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One Spaph Stoppingstg-2

One Spaph Stoppingstg-2

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NTPC/TSTPP OPERATION DEPARTMENT
TS-II/OPN/OI /BLR/10
AREA – Boiler
REV 0.00
UNIT - 3/4/5/6
Operating Instruction For Stopping / Startingany second SAPH in a running Unit .
Date: 20/10/2007
Prepared BySri K.Ch.Satyanarayana,S(O)Reviewed BySri R.N.Das ,SS(O)Approved BySri D.Sarkar ,DGM(O)
Sheet 1 Of 3
A PURPOSE: -
This document is prepared to guide the operating personnel while stopping / starting any second SAPHfor maintenance when the unit is in operation with both SAPH in service in Stage- II.
B SCOPE: -
This shall be applicable to all the 4 units of Stage – II (4X 500 MW units), TSTPP, NTPC Ltd.
C INTRODUCTION: -
Each unit is provided with two bi-sector type regenerative secondary air preheaters to recover the heat from waste flue gas leaving from the furnace and utilised to preheat the secondary air which issupplied to furnace through wind box to ensure complete combustion of pulverised fuel / fuel oil. Air pre-heater consists of mainly rotor housing, cylindrical cellular rotor, guide and Support bearings, oil systemsfor guide and support bearings, soot blower system, Stationary water washing & fire fighting devices,auxiliary air motor drive with over-running clutch, Oil carry over probes , inspection lights air and gasside dampers etc. The complete rotor is supported by a thrust bearing at the bottom and guided by theradial bearing at the upper end. An air motor is provided to ensure the continued operation of the air pre-heater, even if power to electric motor is interrupted. It is also used to control speed of the rotor duringwater washing of heating surface.When ever one APH trips in a running Unit the run back operates & Unit load getsreduced to 300 MW (60 %) . Normally 4-5 Mill operation permissive is available with one APH outof service .
D TECHNICAL DATA OF THE SYSTEMHeater size
:30 VIM 2000-2 nos / boiler 
 Auxiliary drive
: Air motor: Ingersolrand, model IR92-RA022Coupling: Bibby coupling type 124A
 Hot end heating elements
:0.80mm- DU profile, 850mm height, Carbonsteel material.
Cold end heating elements:
 1.2mm-NF 6 profile, 300mm height, carbonsteel material.
 Rotor drive assembly:
Motor-TEFC (main and stand by): Crompton greaves,18.5KW, 415V, 3ph, 50Hz, and 1460 rpm. Frame-160L,class F.
Speed reducer:
Type: 2, 3 input, down shaft seisa / JapanCoupling: 12.75 FCU- pembril make.
 Hot intermediate end heating elements
:0.80mm- DU profile, 850mm height, Carbonsteel material.
 Bearings:Guide bearing:
Spherical roller 23072/CCK/C3/W33
Support bearing:
Spherical roller thrust 294/750E
 D RESPONSIBILITY:UCE /SCE/ BOILER DESK ENGINEERE PROCEDURE FOR STOPPING AND ISOLATION OF ANY SECOND SAPH: -E-1 PRECONDITION OF THE UNIT: -
1.
 
Unit is running at full load (500MW) with 7 mills in operation.2.
 
Both TDBFPs are in service and Feed water control in auto.3.
 
MDBFP # C is available on auto (Rapid start up mode).
 
NTPC/TSTPP OPERATION DEPARTMENT
TS-II/OPN/OI /BLR/10
AREA – Boiler
REV 0.00
UNIT - 3/4/5/6
Operating Instruction For Stopping / Startingany second SAPH in a running Unit .
Date: 20/10/2007
Prepared BySri K.Ch.Satyanarayana,S(O)Reviewed BySri R.N.Das ,SS(O)Approved BySri D.Sarkar ,DGM(O)
Sheet 2 Of 3
4.
 
Unit control is in CMC mode.5.
 
 Airflow control is in auto with both FD fans in service.6.
 
Both PA fans in operation in CAS mode.7.
 
Both PAPH and SAPHs are in service.8.
 
Both ID fans in service and furnace draft control in auto.
E-2 ENSURING THE FOLLOWING : -
1.
 
Running contact of other running SAPH is available .2.
 
Revise the station DC as per the planned shut down programme.3.
 
 Availability of atomizing steam and HFO at requisite pressure & temp (oil: 100ºC / 17-18 kg/cm², Steam:200 – 210ºC / 6.5 kg/cm²).4.
 
Completion of WB/LRSB operation before starting the load reduction.
 
5.
 
 Availability of PAPH / SAPH soot blowers for operation.6.
 
 Availability of auxiliary drive (air motor) of SAPH (which is to be stopped). Air receiver tank pressurenormal (7Kg/cm²).7.
 
Best communication between control room and local.
 
8.
 
TDBFP- A / B recirculation valve auto-closing protection to be taken care
E-3 PROCEDURE FOR STOPPING AND ISOLATION OF ANY SECOND SAPH : -
1.
 
Take the unit control to manual from CMC mode. (Turbine on limit pressure control and Boiler master onmanual).2.
 
Take fuel master to manual and gradually reduce the load to
400MW
by slowly unloading and removing7
th
running mill. Check airflow according to the load (1650T/ hr corresponding to 400MW).3.
 
Take HFO support in one elevation corresponding to any running mill according to the mill combination(At least 3 oil guns in one elevation).4.
 
Gradually reduce the load to
300MW
by slowly unloading and removing 6
th
running mill. Check airflowaccording to the load (1450T/ hr corresponding to 300MW).5.
 
Reduce MS pressure set point according to the load during the process of load reduction.6.
 
Check the loading and suction flow of TDBFP A / B. If suction flow is low corresponding to the speed,Then keep open any one TDBFP- A / B recirculation valve.
 
7.
 
 Adjust the burner tilt position to maintain MS & HRH temperature up to maximum possible
(540C).
 8.
 
Probably kept
five
consecutive mills in service to ensure stable combustion.9.
 
Take airflow control into manual.10.
 
Gradually close the SAPH (which is to be stopped) air outlet damper from local & lock it mechanicallyand simultaneously maintain the flue gas outlet temperature by closing the FG outlet damper of corresponding SAPH. Adjust the PAPH A/B and other running SAPH flue gas outlet dampers fromremote and balance the FG outlet temperatures. Then isolate the damper actuator power supply.11.
 
Check the total airflow for any variation while closing air outlet damper and adjust it.12.
 
Gradually close the air inlet damper from local and lock it mechanically. Isolate the power supply.13.
 
Close flue gas inlet damper from local and lock it mechanically. Isolate the power supply.14.
 
Close flue gas outlet damper fully from remote and lock it. It can be opened to 10% with the help of C& Ito create negative draft in side the SAPH if it is required by BMD.15.
 
Start PAPH – A / B and running SAPH soot blowing. (This is to be done at least twice in a shift as long as

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