SIPAT SUPER THERMAL POWER PROJECT
SIPAT STAGE # 1 BOILER
ECO. O/L LINKS ECONOMISER TO 1 ST PASS TOP HEADERS : OUTLET HEADERS VERTICAL WALL INTERMITTENT HEADERS ECO. JUNTION HEADERS ECO. MIXING PIECE SPIRAL WALL ECONOMISER BOTTOM RING HEADER ECO I/L HDR
ECONOMISER : COUNTER FLOW 4 BANKS 163 ASSEMBLIES 4 JUNCTION HEADERS 224 HANGER TUBES ECO OUTLET HEADER SA 106 C ; SA 210 C SPIRAL AND VERTICAL WALLS : TOTAL SPIRAL TUBES : 440 (102X2 FRONT & REAR; 108X2 LEFT & RIGHT) SPIRAL TO VERTICAL RATIO = 1:3 FRONT VERTICAL TUBES: 336 SIDE WALL TUBES: 648 REAR SCREEN TUBES : 280 REAR HANGER TUBES : 56 TUBES : T22 HEADERS : P12
START UP SYSTEM : SEPERATORS I/L LINKS 1 ST PASS ROOF O/L HEADERS SEPERATOR TANKS STORAGE TANK STORAGE TANK WR WR ZR ZR BCP BCP MIXING MIXING TO ECONOMISER TO ECONOMISER FLASH FLASH PIECE PIECE UG UG TANK TANK CONDENSER CONDENSER FEED WATER LINE FEED WATER LINE BOILER FILL LINE BOILER FILL LINE
2 ND PASS STEAM FLOW : EXTENDED WALL : 1 ST PASS ROOF I/L HDR BACK PASS ROOF I/L HDR BACK PASS TOP LHS HDR BACK PASS TOP RHS HDR EXTENDED WALL EXTENDED WALL HDR BACK PASS BOTTOM RING HDR
BACK PASS WALLS & HEADERS : EXTENDED WALL : FURNACE FRONT ROOF : 168 BACK PASS ROOF : 111 EXTENDED WALL FLOOR : 142 BACK PASS REAR WALL : 111 EXTENDED SIDE WALL : 142 BACK PASS SIDE WALL : 328 BACK PASS FRONT WALL : 167 TUBES : T12 BACK PASS SCREEN : 167 HEADERS : P12 TUBES : T12 FLUID COOLED SPACER TUBES: 3 HEADERS : P12 BACK PASS WALLS & HEADERS : START UP SYSTEM : LINK PIPES : P12 LINK PIPES : P12 SEPERATORS & SEPERATORS & STORAGE TANK : SA 302C STORAGE TANK : SA 302C
DIVISIONAL PANEL : II ND PASS TOP RHS HDR DIV. PANEL I/L HDR FROM II nd PASS BOTTOM RING RHS HDR DIV. PANEL O/L HDR DIV. PANEL O/L HDR DIV. PANEL I/L HDR II ND PASS TOP LHS HDR FROM II nd PASS BOTTOM RING LHS HDR SH DIV. PANEL TUBES : 480 TUBES : T23; T91 DIV. PANEL HEADERS : P12; P23 FLUID COOLED SPACER TUBES : 6 DIV. PANEL
PLATEN AND FINAL SH : PLATEN TO FINAL SH LINK DIV. PANEL TO PLATEN LINK TO HP TURBINE PLATEN PLATEN O/L HDR I/L HDR FINAL SH O/L HEADERS DIV. PANEL I/L HDR FINAL SH I/L HDR DIV. PANEL O/L HDR DIV. PANEL O/L HDR DIV. PANEL I/L HDR PLATEN ASSEMBLIES : 20 NO OF TUBES : 480 TUBES : T12; T23; T91 HEADERS : P12; P23 PLATEN COILS FINAL SH COILS COUNTER FLOW DIRECTION NO OF STAGES : 2 TUBES : T23; T91 ASSMBLIES : 2X55 HEADERS : P23; P91 NO OF TUBES : 935
TO IPT REHEATERS : NO OF BANKS : 3 NO OF TUBES : 111 TO IPT TUBES : SA 210C; T12; T23 HEADERS : SA 106C; P12 LTRH BANKS FINAL RH FROM CRH NO OF ASSEMBLIES : 41 NO OF TUBES : 615 TUBES : T23; T91; SUPER 304H FROM CRH HEADERS : P12; P91
540 ° C, 255 Ksc 568 ° C, 47 492 ° C, 260 Ksc Ksc 457 ° C, 49 Ksc FUR ROOF ECO HGR I/L HDR O/L HDR HRH LINE MS LINE 411 ° C, 411 ° C, 277Ksc 275 Ksc SEPARATOR S T FINAL SH FINAL O LTRH RH R DIV PANELS SH A PLATEN SH G E VERTICAL WW T A G 305 ° C, 49 Ksc ECO N JUNCTION K HDR LPT LPT IPT C HPT O N ECONOMISER D E N S E R ECO I/L FEED WATER BWRP 290 ° C, 302 KSC FUR LOWER HDR FRS
FEATURES OF SUPER CRITICAL BOILER : 1. ONCE THROUGH OPERATION : FEED WATER WALL/ WATER SUPERHEATER ECONOMISER SEPERATOR EVAPORATOR PUMP RECIRCULATION STORAGE PUMP TANK CONSTANT WATER WALL FLOW (below 30% load) FEED WATER WALL/ WATER SUPERHEATER ECONOMISER SEPERATOR EVAPORATOR PUMP ONCE THROUGH FLOW OPERATION (above 30% load)
2. CONSTANT PRESSURE OPERATION : Above 90% & below 30% 3. SLIDING PRESSURE OPERATION : B/W 30% & 90%
ADVANTAGES OF SLIDING PRESSURE OPERATION 1. No additional pressure loss between boiler and turbine 2. Low Boiler Pr. at low loads - Less fatigue of Pr. part components - Longer life of all components, Less wear of components - Less Maintenance 3. Lower thermal stresses in the turbine during load changes 4. Control range of RH temp is extended 5. Overall reduction in power consumption and improved heat rate
660MW PARAMETERS : DESCRIPTION UNIT 660 MW AT BMCR S/H STEAM FLOW T/HR 2225 SH STEAM PR KG/CM 2 256 SH STEAM TEMP 0 C 540 RH STEAM FLOW T/HR 1742 RH STEAM TEMP INLET 0 C 299 RH STEAM TEMP OUTLET 0 C 568 RH STEAM PRESS OUTLET KG/CM 2 46.61 FEED WATER TEMP 0 C 289.64 SECONDARY AIR FLOW T/HR 1732 PRIMARY AIR FLOW T/HR 946 TOTAL COAL FLOW T/HR 472
FEATURES OF 660 MW- STEAM QUALITY PARAMETERS STEAM QUALITY AT SG OUTLET S.NO. PARAMETER DURING START UP DURING NORMAL OPERATION 1 TDS 20 2 2 SILICA 20 2 3 SODIUM 10 2 4 CHLORIDES 0 2 5 COPPER 20 1 6 IRON 10 5 7 CATION <0.2 to 0.25 micro <-0.2 micro CONDUCTIVITY siemens /cm siemens / cm 8 PH 6~8
COMMISSIONING NETWORK
MS Line HT CRH Line HT HRH Line HT SG ECW SYSTEM MS Line Welding CRH Line Welding HRH Line Welding ID FAN # 1A TRIAL RUN Completion Completion Completion FD FAN # 1A TRIAL RUN MS Line Hanger Erection CRH Line hangers Cold HRH Line Hangers Cold Cold Setting Setting Setting SAPH # 1A TRIAL RUN MS Line Insulation CRH Line Insulation HRH Line Insulation BRP TRIAL RUN SACNNER AIR SYSTEM READINESS Temporary Piping Completion FURNACE READINESS FUEL OIL SYSTEM READINESS Boiler Light Up & Steam Blowing CHEMICAL CLEANING OF AUX PRDS READINESS BOILER ACW System COMPRESSED AIR SYSTEM READINESS MDBFP Trial CW SYSTEM READINESS GATES, DAMPERS / VALVES CEP Trial TG : MFT CHECKING SG : TG ECW System HOT Well Readiness DDCMIS FSSS READINESS
LIST OF APPROVED PROCEDURES Boiler Commissioning is carried out based on the guide lines of Corporate commissionin groups. OS) These are the list of approved commissioning procedures which are followed in sipat commissioning activities 1. BOILER HYDRO TEST 2. OIL FLUSHING OF ROTARY MACHINES 3. BOILER & DUCTS AIR TIGHTNESS TEST (ATT) 4. ESP AIR IN LEAK TEST 5. ESP GAS DISTRIBUTION (GD) TEST 6. BOILER CHEMICAL CLEANING 7. BOILER COLD AIR VELOCITY TEST 8. CLEAN AIR FLOW TEST 9. LDO & HFO SYSTEMS COMMISSIONING 10. BOILER & AUX LINES STEAM BLOWING
COMMISSIONING MILE STONES 1. BOILER HYDRO TEST : HP SYSTEM : Hydro test done on 20.12.2006 HP system hydro test is done at 410 KSC. HP system consists of Economiser, boiler 1 st & 2 nd pass, divisional panel, platen & final super heater upto boiler stop valves. MP SYSTEM : Hydro test done on 26.03.2008 MP system hydro test is done at 80.1 KSC. MP system consists of CRH isolator to LTRH, Final Reheater upto HRH isolators. 2. BURNER TILT, OIL GUNS & IGNITOR CHECKING : Checking is completed on 24.12.2007 Burner tilt checking is done from inside the boiler in which burner limits +30 0 & - 30 0 angles adjusted. Oil guns & ignitors clearances are checked inside the boiler. 3. FD, ID & PA FANS COMMISSIONING : FD Fan # 1A trial run taken on 03.03.2010 ID Fan # 1A trial run taken 15.03.2010 PA Fan # 1A trial run taken 18.03.2010
COMMISSIONING MILE STONES 3. FD, ID & PA FANS COMMISSIONING : FD Fan # 1B trial run taken on 22.06.2010 ID Fan # 1B trial run taken 21.06.2010 PA Fan # 1B trial run taken 22.06.2010 Fans commissioning involves following steps: Lube oil flushing of lube oil skid, lube oil lines with flushing oil (32 grade) (bearings bypassed) (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm) Lube oil flushing through bearings (32 grade) Lube oil flushing through bearings (68 grade oil) Blade pitch commissioning & discharge gate commng. Cooling water lines flushing & charging Fan trial 4. AIR PREHEATERS COMMISSIONING : SAPH # 1A trial run taken on 27.03.2010 SAPH # 1B trial run taken on 20.04.2010
4. AIR PREHEATERS COMMISSIONING : PAPH # 1A trial run taken on 29.03.2010 PAPH # 1B trial run taken on 20.04.2010 Air Preheaters commissioning involves following steps: Lube oil motors & main motor no load trial Lube oil flushing of Support & Guide bearings with 32 oil (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm) Lube oil flushing through bearings (32 grade) Lube oil flushing through bearings (680 grade oil) Air motor service air line blowing Cooling water lines flushing & charging Air preheater trial with air motor & electrical motor
4. BOILER & DUCT ATT : Secondary air duct ATT is completed on 01.04.2010 Primary air duct ATT is completed on 05.05.2010 Flue gas air duct ATT is completed on 24.04.2010 Furnace ATT completed on ATT of boiler & ducts is done at 150 mm of water column. Secondary air duct & boiler pressurisation is done by FD Fan. Primary air duct pressurisation is done by PA fan. Flue gas duct pressurisation is done by using temporary blowers 5. ESP COMMISSIONING : ESP Air In Leak test: All passes air in leak test completed on 09.11.2008 The test is done to prove that air in leak into ESP is with in guaranteed value of 1% of design gas flow rate. ESP Rapping system commng. : All passes rapping systems commng. completed on 21.07.2010 Each Pass has 18 nos. collecting electrodes rapping system, 18 nos emitting electrode rapping system & 2 nos. gas distribution plates rapping system.
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