Started two fan, sending fans and flame cooling fan into flame detection
interlock switch cooling fan;
 Fuel system leak test;
 Fuel leak test after passing the purge Chamber and revert MFT 。
7.1.4 Boiler firing
7.1.4.1 MFT After returning, according to the operation rules for adjustment of
secondary air, furnace negative pressure to the required value.
7.1.4.2 Input AB1 Oil gun, check the oil gun ignition normal input AB2 Oil
gun, stopped at the right time after normal AB1 、 AB2 Oil gun, put AB3 、
AB4 Oil gun, check the oil gun ignition normal after starting the heater.
7.1.4.3 Start a fan and seal air blower, seal air fan key locking input. Put
oil heater, improving coal pulverizer inlet air temperature. Dang mill into
wind temperature reaches 150℃, micro-oil ignition ignition angle, carefully
monitor the fuel after oil grease gun is put into normal system operation,
ensure that the micro-oil ignition device is functioning and stable. Put oil
in time mode, Start warm mill grinding.
7.1.4.4 Boiler firing
 Dang A Mill outlet temperatures up to about 60 C, the A Coal pulverizer
inlet air volume Adjust To about 75t/h Start dynamic separators, Start A
Feeder, and measures to boost coal to about 20 t/h Adjust volume to observe
the corners burner ignition, adjust the secondary smaller air damper
opening degree of coal and to ensure normal combustion, stable.
 Monitor A Mills export wind speed, temperature, pressure, and import and
export parameters such as pressure, vibration, if necessary, to provide
coal, inlet air volume properly adjusted, to ensure that A Milling system
is functioning and stable.
 Check A After pulverizing system of a normal, stable exit AB Oil gun, by
micro-oil ignition system for combustion-supporting A Coal pulverizing
system operation.
7.1.4.5 Reheater steam control furnace exit flue gas temperature of not more
than 540 ℃。
7.1.4.6 After ignition of the boiler, care should be taken because of startup
separator of steam-water system in thermal expansion of lead storage tank
water level suddenly increase, should ensure that start-up separator tank
water level control valve In the automatic Control States to ensure that Start
detached normal tank water level and, if necessary, may be appropriate to
reduce the heating rate.
7.1.4.7 After ignition of the boiler should be paid attention to monitoring the
expansion, construction and production units to designate a record expansion.
Find prevent abnormal swelling or swelling, should be reported in a timely
manner, stop boosting. Analysis of causes and take measures before they can
continue to boost.
7.1.4.8 According to temperature booster requirements increase for coal.
Heating boost speed according to the boiler cold start warming boost curve.
7.1.4.9 Heat boost when, on trap should be open, and that monitor the water
wall, superheater, reheater temperature does not exceed the prescribed limits.
7.1.4.10 Adjust the water flow rate is not less than 529.5t/h 。
7.1.5 Hot washing of boiler
Boiler heating process, after the separator pressure rise to 0.4 ~ 0.5MPa
Shi, contact construction hot flange bolts. Separation booster to 0.4~1.0MPa,
contact thermal rinse instrument, contact the chemical rinse sampling tubes.
Water wall outlet water temperature rises to 190℃ stopped heating up,
pressure, hot flush. Monitoring of water quality, as appropriate, adjust the
hot flush of water, hot water when washing requirements, started to Flash tank
drain recovery condenser hot rinse economizer is preserved during flowrate
greater than 529.5T/h, when after the separator tank for water drainage, hot
flush ends. (Steam-water quality data, please refer to the chemistry of the1
Unit red tube and the entire start debugging test steam quality supervision
measures)
7.2 Steam engine turning
After the separator pressure rise to 0.5~0.8MPa Shi should be adjusted so
that steam parameters of turbine bypass system for turbine turning conditions.
At the time of steam turbine bypass system is in use, superheated steam passes
through the bypass system with high and low pressure, vacuum and temperature
into the condenser. Boilers began to heat up after the steam quality boost to
turning of steam turbine parameters to maintain lateral pressure of about
8.5MPa.
1) Steam pressure of steam temperature to turning parameters, contact
steam machine turning. Preliminary determination of turning parameters
are as follows:
           Side of main steam pressure 8.5MPa ;
           Side of main steam temperature 370 ℃ 。
2) after turning, turbine requirements, maintaining or adjusting the
operation parameters of boilers.
 3) steam machine to 3000r/min after constant speed, combined with steam
turbines, electrical electrical test.
4) electrical test ended, going to grid-connected load.
Grid-connected load at the beginning, according to professional
requirements for steam related work.
7.3 Loading phase
7.3.1 Grid-connected units with load:
1) Turbine after the end of the test, grid-connected units with initial
load, according to professional requirements for steam gradually
increasing load.
2) Turbine increase load process of high and low voltage bypass should step
down until the closing.
3) With increasing turbine bypass loads full off, followed by "coal-water
ratio" main steam pressure control, no longer use high side open to main
steam pressure control.
7.3.2 Start a second coal pulverizing system
 According to the heating requirements of booster and furnace pulverized
coal ignition and increasing in due course the A Under rating
pulverizing system.
 Start the first steam-driven feed-water pump under load to switch the
pump to pump.
 When the first rose to about its full output of coal pulverizing system
70% Shi, starting the second set amount of coal pulverizing system
slowly increased. When you increase the amount of coal oil can reduce
the amount of fuel or deactivated guns. After the second set of coal
pulverizing system operation, pulverizer air flow and outlet
temperature and coal can be input automatically.
7.3.3 Wet / State:
1) When steam production exceeding the minimum water separator for storage
tank when the water level decreased gradually, gradually adjust water
tone adjust the water flow of the opening next to the road.
2) Since it is difficult to define the switching point, therefore
increasing load process do not 20% to 30% travel between the rated
load, preventing the diversion of already dry to wet.
3) When the boiler runs into dry, open export overflow piping of the
economizer heating pipe valve, open the warm return water to the
cooling tube road valve, start the system in hot standby.
7.3.3 Increasing load to 660MW
1) Increasing load process when the water supply of small bypass opening is
greater than about 70%, timely switch to water supply according to water
flow change of the main roads, pay attention to water flow, coal and
water, cooling water, main and reheat steam temperature, storage tank
water level changes.
2) Starts the second turbine-driven feed-water pump and cast of " remote
control ". When water flow and pump, main steam pressure, water than coal,
the main steam and reheat steam temperature.
3) When the second system rise to about its full output of 70% Shi, you
can start the third set of milling system and phasing out or reducing the
grease gun.
4) Under load conditions, timely exit oil mode.
5) Starting after the third set of milling system, at a load of 330MW,
load change rate of Unit coordinated control to "6MW/min", target load is
set to "462MW".
6) Load greater than 396MW(or appropriate time according to mill output)
start the fourth set of pulverizing system, boiler combustion stability to
exit the oil system, all coal-oil-free operation, combined with
professional throw thermal furnace negative pressure automatic control,
wind pressure, the total amount of coal-fired.
7) When the electrostatic precipitator inlet flue gas temperature reached
100℃ above, ESP fully operational .
8) When the unit load >495MW start the fifth set of milling system.
9) Load up to about 594MW Shi, maintain stable operation during this time
help manufacturers to reheater, superheater safety hot set test, the whole
process is described in the steam air tightness test and safety valve
adjusting measures. Boiler pulverizing system and preliminary adjustment
of combustion tests, body and throw furnace soot blower, thermal control
specialty throw spray water automatically and adjust Unit coordinated
control system.
10) After passing the complete pilot projects and the quality of steam,
unit load increased to 660 MW Hou, tightness check boiler steam.
11) boiler steam tightness check after passing the test, with the thermal
load change tests professional.
12) combined with turbine load rejection test professional.
 13 ) To cooperate with the appropriate electrical test in question.
14) load rejection test is completed, outage of unit defect elimination
(according to unit test).
7.4 Full load 168 Hour trial operation
After load test run, the unit, the unit runs, oil, investment level
encryption and protection 100% Input, automatic input rate in 95% Above
according to the thermal power construction project started trial operation
and acceptance procedures ( 2009 Year Edition) requirements once the targets
are achieved, can enter the 168 Hour trial operation phase.
Unit 168 Hour trial operation phase is dominated by stable operation, can
be supplemented by combustion adjustment of boiler and so on.
7.5 The hot start of the unit
7.5.1 According to the different shutdown time, start state of the boiler can
be divided into four categories, as shown in table 4 。
Table 4 Start State classification of boilers
Start State Shutdown time T (About) hours
Cold start T>72
Warm start-up 10<T<72
The hot start 1<T<10
Very hot start T<1
  
7.5.2 Hot start of the boiler must be confirmed before repair work undertaken
during the shutdown is over.
7.5.3 To flow 529.5t/h Build water wall start cycle traffic.
7.5.4 Boiler hot start by heating the boiler start-up curve boost.
7.5.5 No water during the shutdown, while not be turned on before starting the
separator in the discharge air.
7.5.6 Turn on steam turbine bypass condenser vacuum has been established
before.
7.5.7 The hot start heating boiler steam water gate in the process control
requirements, such as:
 Sparse Watergate full on superheater and reheater.
 Contact open main steam turbine in front of hydrophobic and reheat steam
piping drainage, heating pipe. Input bypass system, controlling
temperature, boost speed.
 Turbine after turning off of superheater and reheater drain.
7.5.8 Prior to the steam reheater, control of boiler outlet flue gas
temperature of not more than 540 ℃。
7.5.9 Turbine when turning, according to the cylinder temperature closed side
hydrophobic.
7.5.10 According to the turbine with load requirements, other milling system.
And vote in desuperheating steam temperature or temperature to prevent
overheating.
7.6 Boiler
7.6.1 Before the shutdown, should conduct a comprehensive inspection of the
boiler, if problems are found, should make records, wait for the shutdown to
eliminate;
7.6.2 Recommend the normal shutdown sequence
1) load and shutdown before the soot reduction;
2) load shedding process, boiler combustion operation should be seen as
stable combustion oil burner gun, according to boiler load and the
output of coal pulverizing system of stopping in a timely manner;
3) boiler oil gun running, vote for continuous blowing of air preheater.
4) gradually reducing the boiler load;
5) shutdown after the last mill, a fan of stopping and mill seal air fan;

6) shut down all oil burners;

7) after shutdown, keep sending, fan is running, adjust the total volume to
30%BMCR amount of ventilation, the furnace blowing 5 minutes to stop
the blower, induced draft fan;
8) after the wind and smoke system outage, shut down the wind and smoke
system bezel, airtight Chamber;
9) maintain air heater operation, until the inlet of air preheater gas
temperature drops below 150℃ below before you can stop air pre-heater;
10) If the stoppage time only for a few days or longer, should remove all
boiler ash, sulfur dust absorbed moisture can cause corrosion. If
possible, it is recommended that boiler soot before shutdown. It is
worth noting that, remove from heat and thermal furnace is not blowing.
 7.6.3 Water storage tank level control valve shutdown operations
During normal shutdown of the boiler when the boiler load down 30%B-MCR ,
The pressure is reduced to approximately 8.8MPa Shi, warm water storage tank
level control valve should be closed first pipe, water storage tank level
control valve shall be automatic, open drain Flash tank outlet to condenser
electric door, when appears after the water level in the storage tank, water
level in the storage tank consists of storage tank water level control valve
is adjusted automatically, after you stop the water supply, close the tank
water level control valve.
7.7 Fill in the test record
8 The Division of responsibilities
    According to the Ministry of the thermal power construction project started
trial operation and acceptance procedures ( 2009 Year Edition) the relevant
provisions of, responsibilities of the parties are as follows:
8.1 Construction units
8.1.1 Responsible for test equipment repair and maintenance and faults
elimination.
8.1.2 Is responsible for the introduction and the person, a wind machine, mill,
coal machine, air monitoring, inspection and other auxiliary equipment.
8.1.3 Prepare the necessary repair tools and materials.
8.1.4 Cooperate with the unit set to start the debugger debug unit.
8.1.5 Participate in the package to start trial operation on duty.
8.2 Production units
8.2.1 Responsible for the system of trial operation the starting and stopping,
adjusting and handling.
8.2.2 Ready to run procedures, tools, reports and records.
8.2.3 Responsible for commissioning process inspection and regular maintenance.
8.2.4 Operation and maintenance of the normal operation of the unit.
8.3 Debug unit
8.3.1 Responsible for commissioning the preparation of measures and technology
to give the low-down.
8.3.2 Prepare equipment, instruments and tools for testing.
8.3.3 Start a debug command is responsible for the entire work.
8.3.4 Records test data, and tidying.
8.3.5 Assist operators in accident treatment and analysis.
8.3.6 Assist maintenance personnel to determine device failure, develop a
treatment solution.
8.3.7 Complete the commissioning of quality checking and evaluation form.
8.3.8 Write and debug reports.
8.4 Supervisor duties
8.4.1 Responsible for the concrete implementation of the work under
professional supervision;
8.4.2 Set to start the debugger is responsible for boilers review of the
programme of work;
8.4.3 Organization before the commencement of each unit package boiler
inspection and acceptance of the work;
8.4.4 Responsible for sorting, summarizing units set to start trial operation
during system and equipment defects, supervise defect elimination and closed-
loop in a timely manner.
8.4.5 As a construction site, identify problems and pointed out.
9 Security considerations
9.1 Should be strictly enforced for all staff participating in the trial
operation of the electric power construction safety regulations and the
relevant safety requirements, ensure that the unit test work smoothly.
9.2 Abnormality was detected during the commissioning process, should be
adjusted in a timely manner and to report on the command staff.
9.3 In the unit test process such as to endanger persons or the safety of
equipment, should immediately stop the tests and, if necessary, stop running.
9.4 Test the whole process should be among professionals on the job to ensure
safety of equipment.
9.5 Strengthening the inspection and testing of the unit before the
commencement of the work, as much as possible early detection and elimination
of defects. Start according to the required temperature, boost, increasing
load curve.
9.6 Start of boiler, and to periodically check the thermal expansion of the
Department, found incomplete expansion to stop heat boost. Normal to be
processed before they can continue to boost.
9.7 After ignition of the boiler and hot if it is not steam, controls the
furnace exit flue gas temperature of not more than 540℃ And protect the
safety of reheater.
9.8 Oil guns and stop at the cast, starting and stopping when milling system,
pay attention to negative furnace pressure and combustion conditions, timely
adjustment of combustion, maintain combustion stability in furnace.
9.9 Pulverized attention to steam temperature, vapor pressure and other
parameters, timely adjustment of coal / Proportion of water, preventing over
gentle steam temperature change is too large.
9.10 When unit, Unload, and smoothly increase or decrease of coal / Water,
maintenance of suitable coal / Water to prevent sharp fluctuations of
temperature and pressure of steam.
9.11 Pay attention to the exit flue gas temperature of air preheater, to
prevent secondary combustion. When the flue gas temperature is found is not
functioning correctly, in time to put air pre-heater soot.
9.12 Note flame detector, flame TV show correctly, observe the flame, adjust
the combustion, maintain combustion stability.
9.13 Proper furnace negative pressure, main steam pressure and steam
temperature, reheat steam temperature automatic regulating device control,
identify problems and deal with running should pay attention to of reheat
steam temperature of reheater tube wall temperature of the system.
9.14 When the load is below 50%B-MCR Following combustion or combustion
instability in time oil, prevent fire shelling incidents.
9.15 While the boiler is running, the fuel system should be in standby mode,
grease gun after the outage, you should exit the furnace, each class should
check the grease gun.
9.16 Due to the engineering design of coal volatiles is high, running process
to strengthen the wall of coal bunker monitoring, sufficient inert system,
fire-fighting system to run properly.
9.17 Keep the stable operation of coal pulverizing system, fineness of coal
powder R90=22% , Mill exit temperature is about 70 ℃ ( coal ) 。 After casting
powder to adjust slag removal system, monitor the slag removal system.
9.18 Input air pre-heater soot, steam blowing the air preheater on a regular
basis. Start early, continuous blowing of air preheater inputs, low
temperature economizer blower input as required.
9.19 During the trial operation of the boiler should be all the interlock and
protection system according to the requirements. If, for some reason, demand
the removal of a protected, should watch by the test command for approval.
9.20 Note turn the bearing temperature in operation, lubricating oil, cooling
water, find the problem report and handle in a timely manner.
9.21 To regularly tour of inspection equipment, system operation, not less
than twice in each class. We should earnestly implement " two votes, three
systems " to ensure that equipment and personal safety.
9.22 Unit up and running in the process command should be unified,
responsibilities of the parties a clear division of labor.
9.23 Strengthen the security work of commissioning.
9.24 This measure is not matter, according to the operation rules and accident
management procedures implementation. Operation procedures and the measures
when there is a contradiction, in principle, this measure shall, when the
controversial approval of the commissioning commanding group decisions.
 
 
 
 
11 Appendix 1 package boiler start debugging the project checklist
Contro Examination Check Check
Seeking
l no content date results
Full on, all off, switch the
Smoke baffle
1-1 right direction    
Steam valve
Display status
Primary air adjusting the end    
Boiler cold Secondary air flow measuring
   
1-2 Ventilation device calibration test completed
testing The mill inlet air flow measuring    
device calibration test completed
End of each auxiliary equipment    
interlocking, protection test
End of each auxiliary Cheng Qi,    
Interlocks, Cheng stop test
protection, End of each auxiliary engine oil    
and control, test
1-3 The auxiliary button the end    
sound and
light alarm MFT Static test is over    
test BMS End test fuel parts    
BMS Coal-fired tests end    
End of each valve linkage test    
About sound and light alarm test    
End of Blowpipe work    
Demolition of the temporary
1-4 Boiler tube system, resumption of formal    
systems
Finished eliminating all defects    
End of the fuel system for static    
debugging
Grease gun only holds, Cheng Qi,
1-5 Fuel system    
Cheng stop test end
Fuel system of interlocking,    
protection of the end
 End of the static debugging of    
coal pulverizing system
The throttle plate operation of
Coal
coal pulverizing system test    
1-6 pulverizing
completed
system
End of all interlock and
protection of coal pulverizing    
system
Soot-static commissioning    
Soot blowing program static
Soot blowing    
1-7 commissioning
system
Soot-blowing steam source    
security door set qualified
Operation test of valves in ash    
and slag system complete
Ash-slag Ash and residues from the
1-8 disposal interlocking system test    
system completed
Ash and residues from the system    
programmable test completed
Fire
Check cooling fan the fire
1-9 detecting    
linkage test completed
system
Machines,
furnaces, Interlocking relationships
1-10    
radio and correct, reliable
interlocking
Construction company: Debug: Supervisor:
Owner: Production units:
                                      
                   Year Month day
 
12. Appendix 2 boiler start-up curve (for reference only)
 
 
 
 
13 Schedule: Hazard risk source identification and corresponding
preventive measures
 
Seria Potentially
May lead to
l dangerous and
accidents and Prevention and control measures
numbe hazardous
property damage
r factors
(1) Access to production sites, to wear a
Not wearing or
Body combat helmet and fasten a helmet.
1 not correct use
casualties (2) Check the area above and around without
safety helmet
danger of objects falling from a height.
 Not set safety
protection
devices or Causing Check before work safety protection devices
2
security personnel's injury settings set up before they can work.
protection
inadequate
(1) Of operations, operations head
accountable to the stakeholders around the
security measures, precautions and work
Mal-other Equipment damage,
3 environment.
equipment personal injury
(2) Intern, or temporary work must be carried
out under the supervision of, cannot work
alone.
(1) Device before the turn, protection and
interlock input buttons are available.
Equipment turn Equipment damage,
4 (2) Testing and recording equipment to turn
unusual personal injury
the relevant parameters (current, vibration,
temperature, etc).
Entire work area is strictly prohibited
Equipment damage,
5 No Fireworks Fireworks, hot work must be done, measures
personal injury
are in place behind the executable.
Pay attention to monitoring air preheater,
Fire in air Damage to the inlet temperature changes and changes in
6
preheater equipment currents of air preheater. Where necessary,
strengthening air pre-heater soot.
(1) Cleaning of dirt or debris on the ground.
Slips and falls
7 Ground pollution (2) Work with the equipment necessary to put
cause falls
in order.
The entire fuel system must be checked for
8 Fuel leakage Easy to fire leakage of fuel, to have officers patrol
early in the fuel cycle.
Respiratory tract
Pulverized coal-
9 injuries, Take precautions to prevent dust leakage.
dust leakage
inflammable
Initial inspection equipment to prevent
High temperature steam leakage from the flange loosely, on
10 Personal injury
steam the spot checks to stand in a secure
location.