Presentation Risk Management and Plant Commissioning

Supercritical Units: Efficiency Advantage
Improvements in the efficiency of pulverized coal (P.C.) fired boiler/steam turbine power plants have been pursued since the introduction of P.C. fired boilers in the 1920s.
This led eventually in the late 1960s to the introduction of supercritical boilers operating at about 570 Deg C (1060qF) superheat/reheat temperatures and 24 MPa (3400 psi) pressure for the steam. Presently boilers with 300bar and 700 Deg C are being adopted for many of the recent power plants. Since at these pressures and temperatures there is no distinct differences between the water and steam phases, no drums are required in the same.
Dr. Himadri Banerji:Conference on Plant Commissioning Kuala Lumpur 1st and 2nd Nov 2010
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Conventional steam power plants operate at a steam pressures in the range of 170 bar and 565 Deg C. These are Subcritical power plants.
The new generation of power plants operate at pressures higher than the critical pressure.
These are Supercritical power plants. The operating pressures are in the range of 230 to 265 bar. And 565 Deg C
The next generation of power plants will operate with Steam Pressures in the range of 300 bar and 630Temperatures 630700 Deg Centigrade. These are the Ultra Super Critical Power Plants. Plants.
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The lower part of the boiler furnace is arranged in a spiral configuration such that the fluid path wraps around the boiler as it travels up the furnace.
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Comparison of Allowable Stresses between Conventional and Advanced Stainless Steel Tubes, Advanced CrMo Steel Pipes
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Advantages of Oxygenated Treatment OT of Supercritical Boilers The benefits from a once-through supercritical boiler on OT include: Lowering overall corrosion rates by forming a protective, double-oxide layer with a controlled amount of oxygen present in the condensate (This protective layer is considered to be more stable than the oxide layer formed using AVT.) Decreasing boiler chemical cleaning frequency due to reduced amounts of iron transport and deposition Allowing quicker, cleaner start ups and reduced corrosion product transport rates during cold and hot start ups Allowing boiler operation at lower pH with overall objective of minimizing chemical costs Eliminating feeding, handling, and storage of oxygen scavenger products
EPC Contractors Chemistry Challenges
Most once-through supercritical boilers have been converted from previously predominant AVT to OT, with new facilities almost exclusively using OT. allThis chemistry change requires all-ferrous metallurgy in the feed copperwater train, and precludes copper or copper-based alloy feed water heat exchangers in system design and bronze impellers in condensate pumps and valve trims in the condensate system. This is primarily the challenge to the engineering group og the EPC contractor to ensure that this is strictly adhered..all steels contain traces of copper and zinc.
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coalShows the pressure drop history of a coal-fired supercritical plant in Japan that changed the water chemistry from AVT to OWT in 1996. After 7 years operation since the change, there has been no significant increase in pressure drop. This plant has not required acid cleaning since the change, and no future cleaning is planned.
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RISK MANAGEMENT Plant Commissioning
SUPERCRITICAL UNITS: EPC CONTRACTORS CHEMISTRY CONTROL PARADIGM
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EPC Contractors Chemistry Challenges Some once-through supercritical boiler manufacturers have instituted penalties against the allowable pressure drop during initial boiler performance testing, an additional complication that may impact start up and commissioning activities. These penalties are based on extended operation on all volatile treatment reducing (AVT[R]) during start up and commissioning. The reducing environment (negative oxidation reduction potential [ORP]) present when operating on AVT(R) may contribute to increased iron transport, subsequently increasing the pressure drop through the boiler. These pressure drop correction penalties will be fervently debated by the EPC contractor during commissioning and challenged by both owners and plant operators.
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WARRANTY IMPLICATIONS Steam turbine suppliers are also setting limits, in the equipment contract, on the number of hours a turbine can be operated with out-of-specification chemistry. These limits are typically listed in an action-level These limits are typically listed in an action-level format where minor chemistry excursions are allowable for predetermined time periods without violating the equipment warranty.
up Steam Purity Limits During Start up EPC OnceContractor Recommendation for Once-Through Boilers...usually one week
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During steam-side start up and commissioning, the EPC contractor is mostly interested in main and reheat steam chemistry. Table below lists EPRI recommendations for once-through boilers operating under OT, including normal target value and action levels 1, 2, and 3.
Although recommendations listed in Table are acceptable for targeted chemistry limits during operation, EPC contractors would like to see the table: following two columns added to this table: Allowable chemistry excursions during hot start up Allowable chemistry excursions during cold start up
Feed Water
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What Are Action Levels 1, 2, 3
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EPC CONTRACTORS CHEMISTRY CONTROL PROGRAM
Start up chemistry guidelines should primarily focus on main steam chemistry targets, including cation conductivity: it warns of salts and acids that may cause turbine corrosion silica : silicate scaling may contribute to turbine capacity and efficiency losses.
sodium: critical for avoiding corrosion because uncontrolled sodium hydroxide concentrations are known to cause corrosion damage failures in boiler tubes.
Targets for chlorides, sulphates, and organic compounds should be deferred until the end of the commissioning cycle. Degassed cation conductivity is the preferred conductivity to be measured during commissioning since system air leaks are still being discovered and sealed during the start up and commissioning phase. The measurement of degassed cation conductivity will aid in differentiating between air leaks and other contamination sources
Dr. Himadri Banerji:Conference on Plant Commissioning Kuala Lumpur 1st and 2nd Nov 2010 10/29/2010 13
EPC Contractors Chemistry Challenges The two most important parameters in Table are feed water cation conductivity and pH. Cation conductivity should be maintained below 0.15 S/cm during operation on OT. Normal pH range for feed water under OT is 8.0 to 8.5.
The EPC contractor is challenged with controlling pH when feed water cation conductivity increases to concentration levels listed in Table , action levels 1, 2, and 3 (0.3 S/cm, 0.6 S/cm, >0.6 S/cm, respectively).
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The pH/conductivity relationship is crucial for once-through cycles on OT; thus, the EPC contractor implements the chemistry control at its own risk.
Important issues to be addressed when implementing OT include: At what point during the start up and commissioning process should the chemistry regime be switched from AVT to OT to prevent frequent switching back and forth between a reducing and an oxidizing environment? What would be the detrimental effects of going from an oxidizing atmosphere to a reducing (or close to reducing) atmosphere, for temporary periods? How can these detrimental effects be quantified and addressed during design and equipment procurement?
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Stringent steam quality limits implemented by steam turbine suppliers, boiler manufacturers have tightened limits on feed water chemistry.
Yet EPC contractor requires standards to be relaxed during commissioning to permit timely unit start up. The challenge also is in determining the appropriate time to switch from AVT to OT
Once cation conductivity levels are stable below 0.15 S/cm, EPRI recommends operation on OT with oxygen injection in a pH range of 8.0 to 8.5. EPRI guidelines also state that oxygen injection into feed water may continue with pH controlled between 9.2 and 9.6 S/cm S/cm. and cation conductivity between 0.15 S/cm and 0.3 S/cm. However, S/cm, at cation conductivity levels greater than 0.3 S/cm, EPRI recommends that oxygen injection be terminated and AVT resumed. Upsets in cation conductivity may lead to serious corrosion problems if oxygen is continuously fed during upset conditions.
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Comparison of Start-up Systems
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The turbine bypass system was designed to minimize the start-up time by controlling the main steam pressure and temperature before turbine rolling, and enabling the steam to flow through the super heater sections at a short time after light-off. The low-load recirculation system was designed to recover residual heat during start-up by circulation of the un-evaporated water from the furnace back to the economizer inlet, which also can assist in reducing start-up time. As this system is automatically operated, the start-up process is as simple as with a natural circulation (NC) boiler.
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EPC Contractor Guidelines on Feed Water Chemistry Startup

Start up Steam Chemistry Limits
Turbine Rolling Continued AVT(O)
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Turbine Rolling Continued Balance of Commissioning Period Chemistry Limits
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Operation Guidelines with AVT R and AVT O
AVT(R) Feed water Chemistry Control Guidelines
AVT(O) Feed water Chemistry Control Guidelines
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Suggested Start up Feed water Chemistry OnceGuidelines for Once-Through Cycles Without Deaerators
Practical start up chemistry guidelines should be established by consensus among the turbine manufacturer, boiler manufacturer, and EPC contractor early on in project development and outlined in equipment contracts.
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ROLE OF CONDENSATE POLISHERS DURING COMMISSIONING
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Once-through supercritical boilers are commonly installed with full-flow condensate polishers to control corrosive impurities concentration in condensate and feed water systems. The presence of impurities in feed water will significantly affect feed water chemistry, potentially exceeding boiler supplier feed water limits and turbine supplier steam purity specifications.
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Impurities shaken loose during start up may cause a chemistry hold, where plant load increases are temporarily halted until these impurities are removed from the system. For a once-through supercritical boiler, impurities are removed exclusively by condensate polishers subsequent to chemical cleaning and boiler flush. Once impurities are removed, the chemistry hold is lifted and the plant is allowed to continue to ramp up to full load without exceeding allowable boiler or turbine chemistry limits.
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Steam and Water Analysis System (SWAS) shall be furnished for continuous monitoring and control of water and steam purity in the plant cycle
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EPC Contractor Responsibility includes that Chemistry limits are before, during and after once-through supercritical boilers commissioning Control system component cleanliness during shop fabrication Control system component cleanliness during construction Flush system components prior to start-up Implement stringent water quality requirements for hydro testing Perform boiler and feed water system chemical cleaning Flush system components thoroughly following chemical cleaning Perform steam blows to obtain steam cycle cleanliness Implement time-based, progressively improving feed water and steam chemistry targets
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Presentation Risk Management and Plant Commissioning

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Presentation Risk Management and Plant Commissioning

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Supercritical Units: Efficiency Advantage

EPC Contractors Chemistry Challenges

RISK MANAGEMENT Plant Commissioning

SUPERCRITICAL UNITS: EPC CONTRACTORS CHEMISTRY CONTROL PARADIGM

EPC Contractors Chemistry Challenges

What Are Action Levels 1, 2, 3

EPC CONTRACTORS CHEMISTRY CONTROL PROGRAM

EPC Contractors Chemistry Challenges

Comparison of Start-up Systems

EPC Contractor Guidelines on Feed Water Chemistry Startup

Turbine Rolling Continued AVT(O)

Turbine Rolling Continued Balance of Commissioning Period Chemistry Limits

Operation Guidelines with AVT R and AVT O

AVT(R) Feed water Chemistry Control Guidelines

AVT(O) Feed water Chemistry Control Guidelines

ROLE OF CONDENSATE POLISHERS DURING COMMISSIONING

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