Professional Documents
Culture Documents
Best Power Practice Japan PDF
Best Power Practice Japan PDF
The authors
would like to extend their warmest appreciation to individual writers of these books
and Bulletins, as well as to the Societies itself, for their willingness to provide such
valuable information, and thus to make this textbook possible.
April, 2007
The Federation of Electric Power Companies of Japan
List of Authors (Titles Dispensed and Omitted and Listed in Random Order)
Kazuhiro Sakai:
Satoshi Tanishima:
Kenichiro Kawashima:
Tatsurou Yamaoka:
Shinichi Taniguchi:
Terunori Kobayashi:
Noriyuki Sonoda:
Susumu Sakata:
Shin Katayama:
Takashi Maruta:
Takashi Naganuma:
Yoshiaki Fukuzawa:
Yoshitaka Oka:
Secretariat
Masato Hasegawa:
Hirofumi Kazuno:
Tomoaki Koga:
Yasunori Eitoku:
Masato Ishimura:
Table of Contents
Chapter 1
1
1
1.1
1.2
History of the Power Plant and the Role of Thermal Power Generation in Japan
1.3
12
2.1
Operation Control
12
2.2
22
2.3
25
2.4
Performance Management
39
2.5
57
2.6
2.7
133
103
142
3.1
142
3.2
163
3.3
200
3.4
263
3.5
Power Generators
330
3.6
366
376
4.1
376
4.2
Dust Precipitator
393
4.3
Desulphurization Equipment
409
4.4
Denitrification Equipment
427
4.5
448
4.6
457
References
1.2 History of the power plant and the role of thermal power generation in Japan
Electricity consumption in Japan has expanded almost consistently after the world war . Further, in recent
years, the need has intensified for a comfortable life as seen in the progression of computerization and the
proliferation of air conditioners, and even though the Japanese economy has entered a stable growth period,
electric power demand shows no signs of slowing down. In addition, new problems are starting to appear as the
demand increases.
Let consider the current situation and future of electricity consumption.
Due to the betterment of people's living standards, comfortable living is sought and the role of electricity in
living starting with air conditioning is growing increasingly. Moreover, due to the progression of a highly
intelligent community as a result of IT innovation including the computer and communication, the role of
electricity is increasing in all aspects of industry and living. From these facts, over the course of time, the
percentage of electricity consumption among consumption of other energies (electrification ratio) is running high.
Although the electric power demand is dependent on the trends in the business climate and those in politics and
the community, even in recent years when the Japanese economy has entered a stable growth period, it continues
to increase due to the progression of computerization and the proliferation of air conditioners.
Electric power in Japan is supplied mainly by thermal (oil, LNG, coal, etc.), hydro, and nuclear power
generation. There are 1,300 or more power plants in all parts of Japan to meet the electric power demand
growing steadily due to an upsurge in the desire to seek comfortable living, computerization, graying, etc.
PJ (Petajoules=1015J)
(Fiscal )
The role of electric energy, being useful and easy to use, is intensifying year after year, and the ratio of electric
energy to the consumption of all energies has now reached about 40%.
Coal
Natural gas
(LNG)
Hydro
Geothermal power
generation and new
Nuclear power
(Note) 1. Oil, etc. includes LPG, other gases and bituminous mixtures.
2. Due to rounding off, there may be cases where the total value
Source:
does not equal 100%.
3. Total of 10 electric power companies. Power received is included.
4. The numeric values in the graph represent the segment share (%).
Fig.1.2-2:
(Fiscal)
Outline of Fiscal 2005 Supply Program
(March 2005) and others
Power generated increases with each passing year, and we cope with the demand for increasing electric power
while planning departure from the use of oil through the use of nuclear energy, natural gas (LPG), etc.
As our lives become convenient and rich, the role of electricity serving in our lives continues to expand. The
amount of electricity usage varies significantly depending on the time period of the day and the season.
When we look at the electric consumption on an annual basis, in recent years, the growth in the summer season
is significant due to air conditioning, and when we look at it on a daily basis, the maximum consumption is
marked at about 2:00 p.m. when the heat in midsummer reaches its peak. The difference between the maximum
and the minimum values of electricity consumption is more and more on an increasing trend. The increase in
home air conditioners has a significant effect on this.
On the other hand, electricity is an energy that is impossible to be stored. Although a plant that generates
electric power is built to the peak of demand (maximum electric power demand), when the electric power demand
varies significantly according to season and time period, efficiency in the utilization of the power plant lowers,
and as a result, the cost to deliver the electricity will be comparatively high.
(Million kW)
(Time)
(Note) Merging of 9 electric power companies
only in 1975
Fig. 1.2-3 Movements in how the electricity is used over one day in midsummer
For electric power demand, there is a significant difference between daytime and nighttime in one day. This
reflects the fact that while a good amount of electricity is used by plants and offices in the daytime, industrial
activities are not performed much at night. In addition, even in the daytime, the amount of electricity used
decreases from 12:00 to 13:00 p.m. when plants and offices are in a lunch break.
During the day on a hot summer day, electric power demand for air conditioning increases. The consumption at
the peak in the daytime reaches about 2 times that in the time period in a day when the consumption is lowest.
(Million kW)
(All-time maximum)
Fiscal 2001
Fiscal 2004
Fiscal 1995
Fiscal 1990
Fiscal 1985
Fiscal 1975
Fiscal 1968
Fiscal 1967
(Month)
(Note) Merging of 9 electric power companies before
1975
future as well, taking the limited fossil resources, global environmental issues, further economics, etc. into
account, we intend to combine the resources in well-balanced way making use of characteristics of each type of
power generation including hydro, thermal, and nuclear, thereby dispersing the risk by not relying on one source.
Electricity demand varies during the day or at night even in one day. In electric utilities, the features of hydro,
thermal, and nuclear power generation such as operation characteristics, economics, and efforts to cope with
global environmental issues are judged comprehensively to combine various kinds of sources in an optimum
balance.
Pumped-storage
hydroelectric power
Equalizing pool-type
hydro
Water reservoir-type
hydro
Oil
Equalizing pool-type
hydro
Water reservoir-type
hydro
Oil-fired thermal
power
Coal-fired thermal
power
Supply capacity
Characteristics
Supply capacity to
cope with peak
electric power
demand
Supply capacity to
cope with peak
electric power
demand
Supply capacity to
cope with peak
electric power
demand
Supply capacity to
cope with middle
electric power
demand
Supply capacity to
cope with base and
middle electric power
demands
Nuclear power
Run-off river-type
hydro power
generation
Supply capacity to
cope with base
electric power
demand
Supply capacity to
cope with base
electric power
demand
1.3 Movements in thermal efficiency of thermal power plants in Japan and outlook for thermal
power generation technology in the future
Since the first Rankine cycle-based thermal (steam) power generation plant (Steam pressure: 0.59MPa (gage)
(6atg), 7.5kW (10HP) was manufactured by Charles A. Persons in 1884, the thermal efficiency of steam power
generation plants has improved significantly together with improvement of steam conditions (higher
temperature/higher pressure) and larger capacity.
In Japan as well, LNG-fired supercritical pressure (SC) plants whose main steam pressure was 24.3 MPa (gage)
(246 atg) and whose main/reheat steam temperature was 538/566 C came into operation in the form of Tokyo
Electric Power Company's Anegasaki thermal plant Unit No.1 in 1967. Subsequently, similar steam conditions
were adopted for coal-fired plants, and in 1989, 2-stage reheat LNG-fired Ultra Supercritical pressure (USC)
thermal power generation whose main steam pressure was 31.0 MPa (gage) (316atg) and whose ultrasupercritical-pressure/high-pressure/middle-pressure steam temperature was 566/566/566 C came into operation
at CHUBU Electric Power Company's Kawagoe thermal power plant Unit No.1. As described earlier,
improvement of steam conditions has been planned steadily. However, in recent years, the growth of steam
conditions has become relatively slow, and as shown in the figure, the thermal efficiency of steam power
generation moves at little over 40%.
Slowdown trends in rise of thermal efficiency of thermal (steam) power generation achieved a significant
change through the introduction of LNG combined cycle power generation using a full-scale exhaust heat
recovery system with a turbine inlet temperature (TIT) of the 1100- C-class gas turbine as a core at TOHOKU
Electric Power Company's Higashi Niigata Unit group No.3 in 1984. As shown in the figure, through the
adoption of combined cycle power generation system combining the Brayton cycle (gas turbine) and the Rankine
cycle (steam turbine), the thermal efficiency of the thermal power plant rose in a stroke to about 44%. TIT of gas
turbines for commercial use has risen at a rate of about 20 C/year on average due to progression of cooling
technology and development of heat-resistant materials. In November 1999, the advanced combined cycle
power generation cycle (ACC) consisting mainly of a 1,450- C-class gas turbine begun commercial operation at
TOHOKU Electric Power Company's Higashi Niigata Unit group No.4-1, and 50% thermal efficiency, having
which had been a dream for a long time in the thermal power generation sector, was attained. During this period,
a number of LNG combined cycle power generation plants were introduced one after another, and attained an
excellent track record of operation with high thermal efficiency, load change, etc. The installed capacity of LNG
combined cycle power generation at the end of 2001 reached 22 million kW in total across the 6 Electric Power
Companies & 21 groups, coming to account for 17% of the installed capacity of all commercial-use thermal
power generation.
Currently, in addition, TOKYO Electric Power Company's Futtsu thermal power plant Unit group 3 & group 4,
Shinagawa thermal power plant Unit group No.1, Kawasaki thermal power plant Unit group No.1, TOHOKU
Electric Power Company's Unit group No.4-2, etc. are in the advanced stage of construction, and the thermal
efficiency of ACC under construction is planned to be 50 to 53%.
On the other hand, with respect to coal-fired thermal power, improvement in the steam condition of coal-fired
USC thermal power generation continues steadily such as at CHUBU Electric Power Company's Hekinan thermal
power plant Unit No.3 (main steam pressure: 24.1 MPa (gage) (246 atg), main/reheat steam temperature:
538/593 C), Electric Power Development Company's Matsuura thermal power plant Unit No.2, HOKURIKU
Electric Power Company's Nanao Ohta thermal power plant Unit No.2 (main steam pressure: 24.1 MPa (gage)
(246 atg), main/reheat steam temperature: 593/593 C), TOHOKU Electric Power Company's Haramachi thermal
power plant Unit No.2, CHUGOKU Electric Power Company's Misumi power plant Unit No.1 (main steam
pressure: 24.5 MPa (gage) (250atg), main/reheat steam pressure: 600/600 C), Electric Power Development
Company's Tachibanawan thermal power plant Unit No. 1 & No.2 (main steam pressure: 25 Mpa (gage) (255atg),
Kawasaki
Higashiniigata#4
Himeichi#5
Higashiniigata#3
Yokohama #7, 8
Chiba#2
Kawagoe#1
Hitachinaka#1
Kanda#1
Fiscal year
Fig.1.3-1: Developments in thermal efficiency of thermal power generation
Table 1.3-1: Major coal-fired thermal power generation plants in Japan (1959 - 1985)
Era
No.
1
From
1976 to
1985
Power plant
Unit
Approved
output
Steam conditions
Unit No.1
75
10.0MPa-538 C/538 C
Tohoku
Sendai
Unit No.1
175
16.6MPa-566 C/538 C
Kyushu
Minato
Unit No.1
156
16.6MPa-566 C/538 C
Tohoku
Sendai
Unit No.2
175
16.6MPa-566 C/538 C
Chugoku
Mizushima
Unit No.1
125
12.5MPa-538 C/538 C
Tohoku
Sendai
Unit No.3
175
16.6MPa-566 C/538 C
Unit No.2
75
10.0MPa-538 C/538 C
Before
1975
Electric power
company
Manufacturer
Turbine
Generator
Mitsubishi
MHI
MHI
Electric
Corp.
Babcock- GE, Hitachi,
Hitachi, Ltd.
Hitachi K.K.
Ltd.
Mitsubishi
MHI
MHI
Electric
Corp.
BabcockHitachi, Ltd. Hitachi, Ltd.
Hitachi K.K.
BabcockHitachi, Ltd. Hitachi, Ltd.
Hitachi K.K.
BabcockHitachi, Ltd. Hitachi, Ltd.
Hitachi K.K.
Mitsubishi
MHI
MHI
Electric
Corp.
BabcockHitachi, Ltd. Hitachi, Ltd.
Hitachi K.K.
Mitsubishi
MHI
MHI
Electric
Corp.
Toshiba
Toshiba
MHI
Corp.
Corp.
Mitsubishi
MHI
MHI
Electric
Corp.
BabcockHitachi, Ltd. Hitachi, Ltd.
Hitachi K.K.
Toshiba
Toshiba
IHI
Corp.
Corp.
Mitsubishi
MHI
MHI
Electric
Corp.
Mitsubishi
MHI
MHI
Electric
Corp.
Boiler
Operation
started from
1959-08
1959-10
1960-09
1960-11
1961-11
1962-06
0962-07
Chugoku
Mizushima
Unit No.2
156
16.6MPa-566 C/538 C
Kyushu
Omura
Unit No.2
156
16.6MPa-566 C/538 C
10
Shikoku
Saijo
Unit No.1
156
16.6MPa-566 C/538 C
11
Chugoku
Shimonoseki
Unit No.1
175
16.6MPa-566 C/538 C
12
J-POWER
Takehara
Unit No.1
250
16.6MPa-566 C/538 C
13
Hokkaido
Naie
Unit No.1
175
16.6MPa-566 C/538 C
14
J-POWER
Takasago
Unit No.1
250
16.6MPa-566 C/538 C
15
J-POWER
Takasago
Unit No.2
250
16.6MPa-566 C/538 C
16
Hokkaido
Naie
Unit No.2
175
16.6MPa-566 C/538 C
IHI
1970-02
17
Shikoku
Saijo
Unit No.2
250
16.6MPa-566 C/538 C
IHI
1970-06
18
Jyoban Joint
Power Co.
Nakoso
Unit No.7
250
16.6MPa-566 C/538 C
MHI
1970-10
19
Tobata Co-operative
Thermal Power
Company, Inc.
Tobata Cooperative
Thermal Power
Company, Inc.
Unit No.2
156
16.6MPa-566 C/538 C
MHI
20
Toyama Kyodo
Toyamashinko
Unit No.1
250
16.6MPa-566 C/538 C
21
Toyama Kyodo
Toyamashinko
Unit No.2
250
16.6MPa-566 C/538 C
22
Mibugawa
Unit No.1
250
16.6MPa-566 C/538 C
23
Hokkaido
Sagawa
Unit No.3
125
12.5MPa-538 C/538 C
MHI
Fuji
Fuji
1977-06
Unit No.1
350
16.6MPa-566 C/538 C
MHI
Toshiba
Corp.
Toshiba
Corp.
1977-10
Unit No.2
350
16.6MPa-566 C/538 C
MHI
Unit No.1
350
16.6MPa-566 C/538 C
BabcockHitachi K.K.
Unit No.1
500
24.1MPa-538 C/538 C
MHI
24
Sakata kyodo
power company,
Ltd.
25
Sakata kyodo
power company,
Ltd.
26
Hokkaido
27
J-POWER
Sakata kyodo
power
company,
Ltd.
Sakata kyodo
power
company,
Ltd.
Tomatoh
Atsuma
Matsushima
28
J-POWER
Matsushima
Unit No.2
500
24.1MPa-538 C/538 C
29
Hokkaido
Sagawa
Unit No.4
125
17.7MPa-538 C/538 C
30
31
32
33
J-POWER
Jyoban Joint
Power Co.
Jyoban Joint
Power Co.
Hokkaido
Takehara
Unit No.3
700
24.1MPa-538 C/538 C
Nakoso
Unit No.8
600
24.1MPa-538 C/566 C
MHI
Toshiba
Corp.
1964-08
1965-11
1967-03
1967-07
1968-06
1968-07
1969-01
1971-06
1971-09
1972-06
1975-03
1978-10
1980-10
1981-01
MHI
Toshiba
Corp.
Toshiba
Corp.
1981-06
KHI
Fuji
Fuji
1982-05
Nakoso
Unit No.9
600
24.1MPa-538 C/566 C
IHI
Toshiba
Corp.
Tomatoh
Atsuma
Unit No.2
600
24.1MPa-538 C/566 C
IHI
Hitachi, Ltd.
Mitsubishi
Electric
Corp.
1963-08
1983-03
1983-09
Toshiba
Corp.
1983-12
Hitachi, Ltd.
1985-10
Table 1.3-2: Major coal-fired thermal power generation plants in Japan (1986 - 2005)
Era
From
1986 to
1995
Electric power
company
Power plant
Unit
Approved
output
Steam conditions
34
Chugoku
Shinonoda
Unit No.1
500
24.1MPa-538 C/566 C
IHI
35
J-POWER
Ishikawa
Unit No.1
156
18.6MPa-566 C/566 C
KHI
Fuji
Fuji
1986-11
IHI
Toshiba
Corp.
Toshiba
Corp.
1987-01
Fuji
Fuji
36
Chugoku
37
38
39
Boiler
Shinonoda
Unit No.2
500
24.1MPa-538 C/566 C
J-POWER
Ishikawa
Unit No.2
156
18.6MPa-566 C/566 C
KHI
Kyushu
Matsuura
Unit No.1
700
24.1MPa-538 C/566 C
MHI
J-POWER
Matsuura
Unit No.1
1000
24.1MPa-538 C/566 C
BabcockHitachi K.K.
40
Chubu
Hekinan
Unit No.1
700
24.1MPa-538 C/566 C
MHI
41
Hokuriku
Tsuruga
Unit No.1
500
24.1MPa-566 C/566 C
MHI
42
Chubu
Hekinan
Unit No.2
700
24.1MPa-538 C/566 C
BabcockHitachi K.K.
43
Chubu
Hekinan
Unit No.3
700
Generator
Toshiba
Corp.
Mitsubishi
Electric Corp.
Toshiba
Corp.
Toshiba
Corp.
Operation
started from
1986-04
1987-03
1989-06
1990-06
1991-10
1991-10
1992-06
1993-04
1993-06
24.1MPa-538 C/593 C
IHI
MHI
Mitsubishi
Electric Corp.
BabcockHitachi K.K.
Fuji
Fuji
44
Tohoku
Noshiro
Unit No.1
600
24.5MPa-538 C/566 C
45
Okinawa
Gushikawa
Unit No.1
156
16.6MPa-566 C/538 C
KHI
1994-03
24.1MPa-538 C/566 C
BabcockHitachi K.K.
1994-07
46
47
Soma Kyodo
Tohoku
Shinchi
Noshiro
Unit No.1
Unit No.2
1000
600
24.1MPa-566 C/593 C
48
Hokuriku
Nanao Ohta
Unit No.1
500
24.1MPa-566 C/593 C
49
Okinawa
Gushikawa
Unit No.2
156
16.6MPa-566 C/538 C
50
J-POWER
Takehara
Unit No.2
350
16.6MPa-566 C/538 C
IHI
BabcockHitachi K.K.
BabcockHitachi K.K.
BabcockHitachi K.K.
Toshiba
Corp.
MHI
MHI
Toshiba
Corp.
Toshiba
Corp.
Soma Kyodo
Shinchi
Unit No.2
1000
24.1MPa-538 C/566 C
MHI
52
Kyushu
Reihoku
Unit No.1
700
24.1MPa-566 C/566 C
IHI
53
J-POWER
Matsuura
Unit No.2
1000
24.1MPa-593 C/593 C
BabcockHitachi K.K.
MHI
Tohoku
Haramachi
Unit No.1
1000
24.1MPa-566 C/593 C
MHI
Toshiba
Corp.
55
Hokkaido
Tomatoh
Atsuma
Unit No.3
85
16.6MPa-566 C/538 C
MHI
MHI
56
Chugoku
Misumi
Unit No.1
1000
24.5MPa-600 C/600 C
MHI
MHI
IHI
Toshiba
Corp.
57
58
Hokuriku
Tohoku
Nanao Ohta
Haramachi
Unit No.2
Unit No.2
700
1000
24.1MPa-593 C/593 C
24.1MPa-600 C/600 C
59
Shikoku
Tachibana wan
Unit No.1
700
24.1MPa-566 C/593 C
60
J-POWER
Tachibana wan
Unit No.1
1050
25.0MPa-600 C/610 C
61
Hokuriku
Tsuruga
Unit No.2
700
24.1MPa-593 C/593 C
BabcockHitachi K.K.
BabcockHitachi K.K.
IHI
MHI
BabcockHitachi K.K.
BabcockHitachi K.K.
62
J-POWER
Tachibana wan
Unit No.2
1050
25.0MPa-600 C/610 C
63
Chugoku
Osaki
Unit No.1
250
16.6MPa-566 C/593 C
360
24.1MPa-566 C/593 C
IHI
64
Kyushu
Kanda
New Unit
No.1
65
Chubu
Hekinan
Unit No.4
1000
24.1MPa-566 C/593 C
IHI
66
Okinawa
Kin
Unit No.1
220
16.6MPa-566 C/566 C
MHI
67
68
J-POWER
Isogo
Unit No.1
600
25.0MPa-600 C/610 C
IHI
Hokkaido
Tomatoh
Atsuma
Unit No.4
700
25.0MPa-600 C/600 C
IHI
69
Chubu
Hekinan
Unit No.5
1000
24.1MPa-566 C/593 C
IHI
70
Okinawa
Kin
Unit No.2
220
16.6MPa-566 C/566 C
MHI
71
Kyushu
Reihoku
Unit No.2
700
24.1MPa-593 C/593 C
MHI
Toshiba
Corp.
Toshiba
Corp.
Mitsubishi
Electric Corp.
Toshiba
Corp.
Mitsubishi
Electric Corp.
Mitsubishi
Electric Corp.
Toshiba
Corp.
GT: ALSTOM
ST: TOSHIBA
Toshiba
Corp.
72
Tokyo
Hitachinaka
Unit No.1
1000
24.5MPa-600 C/600 C
73
Tokyo
Hirono
Unit No.5
600
24.5MPa-600 C/600 C
MHI
MHI
74
Kansai
Maizuru
Unit No.1
900
24.1MPa-595 C/595 C
MHI
MHI
1995-06
1995-07
1995-12
1997-07
1997-07
1998-03
1998-06
1998-07
1998-07
2000-07
Toshiba
Corp.
Toshiba
Corp.
Fuji
Toshiba
Corp.
1995-03
GE
Toshiba
Corp.
Mitsubishi
Electric Corp.
1995-03
2000-06
1994-12
Toshiba
Corp.
BabcockHitachi K.K.
10
Toshiba
Corp.
Mitsubishi
Electric Corp.
Mitsubishi
Electric Corp.
51
54
From
1996 to
2005
Manufacturer
Turbine
Toshiba
Corp.
No.
Toshiba
Corp.
2000-09
2000-12
2000-12
2001-07
2001-11
2002-02
2002-04
2002-06
2002-11
2003-05
2003-06
2003-12
2004-07
2004-08
Technical development, in general, aims at higher efficiency of power generation for the purpose of reducing
the environmental load and CO2 emission; however, concrete issues include the following:
(1) High-temperature gas turbine aiming at further improvement of thermal efficiency of combined cycle power
generation
(2) Making coal utilization technology starting with coal gasification combined cycle power generation system
more sophisticated
Thermal power plants consist of a boiler, turbine, and generator, and the efficiency of power generation was
increased through the larger capacity of the configuration of the basic equipment and sophistication of running
conditions (mainly higher temperature and pressure of the stem cycle system). Gross thermal efficiency was
increased from about 30% 40 years ago to 40% currently. This 40% was achieved by the ultra-supercritical
pressure power generation system. For the purpose of increasing the efficiency further, the development of
combined cycle power generation technology is in progress. Through this development, we can aim at 50%
efficiency. This technology aims, in addition to the conventional steam cycle, to combine the gas turbine cycle to
improve the efficiency of power generation comprehensively through power generation from both cycles.
Combined cycle power generation using natural gas is becoming mainstream in new thermal power generation
technology as combined cycle power generation. Further, the development of a ceramic turbine blade is in
progress to improve the efficiency by causing higher temperature. With respect to the use of coal related to the
reduction of CO2 emission, although the pulverized coal combustion system has been adopted in recent years for
the purpose of improving efficiency, the integrated coal gratification combined cycle (IGCC) is the target of
development to improve efficiency further.
The fluidized bed generation system is a generation system that uses fluidized bed combustion. The
commercialization of fluidized bed combustion was propelled as a combustion system of flame-resistant materials.
However, in recent years, the excellent environmental characteristics of fluidized bed combustion, such as
desulfurization in furnace and low NOx combustion, are receiving attention. From the viewpoint of improving
efficiency, the development and commercialization of the pressurized fluidized bed combined cycle generation
system (PFBC) are in progress. In light of its intrinsic characteristics, it is also considered that it will pave the
way for mixed fuel power generation with coal and biomass (especially waste).
11
I.
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. 9
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 180 C to 250 C. 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
19
8.5 9.6 ( )
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
40
41
200 or less ( )
100 or less ( )
Load operation
(42)
[1/2MCR
or less]
Greater than
Greater than
Greater than
Greater than
15 and 20 or
15 and 20 or
20
20
less
less
19
19
Economizer
8.5 9.6 ( )
9.0 9.6
8.5 9.6 ( )
9.0 9.6
pH (at 25 C)
11 19
inlet
0.1 or less
0.1 or less
0.1 or less
0.1 or less
Electric conductivity (mS/m) ( )( ) (at 25 C)
11 19
100 or less
100 or less
100 or less
100 or less
(!S/m) ( )( ) (at 25 C)
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)
38
38
20 or more ( )
20 or more ( )
10 or more
10 or more
Hydrazine (!gN2H4/l)
30 or less
30 or less
30 or less
30 or less
Silica (!gSiO2/l)
11 19
0.1 or less
0.1 or less
Furnace
Electric conductivity (mS/m) ( )( ) (at 25 C)
11 19
100 or less
100 or less
water wall
(!S/m) ( )( ) (at 25 C)
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 100!gFe/l or less.
(41)
The target concentration of the iron is 50!gFe/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
The fuel shut-off valve, burner valve, and SH/RH spray valve are closed.
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.
Ws (h0 - hl)
! 100%
Gf Hh
(1)
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 - 150#C with coal and heavy oil (crude oil) fuel, at 165#C with high sulfuric content heavy oil, etc,
and around
100#C 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
Cg
: Average specific heat of dry gas .0 kJ/kg#C
tg
: Air preheater outlet exhaust gas temperature #C
to
: Boiler efficiency standard temperature #C
L1 "
( 2)
L2 "
Mf ($hR % Cm - ts - Cw - ts)
! 100%
Hh
(3)
41
L3 "
( 4)
L5 "
23,700 ! C
(CO)
!
! 100%
Hh
(CO 2) % (CO)
(5)
Where;
23,700
L6 "
33,900 ! C'
! 100%
Hh
( 6)
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
(7 )
l "1
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
#C
43
HR "
(1)
HR "
( 2)
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
Ls
Q
Net Heat Rate "
Ls & LBFP
(3)
( 4)
Q
Ls % LBFP
(5)
Q
Ls
( 6)
(t"
3,600
! 100%
HR
(7)
(t"
(E)
! 100%
( B) & (C )
(8)
Moreover, the following definitions are used to express efficiency of the generation plant.
(E)
! 100%
( A)
(9)
(F )
! 100%
( A)
(10)
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'
"
H o H i s & i1
(12)
( It "
H el ir & i4
"
H o l i r & i3
(13)
( IL "
H eL i4 & i6
"
H o L i 4 & i5
(14)
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 "
GS
3,600
"
PS He(t(s
(15)
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 5#C 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 - 3#C 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
10#C 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)
ix
: Extraction enthalpy
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
)o
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.
Operation control of the ball cleaning device
Control of electrolytic protection device
Measuring of vacuum pump extraction quantity
Control of instrumentations
Tubing brushing cleaning
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.
Drain accumulation in the detection piping
Temperature compensation if the standard temperature differs between the mercury vacuum gauge and
the atmospheric pressure gauge.
Difference between the atmospheric pressure compensated vacuum degree and the transmitter side.
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.
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
( T), 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 %
Q
1
Gc ! c p ! + ! (1 & p )
e
" t1 %
t 2 & t1
1
1& p
e
(1)
Where
p"
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 75 C.
(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 +3 C
b. Trial calculation results
Decrease of extraction quantity by T.D. increase
EXT
Turbine room input heat increase by reheated steam quantity increase by extraction quantity decrease by
T.D increase
Output heat decrease from the turbine room by feed water temperature decreasing
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
Output change
(increase)
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.
Deviation of the theoretical value and actual record value of the sulfuric acid dew point
The relation between the sulfur contents in the fuel and produced SO3 density.
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.
Lowering of exhaust gas temperature by increase in AH air leakage amount
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.
Increase of exhaust gas temperature incident to dry gas quantity increase by Combustion gas O2 (Excess
air factor)
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
Start of
operation
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
Environment
engineering manager
Engineering assistant
manager
+
4 personnel
Operation
management of
environmental facilities
Operation management of
environmental facilities
+
6 personnel
assistant
Control of BTG
generation facilities
manager +
5 groups
Operators (8
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
Control values
under normal
operation
Recorder
Record frequency
Indicator
office
Site
1/
day
1/
month
1/
year
Remarks
As
needed
+
of
or
For generation
Max value
JEAC3717
caution value*
Bearing
No.
Amplitude
61
*
Shaft
Bearing
Over rated
Under 12.5
Under 6.25
pH (25!C)
Silica
Electric
conductivity
pH (25!C)
Silica
Feed water
Electric
quality
conductivity
Dissolve O2
RBOT
All oxidization
Impurities
Lubricate
oil for
Kinetic viscosity
turbine
(40!C)
Water content
Color phase
Unit
Gross
efficiency
Net
Boiler drum water level
Boiler
water
quality
Measure
values
Unit
"gSiO2/l
Control values
under normal
operation
Measure location
Recoder
Record frequency
Indicator
office
Site
1/
day
1/
month
1/
year
As
needed
Remarks
Average
value
Water
quality
standard value
Over 70 mins.
Under 0.3
Under 10
(New
oil
standard) # 10%
Under 500
Under 4
"S/cm
"gSiO2/l
"S/cm
"gO/l
minute
mgKOH/g
mg/100ml
mm2/s
mg/l
ASTM
%
mm
MPa
t/h
t/h
MPa
!C
MPa
!C
MPa
Calculate
value
Highest,
lowest
Maximum
Maximum
Maximum
Maximum
Maximum
Minimum
Maximum
Minimum
Warning value
Rated 1.05
Max operation
Max operation
Rated 1.05
Rated + 8!C
Warning value
Warning value
Warning value
62
Unit
Measure
values
Control values
under normal
operation
%
mm
Maximum
Maximum
mm
mm
Maximum
Maximum
Warning value
rpm
Maximum
Rated 1.05
Measure location
Recorder
Record frequency
Indicator
office
Site
Max operation
1/
day
1/
month
1/
year
Remarks
As
needed
63
Table 2.5.4-2
Setting Standard for Control and Permissible Values for Trial Operation
(Boiler)
Items
Generator load
Pressure
Unit
MW
MPa
!C
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
Temperature
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
$
$
!
!
!C
$
$
$
$
$
!
!
!
A
!C
Wind box
!C
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
!C
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 32
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
Display current
output of each
generator
Performance management
terminal
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 (25!C)
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
22:00
Shift 2
!
Shift 3
!
"
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
Tentacle,
hearing
Leakage
Defects in hangers
Vibration
Leakage
Combustion
condition
Situations inside
Vibration, unusual
sound
Temperature rise,
oil surface, oil
leakage
Leakage
gland part
Method
Remarks
visual,
Visual
Tentacle, hearing
Visual, hearing
Visual
Visual, hearing
Tentacle, hearing
Tentacle,
visual
from
smell,
Visual
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
Tentacle, hearing
Visual, hearing
Tentacle, hearing
Tentacle, see, hear
Visual, hearing
Visual
Visual, tentacle
Visual, hearing
Visual
Visual, hearing,
tentacle, smell
Visual, hearing, smell
Visual, hearing, smell
Visual, hearing,
tentacle, smell
Visual, hearing,
tentacle, smell
Table 2.5.4-6
76
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
efficiency (month)
43.73
Beginning
43.60
Middle
43.90
End
43.70
Year
Table 2.5.5-2
83
(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
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
Hydrogen
Nitrogen
Combustive sulfur
Analysis
Carbon
Remarks
Elemental analysis
CO
O2
AH outlet O2
Boiler outlet O2
Furnace clinker
EP ash
MC ash
"
PC ash
"
Outlet
High standard
Industrial analysis
CO2
Eco
Bituminous mix
crude oil
Analysis items
(Note)
Heavy
! : Items to be analyzed
: Items analyzed when loss method is applied
" : Items analyzed as necessary
! : Items not analyzed
87
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.
Input minimum
Precision /
Measuring
Measurement items
Remarks
Unit
tolerance
position
reading)
0.01%
0.03%
Hydrogen
0.01%
0.15%
Nitrogen
0.01%
0.06%
Fuel analysis
Boiler
"C
! (Central
1"C
#0.5"C
No water base
Carbon
control)
0.01Mpa (1atg)*
MPa
control)
(#0.5atg)*
"C
! (Central
1"C
#0.5"C
Turbine
Reheat steam
Pressure
#0.005Mpa
! (Central
Main steam
control)
*The brackets show the minimum reading values of equipment for power stations requiring meter reading.
Reheat steam
Temp.
Main steam
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
QO (Output heat)
QG
(Generator output)
QEX (Boiler auxiliary heat input)
Boiler room efficiency can be calculated as follows based on heat equilibrium of boiler system;
Qf + QEX = QO + QBS + QBL
Qf QBL = QO + QBS QEX
%B ' (1 -
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 '
'
(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 # iMS
WEj # iEj
WSS # iSS
SH
WSD # iSD
WHR # iHR
WRS # iRS
WLR # iLR
Qf # QEX
RH
Heat loss
Heavy oil
Drain
Heavy oil
heater
WFW # iFW
WSAH # iSAH
WSAH # iSAHD
WSC # iSC
WSC # iSCD
AH
Atomize
steam
Exhaust gas
Combusted air
SAH
Heater
SC
(qsc)
92
%Bi '
Bi)
Qf ' Hf ( Mf
Qf
[kJ/h]
QEX
[kJ/h]
QO
QBS
Hf
[kJ/h]
Mf
:Fuel consumption
[kg/h]
QO=WMS
iMS+WHR
(Heating, etc)
WEj
iEjWSS
[kJ/h]
iSSWRS
iRSWLR
iLRWFW
iFWWSAH(iSAHiSAHD)WSC(iSCiSCD)QEX
WMS
[kg/h]
iMS
[kJ/kg]
WHR
[kg/h]
iHR
[kJ/kg]
WEj
[kg/h]
iEj
[kJ/kg]
WSS
[kg/h]
iSS
[kJ/kg]
WRS
[kg/h]
iRS
[kJ/kg]
WLR
[kg/h]
iLR
[kJ/kg]
WFW
[kg/h]
iFW
[kJ/kg]
WSAH
[kg/h]
iSAH
[kJ/kg]
iSAHD
[kJ/kg]
WSC
[kg/h]
iSC
[kJ/kg]
iSCD
: SC drain enthalpy
enthalpy
enthalpy
enthalpy
enthalpy
enthalpy
enthalpy
enthalpy
enthalpy
enthalpy
[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 !
B1)
Q BL
! L CL ! L BD ! L AT ! L EX
Qf
[kJ/kg fuel]
a.
Cg
[kJ/kg fuel]
1.38
[m3N/kg fuel]
[kJ/m3N K]
["C]
ta
["C]
[kJ/kg fuel]
[kg/kg fuel]
[kg/kg fuel]
: Steam enthalpy at steam pressure 10.1kPa, tg (AH outlet gas temperature) "C
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]
)
*
A 3 PBOT
)800 ! t a * & 100 ! PBOT )t g ! t a *0/
2
100 1 100
100
.
1.05
[kJ/kg K]
[%]
[kJ/kg fuel]
[%]
4CO5
[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]
[%]
Ca
6
100
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]
Theoretical air
Mat !
Mat
$
o( ,
1 '
/
* ) 3.33s (#
&8.89c( ) 26.7- h (
8+
100 %
.
"
0100
c( ! c 2
100
h( ! h 2
o( ! o 2
s( ! s 2
W1
0100
W1
100
0100
W1
100
0100
W1
100
A2
u
100 u
[m3N/kg fuel]
[%]
/
100A ,
*
o ! 100 -- c ) h ) n )
100 W1 *+
.
[%]
[%]
[%]
[%]
97
: Carbon
: Hydrogen
: Nitrogen
: Combustive sulfur
: Oxygen
[%]
W1
[%]
[%]
m!
21
' 0O 1 0.50CO 1$
21 79& 2
#
0N 2 1
"
%
(CO2)
(CO)
(N2)
$
1 '
o( ,
/
* ) 3.33s ( ) 0.8n (#
&8.89c( ) 21.1- h (
100 %
8+
.
"
M gt !
n( ! n 2
0100
W1
[m3N/kg fuel]
100
Wh !
9h (
100
WW !
W2
W1
100
[kg/kg fuel]
W2
100
[kg/kg fuel]
W2
[%]
98
Absolute Humidity Z
Z ! 0.622 2
Ps
Pa
Ps ! PW
[kg/kg]
Ps
0.0008 2 Pa 2 0Td
Pa
: Atmosphere pressure
[kPa]
Ps
: Steam pressure
[kPa]
PW
[kPa]
Td
[3C]
TW
: Wet-bulb temperature
[3C]
4!
[%]
[%]
[%]
QG
2 100
Q O Q TS
5T !
QG
PG
[%]
[kJ/h]
[kWh]
[kJ/h]
5 Pi !
K
K!
QG
2 K2 100
Qf
[%]
Q O ) Q BS Q EX
Q O Q TS
5 P1 ! 5 B1 25 T / 100
[%]
99
TW 1
PGH )
8!
PG
2 PCM
7 PG
2 100
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.
/
.
5 P ( ! 5 P 2 -1
8 ,
*
100 +
[%]
100
(1) Calculation Standards for main steam flow rate are as follows;
a. Main steam flowmeter standard
b. Condenser flowmeter standard
c. Feed water flowmeter standard (Adopted in JIS B-8222 and this manual)
(2) Comparison of each calculation standard
a. Main steam flowmeter standard has a weaker reliability than other methods since steam itself is compressive
fluid.
b. Condenser flowmeter standard ensures high precision due to its low temperature and pressure when used, but
the feed water heater drain flow rate needs to be calculated with low-precision flowmeter or heat balance
calculation, thus showing lower reliability.
c. Feed water flowmeter standard has a problem of deviation error caused by scale attaching to the flowmeters
flow nozzle, but precision is thought to be higher than the aforementioned standards.
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=WFW WSS
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
Pi (WMsi)/n.
d. Calculate P= Pi/n.
P = 8.42
WMS=372.32
f. From above,
WMS !
S3
S1
/
P ) -- WMS
.
S3
S1
,
P **
+
WMS=45.9059P 14.2074
/ S 2
9 ! -- 3
. S1 2 S 2
,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
69
/ 78
Range of volatile
matter
(dry coal/no-mineral
base %)
2
2</ 8
8 < / 14
14 < / 22
22 < /
Agglomeration
characteristic
Not exist
31
7,780
< 69
31 <
7,220
/ <7,780
/ < 7,220
/ < 6,390
/ < 6,390
Exist
6,390
5,830
5,830
5,280
/ < 5,830
Not exist
4,610
/ < 5,280
Generally, exist
103
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
Temperature in furnace ( C)
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 = 1,200 C
Ambient oxygen density = 0.04 ala
K* #
(Wo " WE )
! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! (1)
n$Do 2T
Because, in actual pulverized coal burning boilers, the gas/coal grain temperature and oxygen density change
when coal moves from the burner exit to the furnace exit, and the combustion is largely rate-controlled by
diffusion resistance in the higher temperature area, as well as by chemical reaction resistance in the lower
temperature area. So it is not appropriate to use the burning velocity coefficient K*, which has been measured
under a certain condition, for the calculation of the burnout in the boiler furnace.
The combustion of pulverized coal grains in the furnace is as per the following expression, where the grain size
is Dp:
d , ro$
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/cm2 s)
Kf: combustion velocity coefficient when the oxygen diffusion density in
the gas film is dominant (g/cm2 s)
Kc: combustion velocity coefficient when the chemical reaction rate of
the grain surface is dominant (g/cm2 s)
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 - . ! W) ! (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 W/5.0
= 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
Moisture
amount
(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
-
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
(H2O)
(SO2)
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:
2.667
32
# 2.667 kg or
# 1.867 Nm 3
1.429
12
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 0
21
2.667 0
76.8
# 8.829 or
23.2
79
1.867 0
# 7.024 Nm 3
21
2.667 0
03
6
Ado # 11.50C % 34.54H " 1 % 4.31 & S
82
5
03
6
Ado' # 8.89 & C % 26.7 4H " 1 % 3.33 & S
82
5
(kg/kg)
(Nm3/kg)
Likewise, the theoretical dry gas flow rate (Gdo) is obtained by the following expression:
03
6
Gdo # 12.50C % 26.54H " 1 % 5.31S % N
82
5
(kg/kg)
or,
03
6
Gdo' # 8.89C % 21.14H " 1 % 3.33S % 0.80 N
82
5
(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 ! Ado (kg/kg)
or
Wa = 1.61Xa ! 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) ! Ado (kg/kg)
or
Gd = Gdo + (m-1) ! Ado (Nm3/kg)
Gw = Gd + Wf + m ! Wa (kg/kg)
or
Gw = Gd + Wf m ! 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.
CO2max = (1.867C + 0.69S)/Gdo 0 100
(dry vol%)
CO2 = (1.867C + 0.69S)/Gdo 0 100
(dry vol%)
Also, the other composition in the actual burning gas is obtained from the following expression:
O2 = 21(m-1)Ado/Gd
(dry vol%)
N2 = (0.8N + 0.79m ! Ado)/Gd0100
(dry vol%)
112
H2O = (Gw-Gd)/Gw0100
(wet vol%)
Australian G
coal
Japanese A
coal
Chinese D coal
Raw
coal
Reactor temperature ( C)
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
1400 C while 25-30% is accounted for by Thermal NOx when the reactor temperature is 1600 C.
Figure 8 shows the comparison of NOx generation amounts when the type of coal is changed under the
primary- and secondary reactors temperature of 1350 C.
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 =
1,350 C
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 = 1,350 C
(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
split
From
PAF
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
7
Vc
(8 / 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
amount of PAF air flow rate compared
pressure decreases by the amount of
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
Necessary Q-H characteristic
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
[Background]
Long-term operation
program
[Needs]
[Measures to
increase longevity]
increasing longevity
(prolonging life)
Maintaining operation
through the renewal of
deteriorated equipment
[Measures to
increase longevity]
[Destination]
Stable supply
Cost reduction
Repowering
Replacement
(addition)
Fig. 3.1.1: How to carry out the maintenance of aged thermal power plant (increasing longevity)
142
Maintenance of
aged thermal power
plant
Operation control
Operation
Monitoring of
operation status
Enhancement of operation control
and supervisory function
Reduction of load on equipment
Early detection of problems
Routine inspection/test
Patrol
[Example]
Monitoring of life consumption of hightemperature thick part of boiler and turbine
Diagnosis of boiler combustion
Monitoring of vibration of large rotating
machine
Trip test of safety device
Routine replacement of auxiliary machine
Vibration of auxiliary rotating machine
Operation status of auxiliary machine
Opening of control valve
Daily simplified
maintenance
Inspection & repair
program
Maintenance
Long-term
operation program
Securing of soundness of
plant equipment
Upkeep of function and
reliability level
Securing of economics
Renovation program
[Example]
High-temperature pressureresistant part of boiler and
turbine
High-speed rotor of turbine
Insulation of generator
Periodic inspection,
service, maintenance
Precise inspection,
diagnosis of plant
Improvement of
proof stress
Improvement of
function
[Example]
Renewal and renovation of
deteriorated equipment and parts
[Example]
Improvement of control
performance, strengthening of
supervisory function
Automation, improvement of control
performance
3.1.2.1 Operation & maintenance status of aged thermal power plants (from the 50s to the early 60s of
the Showa period)
Aged thermal power plants were originally designed to operate continuously (operation to cover the base load).
10 thousand kW
1992
(September)
1970 (September)
1960 (January 36)
Time
Pumped-storage
hydroelectric power
example)
Plant
Pumped-storage
power
Oil
Portion to be
inspected
Rotor
Steam
turbine
Moving blade
LNG, LPG and
other gases
Casing
Coal
Boiler
Generator
Superheater
and reheater
tube
Drum
Main steam
pipe
Reheat steam
pipe
Rotor
Transformer
Main body
Electric
motor
Rotor
Nuclear
power
Inspection method
Visual inspection with bore scope
Ultrasonic testing
Magnetic particle testing
Ultrasonic testing
Measurement of lifting amount of
stud part
Structure examination of
representative point (macro)
Ultrasonic testing (weld point)
Tube removal examination from a
representative point
Radiographic test
Ultrasonic testing
Base load operation was carried out at the initial stage of construction. However, because of subsequent changes
in the demand-supply structure, that is to say, an increase in demand (maximum electricity demand), a widening
of the gap in demand-supply between day and night, and an increase of the segment share of nuclear power
generation, base load operation handed over its role to nuclear power and large-capacity thermal machines. As a
result, the operation pattern has changed to the operation of a middle-sized thermal power plant positively bearing
adjustment between demand and supply, i.e., the operation pattern under which load change, reduction of
minimum load, frequent start up and shut down, etc. are performed.
Portion to be inspected
Diagnosis portion
Destruction inspection
Superheater tube
Reheater tube
Larson-Miller method.)
Structural examinations
Boiler tube
Boiler header
Furnace evaporation header
left.
Superheater header
Reheater header
Steam turbine
Axle
Non-destructive inspection
High-pressure axle
Hardness measurement
Medium-pressure axle
Casing
High-pressure internal casing
hours as a guideline.)
Major valves
MSV CV
RSV
ICV
144
For the purposes of securing the reliability and performing strict demand supply adjustment operation such as
DSS (daily start up and shut down), etc. of the plant equipment designed originally based on the premise of base
load operation given that aging progresses, we have basically planned :
An operation pattern that will contribute to demand-supply adjustment sufficiently and where start-up and shutdown loss is minimized
Securing of strength and allowance of a plant sufficient to cope with thermal stress, repeated stress arising from
start up, shut down, load change, etc. and creep damage associated with secular use
Improvement of operability and enrichment of supervisory function so that the operator can cope with the
situation within limited time and simultaneous operation
Early detection and handling when there is an abnormal condition in the plant
Establishment of optimum operation pattern through operation testing
Precise inspection and remaining life assessment for plants whose cumulative operation time has exceeded
100,000 hours (Table 3.1.2.1-1, 2)
Improvement of plant durability (Table 3.1.2.1-3, 4)
Improvement of operability and controllability, enhancement of monitoring function (Table 3.1.2.1-3, 4)
Disk
Curvature
radius
Big
Processed point
Curvature
radius
Big
Small
(a)Processing example
Table 3.1.2.2-1: Examples of improvement in largecapacity machines (Constant-pressure supercritical oncethrough system)
[Improvement of plant durability]
Improvement of superheater header part of boiler (Fig. 9)
Processing of membrane-end part of boiler (Fig. 10)
Improvement of structure of surrounding wall tie-bar of boiler (Fig.
11)
Improvement of passing-through part at boiler tube wall (Fig. 12)
Improvement of support system for main piping of boiler (Fig. 13)
Reinforcement of start system valve of boiler (Fig. 14)
Reinforcement of feed water control valve of boiler (Fig. 15)
[Improvement of controllability and enhancement of supervisory
function]
Improvement of controllability to plan the improvement of
controllability at start up/shut down and when the load changes
Digitization of APC control
Automation of boiler automatic burner
Expansion of automatic start-up control range of turbine
Improvement of controllability on the drain level of feed water
heater
Bringing auxiliaries to group control (master)
Addition of life supervisory function for thick pressure-resistant part
of boiler
Automation, enhancement of supervisory function and man-machine
communication
[Before improvement]
[After improvement]
.
(a) Bringing header tube nozzle to flexible structure
Corner R processing
Nozzle
(b) Corner R processing of header tube nozzle part
Tie-bar clip
Membrane bar
Water-cooling
wall tube
Tie-bar
Tie-bar
Wall
New toe
Torque bracket
Tube leg
A-part
Improvement of structure of tube leg at wall passing-through part
Z-type valve
Angle valve
146
The following are the reasons for renewal according to the equipment of each plant, renewal rate and equipment
whose renewal due to deterioration and damage exceeds 20% extracted from such report:
(1) Boiler plant related (Fig. 3.1.2.2-8)
Furnace tube
Renewal rate:
About 36%
Renewal time:
From less than 40,000 hours to 200,000 hours
The renewal peak falls within the range of 100,000 to 200,000 hours.
! Superheater 1st
Renewal rate:
About 25%
Renewal time:
From less than 40,000 hours to 200,000 hours or more
The renewal peak falls within the range of 120,000 to 140,000 hours.
Reason for renewal: As many renewals have been performed after 120,000 hours, conceivable reasons for
renewal are creep damage, external high-temperature corrosion and ash erosion.
" Superheater 2nd to 4th
Renewal rate:
2nd About 56%
3rd About 66%
4th
About 70%
Renewal time:
2nd: From less than 40,000 hours to 200,000 hours or more
The renewal peak falls within the range of 100,000 to 120,000 hours.
3rd and 4th: From 60,000 hours to 160,000 hours
The renewal peak falls within the range of 80,000 to 100,000 hours.
Reasons for renewal: As there are many renewals for those whose main steam temperature is 550C or
more, for those for WSS (weekly start up and shut down) operation and for heavy
oil-fired ones, conceivable reasons for renewal are creep damage and hightemperature corrosion.
# Superheater weld joint with dissimilar materials
Renewal rate:
About 47%
Renewal time:
From less than 40,000 hours to 180,000 hours.
The renewal peak falls within the range of 80,000 hours to 160,000 hours.
Reason for renewal: As there are many renewals for those whose main steam temperature is high and for
heavy oil-fired ones, conceivable reasons for renewal are creep damage, thermal
stress fatigue and high-temperature corrosion.
The renewal peak falls within the range of 80,000 hours to 120,000 hours.
Reasons for renewal: From the fact that there are many renewals of those whose steam pressure is high for
both the 1st and 2nd reheater, and in the case of the 1st reheater, there are many
renewals of those for DSS operation, a conceivable reason for renewal is thermal
stress fatigue.
& Valves
Renewal time:
Form less than 40,000 hours to 180,000 hours
The renewal peak falls within the range of 100,000 hours to 120,000 hours.
Reasons for renewal: From the fact that there are many renewals of those with many start ups, a
conceivable reason for renewal is seat leak.
' Electrostatic precipitator (discharge electrode, collecting plate, hammering device, charging equipment
(P/P))
Renewal rate:
Discharge electrode About 57%
Economizer tube
Furnace tube
Superheater 1st
Superheater 2nd
Superheater 3rd
Superheater 4th
Superheater Mixed fitting
1st reheater 1st
1st reheater 2nd
1st reheater Mixed fitting
2nd reheater 1st
2nd reheater 2nd
2nd reheater Mixed fitting
1st superheater inlet header
1st superheater outlet header
2nd superheater inlet header
2nd superheater outlet header
3rd superheater inlet header
3rd superheater outlet header
4th superheater inlet header
4th superheater outlet header
1st reheater inlet header
1st reheater outlet header
2nd reheater inlet header
2nd reheater outlet header
Economizer inlet header
Economizer outlet header
Main steam pipe
Main steam pipe TY piece
Reheat steam pipe
Reheat steam pipe TY piece
Degradation
damage
Damage
prevention
Regulation
Coal pulverizer
Stoker
Mill exhauster
Fuel oil tank heater
Fuel oil tank bottom plate
Forced draft fan
Induced draft fan
Gas recirculation draft fan
Gas-mixing draft fan
Discharge electrode for electrostatic precipitator
Electrostatic precipitator collecting plate
Electrostatic precipitator hammering device
Electrostatic precipitator charging equipment (P/P)
EP ash-handling ash flow pump
EP ash-handling blower
EP ash-handling ash feed pipe
Air compressor for control
Auxiliary air compressor
Air compressor for soot blower
NOx removal plant catalysis
Bottom ash-handling jet pump
Bottom ash-handling ash flow pipe
Duct expansion
Desulfurization system absorber
Desulfurization system oxidation tower
Desulfurization system G/G heater
Desulfurization system pump
Desulfurization system fan
148
Performance
upgrading
Degradation
damage
Damage
prevention
Regulation
Performance
upgrading
Renewal time:
(3)
"
151
Degradation
damage
Damage
prevention
Regulation
Performance
upgrading
152
Degradation
damage
Damage
prevention
Regulation
Performance
upgrading
Unit interlock
Auxiliary machine interlock
Combustion control unit
Feed water control unit
Steam temperature control unit
Burner control unit
Governor control unit
(4)
due to deterioration of the signal conversion unit, indication mechanism, etc. of each
controller and increasing difficulty in procuring parts because of discontinuance of
production of similar equipment.
For the renewal due to performance upgrading, many renewals were performed due
to nationalization of imported products or due to change from an air or mechanical
system to an electric or digital type, and it is conceivable that many renewals had the
objective of conversion to APC or full automation, etc.
! Turbine monitor
Renewal rate:
Reasons for renewal: Conceivable reasons that there are many renewals due to degradation damage are
occurrence of many failures attributable to deterioration of the control mechanism,
positioner, etc. or increasing difficulty in procuring the parts because of
discontinuance of production of similar equipment.
% Air source for control, air dryer, air pressure-reducing system
Renewal rate:
Air dryer About 42%
Air pressure-reducing system About 17%
Renewal time:
The renewal falls within the range of 40,000 hours to 140,000 hours.
Reasons for renewal: Conceivable reasons for renewal are occurrence of many failures as a result of
deterioration owing to change of the control mechanism, tower, etc. or increasing
difficulty in procuring parts because of discontinuance of production of similar
equipment.
& Transmitter
Renewal rate:
Feed water flow transmitter About 65%
Main steam flow transmitter About 61%
Spray flow transmitter About 61%
Fuel oil flow transmitter About 50%
Fuel gas flow transmitter About 45%
Main steam pressure transmitter About 63%
Fuel oil pressure transmitter About 54%
Fuel gas pressure transmitter About 44%
Drum-level transmitter About 60%
Deaerator-level transmitter About 57%
Feed water flow element About 12%
Main steam flow element About 8%
Fuel oil flow element About 22%
Fuel gas flow element About 7%
Conveyor scale About 33%
Renewal time:
Renewals of feed water flow, spray flow, fuel oil flow, fuel oil pressure, drum level,
and deaerator-level transmitters fall within the range of 60,000 hours to 180,000
hours.
Renewals of main steam flow and main steam pressure transmitters fall within the
range of 40,000 hours to 200,000 hours.
Reasons for renewal: With respect to degradation damage and damage prevention, conceivable reasons for
renewal are occurrence of many failures due to deterioration of each sensor, signal
converter, etc. or increasing difficulty in procuring parts because of discontinuance of
production of similar equipment.
With respect to performance upgrading, conceivable reasons for renewal are
performance upgrading of equipment and shift of control equipment to the electric
type or digital type.
Side wall
Front wall
Rear wall
Boiler, front
Oil jack
Boiler steel
frame
Collector
beam
Side wall top
header
Jack down
Fig. 3.1.2.4-1
Concept in
dismantling of
furnace wall by
means of jack
down construction
method
In furnace
appear in all areas of boilers, and, for this reason, inspection and repair result in longer time and higher cost. In
particular, heavy damage is found in the metallic substance weld zone of furnace pipe walls, furnace headers and
nozzle weld zones at the reheater header due to fatigue and creep, and fundamental measures are becoming
necessary.
In the future, as these portions are important components of boilers, it is impossible to take fundamental
measures through partial renovation. In addition, from the viewpoint that cost and work will be enormous,
complete blanket renovation of furnace evaporation pipes, headers, etc. is starting to be carried out.
Generator output
Main steam temperature
Main steam pressure
Fig. 3.1.2.4-2
Outline drawing of
renovation work for
Himeji No.2
thermal power Unit
No.2 boiler.
2nd superheater
pipe (replaced)
Reheat pipe
(replaced)
Furnace
evaporation pipe
(replaced)
Steam separator
(added)
1st superheater
Control unit
r(replaced)
Change of control system
Evaporator
Furnace-side
casing
(replaced)
Fuel
Economizer
Furnace
Burner
valve
Feed water
Boiler circulation
pump (added)
Air
Together with this renovation, partial renovation of an accessory plant was performed so that such boilers also
have cutting-edge performance. Further, for the purposes of shortening the renovation construction work period
and securing safety in construction work, the development and introduction of new construction such as jack
down construction (Fig. 3.1.4.2-1) are sought.
(1) Examples of structural improvement measures associated with renovation
(1) Modify the boiler from the skin casing structure to the membrane wall structure to plan a reduction in
thermal stress.
(2) Modify the boiler from a weld construction consisting of the furnace wall and tension plate to a slide
structure to plan the reduction in thermal stress.
(3) Cause the header nozzle part to have sufficient flexibility to plan the reduction in thermal stress.
(4) Modify the furnace wall passing-through part to the double-sleeve structure to avoid a concentration of
stress.
(5) Make the root of the nozzle and weld zone at the fine end smooth to relieve the concentration of stress.
(2) Renovation work examples
In the KANSAI Electric Companys Himeji No.2 thermal power plant Unit No.2 (325 MW), a subcritical pressure
boiler that began commercial operation in 1964, from 1992 to 1993 blanket replacement of the boiler was carried
out. This unit was originally oil fired; however, in 1980, modification to convert it to LNG fired was made and
since then, this boiler has served as base thermal power. Since its start of commercial operation, this plant has
operated for about 170,000 hours (number of start ups and shut downs: 662), and in addition to normal age
deterioration, due to the fact that this plant has been used for DSS operation from 1985, life consumption due to
low-cycle fatigue advanced in all areas of the boiler, minor problems occurred frequently, and the time required
for inspection and repair increased. Then, as a result of study of a repair program according to the increasing
longevity program, as it is more advantageous to replace the furnace water wall part completely than to repeat
minor repairs in terms of cost, then it was decided to carry out total replacement. Further, together with
renovation, performance upgrading including improvement of thermal efficiency and acceleration of the time
required for start up is planned through modification from a constant-pressure to a variable-pressure operation
method. (Fig. 3.1.2.4-2).
3.1.2.5 Technology and construction method for shortening of the term of periodic inspection work
In addition to the peak in the summer season, for the purpose of responding to firm growth of demand in the
winter season, the timing of periodic inspections tends to be concentrated in spring and autumn. On the other hand,
the term of periodic inspection work tends to become longer due to the increase in the amount of repairs
associated with aging of plants, and in the future, as the aging of large-capacity machines will also proceed,
further efforts to shorten the term of periodic inspection work are sought.
As a method to plan the shortening of the term of periodic inspection work, in addition to the effective
classification and planning of repair work associated with aging, improvement of construction method that
includes the following are also pursued.
Improvement of work efficiency through mechanization and broader use of robots
Improvement of work efficiency through labor-saving tools
Cutback in amount of works through blanket replacement of large parts (service, repair, etc.)
In addition, measures will be also be implemented from the viewpoint of the plant (Table 3.1.2.5-1), including:
Earlier start of work through forced cooling stop of the turbine
Improvement of workability through scale-up of manholes
158
Table 3.1.2.5-1 Improvement examples for shortening of the term of periodic inspection work
Examples
Adoption of forced cooling system for turbine
Adopt a high-performance oil-flushing system.
Have gas turbine rotor spares.
Have steam turbine rotor spares.
Adopt a gas turbine static blade-sealing alignment system.
Adopt a casing-tightening hydraulic bolt.
Modify from MHG to EHG.
Have one set of EHG parts spares.
Additionally install an overhead traveling crane.
Making the overhead traveling crane faster.
Develop scaffolding at the furnace bottom part.
Adopt a mobile clinker hopper.
Adopt a turbine rotor dry horning unit.
Adopt a hydraulic torque wrench.
Install a lifting unit for dismantling of major valves.
Adopt a hydraulic bolt for coupling.
Improve in-furnace scaffolding.
Install a floor for carry-in of boiler materials.
Install a shutter at the boiler sound isolation wall opening.
Conduct dismantling and inspection work on the electric valve with greater efficiency.
Contrive dismantling and assembling jigs for the coil-end cover of the generator.
Adopt an ultrasonic expansion-measuring instrument
Turbine blade clearance-measuring device
Adopt a laser-type centering measuring device.
Adopt a turbine casing lifting-level supervisory unit.
Install a crane for light parts.
Rotor center hole horning unit
Adopt a hydraulic jack for dismantling of housing.
Adopt a jig for groove alignment of the boiler-cooling wall pipe.
Upsize the boiler manhole.
Develop an internal surface inspection system of the boiler header part.
Outline
Introduce the outside air into high- and medium-pressure casings through the injection of cooling
air or by means of vacuum pump to shorten the cooling time.
Use the flushing system with a fine-mesh filter.
Have the gas turbine rotor of the combined-cycle generator as a spare to replace it at periodic
inspection.
Have the steam turbine rotor for geothermal heat as a spare to replace it at periodic inspection.
Although alignment at replacement was performed at the manufacturers factory, alignment has
become available through installation of the system at site.
Change the high-pressure turbine casing-tightening bolt from the shrink-fit type to the hydraulic
tension type.
Adopt a simplified lifting unit for lifting work of the main check valve, etc. to plan greater
efficiency of work.
Tighten the coupling by means of a hydraulic tension bolt.
Change the scaffolding from steel pipe scaffolding to steel fit scaffolding.
Install an out-furnace stage for carry-in of in-furnace scaffolding and for material storage space.
Install an opening at the sound isolation wall of the boiler to facilitate carry-in of materials, etc.
Change the power supply connection of the electric valve to the connector system.
Fix the bottom cover to the jig and then cause it to rotate to facilitate removal.
Measure expansion of bolts by means of the ultrasonic measuring instrument.
Insert the sensor into the clearance between the turbine blades to perform automatic measurement to
process its data.
Measure turbine alignment by means of a laser to calculate the corrected value automatically.
Monitor parallelism of the housing to be lifted by installing an ultrasonic-type distance sensor at 4
corners to measure it.
In addition to an overhead traveling crane, install a crane for lifting light parts.
Unit that performs horning of the turbine rotor center hole automatically.
Cause the measuring sensors installed at 4 corners of the housing to synchronize with the hydraulic
jack to lift it horizontally.
Jig for groove alignment of boiler water-cooling wall pipe.
Upsize the bore of the boiler manhole to plan greater efficiency.
Insert it through the header inspection hole to make observation by means of TV and observation
with an optical microscope.
159
3.1.2.6 Support system for creating a work plan for increasing longevity
In order to continue stable operation of an aged thermal power plant after 20 years or more from its construction
and start of operation. While maintaining the economics and its function, identifying the function, performance
and soundness of equipment and presentation (recovery from deterioration) are performed more efficiently than
conventionally.
For this reason, a support system to create a work plan for increasing longevity that takes plant reliability and
economics into account has generally been introduced and made use of.
Creation of a work plan for increasing longevity is performed along each step of flow in Fig. 3.1.2.6-1.
Selection of critical equipment (Fig. 3.1.2.6-2)
Assuming that the service period will be 60 years, the operation time, 400,000 hours and the number of start
ups and shut downs, 5,000, select equipment for which remaining life control is believed to be necessary out of all
equipment comprising the unit. Assess the probability of the occurrence of failure, effect of failure on output when
it occurs, term of recovery work and cost, safety (social influence level), etc. comprehensively by means of the
FMEA technique.
! Investigation of the background of accidents and failures
Collect and organize the records of accidents and failures regarding the selected critical equipment, and
investigate the failure mode, life consumption factor, etc. during a long-term service period.
" Breakdown and defragmentation of equipment (selection of critical points)
Select critical equipment.
Investigate history of accidents and failures.
Break down and defragment equipment.
Select the critical portion.
Select remaining life calculation measures.
Calculate the unit life consumption rate.
Operation history
Future operation conditions
Marginal processing value
Calculate remaining life.
Unit price table
Create a long-term maintenance program list.
Carry out profit calculation.
Create a work program list for increasing longevity.
Fig. 3.1.2.6-1 Flow in creation of work program plan list for increasing longevity work
Equipment
Measuring device
Electric device
Boiler system
Turbine system
Effect-level assessment
Life
consumption
factor
Initial
failure
mode
Final
failure
mode
Rotor
Progression of
manufacturing
defect
Burst
External casing
Crack
Leakage
Internal casing
Crack
Leakage
Nozzle chamber
Crack
Leakage
Creep
Deformation
Axial inclination
Abnormal
vibration
High-pressure turbine
Equipment
Probability
of failure
occurrence
Effect on
output
Degree of difficulty of
recovery from failure
Term of
recovery
Recovery
cost
General assessment
Safety
Score
Critical
equipment
(100 points or
more)
Break down the selected critical equipment to the group that conceivably has the same structure, function, and
design condition, and then defragment them based on the detailed structure to select Point to which maintenance
control should be performed based on life assessment.
# Selection of critical portion (Fig. 24)
Critical point
Critical portion
:
:
Dummy groove
Heat group groove
bottom
Initial failure mode : Crack
Life consumption factor:
Low-cycle fatigue
Low-cycle fatigue +
High-cycle fatigue
High-pressure stage
: Center hole
Critical point
Critical portion
: Control stage bottom
Initial failure mode : Crack
Life consumption factor:
Creep + Low-cycle
fatigue
:
Critical point
Critical portion
:
Initial failure mode :
Rotor body
Central part and others
Deformation
Deterioration of
characteristics
Life consumption factor :
Creep, softening,
embrittlement
Ultrahigh-pressure stage
Governor side
GEN side
Control stage
Critical point
Critical portion
Rotating blade
Outlet side
Inlet side
(a)
(b)
Future
operation
conditions
FEM analysis
Limit processing
value
Consumed life
Temperature
difference
Computer
Output
Processing
limit
Consumed life
Remaining life
Stress
Life
consumption
unit life
(Year)
Repetitions
Operation
history
161
System
Boiler related
Turbine related
Electric related
Measurement related
Total
2226
712
12
12
3002
83
85
62
1
14
15
35
35
37
2
10
83
168
77
50
74
93
268
95
406
20
789
3356
1203
828
70
5457
2008
2010
17
103
374
44
21
54
300
419
17
70
116
320
523
494
'
162
Fan
10%
Valves
5%
Furnace
wall
31%
Ratio of occurrence
of failure for each
component of boiler
equipment
Piping
16%
Wear
5%
Corrosion
5%
Creep
15%
Cause of damage to
pressure-retaining
components
Thermal
fatigue/
corrosion
fatigue
68%
SH/RH/ECO
20%
Overheating
Swelling out
Deformation
Creep
rupture
Rupture by
spouting
Corrosion
Corrosion by low
temperature
Corrosion of the inner
surface of tank caused by
filled water
Excessive increase
in load stress
caused by the
decrease in
effective thickness
Rupture
caused by
static stress
Leakage
Wear
Erosion by ash
Wear by high-velocity air
flow within the component
Fatigue
Thermal fatigue
Mechanical fatigue
Occurrence/growth
of crack(s)
Rupture
caused by
fatigue
Corrosion
fatigue
Occurrence/growth
of crack(s)
Rupture by
corrosion
fatigue
164
Table 3.2.2-1 Portions where thermal stress is generated and measures to reduce the stress
Portion
Cool water
Furnace wall
Tool box
Mechanism of generation of
stress
If the boiler water temperature
should change upon boiler
start/stop operations, temperature
difference occurs between the
furnace wall and the sub-wall or
between the sub-wall and the rear
smoke duct wall, which generates
stress on the fin edge of the
furnace wall.
If the boiler water temperature
should change upon boiler
start/stop operations, temperature
difference occurs between the
furnace wall piping and the seal
box, by which stress concentrates
at the corner.
R-machining
(9) 2 A h
Arch
Tension plate
Slide
End bar
Welded portion
Piping on
the ceiling
Deformation
165
2-step-type skin
casing
End bar
Piping on
the ceiling
Generation of
high stress
Low expansion
Low expansion
Tension plate
High
expansion
High
expansion
Tension plate
Table 3.2.2-1 Portion where thermal stress is generated and measures to reduce the stress
Portion
Piping on
the ceiling
Coefficient of
linear thermal
expansion
Improved
style
SUS rod
SUS steel
Cr-Mo steel
Welded portion of
small-diameter nozzle of pipe
header
Welding-type
saddle
Deformation
(29) Pi i
ti
Piping
reaction
force
Mechanism of generation of
stress
Temperature difference occurs
between the nozzles during
start/stop operations, and bending
stress is generated on the welded
portion that has been locked
between the nozzles and ceiling
hole.
Due to the difference in the
carbon content, carbon migrates
to the metal to be welded from
low-alloy steel, yielding a
decarbonized layer as a result,
and the strength on the low-alloy
side declines. By the difference in
thermal expansion between the
austenitic stainless steel to be
welded and the low-alloy base
steel, thermal stress is generated
on the portion welded. Because of
its high temperature, creep
damage also occurs.
Within a structure supported by a
spacer fixed by welding to the
hanging pipe of the
horizontal-type
super-heater/re-heater, thermal
stress is generated on the
spacer-welded portion due to the
temperature difference between
the upper and the lower pipes.
If the air vent pipe and drain pipe
of pipe header are the type of
such structure as being locked in
the housing hole, thermal stress is
generated at the welded portion of
the nozzle of pipe header.
Flexible
Welding at factory
using Inconel welding
electrodes
Flexible saddle
spacer
Hole to
be fixed
166
Portion
Welded portion to fix the
anchor plate
Mechanism of generation of
stress
Due to the temperature difference
between the anchor plate and
furnace wall piping occurring by
start/stop operations of a boiler,
stress concentrates at the welded
portion of the anchor plate.
Anchor plate
Stand-off
Membrane-edge connecting
waterwall and cage walls
Membrane
Portion
where
cracking
occurs
Waterwall
pipe
Stopper
Desuper-heater main
body
Support
Base pipe
Protection cylinder
Fitting of liner
(Welding type)
Spray
nozzle
Liner
Forepart of
the tank
Welded liner of
super-heater/desuper-heater
Support
ring
Weldi
Waterwall
pipe
Improved
structure
(pin type)
Spray
nozzle
Pin
Portion where
cracking occurs
Main
piping
Membrane
Pin
Stopper
Portion where
cracking occurs
Support
lag
Shear
lag
Main
piping
Thermal
insulation
material
Thermal
insulation
material
Band
Ceiling hole
Crwon
Ceiling
piping
Ceiling
piping
Sliding spacer
Hanging loop
pipe
Pipe header
at furnace
front wall
167
(Oval lag)
Pipe header
at furnace
side wall
However, in a corrosive environment, strength against fatigue declines, which causes cracking at the inner face
within a pipe by corrosion fatigue.
As a characteristic of a cracked surface caused by corrosion fatigue, many cracks are accompanied by pits
caused by the corrosion along the cracks.
As basic countermeasures, such actions to soften the thermal stress are considered important. In such a case, it
is required to change the tension plate support to a sliding type and improve the structure so that the thermal stress
may be softened.
Examples of other corrosion fatigue are introduced below:
Ligament of the pipe header at the inlet of the economizer (Fig. 3.2.2-3)
The occurrence of cracking was experienced at the ligament of the pipe header at the inlet of the economizer
due to the same cause as above. This was also caused by corrosion fatigue.
(4) Mechanical fatigue
In the case of mechanical fatigue, the cracking is a type of transgranular cracking in general. The ruptured face
has a fine fatigue face, and no extension by rupture was detected.
Pipe header at
outside furnace
Fig. 3.2.2-3 Example of corrosion fatigue of the inner ligament of the pipe header nozzle at the inlet of the
economizer
(5) High-temperature corrosion
The surface stainless steel pipe affected by high-temperature corrosion has been damaged by corrosion in a
pockmarked fashion. The corroded portion is composed of an oxide layer a polysulfide layer a carbonized
layer base metal from the outer piping surface. From the viewpoint of microstructure, the corroded and
carbonized structure of grain boundary is found. A drop in expansion as well as a drop in strength can be
detected.
168
Creep
Fatigue
(including creep
fatigue)
Corrosion
Wear
Cause
Measures
Subject portion
Assessment of
remaining life by replica,
ultrasonic testing, TDFD,
ELFOSS, UT inspection
Restriction on
elongation by heat
Add flexibility
Sliding
Shape the stress
concentrates
R-machining, chamfering,
change of shape
Thermal shock
Dissimilar metal
welding (SUS/Cr-Mo)
Inconel solvent
Corrosion fatigue
High-temperature
fatigue, oxidation
Improvement of bearing
force of material, addition
of extra welding
Super-heater, re-heater
Furnace wall
Oxidation of steam
(SUS piping)
Super-heater, re-heater
169
assessment, the geometric shape of the part, the operation history such as temperature, stress, etc., the strength
against creep rupture, and the properties of the materials. The finite element method using a computer makes it
possible to analyze the stress of a complex structure.
With respect to the properties of the material to be used for the analysis, it is required to include the safety ratio
in the laboratory data to some extent considering possible variations of the properties. Therefore, the assessment
result leans towards the safe side.
With respect to such operation history as the temperature, stress, etc. to be used for the analysis, calculation is
performed by dividing the operation history into several typical patterns. In order to cope with the recent complex
operation history, the remaining life is sometimes assessed by installing a life-monitoring device at the pipe
header at the outlet of the super-heater, water separator, boiler circulation pump, etc.
(2) Destructive test method
This is a method of estimating the remaining life through various types of destructive tests by taking out test
specimens from the components actually put under operation. This test method is usually employed for
components (typically, the boiler tube) from which test specimens can be easily taken out. The advantage of this
method is that the remaining life of a given material can be assessed directly, including its history at the time of
manufacture, even if the temperature or stress history of the material in the past is not made clear. The
disadvantage is that sampling is required, the portion where the test specimen has been taken out needs to be
repaired, and time and expense are required for creep rupture testing, fatigue testing, etc.
As a measure making it possible to perform destructive testing by using much smaller test specimens,
destructive testing through a miniature test is available. As shown in Fig. 3.2.3-1, its effectiveness has been
verified.
Conventional test specimen
Stress (MPa)
Conventional test
specimen
Time of rupture
Comparison of strength against creep rupture between a conventional
test specimen of 1 Cr 0.5 Mo Steel and a miniature test specimen
170
Table 3.2.3-1 Non-destructive method of assessing the remaining life of components affected by creep/fatigue damage
Subject
damage
Creep
damage
Method as described
Low-alloy steel
in Attachment 3 of the
Electricity Utilities
Welded
Base metal
Industry Law
portion
Base metal
Welded
portion
!
!
!
!
!
!
!
!
!
!
Ultrasonic method
Fatigue
Steel
!
!
Structure-quantifying method
!
!
!
!
!
!
Creep damage
(a) Deposition intergranular distance method
This method is used for the assessment of creep damage of low-alloy steel base metal. Low-alloy steel is a
material whose strength against creep has been raised by depositions and shows ductile creep damage. When used
for many hours in a high-temperature atmosphere, the intergranular distance of this disposition becomes larger
and, at the same time, resistance against deformation declines, causing the creep to accelerate. This phenomenon
is represented by the creep distortiontime curve in general. The change depends on the temperature and stress of
the subject component. By measuring the intergranular distance between particles of disposition, the creep
distortion at the time of assessment can be obtained. Therefore, the behavior of creep distortion thereafter can be
predicted, and the creep remaining life can be assessed. The intergranular distance of disposition is obtained by
image processing of the replica taken out from the subject component using an electrolytic discharge-type
scanning electron microscope (Fig. 3.2, 3-2).
Disposition
Scanning
line
Replica
Point
Scanning-type electron
microscope
Mean free-path
Average intergranular
distance ("m)
171
172
Extracted replica
Replica
Component surface
(etched surface)
Optical microscope
Scanning-type electron
microscope
Micro-crack
Creep cavity
Metal structure
Damage factors
Mechanical
damage
Microscopic
structure
Analysis electron
microscope
Deposition
distribution
Comprehensive
damage
category
Disposition
Life consumption
ratio by creep
breakage (%)
Material damaged
by creep
Material not
used yet
The creep damage of the component affected by welding heat from these steels is a type of fragile damage and
generates creep voids at the grain boundary. As the generation of voids increases, the electric resistance tends to
become stronger (Fig. 3.2.3-4). The amount of damage is assessed by using the electric resistance ratio of unused
material and the electric resistance ratio of the component being assessed, and by referring to the master curve
indicating the relationship with the amount of damage. Assessment accuracy has been improved by making it
173
easier to grasp the level of damage proximate to the surface by using an alternative current. In addition, it is
required in this method to spot weld a platinum wire to the subject component. If an electrode has once been
installed, building of a scaffold, thermal insulation, removal/restoration of the exterior plate, and polishing of the
subject component for inspection are not required thereafter. Therefore, the costs for inspection can be reduced. In
addition, it is possible to make measurement at any time during operation. This method can also be used for
monitoring the main piping, etc.
(e) Void (cavity) area ratio method
As shown in Fig. 3.2.3-5, voids are generated at the grain boundary when the HAZ portion of low-alloy steel or
9 Cr steel is affected by creep damage. The number of voids increases as the damage grows. The voids become a
crack after growing/combining (namely, the area of voids increases), and finally result in the rupture of the
component material. In this method, the ratio between the total area of voids generated within the observation
visual field and the total observation visual area is defined as a void (cavity) area ratio. Using this ratio together
with the master curve prepared by its correlation with the degree of creep damage, the life is assessed in this
method (Fig. 3.2.3-5).
Replica
Scanning-type
electron microscope
174
Crystal
grain
Direction of stress
Frequency
Direction of stress
Deformation
coefficient Sm
(standard deviation)
Frequency
Maximum
diameter
Regression curve
99% reliable section
99% reliable section of creep
damage ratio +/- 0.09
Formal
distribution
Fig. 3.2.3-7 Assessment of creep damage to Cr-Mo steel base metal through the crystal grain deformation method
incidence of ultrasonic waves from the component surface to the 1st bottom echo, and by carrying out power
spectrum analysis, the area within a certain frequency range is calculated to define it as the noise value. The
assessment flow in the ultrasonic method is shown in Fig. 3.2.3-9.
steel
HAZ-reproduced component with SR
: Application of reaction
PC
Frequency
analyzer
Certified curve
Noise value
Frequency (MHz)
st
1 bottom echo
Component for
assessment
Search
unit
Life assessment
Noise value
Amplitude (dB)
Pulse receiver
Oscilloscope
Noise
analysis
Amplitude (dB)
Data measurement of
component for assessment
Life ratio
176
Magnetic powder
copying film
Magnetic powder
Oxidation scale
Magnetic
field
Crack detection
boundary
Crack
detection
boundary
177
W elding material
Base material
Base material
Transmitter
Surface
wave
Diffracted
wave
Receiver
Wave diffracted on
the crack top
Wave diffracted on
the crack bottom
Fig. 3.2.4-1
Classification of damage to a welded portion
Wave reflected
on the bottom
Crack
Diffracted
wave
Type III damage (damage in a rough-grain area) appears on the external surface of a pipe, whereas Type IV
damage (damage in a fine-grain area) occurs within a thick wall pipe and expands toward the surface. Impure
substances contained in the steel play an important role in Type IV cracks.
(2) Inspection method for Type IV cracks
Typical inspection methods for Type IV cracks occurring within a pipe having a thick wall are explained below.
The inspection method is used alone or jointly with other methods.
TOFD method
As an inspection technology able to assess Type IV cracks occurring from the inside of a thick wall precisely
and quantitatively, the TOFD (Time of Flight Diffraction) method has been developed and put to practical use,
which is an ultrasonic wave flaw detection method using 2 search units for transmission and receipt. A comparison
with the conventional angle beam method is shown in Fig. 3.2.4-2.
The conventional method was in principle designed so as to catch reflecting echoes from a defect. Therefore,
there were some cases where inspection was not possible depending on the direction of the crack. It was also
178
Delay circuit
Vibrator
Angle of
deflection
Focus
Electronic focusing by
delay circuit
If the activation timing of
the vibrator is
changed with the
same interval in the
right and left
directions, an
ultrasonic wave
beam focuses. In
addition, the focal
depth can be freely
set by the duration of
the timing.
179
Scanning
Portion affected by
weld heat
Deposited metal
portion
Plate thickness
direction (mm)
Deposited metal
Base material
portion
Portion affected
Portion affected
by weld heat
by weld heat
Base material
Base material
Fig. 3.2.4.-4 Image processing of flaw detection results through the ultrasonic noise method
(c)
Such impure substances cause overheating of the piping materials, generation of scaling, formation of local
cells, or corrosion due to condensed salts and lead to future swelling out or explosion of the piping.
As shown in Table 3.2.5-1, the thermal conductivity of scale largely varies depending on its chemical
ingredients. Because the size of scale is smaller than that of piping materials, adhered scale blocks thermal
conduction causing overheating or heat loss of piping materials.
Table 3.2.5-1 Thermal conductivity of metal and scale
Type
Thermal conductivity (W/mK)
Mild steel
45 ~ 70
Scale containing silicate as its major ingredient
0.2 ~ 0.5
Scale containing iron oxide as its major ingredient
0.9 ~ 2.3
Fat and oil
0.1
Water
0.6
The water vapor oxidized scale generated in the steam system peels off during operation and accumulates in the
U-shape pipe of the super-heater piping, resulting in its explosion. Its fragments may fly over to the turbine and
damage the blade.
180
181
ZnO
Al2O3
NiO
MgO
CaO
P2O5
Cr2O3
MoO
MnO
Refractory
by acid
H
I
Cu
A
B
C
D
E
F
G
Pipe specimen
Chemical content
Fe3SO4
Boiler
Average
adhering
amount
(mg/cm2)
65.3
25.4
20.4
24.1
23.4
9.6
38.4
58.3
33.0
73.0
97.5
97.9
97.9
1.9
34.5
2.8
<0.1
<0.1
<0.1
1.1
15.1
10.0
<0.1
<0.1
<0.1
<0.1
0.7
0.9
<0.1
<0.1
<0.1
<0.1
14.5
<0.1
<0.1
<0.1
<0.1
10.3
<0.1
0.8
<0.1
<0.1
13.3
<0.1
1.7
0.1
0.2
10.6
0.3
4.9
-
1.8
-
0.7
0.5
2.1
0.2
1.9
<0.1
0.7
<0.1
65.9
<0.1
<0.1
11.3
<0.1
17.8
1.5
1.7
0.3
125.0
125.3
95.4
88.1
<0.1
<0.5
<0.02 <0.1
<0.5 <0.5
<0.2
<0.5
<0.5
<0.4
<0.5
<0.5
1.8
3.3
0.9
0.8
0.4
<0.5
1.3
-
Outer
layer
Inner
layer
Base
material
With respect to boiler E, fine-grain FeOfrom CWT (combined water treatment) adheres to the magnetite, and
the scale has smooth surface.
(e) Boilers G, H, and I generate vapor-type scale. Cr-Mo steel (low-alloy steel) has been used for these
boilers. Two-layer scale, called steam-oxidized scale; one in the neighborhood of piping materials with a
high content of chromium and the other at steam side with a high content of iron oxide are generated as
shown in Photo 3.2.5-2.
182
Final washing
with water
Prevention of
rust by
neutralization
Washing with
water
Cleaning with
acid
Washing with
water
Cleaning by
degreasing
Cleaning with
ammonia
Flushing
During construction
Copper content: high
After
Copper content: low
operation
Copper content: none
Remarks
: Implement.
Implement if necessary.
Before acid cleaning, ammonia cleaning is performed as pretreatment in order to dissolve the copper
content.
In lieu of the above i) and ii) cleaning, chelating cleaning is sometimes carried out. Its cleaning process is:
Ferrous removal
cooling
183
Investigation of scale
!
!
!
!
Scale ingredients
Amount of adhered scale
Scale generation rate
Deterioration level of the material
Implementation
Inspection
! Visual inspection
! Amount of corrosion to be checked
by a test piece
! Amount of scale removed by
cleaning
Dissolution test
! Scale dissolution test
! Material deterioration test
! Investigation of customers
environmental conditions such as
wastewater standards, etc.
! Availability of wastewater treatment
equipment at customer side
! Experimental wastewater treatment
Summary
184
N2 gas
Pressure gage
Flow meter
Side wall
Front/rear
walls
Side wall
Water
supply line
Temporary construction
Temporary
level gage
Steam drum
Sampling
Thermometer
Mixing header
Mixing heater
Inspection nipple
Draw
pump
Hydrazine pump
Pure water
Circulation pump
Steam
Chemicals
injection pump
Tank
Blower
Ejector
Flow meter
Thermometer
N2H4 tank
SH Water-filling pump
Sampling
Cage
N2H4 pump
Steam
separator
Evaporator
Steam
separation
tank
Ceiling wall
Blow line
Steam
Mixing heater
Cold
water
Chemicals
tank
Ejector
Circulation pump
Chemicals
injection pump
From tank-lorry
Economizer
High-pressure supply
water super-heater
To blow line
185
Pure water
Total number
of units
30 years or 25 ~ 29
longer
years
20 ~ 24
years
15 ~ 19
years
10 ~ 14
years
5~9
years
0~4
years
Pump case
(Renewal cycle: 35 40 years)
Generation of
cracks
Motor case
(Renewal cycle: 35 40 years)
Expansion of in-low
clearance
Deformation of gasket
Uneven tightening
Warming shortage
Overlapping of thermal
insulation materials
Abnormal sound
Abnormal vibration
Steam leakage, water
leakage
Cavity abnormal
temperature rise
Heat exchanger
(Renewal cycle: 35 40 years)
Accumulation of
Cavity temperature
scale
rise
Fatigue/corrosion
Water leakage
of welded portion
186
Insulation drop
Ground
fault/unstable life
Non-conformance events
As explained above, non-conformance events have been reduced to date, and the reliability of the circulation
pump of boiler has been largely improved. However, there still remain many plants for which no structural
improvement has been implemented so far. It is required therefore to recheck the non-conformance events in the
past and reflect their results in the completion of details of inspection items and on the plan for repair.
Non-conformance events of major parts are outlined in Fig. 3.2.6-2, which shows the deterioration phenomena
and renewal cycle of major parts (renewal cycle with addition of the effect of the bearing force improvement plan
to the past experiences).
Guideline for implementation of preventive maintenance and inspection
Inspection items are divided into general inspection items and special inspection items. General inspection
mainly involves visual inspection, whereas non-destructive testing is the main item of special inspection, which
should be started from the 10th year after the start of operation to obtain remaining life assessment data.
Concretely, the target regular inspection cycle should be set at 4 years, and a long-term plan of details for
checking/inspection items and details for repair items should be developed Items to be implemented should
be confirmed at the start of the respective regular inspection.
Concept of measures for improvement of bearing force and examples of implementation
Measures for improvement of bearing force of the circulation pump of boiler equipment are promoted under the
2 concepts below, aiming to respond to any change in the operation method of power generation plants
(conversion to WSS/DSS), extension of the inspection cycle, and prolongation of operation life:
(a)
Improvement of structure, materials, and work method
(b)
The motor stator coil has been changed to cross-linked polyethylene wire.
Coils manufactured before 1980 were made of PVC wire, which involved the issue that the rewinding
cycle was short because hardening/fragility of the insulation coat was accelerated due to reduction of
the plasticizer.
187
3.2.7 Fan
(1) Measures to improve reliability and guideline for maintenance and inspection
The present time is called a maintenance age. The number of social systems and production systems subjected
to maintenance are accumulating at a continuously increasing speed. According to a certain trial calculation, the
ratio of costs for maintenance was 10% of social capital investment during the 1970s, whereas it increased to 30%
during the 1990s and to 50% by 2020. Under these circumstances, maintenance costs keep increasing; how to
cope with this in a quantitative manner, how to improve cost efficiency keeping improvement of reliability, and
how to select the type of acceptable maintenance have become serious issues.
Because the fans installed at power generation plants are kept in operation for a long period of time from the
start of operation until the time they are disposed of, the accumulated number of units has been increasing. It is
required to make clear what inspection items are to be applied to these fans and to implement them under a
controlled cycle and implement feedback and feedforward without any reserve. Because efficiency and
rationalization of maintenance costs is directly linked to the management, it is required to develop a general image
of maintenance, determine what is presently missing, and implement these items in a well-planned manner.
Axial fan
As boiler capacity becomes larger, the rotating-type variable axial fan suitable for large-capacity boilers with
reduced power consumption under partial load has been widely used as a ventilating fan for power generation
equipment other than FDF, IDF, PAF, BUF, and high-temperature GRF. Control for improvement of reliability is
further required, because the structure of the rotating-type variable mechanism is complex and the number of parts
is larger than the same of the centrifugal fan.
As a result of measures taken for the improvement of reliability [1] with consideration paid to the problems
with axial FDF experienced over a period of 15 years since 1970, the employment of axial fans started, and the
problem occurrence ratio has been suppressed to its minimum. However, in view of the facts that the installation
of axial fans increased from 1985 onward when many thermal power generation plants were constructed, and that
its usage has expanded, it is desirable to carry out precise inspection of fans used for many years in order to
further secure their reliability.
Centrifugal fan
Although the reliability of centrifugal fan has been improved, many fans have already been in use for 20 years
or longer. It is required to plan and implement measures to improve their reliability further taking into account any
aged deterioration or any change in operation from what was expected at the start of operation.
Because the operation of thermal power generation plants corresponds to the peak power generation capacity,
the number of start/stop operations has increased, which, as a result, requires the improvement of the bearing force
of impellers, bearings, and couplings.
(a) Stress change occurs at the impeller caused by the change in RPM due to start/stop of operations.
Especially with GRF, low-cycle fatigue occurs due to repeated thermal expansion caused by temperature
fluctuation. If you start the operation of GRF at room temperature, the temperature of the intake gas
rapidly changes and the vibration becomes several times larger for some time than the vibration
experienced under stable, steady operation. This is an effect of the difference in thermal expansion
caused by the temperature difference among the components of the impeller. When the temperature of
the impeller becomes stable after continuing operation in a stable gas temperature atmosphere, the
amplification of vibration gradually lowers and the operation becomes stable. In particular, when a
riveted joint is used, this phenomenon frequently appears. Therefore, if a riveted structure has been used
for the impeller, it is recommended to change it to a welded structure and remodel the connection of the
impeller to the shaft/hub to a reaming bolt connection structure from the rivet-fixed type. Because the
effect of thermal distortion concentrates on the riveted structure, non-destructive testing needs to be
carried out for the components concerned when the fan is not in use or regular inspection is carried out.
In the case of the structure of the axisboss shrink fit, any vibration that may be caused by the decrease
in the shrink-fit margin or loosening due to the transitional difference in temperature distribution is of
concern. It may be required to increase the shrink-fit margin or change to an integrated rotor of the
axisboss.
If the level of adherence of the mating portion of the axisboss shrink-fit structure changes as the time
passes, that the vibration may become stronger or the torque transmission ability may drop are concerns.
Ultrasonic waves can be used to test the level of such adherence. Figure 3.2.7-1 shows the inspection
principles when a clearance is available for testing.
(b) Any fatigue damage that occurs to the face of the tooth at the gear coupling due to start/stop operations
is also a concern. Complete inspection is required. It is recommended to change to a tooth face with
improved bearing force or to a flexible coupling having no contact with the face of the tooth.
188
(c) Stress occurring at the impeller is strong. When carrying out non-destructive testing at regular
inspection, such a case is found where the portions and number of occurrences of damage increase as
time passes. In case there is concern that complete reliability may not be secured through regular
inspection or repair only, it is required to change to an impeller of a type whose generated stress has
been reduced by increasing its wall thickness or improving its welding quality.
Precise inspection of large-sized fan
Large-sized fans are disassembled and maintained at each regular inspection. Items subjected to precise
inspection of the respective parts of the centrifugal fan that can be implemented for such aged deterioration
phenomena as corrosion, wear, cracking, etc. are shown in Table 1. Because problems with large-sized fans can
lead to operation stop of the unit or to load limit, it is recommended to carry out full assessment at respective
regular inspection, etc.
The fan is equipped with attachment devices other than the main unit such as the lubricating device, silencer,
measuring apparatus, etc. It is required to secure the reliability of these devices as well as securing the reliability
of the main unit. For inspection of the main unit, disassembling, which requires many processes, is necessary.
Because fewer processes are required for disassembling inspection of attachment devices, it is recommended to
carry out regular maintenance once a year.
Impeller
Impeller hub
Shaft
Mating portion
Hub
Shaft
Transmitted
wave
Sensor
189
(d) Assessment of the cost for the armor system of the blade-shaped centrifugal fan that can be replaced on
site
The researches are mainly focused on the centrifugal blade-type fan, which cannot in most cases be applied
directly to the axial fan, which is the mainstream in Japan.
Axial-type IDF, many of which have been introduced in Japan from around 1985, have already been used for
10 years or longer. It is considered that such study will become necessary as the same EPRI conducted for wear.
Fatigue is divided into low-cycle fatigue caused by start/stop operations and high-cycle fatigue occurring during
normal operation. It is required to fully assess the rotating blade of the axial fan because damage to it is highly
expected. A study is required to be conducted for low-cycle fatigue if the frequency of start/stop operations has
increased in the course of the change in the operation method to more than when the unit was initially installed.
3.2.8
Corrosion of boiler equipment occurring in its water zone and countermeasures against it
Introduction
The purposes of controlling thermal power generation plants by establishing a reference value for each item of
water supply, boiler water, and steam is to prevent any problems from occurring to the equipment composing the
thermal power generation plant caused by corrosion and/or scale due to the quality of water used and to continue
the operation of the plant in a safe and smooth manner. As the pressure and temperature of the main steam rise
higher, the thermal efficiency of the plant becomes higher. However, the plant is likely to be affected by corrosion
or scale, and the level of such effect becomes higher. Therefore, water quality control is an important task that
affects the thermal efficiency and operation efficiency of the unit.
While the water treatment engineering of boiler equipment has remarkably advanced in these years, accidents
often occur from thermal power generation plants caused by the water used by aged equipment or DDS
operation. Those staff responsible for water quality and the staff in charge of operation and maintenance of the
plant are required to understand the importance of water quality control and endeavor to improve it.
Problems arising from water are roughly divided into issues of corrosion, fragility, (cracking) and scale. As
shown in Fig. 3.2.8, most of the problems relating to water occur when multiple causes are combined. Upon
occurrence of any problem, its cause must be analyzed and assessed in detail to establish adequate
countermeasures.
An outline of various types of problem and their causes, handling, and preventive measures is given below.
Attack by ammonia
Erosion of turbine
Inadequate materials
Defective design of orifice
Oxidization of steam
Clogging
Rise in differential
pressure
Adherence of scale
Corrosion of entire unit
Thermal conduction
was blocked
Alkali corrosion
Carry over
Leakage of seawater
Drop in efficiency
Opening by
swelling-out
breakage
Defective control of
combustion
190
boiler equipment at an adequate timing, it is very seldom that the evaporation piping is damaged by overheating
due to the thermal resistance of the scale itself.
[Metal]
(Scale thickness 0.33 0.49 mm)
Appearance of the portion
of leakage
191
off and lifted, and heat conduction was blocked by the steam layers generated between the scale layers. As
countermeasures against this, it is required to capture the level of scale growth by regular pipe sampling
inspection and determine the adequate timing of chemical cleaning.
Corrugated scale
At a plant where volatile matter treatment is undertaken as a method of treating supply water, there are many
experiences where the scale adhered to the inner evaporation piping of a furnace shows a corrugated pattern.
Especially with respect to the supercritical sliding-pressure once-through boiler, the average rate of flow in the
piping becomes higher. Therefore, scale with this corrugated appearance increases the break-through resistance of
the furnace, which may cause problems in operation. The cause of the generation of such corrugated scale has not
yet been clarified. The scale is considered to be generated under such a condition that chemical factors and fluid
dynamics factors have been combined. Namely, dissolution and deposition of the component materials in a
high-temperature, high-pressure atmosphere as chemical factors and cyclic structural change of turbulent
boundary layers as fluid dynamic factors are considered combined, whereby such corrugated scale was generated.
Photo 3.2.8-3 shows an example of the corrugated scale generated within a supercritical sliding-pressure
once-through boiler. In this case, the amount of adhered scale is not so great that chemical cleaning is required,
but problems in operation have occurred because the break-through resistance became stronger due to the shape of
such scale. As countermeasures, the scale is removed by chemical cleaning in order to reduce the break-through
resistance. Thereafter, it was clarified that the generation of such corrugated scale could be suppressed by
changing the supply water treatment to oxygen treatment, according to certain European literature ! z{!and the
test results of oxygen treatment verification carried out in Japan zs!. This oxygen treatment method has the
advantage of a reduction in running costs, including the prevention of such corrugated scale from being generated.
Therefore, this oxygen treatment method is currently being rapidly introduced to once-through boilers in Japan.
Direction
of flow
192
water (flow nozzle), and the high-pressure supply water system (strainer of the water supply pump, rectifying
cylinder of the high-pressure supply water heater, heater piping), etc. This scale adheres to portions where there is
no thermal load, which however is present in the evaporation piping. It is considered that the adherence of scale is
a phenomenon that occurs when chemical factors, fluid dynamic factors, and static electric factors (charged
grains) are combined.
Temperature ("C)
193
Scale
Orifice
194
Oxygen treatment
Photo 3.2.8-6 Example of scale adhering to rectifying cylinder of high-pressure supply water heater
(1) Corrosion at the furnace water-wall tube of coal-fired boilers
Corrosion
It has been known from long ago that strong corrosion occurs at the furnace wall of coal-fired boilers by flame
impingement (flames hit the waterwall piping directly in the neighborhood of the burner zone)!z!
In such a case, it is considered that the area exposed to flames is locally placed under low oxygen partial
pressure, because a lot of unburned carbon, FeS, etc. are contained in the adhered ash. As shown in the chemical
formula below, FeS contained in the adhered ash reacts with the Fe contained in the waterwall piping to yield
FeS. Because FeS contains more grid defects than such oxides as FeO, the protective capability of the coat
becomes poorer, causing strong corrosion.
Recently, many cases are found such as the 2-step-type combustion process being employed for many boilers
for power generation as a measure to satisfy low NOx yield. In such a process, the area in the neighborhood of
burner zone becomes an atmosphere of low oxygen partial pressure containing HS. Figure 3.2.8-2 shows the
impact of air ratio on the balanced structure of gas when Datong (Chinese) coal containing 0.63% S is burned at
1300. When the air ratio is 0.8 or less, it is obvious that a lot of reduced contents such as H, CO, HS, etc. is
contained in the combustion gas. In particular, when such coal containing a lot of S content is used as fuel, the
HS density becomes higher, creating a severe corrosive environment. Corrosion of the furnace waterwall piping
caused by high-temperature sulfide becomes a critical issue. Coal combustion gas is composed of CO, CO, HO,
HS, COS, N, etc. As a result, the environment has become a family of so-called C-H-O-S. The critical factors of
corrosion are oxygen partial pressure and sulfur partial pressure in the atmosphere. In an atmosphere where the
oxygen partial pressure is high, oxidation plays a leading role in the corrosion of materials, whereas in an
atmosphere where the sulfur partial pressure is high, sulfuration plays a leading role. In an atmosphere where
oxidation is the leading player, the protective characteristic of the oxidized coat becomes excellent, resulting in a
negligible level of corrosion. On the other hand, in an atmosphere where sulfuration is the leading player, the
protective characteristic of the sulfide coat becomes remarkably poor, resulting in strong corrosion.
With respect to the corrosion occurring in an atmosphere of low oxygen partial pressure and high sulfur partial
pressure, it is considered that the reaction mentioned below is the leading player.
195
Air ratio
Fig. 3.2.8-2 Impact of air ratio on the balanced structure of combustion gas at 1300
H2S + Fe Fes + H2 ...........................................................................................................(7)
2CO + SO2 + Fe
This corrosion gradually grows to complete corrosion in general. At a portion where repeated thermal stress is
strong, the corrosion may grow in a groove shape in the direction of the circumference (which is called
elephant-hide alligator-skin cracking).
Other than the above corrosion, it has been reported that corrosion involving such vitriols as XSO, XSO
(X: Na or K), etc. contained in the adhered ash or pyrosulfate can occur when the SO density in the combustion
gas is high z!. However, cases of corrosion of the waterwall piping by these alkali compounds are not reported
very frequently.
In UK where coal containing lot of Cl is used, acceleration of corrosion of waterwall piping caused by HCl
contained in the combustion gas has been reported. Because the coal currently used in Japan contains a very small
amount of Cl, no corrosion caused by HCl contained in the combustion gas has been reported to date. From the
standpoint that poor-quality coal may be used in future as fuels to be used diversify, it will be required to capture
well the influence of HCl on corrosion.
196
Photo 3.2.8-8 includes EPMA photographs of corrosive scale. The scale in the outer layer is composed of FeS,
whereas the inner layer is composed of a mixture in which FeO is the main content. It is typical corrosion in an
atmosphere of low oxygen containing a considerable amount of HS. In the neighborhood of the waterwall piping
surface where strong corrosion occurred, it is indicated that the content of HS in the combustion gas was 300
ppm, H was 1.5%, and CO was 6.1%, and the air ratio at the moment of combustion was 1 or less.
An example of groove-shape corrosion of the waterwall piping is shown in Photo 3.2.8-9. The appearance of
the corrosion is similar to that occurring at heavy oil-fired boilers. The causes of such groove-shape corrosion
are considered to be follows. Namely, the oxidized coat on the piping surface has cracked by repeated thermal
stress arising from any combination of adhered substances to the inner piping (FeO), condensation of air
bubbles, or local falling off of scale from the surface of the furnace piping. It is considered that corrosive gas
entered through the cracks and that the corrosion was accelerated at this gas-entered portion zs!.
Considerable actions to prevent corrosion of waterwall piping are as follows:
(a) Measures to be taken in the design
(b) Selection of materials
(c) Employment of surface treatment
The most effective action is the use of coal with a lower S content. Such actions as employment of low-NOx
burners, use of fined coal to promote complete combustion, increase in the oxygen partial pressure on the piping
surface by filling boundary air (to create an air curtain along the waterwall piping) over the waterwall piping
surface, etc. are also considered effective z! z!.
Photo 3.2.8-10 shows the EPMA observation result of the scale on the piping surface before and after filling of
boundary air. By filling of air, the scale mainly containing sulfide has changed to scale mainly containing oxide.
As measures against groove-shape corrosion, suppression of the generation of substances adhering to the inner
portions through thoroughgoing water treatment or prevention of air bubbles from condensation by employing
rifle pipes is considered effective s{!.
197
S: X-ray image
C: X-ray image
O: X-ray image
K: X-ray image
Photo 3.2.8-9 Appearance of groove-shape corrosion of waterwall piping in the neighborhood of the burner
With respect to the materials, use of the double piping system composed of an outer pipe made of materials
excellent in corrosion resistance such as SUS 347 H, SUS 310 S, etc. and an inner pipe made of carbon steel is
considered sz!. These materials have been already put to practical use where the materials are exposed to severe
combustion gas containing HS and HCl ss!.
For surface treatment, chromizing treatment by raising the Cr density by having Cr diffuse and penetrate is
effective for prevention of corrosion also. In addition, thermal spray coating of corrosive materials by plasma
thermal spray is effective for prevention of corrosion. Thermal spray process using 50 Cr 50 Ni as its material
has been put to practical use.
In the case of thermal spray, however, entry of gas into the layer of the metal/thermal spray cannot be avoided.
This process has not yet been put to practical use as a permanent countermeasure.
198
O: X-ray image
Before filling
boundary air
S: X-ray image
After filling
boundary air
O: X-ray image
S: X-ray image
Photo 3.2.8-10 EPMA observation result of corrosive scale adhering to waterwall piping before and after filling
boundary air
199
200
PO4
45.6
23.8
0.2
0.5
0.2
0.8
0.2
0.1
0.2
0.1
Water Quality
Requirements
Average pH
Silica (ppm.)
Pressure (psig)
Fig. 3.3.1-1: Impact of Pressure, pH and Concentration of Silica in Water to the Ratio of Silica under the Steam
Generation Volume of 5lb/h and in Static Condition
201
Silica (ppm.)
All volatile
treatment: pH:
approx. 9.0
Pressure (psig)
Fig. 3.3.1-4: Boiler Pressure and Maximum Permissible Silica Concentration Limit in Boiler Water
202
Table 3.3.1-2: Maximum Permissible Total Soluble Solid Material in Steam (Unit: ppb)
Material
NaCl
Na2SO4
Na3PO4
NaOH
SiO2
Total
Permissible
Concentration for
Continuous Operation
400
400
60
30
8
898
Permissible
Concentration for
Conditioned Operation
2000
2000
150
60
20
4230
Permissible
Concentration for
Intermittent Operation
4000
4500
300
150
45
8995
Chestexfield
170 MW
2600 psig
7.5 ppm
0.0021 ppm
0.028%
9.4 ppm
0.057%
Ashtabula
2500 psig
10.6 ppm
0.0029 ppm
0.027%
15.3 ppm
0.047%
Referring to the above reports, the concentration of silica was set to 0.02 ppm or below.
The tolerance of silica concentration in boiler water depends on the ratio of silica distribution in saturated steam.
It also depends on pressure and pH, as shown in Fig. 3.3.1-1. Based on the distribution ratio, Fig. 3.3.1-2 is drawn
and C.E used Fig. 3.3.1-3.
In Fig. 3.3.1-2, the silica concentration is 0.18 to 0.19 ppm under the pressure of 186 to 188k and a pH of 7.8 to
9. From these data, the silica concentration was set as 0.2 ppm.
As the silica concentration in boiler water tends to rise when the boiler starts operation, due to the silica scale
deposited on the turbine low-pressure blades being washed away by wet steam, a silica purge must be
implemented to raise pressure by blowing the boiler, while ensuring the silica concentration is limited to within
the designated value. This is the main cause of delays and increased load when starting the drum type boiler.
Therefore, looser values were set, as shown in Fig. 3.3.1-4, for the concentration of silica when starting a boiler.
The silica-washing device installed in a drum manufactured by Babcock-Hitachi K.K. showed a remarkable
ability to reduce the silica concentration in steam, doubling the permissible concentration of silica in the boiler.
(5) Total Soluble Solid Materials
As for the total soluble solid materials, the following reports were issued in the U.S.:
1) Fig.3.3.1-2 shows the permissible concentration for continuous operation (the maximum concentration that
does not cause significant silica deposit after operating a turbine for 8,000 hours), the permissible
concentration for conditioned operation (the maximum concentration after repeated stopping and restarting
or under such operation conditions as variable pressure operation) and the permissible concentration for
intermittent operation (the maximum concentration that does not cause any silica deposits for a relatively
short turbine operating period). The permissible concentration for continuous operation is approx. 1 ppm.
2) No significant silica deposits were observed in the concentration range of 0.1 to 0.2 ppm.
3) In order to operate a turbine without any washing for an extended period, the silica concentration must be
controlled to 0.05 ppm or below.
Experience at Himeji No. 2 Power Plant showed that deposits were rarely seen when a turbine was operated
with cationic conductivity of 0.3S or below. This corresponds to a silica concentration of 0.05 ppm.
Based on the above, the cationic conductivity and the silica concentration were determined as 0.3K-S/cm or
below and 0.05 ppm or below, respectively.
In order to determine the limit value for the total solid materials in the boiler water, the carry-over ratio of the
drum should be considered. With this in mind, the following data is issued:
1) The design value is 0.25%.
2) The value measured in the U.S. is 0.05% or so, as shown in Table 3.3.1-3.
3) The value measured in Himeji No. 3 Power Plant was approx. 0.15%.
Based on the above, the value was determined as 0.2%, taking safety into consideration, and the total solid
materials in boiler water was set as 25 ppm.
As the measurement of water quality under the all volatile treatment is 5K-S/cm, or 10K/S/cm at worst, the
total solid materials in boiler water was determined as 10 ppm.
203
Ignition
Normal values
Combined
feeding
Time (h)
Time
Time
Permittivity of
Cation-Exchange Resin
Condensate
t
Exit of WW
Entrance of ECO
Second stage low temperature
reheated steam
KC-floc used
204
(6) Hydrogen
As for hydrogen, it only indicates the corrosion condition of a tube and no measures can be taken based on it .
The generation of hydrogen can be determined as stable, because it remains commensurate with the surface
area, regardless of the volume of steam generated. Thus, it seems normal that the hydrogen concentration doubles
when the flow decreases by half.
As seen in the example where the hydrogen concentration is 2 to 4 ppb under stable operation, the chemical
reaction of iron and water continues to a certain extent, even under stable operation. This means the magnetite
coating undergoes a cycle of damage and recovery to a certain extent.
Increased hydrogen generation tells that the following events are happening:
1) The magnetite coating incurs significant damage. : E.g.: After chemical cleaning, the magnetite coating is
removed and thus hydrogen increases, returning to the normal level as the coating is formed (Fig. 3.3.1-5).
2) A new steel surface has appeared. : E.g.: Iron powder is generated by the flying apart of turbine blade; a
new metal surface appears on it, on which a chemical reaction progresses rapidly (Fig. 3.3.1-6).
3) The metal temperature has surged abnormally. : There is a report that the hydrogen concentration increased
by about 10 ppb when a reheating pipe caused creep damage for a relatively short period.
4) Organic materials (sugars) inputted have been decomposed (Fig. 3.3.1-7): There is a report that fine resin
leaked out from a condensate demineralization tower when water was introduced into it immediately after
replenishing the resin.
(7) Malfunctioning of Boilers in the U.S.
Table 3.3.1-4 indicates the result of investigations by the American Society of Mechanical Engineers (ASME)
on 116 boilers in the U.S. from 1950 to 1959. As stated in the table, 40% of boiler showed some pipe damage,
while 28% of boilers caused crater-shaped corrosion, which is considered alkali corrosion. Fig. 3.3.1-8 shows the
relationship between crater-shaped corrosion and hydroxy-ions, expressly showing how the concentration of the
latter may decline as pressure goes up.
205
42
49
14
8
3
36
42
12
7
3
13
21
53
26
3
11
18
46
22
3
6
33
26
28
23
5
28
23
24
20
0
15
80
21
0
13
69
18
0
68
3
46
0
59
2
39
72
36
4
4
62
31
3.5
3.5
7
4
5
7
18
28
18
11
7
8
3
6
3
4
6
16
24
16
9
6
7
3
101
15
87
13
Deaeration unit
Used
Not used
Final treatment of makeup
water
Deionizer is used.
Steam evaporator is used.
Boiler water treatment
Sodium sulfite
Hydrazine
Caustic soda
Phosphate
Potassium salt
Organics
Condensate water treatment
Morpholine
Cyclohexylamine
Ammonia
Problems
No corrosion losses
observed to pipes
Crater-type corrosions
89
27
77
23
50
66
43
57
80
41
81
111
3
13
69
35
70
96
3
11
76
12
12
65
10
10
70
60
32
28
(20 to 23% are of
fluidity
hindrance.)
Year of Operation
Before 1950
1950
1951
1952
1953
1954
1955
1956
1957
1958
1959
Economizer
Used
Not used
No. of Boiler
5
2
1
4
2
1
13
11
5
13
9
4
11
8
(Water-soluble
9)
Carry-over of silica
Acid washing
With acid washing
No acid washing
With initial acid washing
No initial acid washing
Total number of acid
washings
Once
34
82
45
37
29
71
44
(Initial acid
washing 22)
Twice
14
(Initial acid
washing 7)
Three times
21
(Initial acid
washing 13)
Four times
2
(Initial acid
washing 2)
Five times
1
(Initial acid
washing 1)
For users, chemical cleaning to prevent any damage, for manufactures, designs to avoid hot spots or fluidity
hindrances, for consultants, the removal of dissolved oxygen, carbon dioxide and sulfur dioxide from the
pre-boiler, curtailment of dissolving iron and copper and research into controlling the pH level are requested.
206
Concentration
Mother Water of
Boiler Water
Temperature
Concentrated
boundary Film
Number
of Cases
Year
Example
Overheat
Ash
Corrosion
Corrosion
Fatigue
Ash
Corrosion
Stress Corrosion
Brittleness against
Hydrogen
Alkali Corrosion
concentrated sodium hydroxide formed. According to an example of calculation , a 100k-class boiler containing
100 ppm of sodium hydroxide shows the temperature of inner surface of a pipe is increased by 5F when it is
heated at comparatively low heat flow rate of 25,000 BTU/ft2h, boosting the sodium hydroxide concentration by
10%.
Another report shows that the temperature of the inner surface of the pipe is increased by 30 C at some hot
spots . The occurrence of such hot spots is considered attributable to film boiling that is likely to occur due to the
enlargement of heat flux in a large-sized boiler, steam blanket, lack of flow rate, inappropriate burner positioning,
contact of flame due to insufficient combustion control, biased combustion and gas flow, inclusion of slabs in the
welded parts, blow holes and lack of fusion.
Sodium hydroxide can result in corrosion of steel at a concentration of 5%. When the concentration reaches 5%
or above, it dissolved the protective oxide layer, causing the inner metal surface to become exposed and corroding
it due to the reaction of water and steel. The hydrogen generated by the reaction penetrates into and damages the
steel.
In Japan, alkali corrosion cases were also reported. As Fig. 3.3.1-10 shows, statistically speaking, this has been
responsible for the highest proportion of boiler accidents having occurred to date.
The alkali corrosion is otherwise known as a caustic attack, or in the U.S., as crater-shaped corrosion, due to its
shape. These differ from conventional caustic embitterment.
After such accidents, the injection of sodium hydroxide was stopped. Thereafter, a new finding was reported:
namely that hideout of phosphate ions causes not trisodium phosphate but 2.65-sodium biphosphate at 689F and
2.85-sodium biphosphate at 572F respectively. This means 0.35 to 0.15 of trisodium phosphate in the system is in
the form of sodium hydroxide. It thus emerged that phosphate containing sodium less than 2.6 sodium
biphosphate should be used.
However, even if such phosphate is used, it was found that pH in boiler water increased past this level due to
trisodium phosphate. The cause was identified as a leakage of sodium from a deionized water system. In order to
avoid leakage, a double-bed operation was used to place the deionized water system just after regeneration to the
latter stage. Due to the fact that the movement of the system used at the latter stage to the front stage resulted in a
more significant leakage, a mixed type system was installed at the latter stage to use it dedicated to a polisher.
Thanks to such measurements, no further alkali corrosion has been reported since 1963.
(9) Shift to All volatile treatment
The No. 2 boiler of the Karita Power Plant (a 170k forced circulation boiler) started its operation in June 1959
showed alkali corrosion to evaporator tube at the 3,700th hour. This was attributable to sodium hydroxide and the
use of the chemical was stopped. The investigation showed that powder scale was attached to its turbine blades,
especially the final stage of the medium-pressure turbine, mainly consisting of sodium bicarbonate. Gilbert
suggested the use of sodium acid phosphate to maintain the pH level of boiler water and make-up water at around
8.5 to 9.5. The phosphate ion was dramatically reduced two days after feeding phosphate ions into the drum. As
this resulted in heightened conductivity of saturated steam and carryover to the turbine, the use of phosphate ions
was terminated in February 1960.
As the volume of hydrazine was maintained, the pH level of boiler water was lower by 0.4 to 0.5 than that of
make-up water, which was well below 8.5 and maintained at that level.
Regarding the risk of leakage within the condenser, trisodium phosphate is fed and a drum blow operation is
started. After repairing the leakage, the concentration of phosphate ions decreased to 0.0 ppm.
In the U.S, all volatile treatment was used due to the heavy carryover having occurred, and an ambiguous trial
just to maintain turbine operation started. For them, there was no choice other than the use of the treatment
method.
208
Table 3.3.1-5: pH Control Methods of the Pressure Boiler of 130kg/cm2 or above by C.E.
How to Adjust pH
(1) Caustic Based
pH10.5 to 11.0
(Caustic alkali and phosphate ions are used.)
(2) Low Caustic Control
pH10.0 to 10.5
(Same as above)
(3) Cordinated Phosphate pH Control pH10.0 to 10.5
(Coordinated phosphate treatment is used and caustic alkali is not used.)
(4) All volatile treatment: pH 8.5-9.0
(Hydrazine and ammonia treatment is used and no solid chemicals are used.)
No. of Boilers
37
8
29
21
Scale Thickness
All volatile
treatment
Approx. 15%
Ingredient
strength
Approx. 80%
Approx. 10%
209
Total
125K Class
170K Class
140K Class
Year
Sodium
hydrate
Sodium
phosphate
Year
210
Table 3.3.1-6: Survey on Boilers whose Water Treatment Method was Switched from
All volatile treatment to Low Phosphate Treatment
When Phosphate
Materials for the Condenser
Treatment was
Started
Condensate water Part
Air Cooling Part
(Year/Month)
53.3
Aluminum brass
Nickel-plated
aluminum brass
48.1
Aluminum brass
Cupronickel
45.3
Aluminum brass
Cupronickel
51.5
Aluminum brass
Monel metal
Aluminum brass
Cupronickel
53.2 (50.6P"A)
53.5
Aluminum brass
Titanium
Unit
No.
Capacity
(MW)
Furnace
Type
Circulation
Method
36
375
Single
Natural
Start of
Operation
(Year/
Month)
47.11
65
66
67
70
78
156
156
350
156
156
Divided
Divided
Divided
Divided
Divided
Natural
Natural
Natural
Natural
Natural
39.8
41.2
44.1
39.6
48.4
86
87
250
250
Divided
Divided
Natural
Forced
42.7
43.7
49.4
52.6
Aluminum brass
Aluminum brass
88
250
Divided
Forced
44.1
52.2
Aluminum brass
89
90
106
108
265
265
350
265
Divided
Divided
Divided
Divided
Natural
Natural
Natural
Forced
42.5
44.9
47.2
35.10
47.5
50.10
54.1
54.11
Aluminum brass
Aluminum brass
BKCB
Aluminum brass
109
112
265
350
Divided
Divided
Forced
Forced
37.9
41.7
54.10
53.6
113
118
350
350
Divided
Divided
Natural
Forced
42.1
43.1
55.12
53.7
122
147
250
350
Single
Divided
Forced
Natural
45.6
44.9
54.1
53.6
Aluminum brass
Aluminum brass
Titanium
Aluminum brass
Aluminum brass
Cupronickel
Aluminum brass
Aluminum brass
148
168
169
181
350
250
350
400
Divided
Divided
Single
Single
Natural
Natural
Forced
Forced
45.1
46.1
48.1
52.9
55.12
51.3
53.12
56.3
Aluminum brass
Aluminum brass
Aluminum brass
Aluminum brass
Cupronickel
Nickel-plated
aluminum brass
Nickel-plated
aluminum brass
Titanium
Titanium
Titanium
Nickel-plated
aluminum brass
Titanium
Titanium
Aluminum brass
Monel metal
Copper arsenate
Copper arsenate
Aluminum brass
Copper arsenate
Aluminum brass
Aluminum brass
Aluminum brass
Monel metal
Monel metal
Carbon steel
Monel metal
Alloy steel
Carbon steel
Alloy steel
Alloy steel
Aluminum brass
Alloy steel
Copper arsenate
Copper arsenate
Aluminum brass
Copper arsenate
Carbon steel
Carbon steel
Carbon steel
Monel metal
Copper arsenate
Copper arsenate
Monel metal
Alloy steel
Titanium
Aluminum brass
Copper arsenate
Aluminum brass
Alloy steel
Alloy steel
Cupronickel
Titanium
Aluminum brass
Aluminum brass
Titanium
Cupronickel
Cupronickel
Titanium
Aluminum brass
Aluminum brass
Aluminum brass
Aluminum brass
Alloy steel
Alloy steel
Carbon steel
Carbon steel
Carbon steel
Carbon steel
Carbon steel
Table 3.3.1-7: Corrosion Damage Reported in the U.S. on Drum Boilers (125k Class or above)
Periods
1955-1960
1961-1965
1966-1970
New damage
reported
48
39
27
Number of units in
operation
219
385
481
Ratio of annual
damage occurred
3.6%
2.0
1.1
just 5 to 500 ppb. In order to obtain such low concentrations, it is necessary to avoid mixing solid substances into
the feed water.
Generally speaking, the following are considered sources of solid substances into feed water :
! Solid substances derived from construction phase
! A mixture of cooling water into the system, due to leakage of the condenser
! Corrosion products derived from the feed water system
! Solid substances in supplementary feed
! Solution of resin from the deionized water system
Among them, leakage of the condenser occupies the largest part. To eliminate this, condensate purification
equipment is installed. This unit is relatively effective in removing dissolving metal.
When an equilibrium between the protective coating on the metal surface and the water contacting it is lost, due,
for example, to load fluctuation, and system start-up and stoppage, the volume of corrosion products contained in
feed water rapidly increases.
In order to maintain the stability of the metal surface during a system stoppage, the system should be carefully
protected while not in use, with the use of hydrazine water of high pH and nitrogen sealed in tubes.
At the same time, a clean-up operation should be implemented before the system restarts operation. As for the
solution of resin from the deionized water unit, resin slightly dissolves into water during the initial phase of the
unit start-up, until it reaches a stable condition, meaning fine-powdered resin mingles into the supplementary feed.
The effects thereof were not the subjects of research in 1959. In those days, it was considered that installation of a
fine pore filter before and after a condensate purification equipment was effective in removing fine powder resin.
As chemicals capable of solidifying must not be used, hydrazine, ammonia and amines should be used.
However, amines are not recommended because they decompose at high pressure.
Table 3.3.1-8: Damages to Boilers by Pressure and by the Water Treatment Method
Pressure
All volatile treatment
Sodium Phosphate Treatment
Sodium Hydroxide Treatment
Potassium Salt Treatment
Total
125k Class
5
12
41
5
63
140k Class
7
3
18
5
33
170k Class
11
8
4
23
Total
23
23
63
10
119
The No. 2 Boiler of the Himeji No. 2 Power Plant was imported from the U.S. and commenced comercial
operation in 1964. Table 3.3.1-9 shows the water quality standards, set based on actual operation performance.
This boiler uses hydrazine and ammonia injected into the outlet of its condensate purification equipment and
ammonia into the outlet of its deaeration unit.
(1) Condensate purification equipment
Condensate purification equipment normally consists of a mixed bed condensate demineralization tower and
filters placed in front of it. Some act as a polisher of supplementary feed.
The following three major objectives are associated with the use of condensate purification equipment:
1) To prevent damage to the entire system due to the leakage of a condenser
2) To purify the supplementary feed
3) To remove corrosion products from the feed water system
The secondary objectives include:
1) to purify various drain water before it enters into the system, and
2) to purify the system during the initial start-up and shutdown operations.
Contamination of ion-exchange resin by metal oxides and pressure loss of the condensate demineralization
tower impose significant impacts to the system when a high-speed ion exchange takes place. Due to this, a filter is
installed just before the tower to remove them and prevent the ion-exchange resin from deterioration.
As for appropriate materials to use for the filter, cellulose, diatomite, leaf-type and other fine pore filters are
recommended.
As for the condensate water condensate demineralization tower, although the impact of dissolved resin to the
tower has not yet been clearly identified, some say that the use of a filter, which puts after the demineralization
tower, can eliminate leakage from the tower. Himeji No. 2 Power Plant employs a combination of filters made by
United Filters, Inc. and Permutite Company. The label said the design conductivity was 0.2S/cm, and that design
silica, iron and copper concentrations were 7 ppb, 5 ppb and 5 ppb respectively, although these are not guaranteed
values.
The imported item of Himeji No. 2 Power Plant uses a horizontal leaf type pre-coat filter and Solka floc
212
BW-100 and -40 were used at a ratio of 1 to 1 as filtering agents. The agents heavily leaked out, were deposited on
the resin surface of the condensate demineralization tower caused pressure loss of the tower. The reasons for the
leakage were attributed to leaf-end gaps, the distance of leaf hubs, the non-parallel arrangement of the same,
variations in the water flow, an excessive design flow rate and the screen structure. The pressure loss exceeded the
design value, after pre-coating, it was attributable to the excessive flow rate and an overly small shaft and shaft
hole diameter. To eliminate the pressure loss, the system underwent renovation, but the loss still exceeded the
design value. So, other filter unit was added.
It is believed that the black carbon precipitated to the boiler tube when the filtering agent leaked in large
amount.
The condensate demineralization tower showed resin leakage, which was attributable to the gap of the disc
strainers, the distances between a disc strainer and the strainer plate and between the strainer plate and a bottom
plate.
In addition, sending resin to the regeneration tank led to massive amounts of residual resin accumulating at the
bottom of the tower, resulting in an insufficient regeneration process and imbalances between the cation and anion
resins. This was due to a structural defect at the bottom of the tower.
As the pressure loss of the condensate demineralization tower became abnormally high, resin with less than 60
mesh was filtrated using a filter (Permatite Q and S-1). The total annual fraction ratio came to approx. 45%, with
the ratio of damaged anion resin particularly high. As for the cause of the fractured resin, this was found to be
attributable to the relatively high design flow rate of 119m/h (51). Due to such experiences, a flow rate of 80m/h
was recommended.
However, despite such measures, the water purity showed no improvement. Even after investigation by a
Japanese condensate demineralizer manufacturer, no causes were identified. So, the staff was so desperate for help
that they used a sieve to remove small resins, whereupon the water purity showed improvement.
Table 3.3.1-9: Criteria for a Once-through Boiler
Pressure
Condensate water
Demineralized
Condensate water
Feed Water
ClO2
Electrical Conductivity
ppm
ppb
S
Subcritical
Pressure
0
40
0.2
Supercritical
Pressure
0
40
0.2
pH
9.0-9.5
9.2-9.7
O2
5
ppb
5
N2H4
ppb
5-30
5-30
0.2
0.2
Cationic conductivity #S/cm
10
10
Fe
ppb
5
3
Cu
ppb
20
10
SiO2
ppb
Values not shown in the form of a range (a ~ b) are the maximum allowable values.
213
(2) Cleanup
(Inlet of an economizer in front of a
boiler unit of Himeji No. 2 Power Plant)
Lowest Range
Time
Highest Range
Start of switchover to a high
pressure heater (second time)
B-Line Feed Water
eliminated by a 0.45m filter. In Japan, as shown in Table 3.3.1-10, it was found that, when except a deaerator
tank, iron particles of 0.45m or above in size occupied more than 60% at the position requiring final assessment
and at the time measurement required just after starting up the plant.
These results were based on the plant being in continuous operation mode, with shutdown rarely occurring. The
successful results were attributable to the fact that large-sized particles detached from the boiler surface, etc., were
flown out temporarily into water in the lines when the plant started operation.
However, stopping the system frequently during the DSS operation gradually reduces the volume of such
particles of larger size. On the other hand, it was reported that the size of the needle-shaped corrosion products
generated in a condenser during plant stoppage and restart consisted of FeOOH of 0.02 to 0.1m and that other
products, such as magnetite, also detached from the boilers of which the size and shape were apparent in the form
of thin films of approx. 0.02m and square-shaped products of approx. 0.1m respectively. As the ratio of fine
particles of 0.45m in size or below newly generated from the system letup to restart tended to increase, it was
necessary to examine whether a filter of 0.45m should be continuously used or not.
Recently suggestions include, given the variability in the optical properties of FeOOH, Fe2O3 and Fe3O4, that
the color strength of these three products should be measured and quantified.
Table 3.3.1-10: Particle Diameter Distribution of Suspended Iron Oxides in System
Water when the System is Started
Specimen
Outlet of the
Condensate
pump
Sampling
Time*1
1
2
3
4
Deaerator tank
1
2
17
30
30
100
23
40
30
100
23
40
30
100
1
2
3
4
Inlet of an
Economizer
1
2
86
57
31
100
116
77
31
100
126
84
31
100
1
2
3
4
Outlet of
Furnace
1
2
86
57
31
100
116
77
31
100
126
84
31
100
1
2
3
4
* Sampling Time
[No. 4 Unit of Himeji No. 2]
1973.6
1: After boiler inspection
2: Cleanup at 117 C
*2 The upper line of each column shows the concentration of iron collected by 0.45m, 0.22m
and 0.025m filters, while the bottom line shows the percentage of iron oxides of more than
0.45m, .22m and 0.025m in size relatively to the total iron.
1
2
3
1
2
3
1
2
3
3
37
6
73
4
54
4
50
6
73
4
63
11
73
11
83
6
88
12
80
12
87
6
96
44
94
58
95
3
72
45
96
58
96
3
72
As in the U.S. a supercritical pressure unit started operation without identifying the movement of impurities in
water under supercritical condition, many troubles of copper scales to a high pressure turbine was reported due to
the copper dissolved in steam. The troubles became a synonym of a trouble peculiar to supercritical pressure unit,
that had not been experienced in subcritical pressure units. For example, Avon No. 8 unit experienced a copper
scale deposit of 1.5 to 2.3mm in thickness and 5.5 lbs. in weight during its three-year operation, and the load of
250 MW was decreased to 216 MW.
Subsequently came the introduction of a supercritical pressure unit aiming to meet the increased power demand
during periods of high economic growth. As the new unit handles supercritical pressure, completely different from
subcritical pressure, the latest water treatment system was employed to handle the latest water treatment
technology at that time.
There remained some challenges to be overcome in water treatment after the introduction of a supercritical
pressure unit. The following are the experiences of the No. 4 unit in the Himeji No. 2 Power Plant.
(1) Copper and Condensate purification equipment
As explained above, the concentration of copper must be minimized, as it deposits on turbine blades. Referring
to experiences in the U.S, 2 ppb was determined as a target for the copper concentration.
To eliminate copper, there are two methods; namely removing copper alloys from plant and using condensate
purification equipment.
For the former, steel pipes were used for the feedwater heater in lieu of copper alloy pipes. The No. 4 unit of
Himeji No. 2 Power Plant only used copper alloy for its low-pressure heater No. 1 and 2.
There was no alternative to the use of aluminum brass and copper dissolved from a condenser can be removed
by condensate purification equipment. However the condensate purification equipment manufactured by Graver
and installed as the No.4 unit of Himeji No. 2 Power Plant met the guaranteed value of 0.3S for electrical
conductivity, while the iron, copper and total dissolved solid material concentrations of 10 ppb, 3 ppb and 35 ppb
respectively were only the target values. The condensate demineralizer used was an external regeneration system.
With this in mind, the criteria for the copper concentration of the No. 4 unit of Himeji No. 2 Power Plant was
set to 3 ppb, although the actual concentration could be contained at almost 2 ppb. All the units installed in the
Power Plant thereafter used steel pipes for all feed heaters and the criteria was changed to 2 ppb, which was
successfully met thereafter.
Temperature
Deposition
ignited. As Fig. 3.3.1-15, a result of experiments at B&W, shows, the iron starts depositing in a generating tube at
a temperature of 450F (232 C). Therefore at this temperature or below, iron deposited at the inlet of an
economizer need not be considered. In actual practice, a boiler is cleaned by keeping its temperature at 350F
(177 C) at the outlet of the WW to suspend foreign matter deposited on the wall of pipes, which is then removed
using a condensate purification equipment. The temperature at the outlet of the WW may be risen up to 400F. It
is reported that Breed and Philo experienced circumstances whereby most iron oxide contained in feed water went
through the boiler at an outlet temperature of 260 C to 288 C, and all of it was deposited on the pipe wall at a
temperature of 316 C or above.
The following are the criteria for giving final approval to a boiler that cleanup be completed at a temperature of
177 C:
Inlet of an economizer: Iron 50 ppb
Copper 20 ppb
Silica 30 ppb
Oxygen 10 ppb
Outlet of a WW:
Iron 500 ppb
If the iron concentration is 500 ppb or below at the outlet of WW when the deaeration feed water contains 50
ppb of iron, the contamination on the WW surface is minute. This is because it is said that experiences indicate
that iron will not separate out at the WW when the temperature at the outlet of the WW is 218 C at the highest.
Experiences also indicate that the permissible level of iron concentration at the outlet of WW may be up to 500
ppb, rather than 50 ppb, without sacrificing cleanup effects or boiler performances.
Lax water quality is allowed after cleanup so that units can be installed in juxtaposition to obtain a reasonable
flow rate. Moreover, since the cleanup does not take long, slightly deteriorated water quality will not cause any
scales to be deposited.
Based on experience, when the iron concentration comes to 50 ppb, both copper and silica concentrations
satisfy the limit values, and the acceptance of cleanup is determined by measuring the iron concentration at the
inlet of an economizer only.
If the iron concentration at the inlet of the economizer reaches 50 ppb, both copper and silica concentrations at
the same location should satisfy the limit values.
After the cleanup at 177 C, the temperature may be uplifted. During the temperature rise, the iron concentration
at the inlet of the economizer should be kept at 50 ppb or below. Beyond 177 C, even if the spillover of the
economizer is closed, the iron concentration can be maintained at this concentration or below. In the case that the
concentration exceeds this value, the spillover should be increased, whereupon, the iron concentration can be kept
at this level till combined input.
(3) Steel Pipe Heater and pH Rise
As a result of a test , when the pH of the feed water at the inlet of the economizer was uplifted to 9.5, the iron
separated out into the feed water system was significantly reduced. As for copper, no significant change was
observed after the pH uplifted to 9.5. So the value of 9.5 was determined for pH.
The reason that the pH was limited to 9.5 was because more ammonia should be used if the value exceeds this
level and because of curtailing chemical costs due to an increase in the number of regenerations and due to a
deterioration in the water intake capacity of a desalination tank.
3.3.1.4 Advancement of Condensate purification equipments
(1) Ammonia-Type Resin
Though the cation and anion resins contained within a condensate demineralization tower do not lose the
function of removing ions such as sodium, iron and copper for the former and chloride ions and silica for the latter,
they are prone to break down due to the ammonium ion exchange caused by a pH regulator.
Based on experience, an idea was proposed to use NH4 type ions as exchanger bases for cation resin to
optimally utilize the resin functions. In the U.S, a series of simulation tests was conducted at the end of 1966,
followed by the practical implementation of the method.
At the No. 4 unit of the Himeji No. 2 Power Plant, a series of tests using an actual unit was conducted from
1969 to 1970, following an experiment using a small-sized unit.
Consequently, it emerged that this method can withstand even a leakage occurring within the condenser.
However, the findings were attributable to the fact that during the test, the unit was handled with extreme care, the
ratio of regeneration was almost 100% and that due to this, the water quality at the inlet was excellent. With this in
mind, the design of actual units required thorough consideration of various points. This consideration was made
after the test and the method was implemented.
(2) Electromagnetic Filter
217
A pre-coat filter was in use for 20 years. The shortcomings were the fact that it took 2 hours to regenerate and
that dissolving a pre-coat agent requires handling by operators, because this did not take place automatically. In
addition, the pre-coat filter requires a pre-coat agent, resulting in a high running cost, and effluent sludge needs to
be treated.
An electromagnetic filter was first used in a Kiel Power Plant (320MW). At the Power Plant, condensate water
and a low pressure drain were treated at a temperature of 130 C, while the capacity of the electromagnetic filter
was disclosed in 1966, as shown in Fig. 3.3.1-16. As the system water temperature rose at startup, the magnetite
volume also increased. Alongside the same, the ratio of removing foreign matter was on the rise; 90% of total iron
and 97% of magnetite were removed successfully. However, as the concentration of total iron fell to 10 ppb, the
ratio was reduced to 80%.
After an electromagnetic filter had been developed in Japan, it rapidly spread to all newly installed units. The
filter generates a high gradient magnet field by subjecting a solenoid coil to a direct high density current. It shows
high removal performances against ferromagnetic and paramagnetic iron oxides when a filler is charged into the
tower, making it an electric magnet, in combination with the mechanical filtration of the filler. The water feed
filtration velocity (LV Value) is approx. 10 times higher for an electromagnetic filter than that for a conventional
filter, and the whole unit can be miniaturized. As it facilitates regeneration relatively easily, this helps save
significant amounts of both energy and labor. Moreover, no stand-by unit is required because flushing the unit
takes as little as 15 minutes, including the preparation time. In addition, no meticulous operation control is
necessary, the volume of effluents from of the unit is modest, no filtration auxiliary agents or other chemicals are
required and the volume of sludge can therefore be minimized.
However, the shortcomings, according to a report, include its inability to remove high levels of paramagnetic
-Fe2O3 and -FeOOH of fine powders and amorphous bodies, while its capacity to remove irons is slightly
worse .
Normal Operation
(0.3m/s)
Magnetite
Total iron
Heat up of a plant
Iron (pbb)
U.S., e.g. from Europe, where methods unique to this continent are used.
In Germany, an oxygen treatment method was developed in the latter half of 1960s and registered in VGB in
1972. Due to the lack of any ammonia attack on the condensate water pipes, the iron concentration in feed water
can be retained, at least at a level equivalent to that of volatile chemicals and other benefits, and this oxygen
treatment method has penetrated all over Europe. Indeed, the former Soviet Union employed the method in the
mid-1970s for practical use. In Japan, the method has been applied to all boiling water reactors (BWR), in systems
where chemical treatment cannot be applied to the primary cooling system, and a good operational record has
been accumulated to date.
It was considered that, in order to apply the oxygen treatment method to thermal power plants in Japan, it was
necessary to more clearly identify its impacts on reducing scales, the effects of curtailing boiler differential
pressure, the influences on turbine materials, water treatment conditions when stopping and starting the system
and other aspects. For this purpose an oxygen treatment method assessment committee was established,
featuring the membership of 10 electric power companies and the Central Research Institute of Electric Power
Industry (CRIEPI). CRIEPI aimed to identify the above issues and commenced basic research into the practical
use of oxygen treatment method to a once-through boiler in April 1988. The research period was 2 years.
Joint basic research carried out by the 10 electric power companies and CRIEPI was primarily focused on the
following three examination items, and the committee was used as a venue for discussing and assessing in a
comprehensive manner.
(i) The impacts of oxygen on the anti-corrosive performance of boiler pipes against high temperature water
(ii) Impacts of oxygen on SCC and the corrosion fatigue of steam turbine materials
(iii) Assessment as to how the oxygen treatment method is used in plants outside Japan and the provision of
temporary guidance for the practical application of this method to an actual system
Various types of these tests, as well as a case assessment of how the method is used in overseas plants, were
summarized as shown below.
The oxygen treatment method was found to have at least equivalent scaling and anti-corrosion performances to
the all volatile treatment method. Case assessment showed that the oxygen treatment method had the effect of
curtailing a surge of boiler differential pressure and decreasing the generation of scales as well as no new system
reports being reported. With such affirmative results, it was confirmed that the oxygen treatment methods could
represent an ideal feed water treatment method to a once-through boiler.
3.3.1.6 Introduction of the Oxygen Treatment Method
The Chubu Electric Power Company Limited conducted an experimental research involving the application of
the oxygen treatment method to the No. 1 unit of its Chita No. 2 Thermal Power Plant jointly with Hitachi, Ltd.
(boilers) and Toshiba Corporation (turbines) in 1990. This was the first of its kind in Japan.
Some favorable results were obtained, including the curtailment of the differential pressure surge of boilers,
decreased BFP powers and prolongation of the chemical cleaning intervals of boilers. As no adverse effects of
corrosion and erosion were observed, the system was assessed as being applicable for practical use.
With such favorable assessments, the system will be introduced mainly to 18 once-through boilers of
supercritical pressure class or above.
The following chapters explain the result of the research, final assessments and introduction plans.
Application of the Oxygen Treatment
Method
Change of scale
characteristics
Curtailment of wave-shaped
scale production
Curtailment of
pressure surge at the
outlet of a feed water
pump
Curtailment of
overheating to the
generating pipes
Decreasing
power
consumption of
the feed water
pumps
Enhanced cost
performance
Enhanced reliability
219
FY1990
FY1991
FY1992
FY1993
Facility Design
and Construction
(Regular Inspection)
Feasibility Test
(Inspection of
Facility)
Analysis and
Assessment
Analysis
Intermediate
assessment
Analysis
Comprehensive
assessment
220
(Legend)
(Legend)
Oxygen
Oxygen
Outlet of a
Outlet of an Outlet of a Outlet of a Outlet of an Main
Condensate Electromagnetic Condensate Deaeration Economizer Steam
water Booster Unit
water Pump
Filter
Pump
Outlet of an Economizer
(Legend)
Chemical
cleaning
Regular Inspection
(Chemical cleaning)
Regular
Inspection
Start of CWT
Regular
Inspection
Number of Months
1-2
6.7
5.3
(Legend)
(2.5 years)
4 years
9.5 years
Fig. 3.3.1-22: Water Pipe Scale Generation Speed of the Unit used for This Research and
the No. 4 Unit of the Ulsan Thermal Power Plant
(Legend)
Upper
part
Lower
part
(Coal economizer)
Furnace Furnace
material
side
side
Furnace
side
Furnace Upper
material part
side
Lower
part
(Generation unit)
223
224
Resin
Resin
Scale
Scale
Pipe
Wall
Pipe
Wall
(Legend)
Main
Turbine
BFP
Turbine
High Pressure
Water Supply
Heater Flow
Rectification
Tower
BFP
Strainer
Rotator
at the
Inlet of a
BFP
Adjusting
Valve of
High
Pressure
Water
Heater Drain
Table 3.3.1-13: Results of Analysis on Scales Deposited on the Main Turbine (Unit: Fe: %, Others: mg/kg)
Fe
Cu
Cr
Ni
Mo
SiO2
Na
Cl
SO4
AVT
Medium-Pressure
Low-Pressure
Unit #9
Unit #15
64.1
61.1
9400
4900
9000
12400
1100
810
3300
3100
3600
13800
3300
5400
7
120
210
450
CWT-1
Medium-Pressure
Low-Pressure
Unit #9
Unit #15
62.1
64.1
4000
8200
10000
9400
2200
1500
2600
3800
4100
5900
1100
1500
4
<1
250
940
CWT-2
Medium-Pressure
Low-Pressure
Unit #9
Unit #15
61.4
62.9
800
5900
8400
9500
330
1000
2500
3600
3800
4800
500
560
24
17
93
220
An investigation was conducted on seven kinds of valves including the main steam stop valve. As a result, there
was no significant difference when compared to AVT generally.
The maximum depth of erosion to a sub-valve of a main steam stop valve was 4 to 5 mm, which is equivalent to
that observed in AVT.
(c) Instrumentation and Control Valves
A series of investigations was conducted to 9 types of valves, including BFP overheat prevention valves.
Consequently, the drain control valve attached to a high pressure feed water valve No. 3 showed a significant
decrease in the volume of scales (while in AVT, valve sticks were observed due to the deposition of scales), of
which the thickness was one fifth or below compared to AVT (0.6 to 3.0 mm ! 0 to 0.5mm). The scale was soft
and easily removed and maintained.
As for corrosion and erosion performances, no significant changes emerged between AVT and CWT except for
erosion, as explained in 3.3.3.1.6-(3)-d Parts Using Stellite Materials observed on the BFP overheat prevention
valves.
Picture 3.3.1-3: Scales Deposited on the Flow Rectifying Tower of the High Pressure Feed Heater
Good
Bad
227
Carbonized Cr-W
Co-Cr-W
crystals
Damage Conditions
Carbonized Cr-W
Co-Cr-W crystals
Damage Mechanisms
229
e. Cautions in Operations
(1) How to Operate a Deaeration Unit
Based on experiences in Germany, the vent valve of a deaeration unit was kept closed from the onset of
switchover to CWT. This, however, caused an abnormal surge in the DO concentration (600 ppb or above) at the
outlet of the deaeration unit during the unit operation at low load. This was because, due to the closure of the vent
valve, the high concentration of oxygen, which was deaerated during high load operation, was stagnant in the
upper part of the unit, before expanding in volume, being scattered away and then redissolved in water due to the
decreased pressure inside the unit.
To reverse this situation, the vent valve was left open. This, however, caused deaeration and discharge of DO,
making the environment the same as AVT with low pH and causing the iron concentration at the outlet of the
deaeration unit to surge.
Due to such experiences, the vent valve was again left closed, and only reopened when the DO concentration
surged (intermittent operation).
(2) Increased Differential Pressure of the Electromagnetic Filter (EMF)
Once the use of CWF had commenced, the initial differential pressure after backwashing and regeneration of an
EMF occurred and its post-regeneration operation life was shortened (in 7 months, the operation life was
shortened to one tenth (or 2 days) compared to that used in AVT). The reasons for this are believed to include: (i)
the fact that CWT tends to have higher iron loads than AVT, (ii) an increase in fine particles of FeOOH (the
number of FeOOH particles of 1 m tripled or quadruplicated), which split into the depth of the element and (iii)
the fact that needle-shaped iron crystals reinforced the iron deposit layer, which could not be removed by a
backwash and regeneration process.
To reverse such conditions, jet washing of elements was employed and the elements were replaced with new
ones.
In order to implement permanent measures, the following items are subject to examination: (a) Decreasing iron loads at the inlet of an EMF (pH to be increased to 9.0 : effectiveness confirmed)
(b) Improvement of the regeneration methods
(c) Improvement of elements
f. How to Start and Stop the Unit
For several months after the use of CWT, the unit cleanup time tended to be longer than for AVT, due to
unstable hematite protection layers and for other reasons. This was successfully solved through measures to
improve the cleanup process, such as stabilization of the protective layers, lapping of the boiler and pre-boiler
processes and an improved flow rate and numbers of swinging, as shown in Fig. 3.3.1-14.
Fig. 3.3.1-14: Cleanup Time
Acceptance Assessment
Water
Treatment
Method under
Normal
Operation
Let-up
Time (h)
Hydrazine
Injected or
not
AVT
24.5
Injected
CWT
31.0
Injected
CWT
29.0
Not injected
-8
Deaeration
Unit
-6
-4
Pre-boiler
Circulation of Condensate
water
Circulation of
Deaeration Unit
230
-2
Boiler
Deaeration
Unit
Storage
Leakage of seawater
Deaeration unit
Condensate water
desalination unit
Startup
Conventional method (AVT)
Minimum loads or above, and
Electric conductivity of 0.2S/cm or
below
Stop
Conventional method (AVT)
At least 3 hours before the planned
time for disassembly of the unit
Reason: All water must be
circulated once during the period
between the switchover from AVT
and before shutdown of the plant.
An operation test without using hydrazine was conducted by stopping the unit (WSS), but no significant
differences in cleanup time and water quality were observed. However, hydrazine is a reducing substance and its
use renders the hematite protective layer unstable, which means it may be better to avoid this substance.
In addition, the unit was subject to a startup and stop test while CWT was used in DSS, and no deterioration in
water quality was detected.
The author is determined to continue studies and tests to establish optimum system operation when it is subject
to stop and startup.
Table 3.3.1-16: Problems Attributable to CWT and Measures
Problem
Damage to the BFP
overheat prevention valve
seat
Cause
Erosion caused by high differential
pressure and flow rate attributable to
the selective corrosion of carbonized
stellite
Emergency Measure
-
Permanent Measure
To change to a soft seat
(However, a large-sized valve
must be developed for
Kawagoe Thermal Power
Plants Nos. 1 and 2.)
The use of ceramic coating,
etc.
Recoating of Cr
plating during the
regular inspection
period
Chemical cleaning of
elements
Increase of EMF
bypassing
Others
Surge of differential
pressure of EMF (clogged
elements)
3.3.1.6.4 Assessment
Based on the results of these studies and findings in and out of Japan, an assessment was made.
As a result of the assessment, it was found that CWT can be applied to actual units, and is more reliable and
economical than AVT. The assessment details are explained below.
(1) Optimized CWT Operation Method
The author believes Fig. 3.3.1-15 shows the optimized CWT operation method. In this case, no hydrazine will
be used in startup and stop, and neither will any switchover from AVT to CWT take place.
(2) Technical Assessment Comparing to AVT
a. Corrosion of Components
231
Similarly to AVT, the author believes CWT will not have any particularly adverse impacts on the corrosion and
erosion of components.
Moreover, the author also believes that, due to the problems associated with parts using stellite, no basic issues
arise that could deny the CWT applicability. Permanent measures against foreseeable problems are shown in Table
3.3.1-16, while measures for the seat of a BFP overheat prevention valve have already been established. For other
parts, examinations are ongoing.
b. Powers to BFP, etc.
The author believes that the time course increase of steam used for driving BFP found in the acceptance
performance test of the unit using CWT (total amount of heat of low pressure and high pressure steam) can be
substantially decreased to approx. a third compared to AVT, because of the reduced differential pressure of boiler
and of scales deposited.
The author also believes that the functional loss of a high pressure feed heater can be reduced to approx. two
fifths compared to AVT, because of the reduced deposition of scale.
c. Frequency of Chemical Cleaning of Boilers
As shown below, as regards the frequency of chemical cleaning of boilers using CWT, the author believes, in
the case of the No. 1 unit of the Chita No. 2 Thermal Power Plant, that this can be extended from the current 1.5
years to 9.5 years, while for other once-through boilers of supercritical pressure or above, the current 1.5 to 4.5
year period can be significantly extended to 10 to 15 years.
In line with the extension in chemical cleaning frequency, the author believes that regular inspection periods
can be shortened and the disadvantageous transfer of loads eliminated.
(i) Assessment in terms of Boiler Differential Pressure
The interval of chemical cleaning for the unit used in this study, which uses AVT, was 1.5 years due to an
increase in the boiler differential pressure. After switching over to CWT, this increase was eliminated, which
meant the interval of chemical cleaning was extended.
Fig. 3.3.1-27 shows the trend of boiler differential pressure experienced by the Ulsan Thermal Power Plant of
Korea Electric Power Corporation after switching to CWT. The operation time till the pressure rose to the
acceptable limit was 9.5 years, whereupon chemical cleaning took place.
It is considered that the trend of the boiler differential pressure surge of the unit used in this study tends to
follow a path of gradual increase compared to that experienced in Ulsan Thermal Power Plant. However, with
certain allowances taken into consideration, it is estimated that it will take 9.5 years for the unit used by this study
to reach the allowable limit for differential pressure. The author, therefore, believes that the interval of chemical
cleaning for the unit can be extended from 1.5 to 9.5 years.
(ii) Assessment based on the Volume of Scales Deposited on Generation Pipes
The acceptance criteria for the chemical cleaning of boilers employed by this company is around 30 to
45mg/cm2 of scale deposited on generation piles unless other problems, such as abnormal boiler differential
pressure, are observed.
As indicated in 3.3.1.6-(3) Main Components of Boilers, the speed of the scales generated will be
0.5mg/cm21,000h.
Thus, the chemical cleaning intervals calculated from the scale generation speed are 10 to 15 years, based on
the conditions of the unit utilization ratio of 70% (30 to 40mg/cm2 0.5mg/cm2 1,000h 365 days 24 hours
0.7).
Based on the above arguments, in the case of other once-through boilers of supercritical pressure or above, for
which no boiler differential pressure need be considered, the author believes that the interval can be extended
from the current 1.5 to 4.5 years to 10 to 15 years.
d. Vibration of BFPs
In the case of the unit used in this study, BFPs were not subject to any vibration, even when using AVT, and
anti-vibration measures remained unconfirmed during the switchover to CWT. However, in the absence of any
waveform scales and the fact that the volume of scales was reduced to approx. one fifth compared to AVT, the
author believes that CWT can represent the ultimate measure against the vibration of BFPs.
e. Environmental Aspects
The use of CWT can eliminate chemicals used to treat feed water and regenerate condensate water desalination
units as well as effluents generated from the chemical cleaning of boilers, thus reducing effluent contamination
loads.
Based on these aspects, CWT can be considered an environment-friendly feed water treatment method.
232
(Legend)
The unit used in this
study
No. 4 unit of the Ulsan
Thermal Power Plant
Chemical cleaning
Time
Fig. 3.3.1-27: Differential Pressure of Boilers for the Unit used in this Study
and the No. 4 unit of the Ulsan Thermal Power Plant
233
Table 3.3.1-17: Annual Cost of the No. 1 Unit of the Chita No. 2 Thermal Power Plant
Item
Cost of Power Loss for BFPs
Cost of Functional Loss for High Pressure
Feed Heater
Cost of Installing a Boiler Chemical
cleaning System
Cost of Loss Transferred in relation to the
above
Cost of Chemicals for the Treatment of
Feed Water
Cost of Operating a Condensate water
Desalination Unit
Total
AVT
CWT
100
33
100
40
100
16
100
16
100
17
100
32
100
28
Economization
Ratio
Remarks
Incremental increase of steam used for driving the
BFPs (actual)
Deterioration of heat transfer performance (actual)
67
60
84
84
83
68
72
Daily
!
Turbidity
pH
Conductivity
Ca2+
Mg2+
Fe2+
Alkali ions
Frequency
Weekly Monthly
!
!
!
!
!
!
ClSO42HCO3-
!
!
!
!
!
!
!
Total iron
Residual chlorine
COD
Colloidal silica
Water temperature
Remarks
(CO2)
By
calculation
!
!
(Cl2)
!
!
!
shows a list of water quality monitoring items generally applied for maintaining and controlling the system, and
their measurement frequencies. The frequency must be increased whenever significant fluctuation is observed in
the quality of raw water, or a new water source is employed.
Table 3.3.2-2: Turbidity Assessment Indicators
Water Quality
Indicator
MF
MFC
Measurement Method
Characteristics
+t
(
MFC - 2 ln ) 1 , 1&
*t2 '
FI
(=SDI)
PI
PN
Turbidity
SS
100 + T1 (
)1 , &
15 * T2 '
Phenomenon
Cause
Inappropriate use of chemicals
Coagulation agent
Coagulation auxiliary agent
pH adjuster
Floc strength
Decrease in
amount of
obtaining
water
A slurry circulation type coagulation sedimentation unit requires the maintenance of slurry concentration at an
optimum level, while a sludge blanket type needs the sludge blanket to be kept stable. For both types, the key is
how to adjust the volume of chemicals used as well as that of the sludge discharged from the units. Even without
any dramatic fluctuation in the turbidity and alkali level of raw water, the water temperature varies seasonally,
with a lower water temperature leading to a deterioration in floc formation performance. Experience states that the
threshold temperature is at 10!C or so. If the temperature descends from this level, an auxiliary agent should be
increased to facilitate the floc formation. In the case of a coagulation filtration unit, high water temperature
excessively increases the size of the floc formed and when this happens, the volume of the auxiliary agent should
be decreased. When a separation membrane is used for the desalination unit, the water quality, including the
turbidity and FI (Fouling Index) at the outlet of a pre-treatment unit, must be maintained within the criteria
determined for them. Table 3.3.2-2 shows some examples of turbidity assessment indexes.
In many cases, the problems of a pre-treatment unit are mainly caused by insufficient regeneration of filter
layers due to contamination, which can sometimes be the result of mad balls and mechanical failure of the unit.
When problems involving the filtration unit surface, these can be identified by a deterioration in the quality of
processed water and reduction in the cyclic sampling volume. Table 3.3.2-3 shows the major problems anticipated
to occur with the pre-treatment unit and their measures.
3.3.2.1.3 Control of Deionized Water Generation Unit for Maintaining its Performance
As makeup water for a high pressure boiler requires highly pure demineralized water, the quality of the makeup
water must be controlled. Water treatment items for this purpose include electrical conductivity and silica, and an
indicator and recorder with an alarm are installed at the anion tower of a deionized water generation unit and at
the exit of a polisher to continuously monitor these items. Table 3.3.2-4 shows some examples of water quality
criteria for makeup water used at thermal power plants. The actual values measured by each company, as indicated
in the table, are 1.0S/cm and 0.01mg/l or below for conductivity and silica respectively.
The following items are examples of daily control items, which should be monitored daily at a fixed time if the
values are measurable:
! Operation cycles and collection volume per cycle
! Volume of regeneration agents used and stored
! Temperature when chemicals are injected to regenerate the anion exchange resin
! Inner pressure of each ion-exchange resin tower (before and after regeneration)
! Conductivity of water sampled at the inlet of a deionized water generation unit
! Conductivity of processed water
! Silica concentration in processed water
236
Ion-exchange resin should be controlled once a year to measure the total volume of resin replaced and volume
of neutral salt decomposed. At the same time, check the volume of ion-exchange resin remaining in each tower
and inspect whether the resin is finely-divided or not. As for the replenishment of ion-exchange resin, the volume
of resin to be replenished for cation resin is 5% -10% per year, including those finely divided, provided that no
swelling and/or contamination is observed. In the case of anion resin, the volume to be replenished comes to 10%
to 20% per year in general, because it is subject to aging besides the pulverization.
The troubles a deionized water generation unit may encounter mainly include decreased collection volume and
deterioration of the quality of processed water (incl. high conductivity and silica concentration). These problems
are often associated with pre-treatment unit troubles. Table 3.2.2-5 shows the cause of the troubles and their
measures as well as check items.
Table 3.2.2-4: Examples of Criteria set by Each Electric Power Company for
Water Quality at the Outlet of a Circulation Boiler Makeup Water Desalination Unit
Company Name
Pressure Category
(kgf/cm2)
Item
Conductivity (S/cm)
Silica (mg/l as SiO2)
A
100 Class
5 or below
0.05 or
below
130 Class
B
170 Class
100 Class
1.25 or below
0.015 or
below
130
Class
5 or below
0.01 or
below
0.1 or
below
0.05 or
below
C
170
Class
100
Class
3 or
below
0.02 or
below
5 or
below
0.1 or
below
130
Class
170
Class
1.0 or below
0.015 or below
Table 3.2.2-5: Troubles (reduced collection volume and decreased purity of processed water)
of a Deionized Water Generation Unit, Their Causes and Measures
Root Cause
Change in Raw Water
Quality
Oversampling
Incomplete
regeneration
237
Measure
! Conduct a total analysis of the raw water and file the data every
month (Conductivity must be measured and recorded every
month).
! Check the water sources.
! Adjust the ratio of water intake from various water sources.
! Compare the data with that of an instantaneous flow meter.
! Operate by uplifting the water flow.
! Refer to the instruction manual attached to the instrumentation
unit.
! Compare the data with that of a portable water quality meter,
etc.
! Connect a resistance box attached to the unit to a cable in lieu
of a communicator. If the values coincide with each other, then
the communicator is damaged.
! Refer to the instruction manual attached to the instrumentation
unit.
! Sampling valve is too far closed or totally closed.
! Sampling valve is too open.
! Damages or water leakage to the communicator case.
! Regenerate the volume specified in the instruction manual. (Or
increase the level of regeneration)
! Feed chemicals at an appropriate concentration.
! Repair the damaged pipe.
! Failure of a chemical feed pump
! Clogs of ejectors and nozzles
! Excessive decrease of the diluted water flow rate
! Backwash for more than 30 minutes.
! Check and remove clogs from the lower water collection and
dispersion unit.
Root Cause
Incomplete
regeneration
Flow-out of
ion-exchange resin
Contamination of
ion-exchange resin
Channeling
Measure
! Measure the specific gravity of regeneration effluents
(to confirm whether the extrusion force is sufficient or not)
! Analyze the washing effluents
(to confirm whether the concentrations of Cl" of the H tower
and Na+ of the OH tower are the same as those in their inlet
position)
! Make the total time for chemical injection and for extrusion at
least the same as those designated
! Make the temperature of chemical injection as 35r5!C
(if the temperature is lower than this, silica will leak out and if
it is higher, then the resin performance will be deteriorated)
! Readjustment of chemical injection volume and slip water
volume
! Replacement of the mixture of resins in the middle position
! Check the backwashing speed
! Check the water temperature
! Repair the damaged parts
! Conduct a functional test of resins (coarseness distribution,
etc.)
! Valve failure
Iron Solubility
Iron Concentration
the air cooling zones of a condensing unit and nickel plated copper alloy cooling water pipes are laid around the
exterior of the unit.
Solubility
Iron Concentration
in Feed Water
Temperature
Saturation solubility
of Cu(OH)2 in
deionized water
Solubility
Saturation solubility
of CuO in deionized
water
Concentration
(Iron)
(Copper)
(Nickel)
Fig. 3.3.2-3: Shift in Metal Ion Concentration due to a Change in the Feed Water pH
water is close to zero under normal operation, thanks to the upgraded performance of a deionized water generation
unit. However, in the case of seawater leakage, dissolved salts slip into the system. Depending on which materials
are used for the feed heater pipes, namely copper alloy or steel, the means used to control pH to prevent corrosion
of the materials vary. In the case of copper alloy, the pH control mainly targets copper and the value is limited to 9
or so, because dissolved copper ions accelerate the corrosion of iron. The slight volume of ammonia generated by
thermal decomposition of the hydrazine used as a deoxidizer is used to control the pH. Fig. 3.3.2-2 shows a
behavior model of iron in condensate water and feed water systems. The higher the temperature rise, the more iron
ions are generated. Around a high pressure feed heater, the iron ion concentration goes beyond the iron solubility
curve meaning ion deposits are generated. The iron is then deposited in the high temperature zones of high
pressure feed heaters, economizers, boilers and other units. In order to prevent such scales from being deposited, it
is important to minimize the iron ion volume. Fig. 3.3.2-3 shows a change in the iron ion concentration in a course
of a shift in the pH of feed water. As indicated, the pH should be kept high. Fig. 3.3.2-4 shows the solubility of
magnetite (Fe3O4), a corrosion coating. In the high temperature zone, the curve bottoms out at a pH level of
around 10. As iron ions tend to accelerate its oxidization under the existence of dissolved oxygen, hydrazine is
added to the feed water to remove oxygen, so that the generation of dissolved oxygen can be minimized.
N2H4+ O2+2H2O
A unit using steel pipes is subject to a control pH at around 9.5. Ammonia is directly added to the outlet of a
condenser or deaeration unit as a pH adjuster, and hydrazine is added at the outlet of a deaeration unit as a
deoxidizer respectively.
(3) Boiler Water
Most substances dissolved in boiler water are separated out as the temperature rises, due to the low solubility
and known as scale and sludge. This scale and sludge has low thermal conductivity, causing thermal efficiency to
deteriorate and corroding the boiler generation pipes. With this in mind, the generation of scales and sludge must
be avoided as far as possible. As shown in Fig. 3.3.2-3, the pH of the boiler water must be retained high to prevent
corrosions of generation pipes. Silica contained in boiler water flows out to the steam side and is separated out on
the turbine blades as scales, causing the efficiency of the unit to deteriorate. Therefore, silica concentration must
be minimized as far as possible.
Table 3.3.2-6: Feed Water Quality
Feed Water
Category
[Drum Type]
Max. Operating Pressure (MPa or kgf/cm2)
Evaporation Rate of the Heat Transfer Surface
(kg/(m2 h))
Types of Makeup Water
pH (at 25!C)
Hardness (mgCaCO3/l)
(mg/l)
Dissolved Oxygen (mgO/l)
Iron (mgFe/l)
Copper (mgCu/l)
Hydrazine (mgN2H4/l)
Conductivity ("S/cm) (at 25!C)
10 - 15
(100 - 150)
-
15 20
(150 200)
-
Ion-exchange water
8.5 9.6
0
Ion-exchange water
8.5 9.6
0
0.007 or below
0.03 or below
0.01 or below
0.01 or above
0.5 or below
0.007 or below
0.02 or below
0.005 or below
0.01 or above
0.5 or below
15 - 20
(150 - 200)
20 or above
(200 or above)
Volatile
Oxygen
Substance
Treatment
Treatment
9.0 9.6
6.5 9.0
0.25 or below
0.2 or below
0.007 or below
0.02 0.2
0.01 or below
0.01 or below
0.002 or below
0.002 or below
0.01 or above
0.02 or below
0.02 or below
Feed Water
Category
[Once-through Type]
Max. Operating Pressure (MPa or kgf/cm2)
Treatment Method
pH (at 25!C)
Conductivity ("S/cm) (at 25!C)
Dissolved Oxygen (mgO/l)
Iron (mgFe/l)
Copper (mgCu/l)
Hydrazine (mgN2H4/l)
Silica (mgSiO2/l)
Volatile
Substance
Treatment
8.5 9.6
0.3 or below
0.007 or below
0.02 or below
0.003 or below
0.01 or above
0.02 or below
240
Oxygen
Treatment
6.5 9.0
0.2 or below
0.02 0.2
0.1 or below
0.05 or below
0.02 or below
Category
Boiler Water
10 - 15
(100 - 150)
-
15 - 20
(150 - 200)
Ion-exchange water
Ion-exchange water
All volatile
treatment
8.5 9.6
-
Sodium phosphate
treatment
8.5 9.8
-
pH (at 25!C)
Oxygen consumption (pH at 4.8) (mgCaCO3/l)
Sodium phosphate
treatment
8.5 9.8
-
60 or below
2 or below
0.1 3
-
20 or below
1 or below
60 or below
20 or below
2 or below
1 or below
0.1 3
0.3 or below
8.5 9.6
-
0.2 or below
Criteria
0.3 or below
0.02 or below
Table 3.3.2-9: Facility Outline of Unit Nos. 1 to 4 Units of the Nishi Nagoya Thermal Power Plant
Unit
Output
Operation started in:
Boiler type
Turbine steam pressure
No. 1 Unit
220 000 kW
July 1970
Reheating natural
circulation type
169 kg/cm2G
No. 2 Unit
220 000 kW
December 1970
Reheating natural
circulation type
169 kg/cm2G
No. 3 Unit
375 000 kW
July 1972
Reheating natural
circulation type
169 kg/cm2G
No. 4 Unit
375 000 kW
September 1972
Reheating natural
circulation type
169 kg/cm2G
(4) Steam
Impurities contained in steam are those carried over from the boiler water, which cause corrosion of superheater
systems and the deposition of scales onto turbine blades. Such impurities include chlorine ions, sodium, silica and
copper. Fig. 3.3.2-8 shows their JIS criteria.
241
As success in steam quality control is significantly dependent on the boiler water quality, for a drum type boiler,
the conductivity of boiler water and its silica content, and - for a once-through boiler - those of feed water at the
inlet of an economizer should be carefully monitored.
Drum
Deaeration unit
Flush
tank
Condenser
Conden
sate
water
pump
Ground
steam
condenser
Flush valve
Flush pipe
drain tank
Makeup
water
tank
Makeup water
pump
Flooding pipe of boiler
Sampling point
Boiler
water
Drum water
Conductivity
"S/cm
Conductivity
"S/cm
pH
Conductivity
"S/cm
Total iron
Total copper
Dissolved
oxygen
"g/l
"g/l
Conductivity
"S/cm
Total iron
Total copper
Dissolved
oxygen
Total iron
Total copper
"g/l
"g/l
Criteria
Measurement
Method
Measurement
instrument
Measurement
instrument
Anytime
Measurement
instrument
Once a year
Once a year
Measurement
instrument
Measurement
instrument
Once a year
Once a year
"g/l
"g/l
"g/l
pH
Conductivity
"S/cm
Total iron
Total copper
Hydrazine
"g/l
"g/l
"g/l
pH
Conductivity
"S/cm
Silica
"g/l
Phosphate
ion
Total iron
Total copper
"g/l
Control Item
Unit
"g/l
All volatile
treatment
1.5 >
Phosphate
Treatment
Same as left
Normal Operation
Value
ANN
Value
0.5 1.0
1.5
0.15
0.5
8.6 9.0
Same as left
8.8
0.3 >
Same as left
0.15
0.3
(10 >)
(5 >)
Same as left
Same as left
10
3
*
*
40 >
Same as left
10
40
12
(10 >)
(10 >)
Same as left
Same as left
10
5
*
*
Anytime
7>
Same as left
Once a year
Once a year
Measurement
instrument
Measurement
instrument
Once a year
Once a year
Anytime
Measurement
instrument
Measurement
instrument
Measurement
instrument
*
*
*
*
10
5
*
*
8.6 9.0
Same as left
8.9
8.9 9.0
0.3 >
Same as left
0.15
0.3
10 >
10 >
(10 30)
Same as left
Same as left
Same as left
10
5
10
*
*
*
8.6 9.0
8.6 9.5
8.7
8.6 9.5
Anytime
"g/l
"g/l
0.3 >
15 >
1.5
0.2 >
0.2 >
0.05
0.2
3>
03
Once a year
*
(50 >)
20 50
Once a year
*
(20 >)
5 - 15
Measurement
Conductivity
0.03 >
*
0.1
Steam at the inlet of
"S/cm
instrument
Steam
superheater
Silica
Anytime
0.02 >
*
0.005
"g/l
Note 1: The figures in parentheses refer to the values that should be maintained.
Note 2: The figures prefixed with refer to the value after the treatment of cation resins.
Note 3: The pH level of the boiler water is 8.5 to 9.0 after all volatile treatment and 8.5 to 9.5 after the injection of sodium tertiary phosphate.
243
*
*
0.3
*
244
Ignition Temperature up
Pressure
up
vacuum up
Switchover of burners
Startup of turbines
Turning on of a
disconnect
switch
Parallel in
Switchover within
the plant
Load dispatching
operation
Check item
Operation item
Main steam pressure
Operation check
Ignition and
temperature/pressure up
Startup of condenser
Water quality check
Start up of the feed pump
Start injection of hydrazine
Parallel in
Up of vacuum
Startup of turbines
[Dissolved Oxygen]
(Condensate water)
The concentration of dissolved oxygen falls alongside the
vacuum up in the condenser.
(Feed Water)
The dissolved oxygen concentration declines alongside the
surge of pressure of the deaeration unit.
Condensate water
Feed water
245
[Silica]
When turbines are started, silica scale deposited on the low
pressure blades comes off. (Part of the silica scale comes
from the dead space of the pre-boiler system.)
The silica concentration comes down as the blow
operation starts.
Boiler water
[pH]
(Feed Water)
Due to the injection of hydrazine at system ignition, the pH
level rises.
(Boiler Water)
Due to the injection of hydrazine at system ignition, the pH
level of the feed water rises, as well as that of the boiler
water.
[Conductivity]
(Condensate water)
When the system is subject to a parallel off, the
conductivity of the condensate water rises due to the
influence of carbon dioxide gas contained in the air, but
falls as the degree of vacuum increases.
(Feed Water)
Similar to condensate water, the level falls as the degree of
vacuum increases. However, the downward curve tends to
be moderated for about 1 hour from the parallel in point
because of contamination of the feed water, condensate
water and the whole system.
(Saturated Steam)
For about 1 hour from the juxtaposition point,
contamination of boiler water is conspicuous. Due to this,
the level of conductivity tends to peak due to a carryover
and for other reasons, before subsequently following a
moderate downward course.
Feed water
Boiler water
Condensate water
Feed water
Saturated steam
Fig. 3.3.2-6: Standard Startup Command (Operation) Sheet and Startup Water Quality
Up loads (100MW)
Fig. 3.3.2-11 Methods of Blow Except the Boiler Water System at Startup
Boiler water blow is implemented until water quality of the eco inlet, the boiler, and the
saturated steam is at the standard value or less, and the conductivity at the CP outlet
shows a declining trend (0.5 to 0.6"S/cm).
Silica
Conductivity
Eco inlet
or less
Boiler water
or less
Saturated steam
or less
Boiler water blow stop
(ANN of silica and conductivity
Conductivity
CP outlet
0.5 or less
Shall be on a down note.
The silica concentration in boiler water sometimes exceeds the standard value (0.2mg/l) when the boiler is
sealed (steam sealing) after the unit shut down. The cause seems to be the fact that when the boiler is stopped and
sealed, silica scale separates from the turbine blades, etc., is channeled to the boiler and concentrated when it is
started. To reverse such situation, the following measure is implemented while the boilers are sealed in order to
avoid boiler blow loss and gaining load up during the early stages. When the level of water in a condenser goes up
while the boilers are sealed, the silica concentration in condensate water is measured. If the value is 0.02 mg/l or
more, water is added to the condensate water after total blowing, whereupon the system is started. Following the
implementation of the measure, no abnormal silica concentration up was reported.
(3) Water treatment at Seawater Leakage
It is essential to detect any seawater leakage at an early stage to implement measures. The means of controlling
water quality depends on the seriousness and conditions of the leakage, with appropriate water control measures
sought. For this purpose, conductivity is measured within the condenser, at the outlet of the condensate pump, the
inlet of an economizer and in the boiler water. When the value is found to be high, seawater leakage is present.
Two lines of cation resin towers are installed at the front stage of the condenser and the conductivity meter at the
outlet of the condensate pump, so that the letup time for replacing the resin can be minimized, in the case of
emergencies such as seawater leakage. How to inject chemicals and how to blow boiler water are determined as
controlling water quality in the event of seawater leakage. Also, in a leakage, a process which requires prompt and
correct action is decided. For this purpose, a seawater leakage accident control sheet (Fig. 3.3.2-7) is used to cover
such items as operation method, actions done and restoration.
(4) Water treatment Values and Monitoring
Water quality during the normal operation time is monitored and checked for each specimen, using
pre-determined control items and the measurement frequency. All measurement values can be monitored by the
CRT and recorders of the central control room, where staff members are stationed to monitor during the normal
system operation. In the case of an accident, an alarm is activated. Accidents are handled referring to the measures
defined in Water Quality ANN Messaging Procedure (Fig. 3.3.2-12).
As water quality requires monitoring of long-term trends, a daily control sheet is formed. Appropriate and
stable operations of the unit are assured and good water treatment methods are established by collecting total
measurement data of iron and copper concentration and in-house inspection results obtained from a regular
inspection and other measures to ensure that water is appropriately treated.
246
3. Causal
investigation
1. Occurrence of an
accident
Conductivity high ANN turns on.
Causal investigation
Accident handling
Point of leakage
(1) Caustic silver check
(2) Switchover of thermometer
takeout points
S/cm of
recovery
water
0.3S/cm or below
15 or below
Restoration
measures
Repair completed
3 or below
Conductivity
("s/cm)
4. Restoration
measures
As low as possible
Turbine E-STOP push button ON
Note 1:
In order to avoid any stress corrosion cracks of SH and RH pipes, boilers should be subject to vapor washing when the unit is restored from seawater
leakage (at the turbine rotation of 3,600 rpm).
Note 2: Considering the working environment while only one condenser is in operation, the vacuum is set as 690 mmHg or above (according to a test result in
1980).
Reference information: The conductivity of condensate water was once seen to surge due to pinhole damage of the exterior housing of a condenser water pump.
Table 3.3.2-12: Check Sheet for Unit Nos. 1 to 4 Water Quality When ANN is Transmitted
1. Silica and Dissolved Oxygen
* Whether silica and dissolved oxygen concentration tend to be high
or not is checked by referring to the checksheet.
Check Item
Description
Cause
Silica
concentration is
high.
Makeup water
1.5S/cm or above for the makeup
c
water
10g/l or above at the outlet of the
makeup water desalination unit
Load
Load surged
(when silica is purged)
i
Measurement
The ANN of a measurement
d
instrument
instrument is transmitted.
The dissolved
oxygen
concentration is
high.
Load
Load decreased
e
Deaeration unit
Check the inner pressure of the
f
system.
Switchover of
Check whether any O2 is leaked or
g
the condensate
not by switching the condensate
pump
pump
Drain pump
Check whether any O2 is leaked or
g
not at the drain pump seal.
Measurement
The indication does not change
d
instrument
after switching the specimen
water.
2. High conductivity/CondenserHigh conductivity/Seawater
leakage at startup
Check Item
Description
Cause
Check the
The conductivity of the
relationship of the
condensate water and water in the
following:
system suddenly surges from the
a
Condensate water, normal level, followed by feed
feed water, boiler
water, boiler water, saturated
water, saturated
water. The makeup water is intact.
steam and
The conductivity of the makeup
makeup water in
water surges, followed by others
c
the system
such as condensate water.
Chloride ions
Adding caustic silver changes the
a
water turbid in white.
Measurement
Their conductivity fluctuates
d
instrument
separately.
3. Abnormal pH Level
Check Item
Description
Feed water pH
High (or low)
Boiler water pH
High
Low
Makeup water
There is considerable conductivity of
makeup water.
Chemicals
Chemical
Chemical concentration and type
concentration
Failure of pumps
Switchover test of injection pumps
Addition of
chemicals
Stroke and valve operations
Cause and Measures
Cause
a. Seawater leakage
Cause
b d
bdh
abd
c
Measures
See the section of seawater
leakage.
See Accident Action Procedure.
b. Adjust the injection volume.
a.
c.
Boiler capacity
Steam pressure
Steam temperature
Fuel used
(MW)
(t/h)
(kg/cm2)
(!C)
No. 1 Unit
600
August 1974
Reheated
once-through
type
1 900
246/42.1
538/566
LNG
No. 2 Unit
1 000
September 1975
No. 3 Unit
1 000
February 1977
No. 4 Unit
1 000
August 1979
Same as left
Same as left
Same as left
3 110
246/40.1
Same as left
Same as left
Same as left
Same as left
Same as left
Same as left
3 170
Same as left
Same as left
Same as left
d. Replenishment of Resins
Referring to the results of the performance check, resins are replenished to maintain the function of a
condensate water desalination unit at the appropriate level. The volume of resins replenished annually is 10% for
248
cation exchange resin and around 20% for anion exchange resin.
Table 3.3.2-14: List of Water Quality of Supercritical Pressure Through the Flow Boiler at Normal Times
Specimens taken
Makeup water
Outlet of a condensate
pump
(CP out)
Outlet of a condensate
water desalination unit
(CBP out)
Outlet of a
desalination unit
(Dea out)
Inlet of an economizer
(Eco in)
Analysis item
Conductivity
Silica concentration
Conductivity
Criteria
< 0.5 "S/cm
< 30 "g/l
< 0.5 "S/cm
Conductivity
Sodium concentration
Total iron concentration
Total copper concentration
Dissolved oxygen
concentration
pH
Conductivity
Total iron concentration
Total copper concentration
Hydrazine concentration
Silica concentration
9.3 to 9.6
< 0.25 "S/cm
< 5 "g/l
< 2 "g/l
< 10 "g/l
< 20 "g/l
Analysis item
Conductivity
Silica concentration
Iron concentration
Cooper concentration
Sodium concentration
Conductivity
Dissolved oxygen concentration
Dissolved oxygen concentration
Frequency
Once a month
Once a month
Once a month (once a week)
Once a month (once a week)
Once a month (-)
Once a month (once every three days)
Once a month (once every two weeks)
Once a month (once every two weeks)
pH
Once a month (once every three days)
Conductivity
Total iron concentration
Once a month (once every three days)
Total copper concentration
Once a month (once every three days)
Hydrazine concentration
Once a month (once every two weeks)
Silica concentration
Once a month (once every three days)
Main steam
pH
- (once every two weeks)
Conductivity
- (once every two weeks)
Silica concentration
- (once every two weeks)
Items in parentheses indicate the frequency of analysis within six months of the start of operation.
Table 3.3.1-16: List of Storage Methods when the Plant is Subject to Shutdown
Stop time
Boiler
Within 56 hours
Hot banking
Within 72 hours
More than 72
hours
(Hydrazine: 20 to 30
mg/l)
Dry storage after sealing
N2
(RH: Dry storage)
Deaeration unit
Condenser
In circulation mode
Dry storage
(Hydrazine: 20 to
30 mg/l)
Storage by sealing N2
or by filling water
(Hydrazine: >300
mg/l)
(2) Water treatment at Startup and while the Unit is not used
a. Water treatment while the Unit is not used
The most important thing in water treatment while the unit is not used is to minimize the inclusion of exterior
air inside the system to prevent corrosion. The following three measures are conducted for this purpose:
(1) Hot banking that puts a boiler under a pressurization condition to eliminate the inclusion of exterior air
(2) After a boiler has cooled down, a high concentration of hydrazine is infused to minimize the area
contacting with air, while also helping remove the dissolved oxygen from the contact area.
(3) After a boiler comes to a stop, boiler water is purged and blown out by pressurized nitrogen while keeping
the boiler temperature at 100 or above to keep it in a dry condition.
249
Fig. 3.3.2-16 shows how to store the plant when it is not in use. The table categorized the storage method by the
period of storage. In the case that the planned short time storage is subject to change in the longer storage period,
the storage method for the plant must be changed. Sampling racks are stored by closing the valves and after filling
with deionized water.
b. Water treatment at Startup
Before starting the plant, it is subject to a cleanup process by dividing the system into 3 blocks of condenser,
feed water system and boilers respectively. The controlled items for this purpose include, for a cold cleanup
process, iron and mill scales, etc., with those that are generated during the time the plant is not in use analyzed. To
check the iron concentration, two methods are used; the membrane filtration and automatic measurement methods.
The former compares the color of the filter after filtration of sample water with the standard color, while for the
latter, an iron meter of the particle counting method or the scattered light method is used. The control criteria of
the iron concentration is set as 300 g/l or below as a target, while Fig. 3.3.2-17 shows other water control criteria.
In addition, the injection of ammonia and hydrazine, etc. is possible to combat corrosion of the system and
maintain the quality of water in the systems at the appropriate level. In injecting chemicals, Mode PB on the
sampling rack is selected. Fig. 3.3.2-18 shows a worksheet of a chemical feed unit.
In the Sodegaura Thermal Power Plant, a patterned operation is used for the blowing time and chemical
injection in order to control iron concentration, etc. at the appropriate level. The pattern was formed based on the
experience of the plant. More recently, more plants have been able to automatically control and operate water
treatment and chemical injection using a computer. In the Sodegaura Thermal Power Plant, the iron concentration
of feed water at the inlet of an economizer after ignition of the plant is controlled to 50g/l or below as a target.
The criteria for collecting drain water generated by each process is, 300g/l or below for iron collected by a
condenser, and 50g/l or below for that collected by a feed water system.
250
Table 3.3.2-17: List of Water Quality of a Supercritical Pressure Through a Flow Boiler at its Startup
Startup process
Surge of condenser vacuum
Sampling at:
-
Analyzing item
-
CP out
Dea out
CP out
WW out or SH
out
Eco in
WW out
Humidified circulation
Drain water
collection
Collection by condenser
Collection by condensate
water and feed water systems
Eco in
WW out
Eco in
pH
Conductivity
pH
Conductivity
Total iron concentration
Total copper concentration
Dissolved oxygen concentration
Silica concentration
Conductivity
pH
Total iron concentration
Total copper concentration
Silica concentration
Total iron concentration
Total iron concentration
Criteria
Condenser Vacuum
> 680 mmHg
< 300 "g/l
< 10 "g/l
< 300 "g/l
< 10 "g/l
9.2 to 9.6
< 100 "g/l
< 50 "g/l
< 300 "g/l
< 10 "g/l
9.2 to 9.6
< 1.0 "s/cm
< 50 "g/l
< 10 "g/l
< 10 "g/l
< 30 "g/l
9.2 to 9.6
< 1.0 "g/l
9.2 to 9.6
< 1.0 "s/cm
< 50 "g/l
< 10 "g/l
< 10 "g/l
< 30 "g/l
< 1.0 "s/l
9.2 to 9.6
< 50 "g/l
< 10 "g/l
< 30 "g/l
< 300 "g/l
< 50 "g/l
251
Circulation of
condensate water
PB process
Normal operation
Stop
Hot banking
DO: 50 ppb
or below
10 ppb or above
High
pressure
heater
Low
pressure
heater
N2H4: 10 ppm or
above
Storage method
Hot
banking
Ordinary
storage
Stop
Kick signal
Ammonia pump
Stroke length
control
Injection of a high
concentration of hydrazine
for 4 hours
Constant value control of conductivity at the inlet of a deaeration unit with the
conductivity at the outlet of a demister as a preceding signal
RPM control
Injection of a
constant volume
Stroke length
control
Constant value control of conductivity at the inlet of a deaeration unit with the
conductivity at the outlet of a demister as a preceding signal
RPM control
Injection of a
constant volume
Stroke length
control
Ammonia
In proportion to the
condensate water flow
Injection of a constant
volume (CONC)
In proportion to the
condensate water flow
Injection of a constant
volume (CONC)
Open
Hydrazine
Hydrazine pump
As above
Stroke length
control
Open
Open
Outlet of a
condensate water
desalination pump
Conductivity
(S/cm)
[Cationic
conductivity]
< 0.5
0.5 to 3.0
< 0.1
0.1 to 3.0
> 3.0
> 0.3
> 0.15
> 0.1
Chlorine
Ion
(mg/l)
Determination
of Leakage
Normal
Minute
leakage
Significant
leakage
Significant
leakage
How to Operate a
Desalination Unit
H Type:
NH4 Type:
H Type:
NH4 Type:
H Type:
-
1
2
2
1
3
252
To the outlet of
HPHTR
From HP 1HTR
From HP2HTR
To the
boiler
blow
tank
LP-HTR
Drain P
To the boiler
blow tank
Drain tank
Steam A
and B
253
From the
outlet of
CBP
To the
startup
LP.HP HTR Drain
effluent pit
Fig. 3.3.2-8: Water Treatment Flow Chart of the No. 1 Unit of Kawagoe Thermal Power Plant
To the startup
collection pit
NH4 Type
H Type
Conductivity
Sodium ion concentration
384 000
35 000
0.15
5.0
(m3)
(m3)
("S/cm)
("g/l)
e. Drain Collection
Drain is blown to the outside of the system at the same time with the startup of the feed water heater. Drain of
the low-pressure feed water heater is collected to the condenser when the iron concentration becomes 500 "g/l or
less. Moreover, when the iron concentration becomes 50 "g/l or less, it is collected to the condensate water pipe.
Similarly, drain of the high-pressure feed water heater is collected to the condenser when the iron concentration
becomes 50 "g/l or less. When the iron concentration becomes 50 "g/l or less, it is collected to the deaerator.
254
Fig. 3.3.2-21: Stoppage Patterns (Category) and How to Store each Component
Stoppage
Category
Component
Stop time
Boiler stop
condition
Condenser
vacuum
Within 72 hours
Normal stop
Forced cooling
Normal stop
72 hours to 1 week
Forced cooling
1 week or longer
Normal stop
Forced cooling
Retained
Destructed
Retained
Destructed
Retained
Destructed
Retained
Destructed
Boiler body
Hot bank
When the pressure is
decreased
Pressurized sealing of
N2
Same as left
Pressurized sealing
of N2
Same as left
Hot bank
After decreasing the
pressure, the boiler is
filled with 100mg/l of
hydrazine for storage.
Storage after
filling 100mg/l
of hydrazine
Hot bank
After decreasing the
pressure, the boiler is
filled with 200mg/l of
hydrazine for storage.
Pre-boiler
Same as left
Same as left
Same as left
Same as left
Like the case of a
boiler, the pre-boiler is
filled with 100mg/l of
hydrazine for storage.
Storage after
filling 100mg/l
of hydrazine
Same as left
Like the case of a boiler,
the pre-boiler is filled
with 200mg/l of
hydrazine for storage.
Deaeration unit
Hot bank
When the pressure is
decreased
Pressurized sealing of
steam or N2
Same as left
Pressurized sealing
of N2
Same as left
Hot bank
Like the case of a
boiler, the pre-boiler is
filled with 100mg/l of
hydrazine for storage.
Storage after
filling 100mg/l
of hydrazine
Hot bank
Like the case of a boiler,
the pre-boiler is filled
with 200mg/l of
hydrazine for storage.
Same as left
Same as left
Same as left
Same as left
Like the case of a
boiler, the pre-boiler is
filled with 100mg/l of
hydrazine for storage.
Storage after
filling 100mg/l
of hydrazine
Same as left
Like the case of a boiler,
the pre-boiler is filled
with 200mg/l of
hydrazine for storage.
Cleanup
Circulation continued
Same as left
Same as left
Same as left
Same as left
Like the case of a
boiler, the pre-boiler is
filled with 100mg/l of
hydrazine for storage.
Storage after
filling 100mg/l
of hydrazine
Same as left
Like the case of a boiler,
the pre-boiler is filled
with 200mg/l of
hydrazine for storage.
Retained under
vacuum condition.
Valve is closed like
during normal
operation.
Pressurized
sealing of N2
Same as left
Retained under
vacuum condition.
Same as left
Pressurized
sealing of N2
Same as left
Same as left
Same as left
Same as left
After decreasing
the pressure, the
boiler is filled
with 200mg/l of
hydrazine for
storage.
After decreasing
the pressure, the
boiler is filled
with 200mg/l of
hydrazine for
storage.
After decreasing
the pressure, the
boiler is filled
with 200mg/l of
hydrazine for
storage.
After decreasing
the pressure, the
boiler is filled
with 200mg/l of
hydrazine for
storage.
After decreasing
the pressure, the
boiler is filled
with 200mg/l of
hydrazine for
storage.
Same as left
Same as left
Same as left
Same as left
Same as left
255
Condensate
water
Blowing
Circulation
Deaeration
unit
Blowing
Circulation
Pre-boiler
Boiler
Blowing
Water quality
measurement
point
Outlet of a
condensate
pump
Outlet of a
condensate
pump
Outlet of a
deaeration
circulation
pump
Outlet of a
deaeration
circulation
pump
Pre-boiler
cleanup pipe
pH
9.8
9.4
to
9.7
0.15 or
below
9.5
to
9.7
0.50 or
below
9.5
to
9.7
0.50 or
below
9.5
to
9.7
0.50 or
below
Circulation
Pre-boiler
cleanup pipe
9.5
to
0.7
0.50 or
below
Blowing
Outlet of a
water separator
0.50 or
below
Circulation
Outlet of a
water separator
9.5
to
9.7
9.5
to
9.7
0.50 or
below
0.200
0.050
(Outlet of a
condensate water
booster pump)
0.500
0.10 or
below
0.200
0.050
0.500
0.10 or
below
0.200
0.050
0.500
0.10 or
below
0.200
0.050
Scope of
cleanup
Remarks
From a
condenser
to the inlet
of a low
pressure
feed water
heater
From a low
pressure
feed water
heater to a
deaeration
unit
From the
outlet of a
deaeration
unit to a
high
pressure
feed water
heater
From the
outlet of a
high
pressure
feed water
heater to a
boiler
Sampling
Sampling
valve
Resin tower
Conductivity
meter
Flow meter
Resin tower
Sampling
Sampling
valve
Return valve
Condensate water
pump
For this reason, when seawater leakage is detected, its remaining capacity is checked immediately. During normal
operation, an ammonia type sampling is switched to H type sampling, on a par with the volume of leakage, and
the standby tower starts operation. With these measures, loads are reduced as soon as possible to contain the
volume of seawater slipping into the system. Table 3.3.2-14 shows the actions taken for a 1,000MW class boiler.
Lower than
6
Rated
load
Lower
than3
6 or above
3 or
above
10 or
above
5 or
above
20
10
Actions Taken
Actions for Operation
1. To strengthen
monitoring by
monitoring
instruments
2. Determination of the
location and degree of
leakage
3. Examination for
starting operation and
inspection plans
1. One condenser
operation
(To stop damaged
condenser and to
operate the intact
condenser
continuously at the
1/2 load)
2. To confirm that the
conductivity at the
outlet of CP, etc., has
decreased
1. Reduction or stop of
the spray flow rate for
a superheater and
reheater
2. To reduce load
1. To stop the unit in
principle
Chemical Injection
1. Continuous blowing
a. To be done
immediately after
detecting seawater
leakage
b. Intermittent blowing
depending on the
leakage conditions
(manual inspection,
etc.)
2. Blowing of condensate
water
a. To be done
depending on the
leakage conditions
1. Continuous blowing
To be done
continuously
2. Rapid blowing
To be done in the case
that water quality check
revealed it necessary
(Openness: 10% to
15%)
3. Blowing of condensate
water
To be done
continuously
(Fully open in
principle, but subject to
adjustment depending
on conditions)
1. Total boiler blowing as
necessary
1. Chemical injection
to boilers
a. To inject 10l of
sodium tertiary
phosphate to the
drum when
continuous
blowing starts
b. To inject an
appropriate
volume of sodium
tertiary phosphate
so that the pH
level of boiler
water can be
maintained at
around 9.5
2. Chemical injection
to feed water
a. To switch
hydrazine
injection from
automatic mode
to manual mode
(Target: pH of
feed water to be
around 8.8)
* As seawater
elements causes
an uplift of
conductivity, it is
not possible to
control the pH
level by adjusting
it.
Others
1. To close the
condensate water
return valve
connected to a
distilled water
tank
2. To conduct a
water-pressurized
leak check
1. To check and
repair the
damaged
condenser while
operating the
intact one
(Inspection using
a vinyl sheet)
Cl-Concentration
of Condensate
water
0.3 ppm or
above
0.5 ppm or
above
1. To check and
repair the
damaged
condenser
1.0 ppm
which water heated up in a heat exchanging process is evaporated in a cooling tower to be cooled by discharging
evaporative latent heat for use in recycling, and a closed circulation type, in which heated water is cooled down in
a cooling water cooler using seawater. A large capacity power generation plant in Japan uses the closed circulation
type, which can then be categorized into systems where bearing cooling water tanks are installed and those using
stand pipes. Recently, the latter has been frequently used because of the ease of water treatment.
These component cooling water systems incorporate an oil cooler that cools down the lubricants used for
turbine rotors, etc., a hydrogen cooler that is used for cooling generator and a coolant cooler. These units are made
of aluminum brass. Controlling the water quality of such component coolants should involve consideration of the
selection of an appropriate coolant circulation method and the use of steel, copper and copper alloys. Based on
such views, the water treatment of component coolants involves the introduction of anti-corrosion agents into the
coolants, in order to prevent the corrosion of the heat exchanger cooling pipes as well as other pipes, in turn, to
prevent scale deposits on the heat exchanger and avoid deterioration of its heat exchanging function.
Chemicals Used
Water Quality
Treatment Periods
Results of Effects using a Test
Piece
Result of a Regular Inspection
20,000 m3/h
13,000 m3
8!C
2.5 times
Initial injection:
Anti-corrosion agent:
Kurizetto S370 (polymer phosphate series)
400mg/l
Anti-scaling agent:
Kurizetto T225 (polymer series)
200mg/l
Normal operation:
Alkali treatment agent:
Kurizetto S113 (phosphate - polymer series)
40mg/l
Chlorine treatment:
0.5 to 1.0mg/l(Cl2) 3 h/day
Slime control agent:
Polyclin A496 (nitrogen compounds - polymer series)
50mg/l month
Sand filtration:
3% (against circulation water volume)
Makeup water
2
8.1
350
170
180
20
31
7
Turbidity (degree)
pH (at 25!C)
Conductivity (S/cm)
Calcium hardness (CaCO3 mg/l)
M alkali level (CaCO3 mg/l)
Chloride ion (Cl-mg/l)
Sulfate ion (SO42-mg/l)
Silica (SiO2 mg/l)
7 years
Corrosion rate (SPCC) [mdd]
Circulation water
5
9.0
1 000
380
400
63
79
18
3 to 4
A small volume of scales and sludge was observed in several low speed heat exchangers, but other heat
exchangers were in good condition without any corrosion scales, slime and sludge damage.
Unlike highly hard water, water with low calcium hardness tends to require an increased concentration of
anti-corrosion chemicals and it is necessary to raise the concentration of anti-corrosion agent to 10 to 15
mg/l(T-PO4) under the calcium hardness of around 100 mg/l(CaCO3) and 15 to 20 mg/l(T-PO4) in the case of 50
mg/l (CaCO2). This is because the phosphate series anti-corrosion agent is influenced by dianoinic metals, such as
calcium ions, and because the combined use of phosphate and zinc salts with a strong coating forming
performance can achieve good anti-corrosion performance, even if the concentration of anti-corrosion chemicals
is kept to a low level. In a low hardness cooling water system, scales such as calcium phosphate can be formed in
a high temperature zone, and anti-scaling agents, such as acrylic acid series polymers and maleic acid series
polymers, are generally used in combination with these chemicals. In an open circulation type cooling system,
operation under a high concentration of chemicals to save the volume of water can thicken nutrients contained in
the water and within such an environment, microbes can pullulate and slime be formed relatively easily. In order
to prevent this, measures are taken by sterilizing the microbes and adding anti-slime agents that are effective in
curtailing the reproduction of the same. For such purposes, the hypochlorites and cyanurates previously used have
been recently replaced by carbonyl series compounds with no corrosion effects. Tables 3.3.2-24 and 3.3.2-25 show
examples of water quality treatment at open circulation type cooling systems.
Table 3.3.2-26 shows the water quality analysis items and frequency of analysis that are usually used for the
operating control of an open circulation type cooling system, while Table 3.3.2-27 shows the significance of these
water quality analysis items.
Table 3.3.2-25: Example of Water Quality Treatments to a Low Hardness Cooling Water System
Operation Condition of Cooling
Tower
Chemicals Used
Water Quality
Treatment Periods
Results of Effects using a Test
Piece
Result of a Regular Inspection
5 000 m3/h
2 400 m3
12!C
3 times
400mg/l
100mg/l
Normal operation:
Anti-corrosion agent:
Kurizetto S603 (phosphonates, phosphates and zinc salts)
50mg/l
Anti-scaling agent:
Kurizetto T225 (polymer series)
30 mg/l
Chlorine treatment:
Polyclin A411
0.3 to 1.0mg/l(Cl2) 3 h/day
Sand filtration:
3% (against circulation water volume)
Makeup water
2
7.2
100
24
23
5
6
6
Turbidity (degree)
pH (at 25!C)
Conductivity (S/cm)
Calcium hardness (CaCO3 mg/l)
M alkali level (CaCO3 mg/l)
Chloride ion (Cl-mg/l)
Sulfate ion (SO42-mg/l)
Silica (SiO2 mg/l)
8 years
Corrosion rate (SPCC) [mdd]
Circulation water
7
7.9
254
72
47
18
15
15
3 to 5
Corrosion, scale and slime were hardly observed and the result was very good.
Table 3.3.2-26: Water treatment Items and Analyzing Frequency for Operation Control of an Open Circulation
Type Cooling System (Standard)
Frequency of Analysis
Makeup Water
Circulation Water
Once a week
Once a week
Once a week
Once a day
Once a week
Once a day
Once a week
Once a week
Once a week
Once a week
Once a week
Once a week
Once a week
Once a week
Once a week
Once a month
Once a month
Once a day
Analysis Item
Turbidity
pH
Conductivity
M alkali level
Calcium hardness
Chloride ion
Sulfate ion
Silica
Total iron
Residual chlorine
CODMin
Anti-corrosion agents
(degree)
(at 25!C)
(S/cm)
(CaCO3 mg/l)
(CaCO3 mg/l)
(Cl-mg/l)
(SO42-mg/l)
(SiO2 mg/l)
(Fe mg/l)
(Cl2 mg/l)
(O mg/l)
(mg/l)
There are several ways to monitor the effectiveness of an anti-corrosion agent, the representative methods of
which include (1) measuring the corrosion speed of a test piece, (2) measuring the corrosion speed using a
corrosion measurement device using a polarization resistance method (an electrochemical method), (3) confirming
the conditions of corrosion and erosion depth on the heat transfer surface of a pipe using a heat exchanger for
260
monitoring purposes. The use of a test piece or a corrosion measurement device to measure the corrosion speed
cannot confirm the corrosion conditions on the heat transfer surface, in which case a heat exchanger for
monitoring purposes can be used. However, this method is not generally used, because the conditions of pipes
cannot be confirmed during test periods (normally 1 to 3 months) and because it requires significant plant and
operation control costs.
Table 3.3.2-27: Significance of Each Water Quality Analysis Item
Item
pH
(at 25!C)
Conductivity
(S/cm)
Turbidity
(degree)
M alkali level
(CaCO3 mg/l)
Calcium hardness
(CaCO3 mg/l)
Chloride ion
(Cl-mg/l)
Sulfate ion
(SO42-mg/l)
Silica
(SiO2 mg/l)
Ammonium ion
(NH4+/l)
Consumption of oxygen
[CODMin ]
(O mg/l)
General microbe count
(pcs/ml)
Total iron
(Fe mg/l)
Concentration of
anti-corrosion agents and
anti-scaling agents
(mg/l)
Significance
Measured to obtain the trend of corrosion behavior and scale formation of water. The pH level of circulation water
is normally controlled at 7.0 to 9.0. Where the level is decreased to 6.5 or below, it must be raised by the addition
of alkali agents. In this case, the appropriate pH level is 8.0 to 9.0.
Measured to determine the trend of salt concentration dissociated into water as ions. Generally speaking, water
quality with high conductivity tends to be bad and is frequently a cause of corrosion damage.
Measured to determine the volume of suspended matter in water. Since the presence of such suspended matter in
the system can cause deterioration of efficiency and erosion damage to a heat exchanger, the turbidity of the
circulation water should be retained as low as possible.
There is a certain degree of connection between pH and the degree of alkali. The M alkali degree is an indicator of
the trend of calcium carbonate forming scales.
This indicator is important to control the concentration of circulation water and to determine the trend for the
formation of scales by calcium and other compounds such as calcium carbonate.
This is generally used as an indicator for controlling the concentration of circulation water. For a system where
chlorine treatment is performed, this indicator is used in combination with others, such as conductivity, calcium
hardness and silica concentration, etc. Water containing high chloride ions tends to have strong corrosive
performances.
Water containing a high concentration of sulfate ions tends to have a strongly corrosive performance. As for HAVC
coolants, the inclusion of sulfur acid gas contained in the air into the system causes a high concentration of sulfate
ions and decreases the pH level, forming a highly corrosive environment.
Silica is one of the causes of scale formation.
Water containing a high concentration of ammonium ions is highly inclined to generate slime. For a system using
copper series materials, ammonium ions and copper react with each other to form a complex ammonium ion salt,
which is a cause of corrosion.
A system with a high consumption of oxygen tends to cause slime, meaning appropriate slime control measures
must be implemented.
It can be an indicator to know the generation of slime. It can also be used to judge the effectiveness of the
microbicide.
The total iron content in the circulation water includes iron ion and colloidal ion derived from the makeup water as
well as other iron generated by corrosion of the system. The existence of iron can cause secondary corrosion,
meaning the total iron concentration must be kept as low as possible.
It is necessary to constantly maintain the concentrations of anti-corrosion and anti-scaling agents at an appropriate
level. In the case of significant fluctuations, effective anti-corrosion and anti-scaling performances cannot be
expected.
also used in a one-off manner for this purpose. As nitrate salt anti-corrosion agents cannot expect anti-corrosion
performance equivalent to that of polymer phosphate series agents, a special agent to prevent corrosion to copper
must be used in combination. In addition, as nitrite salts can cause decreased concentrations, due to the act of
microbes (nitrification due to action of oxidative bacterium against nitrate salts such as nitrobactors), it is
necessary to use an inhibitor in combination with the agents or to use deionized water containing less uncertain
elements. In the case of the nitrate salt series agent, after the initial injection of 200 to 300ppm of this agent, the
concentration is kept at a level of 60 to 130 ppm. In the case of hydrazine, the initial concentration is 20 ppm,
following which the concentration is maintained at 5 to 10 ppm when the concentration reaches a stable stage,
whereupon a good anti-corrosion performance can be obtained. The frequency of administering anti-corrosion
agents ranges from once a week to once every two weeks to obtain good water treatment.
Table 3.3.2-28: Outline of Anti-Corrosion Agents for a Closed Circulation Type Cooling System
Anti-Corrosion
Agent
Polymer Phosphate
Series
Corrosion Rate
Molybdate
Polymer Series
Remarks
As this agent facilitates the discharge of corrosion products
outside the system, a corrosion speed of 5 to 20 mdd may
be acceptable.
Use polymer agents in combination with it to reduce the
generation of scales on heat transmission surfaces.
As this agent does not allow the easy discharge of corrosion
products outside of the system, a chemical that ensure
favorable anti-corrosion performance must be used.
As the maximum temperature of bearing coolants is 40!C
or below, which is within the optimum growing
temperature for microbes oxidizing nitrate salts (generally
15 to 30!C), it is necessary to use its inhibitor in
combination with it.
When this agent is used in a system in which no or
insufficient anti-corrosion treatment is performed, iron
oxides existing in the system can be washed away turning
the color of the coolant red. In such systems, it is necessary
to flush it before starting injection of this chemical.
262
263
3.4.1.4
Special Maintenance
Accumulated operating hours of many of the then new and advanced thermal power plants in Japan that were
the motive power for the rapid development of the Japanese economy are reaching one hundred thousand hours or
more. It is time for them to be thoroughly inspected in a systematic manner.
Desirable items to be inspected are listed below.
(1) Rotors of high, medium and low pressure turbines
a. Center hole......................... Visual inspection by means of a bore scope, magnetic particle test, liquid penetrant
test and ultrasonic test
b. Surface of the rotors .......... Hardness test at the designated points, structural examination by means of a
microscope, liquid penetrant test of general surface, magnetic particle test, hardness
test
(2) Blades
a. Embedded portion.............. Inspection to check whether the roots of the first and second stage rotors of the high
and the medium pressure turbines that are exposed to high temperature have lifted
Ultrasonic test of the rotating blades in each of the high, and the medium pressure
stages
b. Shroud tenon...................... General inspection to check whether it lifted and how it lifted
(3) Main steam check valve... Liquid penetrant test of the inside and outside surface, magnetic particle test,
ultrasonic test, hardness test and structural examination by means of a microscope
(4) Turbine casing.................. Penetrant test of the inside and outside surface, magnetic particle test, structural
examination by means of a microscope
3.4.1.5
Content of the Periodic Inspection
Content of the periodic inspection for a steam turbine is summarized as follows.
264
Legend
Operation : Inspection
No.
1
Place to be Inspected
Inspection Method
Number of
Tested Samples
Inspection
Frequency
100% inspection
V T: Visual Inspection
P T: Penetrant test
M T: Magnetic particle test
Remarks
U T: Ultrasonic Test
R T: Radiographic test
Usual inspection
(1) Casing
a. Corners and the inside
surface of each pipe
seat
V T, M T
The inside
of a pipe
seat
A corner
b. Nozzle chamber
(a) The inner and the
outer surfaces
V T, M T, A mirror
for inspecting the
inside of a pipe
100% inspection
M T, U T
100% inspection
(c) Profile
Dimensions
(Deformed amount)
100% inspection
Dimensions
(Clearance)
100% inspection
(e) Vane
Dimensions
(Eroded amount)
100% inspection
A welded
connecting part
M T, U T
Measuring point
Eroded amount
265
Operation : Inspection
No.
Place to be Inspected
Inspection Method
Number of
Tested Samples
Inspection
Frequency
100% inspection
Remarks
V T, M T
V T, M T,
Dimensions
100% inspection
M T, Dimensions,
Shape of the screw
threads
100% inspection
f. Balance tube
g. Welded part
h. Key
M T, U T
(Wall thickness)
V T, M T
100% inspection
100% inspection
V T, Dimension
(Clearance)
100% inspection
V T, M T
100% inspection
Hole Plug
Inner Casing
Inner
Casing
100% inspection
266
Outer
Casing
Operation : Inspection
No.
Place to be Inspected
Inspection Method
Number of
Tested Samples
Inspection
Frequency
Remarks
(3) Rotor
Rs
V T, M T
100% inspection
b. Shoulders of the
grooves in the rotor of
the medium pressure
turbine where the
blades are embedded
V T, U T
100% inspection
Dimensions
V T, M T, U T
100% inspection
V T, M T
100% inspection
A crack
Erosion
Lifted amount
(1) V T, M T,
Measurement of
the lifted
amount of the
shroud ring
100% inspection
(2) Measurement of
the eroded
amount of the
tenon
100% inspection
V T, P T
100% inspection
Measurement of the
eroded amount
100% inspection
267
Tenon
Shroud
Tenon
Shroud
Rotating
direction
Cross-section
of a blade
Operation : Inspection
Place to be Inspected
d. The blade root area of
the side entry blade
Inspection Method
V T, M T, U T
Number of
Tested Samples
Inspection
Frequency
100% inspection
Remarks
Both for the blade and the disk, the highest
stress is experienced at the corner on the first
tooth. The inspection is to be effected by
means of M T and U.T according to necessity.
However, in case the inspection has to be
carried out in a limited space such as the high
or medium pressure stage, P.T will be used.
VT
100% inspection
PT
100% inspection
R T (or U.T)
When recoated
100% inspection
The blade
base metal
Erosion
Measurement of
eroded amount
Silver
solder
Separation
A crack
An image taken during R.T showing
incomplete fused spray of stelite
Erosion
Blade Ring
No.
V T, M T
100% inspection
V T, M T
100% inspection
268
Operation : Inspection
No.
Place to be Inspected
Inspection Method
Number of
Tested Samples
Inspection
Frequency
Remarks
c. Valve Seat
V T, M T (P T)
100% inspection
Hardness
Representing
points
VT
100% inspection
M T (Fluorescent
magnaflux)
Hardness
UT
100% inspection
Hammering test
100% inspection
Dimensions
About two
representing
bolts per area
Checking of the
thread profile
- ditto -
269
Actual profile
Standard profile
Operation : Inspection
No.
2
Place to be Inspected
Inspection Method
Number of
Tested Samples
Inspection
Frequency
Remarks
V T, P T, M T, U T
Dimension
(inner diameter)
Once at 100,000
hours in service
and every ten
years thereafter
V T, M T (or by P.T)
Once at 100,000
hours or so in
service
Blades
Rotor
Caulking Piece
A crack
A crack
Rotating Blade
V T, U T,
Measurement of
lifted amount
100% inspection
Stopper Pin
A crack
Lift
b. Portion representing
the profile
(Blades near the main
steam and the reheat
steam inlets)
Measurement of
hardness
(by means of X-ray
diffraction or other
methods)
Several
representative
rotors
270
Rotor
Measurement of
hardness of the surfaces
representing the profile
Operation : Inspection
No.
Place to be Inspected
(3) Stationary blades
(Blades near the main
steam and the reheat
steam inlets)
Inspection Method
Measurement of
inclination amount
of a blade row
Number of
Tested Samples
100% inspection
Inspection
Frequency
8th to 10th year
and every four
years thereafter
Remarks
It is a matter of concern that creep deformation
occurs to the stationary blades in the 1st stage
of the high or the medium pressure turbine
after prolonged exposure to steam of high
temperature and high pressure so that
difference in elongation between the rotor and
the casing is constrained.
Steam
Amount of inclination
Destructive test
One or two
representative
bolts per material
271
3.4.2
Maintenance of Condensers
3.4.2.1
Inspection and Measures
Table 3.4.2-1 shows content of the maintenance and inspection to be effected at the periodic inspection.
Table 3.4.2-1: Content of the Maintenance and Inspection to be Effected at the Periodic Inspection
Item
Timing of
Maintenance
Purpose or Method
Inspection
Method
Countermeasure/Improvement
VI
ET
VI
VI
VI
PHT
VI
PT
VI
PT
WT
Connecting piece
the rubber
expansion joint
Inspection of deterioration of
the rubber expansion joint by
viewing from the inside of the
body
VI
ST
WT
The extraction
steam pipe
expansion joint
VI
PT
VI
PT
3.4.2.2
Cleaning of the Water Chamber and the Surface of the Pipe Plate
Negligence in cleaning of the water chamber and the surface of the pipe plate allows marine creatures to
adhere to them and strongly propagate on them so that the cooler pipes are so persistently clogged, requiring too
much labor to remove them. Therefore, cleaning of the water chamber and the pipe plate shall also be scheduled
whenever a planned shutdown or opening of the water chamber is expected.
272
3.4.2.3
Cleaning of the Inside of the Cooling Pipes
Cleaning of the inside of the cooling pipes is important to maintain the performance of the condenser, and
Table 3.4.2-2 shows the method of cleaning. However, it is necessary to check the properties and condition of
the scale deposited on the inside wall and to select an effective method since it may be different according to such
properties and condition. When the pipe is clogged with foreign matter, remove it first, and then carry out the
cleaning.
Table 3.4.2-2: Cleaning Methods for the Inside of a Cooling Pipe
Cleaning Method
Algae-containing
scale
Feed the nylon brush through the pipe by pressurized water from a pressure
feed-type water gun.
The water gun pressure should be about 0.6 ~ 0.8 MPa.
Attach a rubber guide to the tip of the water gun in order not to damage the tip
of the cooling pipe.
Wet the nylon brush in advance.
Feed the nylon brush against the direction of the flow of the cooling water.
Take a precautionary measure using a protective sheet so that the brush does
not directly touch the rubber lining in the water chamber on the opposite side.
Slimy scale
Feed by pressurized water several granulated balls per pipe that are used by a
ball cleaning equipment through the pipes with a water gun.
Feed the balls against the direction of the flow of the cooling water.
Cleaning with a
rotary tube cleaner
Scale containing a
small amount of algae
Cleaning with a
chemical detergent
Hard scale
3.4.2.4
Leak Test of the Cooling Pipes
In the event that leakage from a cooling pipe is found, it is necessary to exactly identify from which pipe
among thousands or ten of thousands of pipes the leakage is occurring. Figure 3.4.2-1 shows the methods of
checking.
Point of leakage
Point of leakage
Rubber
plug
Wrapping sheet
Point of leakage
Manometer
Black light
Rubber
plug
Rubber packing
Point of leakage
Point of leakage
Transparent
acrylic resin
Foam
cap
Rubber packing
Point of leakage
Application of
soapy water
A vacuum meter
Rubber plug
Vacuum-breaker
Vacuum pump
(an ejector)
Compressed air
273
3.4.2.5
Checking of air leakage
Too much air leakage to the condenser lowers the steam-condensing capability and the degree of vacuum,
resulting in inability to limit the load on the steam turbine or in inability of operation. Checking of air leakage
can be effected with flon or helium gas as shown in figure 3.4.2-2. But flon is a regulated material from an
environmental protection viewpoint. This method is suitable for checking of the many parts of the unit including
the turbine and the piping. In the event that the degree of vacuum is lowered before or after the periodic
inspection, parts dismantled and repaired in the meantime and connecting parts such as flanges should mainly be
checked. The water-filling method explained above may be used when the checking is just for the condenser
system.
Breakable diaphragm
Turbine casing
Flon or
helium gas
Rubber expansion joint
Low-pressure
feedwater heater
Connecting piping
Connecting piping
Gas detector
Connecting
piping
Connecting piping
Air-cooling section
Vacuum pump
3.4.2.6
Eddy Current Test (9)
The built-in-type eddy current test is a checking method to find damage to the cooling pipes. This checking
should be effected at every periodic inspection, and the data should be compared and arranged in good order
according to the passage of time. The eddy current test is a detection method that utilizes electromagnetic
induction. There are two methods: synchronized detection and phase analysis. Both or only the latter should be
effected. As shown in Figure 3.4.2-3, passing an alternative current through a coil situated near a metallic
material causes an eddy current in it due to electromagnetic induction. Such defects as cracks or any variation in
the material properties would change the eddy current, changing the impedance of the coil.
The cooled pipes
The AC coils
Synchronized
detection method
Synchronized
detection method
Phase analysis
method
Phase analysis
method
Synchronized
detection method
Synchronized
detection method
Phase analysis
method
Phase analysis
method
3.4.2.7
Replacement and Blocking of a Cooling Pipe
Replace and block a cooling pipe from which leakage is found. Figure 3.4.2-5 shows the procedure for
effecting the methods.
(1) Crimping of the end of the pipe
Pipe
plate
Old
pipe
Pipe
plate
Rubber plug,
brass rod, etc.
Copper rod
Pipe
plate
Old
pipe
Expander
Pipe
plate
A rubber plug
New pipe
3.4.2.8
Checking of a Connecting Piece Rubber Expansion Joint
The service life of a rubber belt is about ten years. So, the following checking and measurement shall be
effected once a year after five years since the start of operation, and replacement shall be prepared after ten years.
(1) Visual inspection
Check whether or not any cracks,swells, or irregularities due to aged deterioration are found.
275
3.4.2.9
Repair of the rubber lining
Figure 3.4.2-6 shows a typical method and procedure for the repair. Cut the damaged part off and grind the
appropriate part and the surroundings with a grinder. Apply adhesive over it, attach a vulcanized rubber sheet,
and shape them with pressure using a roller or some other tool. Make sure by visual check or by using a pin hole
tester that there are no irregularities.
Application of an adhesive
Vulcanized rubber
Metal part
Water chamber
(3) Removal of
the copper alloy pipes
The stakes
Welding of the
titanium pipe
(5) Insertion of
the titanium pipes
Supporting plate
Figure 3.4.2-7: Procedure for Replacing of the Aluminum Brass Alloy Pipe Condenser by the Titanium Pipe
Condenser
2.4.2-1
Maintenance of the Feed water Heater
Table 3.4.2-3, 3.4.2-4, and 3.4.2-5 show examples of the main failures occurring in the feed water heater, those
of aged deterioration, and the main items of maintenance, respectively.
These items of maintenance and their frequency are just for reference, and they depend on the kind of a plant.
Therefore, it is necessary to obtain information on other plants and to operate a plant in cooperation with the
supplier.
276
Table 3.4.2-3: Examples of Main Failures Occurring in the Feed water Heater
Part Name
Item of Failure
Monel metal
Brass
Heating
Steel pipe
Stainless
Fatigue damage
Deterioration of Materials
Deterioration of
Function
Item
Content
Deteriorated function of the desuperheating system, the draincooling system, and the vent
system
Deterioration of the
diaphragm of the cylindrical
water chamber made of
forged steel
277
Maintenance
Frequency
Operation Mode
In service
Once a day
In service
Once a day to
once a month
In service
Once a month to
once a year
In service
Once a year
3.4.2-2
Maintenance of the Deaerator
Table 3.4.2-6 and Table 3.4.2-7 show an outline of the main failures and aged deterioration that may occur in
the deaerator, respectively. Maintenance during operation is required in order to prevent and relieve these
failures and deterioration and to enhance reliability.
Table 3.4.2-6: Examples of Main Failures of the Deaerator
Part Name
Item of Failure
Spray nozzle
Welded part
Deterioration of
Materials
Deterioration of
Function
Item
Content
Table 3.4.2-8 shows the main items of maintenance. These items of maintenance and their frequency are just
for reference, and they depend on the kind of the plant. Therefore , it is necessary to obtain information on other
plants and to operate a plant in cooperation with the suppliers in the same manner as explained later on the causes
of and measures against representative examples of failures listed in Table 3.4.2-6.
278
Maintenance
Frequency
Operation Mode
In service
Once a day
In service
Once a month
In service
Once a month to
once a year
In service
Once a year
3.4.2-3
Maintenance of the Cooler
3.4.2-3.1 Maintenance and Control during Operation
The following maintenance and control shall be effected during operation of a power plant.
(1) Monitoring of the attached instruments and the measured data
Monitor the data on the temperatures at the outlet and the inlet of the cooler measured by temperature meters
or some other instruments to make sure that no irregularities related to function and performance occur.
Especially for seawater coolers, the pressure of the outlet and inlet of the cooler and, the opening angle of the
temperature control valve (the lower the performance, the wider the opening) on the cooling water side shall also
be monitored because its performance may be deteriorated due to deposited marine creatures clogging it and also
because the cooling pipes may be corroded.
(2) Checking of the appearance of each cooler
Check whether or not any leakage from the flanges is found and some other items.
(3) Inspection of the attached equipment
If an electrochemical protection device supplied with off-device electricity is used, make sure that the
corrosion control current and the corrosion control potential during operation are within the specified ranges. If
a seawater strainer (seashell filtering device) is installed, check the pressure difference, washing frequency, etc.
(4) Water quality control
When iron or chlorine is injected into seawater, the concentration of the solution to be injected and frequency
of injection shall be controlled.
(5) Storing of a device whose operation is suspended
If there is a spare seawater cooler or oil cooler, or in the event that the condenser cooler is bypassed in the
summer season, its operation is suspended for a long time. In this case, seawater in the seawater system of the
cooler shall be completely discharged, and the cooler shall be completely dried out for storing.
Table 3.4.2-9: Maintenance Items to be Effected during Scheduled Suspension of Operation and Periodic
Inspection
Name of Equipment
Seawater cooler
Condenser cooler
Oil cooler
Inspection Item
Method
Frequency
Countermeasures
Inspection of corrosion
of the cooling pipes
Inspect corrosion of
both the inside and the
outside of the pipes
using ECT.
Once a year
Inspection of leakage
from the expanded part
and other parts of the
cooling pipes
Inspection of the
surface of the pipe plate
Visually inspect
corrosion of the pipe
plate surface (V.I.).
Inspection of the
galvanic anode plate
Once a year
Inspection of corrosion
of the cooling pipes
Inspection of leakage
from the expanded part
of the cooling pipes
ECT:: Eddy current test W.T.: Pressure test (Water, Air, or Oil pressure)
It is necessary to effect an eddy current test (ECT) at every periodic inspection for a cooler using seawater.
However, the frequency of ECT for a condenser cooler and an oil cooler may be somewhat reduced provided that
the water is appropriately treated to reduce the causes of cooling pipe corrosion.
A stop plug must be fitted in a pipe whose wall thickness is found by ECT to be too greatly reduced or when
such a pipe must be replaced with a new one. Figure 3.4.2-8 shows the procedure for fitting a stop plug in a pipe.
Pipe plate
Cooling pipe
280
3.4.3
3.4.3.1
Effects
Creep
A creep deformation
A creep rupture
Time
Temperature
Aged deterioration
(Aged deterioration
of quality)
Fatigue
Low-cycle fatigue
High-cycle fatigue
Material deterioration
Increased
possibility of
damage
Embrittlement
Stress
Environment
Start and stop
Load fluctuation
Corrosive
Corrosion
Corrosion fatigue
Stress corrosion
cracking
Strength reduction
Increased
operating cost
Performance down
Erosion
Solid particle attack
Drain attack
Softening
Abrasion
1.1 Creep
A material that is subjected to a load under high temperature gradually deforms and finally cracks and breaks.
This phenomenon where a material gradually deforms is called creep, and the cracking or the breaking is called
creep rupture.
(1) Creep deformation
Deformation due to creep can be a cause of aged bending of the steam turbine rotor, aged deformation of the
wheel casing, and aged lifting of the rotating blade.
(2) Creep rupture
When creep enters an acceleration zone, the strain increases and the material finally breaks.
A design to prevent creep rupture and cracking life assessment are effected based on creep rupture
characteristics (time taken until a rupture occurs under a certain temperature and stress).
Macroscopic deformation of a material caused by creek can be detected by measurement of the dimensions and
lifted amount of the rotating blade and the shroud.
(3) The mechanism of a creep rupture
The assumed process of a creep rupture is as follows. (1) A microscopic crack or a small void appears at the
grain boundary during a creep deformation. (2) Such cracks or voids grow and combine. (3) Finally an intergranular rupture occurs. Figure 3.4.3-2 systematically shows this process.
281
Inter-granular slide
A start of a
microscopic crack
Growth of a
microscopic crack
A void is formed
1.2 Fatigue
Figure 3.4.3-3 systematically shows the process of formation and diffusion of a fatigue crack.
The direction of
repeated stress
A crack in the slip
zone appearing at
the initial stage
A crystal grain
The outside
(The inside)
A cleavage crack
The direction of growth
The inside
(The outside)
A ductility striation
A brittle striation that appears mainly
under a corrosive environment
The final slant
The second stage
separation fracture
The
first
stage
(Formation)
(Diffusion of a crack)
1.3 Embrittlement
Materials used for steam turbines are exposed to high temperature during operation for a long time, and their
toughness and ductility are reduced. Brittleness is the result of this process and is progressive as time passes.
The turbine wheel casing, the rotor, the main valve, etc. that are used under high temperature are liable to
suffer from this phenomenon.
Generally speaking, brittleness that appears after heating at high temperature for a long time is caused by
segregation of such trace elements as phosphorus (P) and tin (Sn) reducing the grain boundary strength.
Figure 3.4.3-4 systematically shows the process of aged brittleness occurring to the materials used in steam
turbines.
282
Diffusion of trace
elements
Condensation and
bulkinization of carbides
Precipitation of grain
boundary carbides
Acceleration of bulkinization
and embrittlement
1.4 Corrosion
The stage of a turbine near the dry-wet alternating area that becomes wet with a heavy load and dry with a
light load is an area where corrosion must be especially observed. In such an area, a phenomenon occurs where
traces of corrosive substances dissolved in water droplets sometimes condense due to the alternation between a
wet condition and a dry condition caused by load fluctuation or by starting and stopping.
And corrosion and pitting occur more or less in a steam turbine that has been operated for a long time because
when the steam turbine stops, steam becomes droplets that attach to the metal surface even near the last stage
where wet steam flows and in the higher stage where the temperature is higher.
(1) Corrosion fatigue
Corrosion fatigue occurs when corrosion and repeated stress exist concurrently.
The fatigue strength of a material is lowered under a corrosive environment. This phenomenon is
conspicuous especially in the case of high-cycle fatigue. The tenons and the shroud for the rotating blades in the
wet area are liable to be affected.
In the case of corrosion fatigue, the higher the concentration of the corrosive substances and the longer the
exposure to corrosive substances, the more the fatigue strength is lowered. The fatigue limit is outstandingly
lowered compared with that in a dry environment.
(2) Stress corrosion cracking (SCC)
The type of stress corrosion cracking is either a crystal grain boundary fracture or a transgranular fracture
depending on the material, the stress, and the environment.
The feature of SCC is a delayed fracture under a specific stress, and it can occur under a stress that is only a
fraction of the stress with which a material fracture occurs under a non-corrosive environment.
Under the same corrosive environment, SCC is more likely to occur with higher stress, and with the same
stress, it is more likely to occur to a material with higher strength.
1.5 Erosion
Erosion that occurs to materials used in a steam turbine is mainly caused either by solid particles or by drain
(water droplets).
(1) Erosion by solid particles
Small solid particles of oxidized scale flying in steam from the boiler are in some cases the main cause of
erosion of the nozzles and the rotating blades in the high- and medium-pressure stage. Erosion often occurs
especially to the nozzle plate in the first stage, where stress working on the rotating blades in the first stage is
increased, affecting the reliability of the rotating blades in extreme cases.
In the event that the area of the nozzle throat is increased or the profile of the effective part of a rotating blade
is changed by the influence of erosion, the efficiency of the turbine is reduced.
(2) Drain (wastewater) attack
Erosion occurs mainly to the rotating parts by wastewater produced in the wet area.
283
1.6 Softening
The necessary strength and ductility of the materials used for the parts exposed to high temperature are
maintained by heat treatment. However, various mechanical properties related to the strength are deteriorated
due to the effects of temperature and stress caused by operation under high temperature for a long time. One of
these phenomena is softening.
The higher the temperature and the stress, the more conspicuous the softening.
Softening of a material used in a turbine can be detected by measurement of hardness.
1.7 Abrasion
Although the gasket installed between the rotor and stationary parts such as the nozzle is a non-contact type,
light contact between them may occur due to deformation of the wheel casing during a thermal transitional period
such as the start-up of the turbine.
Gaskets are gradually abraded due to light contact resulting in increased leakage of steam between two stages
to cause aged deterioration of efficiency.
Journals of the rotor and bearings can suffer from abrasion and sliding scratches after prolonged operation.
2. Object Components and Areas in a Steam Turbine to be Assessed and Damage to Them
2.1 Object Components and Areas to be Assessed in a Steam Turbine
The rotor, the wheel casing, the rotating and stationary blades, and the main value are the objects of periodic
maintenance and life control because they are the main components of a turbine.
Figure 3.4.3-5 to 9 show the object components and areas of each item of main equipment for which life
assessment must be effected.
The high-pressure
rotating blades
A rotor
The center hole
Figure 3.4.3-5: Object Components and Areas of the High- and Medium-pressure Rotor (reaction type)
for Which Life Assessment Must be Effected
The place of the tenon
A disk
A disk
The profile
The medium-pressure
rotating blades
A disk
The dub tail type
An enlarged view of the blade groove
Figure 3.4.3-6: Object Components and Areas of the High- and Medium-pressure Rotor (impulse type)
for Which Life Assessment Must be Effected
284
The profile
The low-pressure
rotating blades
A disk
A corner R portion
A corner R portion
A bolt
The flat
portion
Section A - A
Figure 3.4.3-8: Object Components and Areas of the High-pressure Wheel Casing
for Which Life Assessment Must be Effected
A bolt
The valve rod
Figure 3.4.3-9: Object Components and Areas of the Main Valve (Steam-adjusting Valve)
for Which Life Assessment Must be Effected
285
Abrasion
Softening
Erosion
Corrosion
Embrittlement
Place/Component
Fatigue
Equipment
Creep
Remaining life
assessment
UT
MT
PT
VT
The low-pressure
rotor
The low-pressure
rotating blades
The nozzle
The profile
MT: Magnaflux Flaw Detection Test PT: Penetrant Flaw Detection Test
Photo 3.4.3-1: Creep damage to the Tenon for a medium-pressure rotating blade
286
(2) Fatigue cracking damage to the base part of the high- and medium-pressure disk
Photo 3.4.3-2 shows an example of low-cycle fatigue cracking damage occurring to the base part of the highand medium-pressure rotor due to repeated thermal stress caused by starting and stopping of the turbine.
Thermal stress occurs due to temperature difference between the inside and the surface of the disk. This is
caused by the large heat capacity of the rotor, leading to disagreement in temperature between steam and the
metallic part when the steam is introduced and also to inability of the inside of the disk to follow the rapid
increase in temperature afterwards.
Moreover, since stress concentration occurs around the corner and the groove parts of the rotor surface, plastic
deformation is repeated every time the turbine is started and stopped, leading to accumulated fatigue and finally to
cracking.
Photo 3.4.3-3: Corrosion Fatigue of the Part of a Rotor Where Blades are Embedded
(4) Erosion of the nozzle of the first stage (1)
Chipped parts are often found on the first-stage nozzle of the high- and medium-pressure turbine, and Photo
3.4.3-4 shows an example of the chipped part. This is assumed to be caused by oxidized scale that has been
separated from the boiler pipe flying into the turbine and finally crashes into the nozzle at high speed. This
phenomenon is called solid particle erosion (SPE). Since there is concern that the developed erosion would
reduce the internal efficiency and have a bad influence on the first-stage rotating blades, repair needs to be
effected in a timely manner.
Creep
Fatigue
Embrittlement
Assessment Method
Parameters to be detected
Instruments/Measuring Method
Measurement of hardness
Hardness
Hardness
Electric resistance
An electric resistance-measuring
device
By A parameters
Creep void
Creep void
Creep void
Carbides
Measurement of microscopic
cracks
Measurement of hardness
Hardness
Hardness
Half-value width
Polarization
Current density
Chemical etching
288
Before heated
Temperature
( C)
450
500
550
550
Heated
Materials that
material received creep
with no load
damage
!!
!
!
Materials
that received
creep
damage
[Cr-Mo-V steel]
Figure 3.4.3-10: Relation between the Temperature Time Parameter and Hardness
The hardness test method assesses the creep damage rate by means of the amount or rate of hardness drop
measured in actual steam turbines. Figure 3.4.3-11 shows the relationship between creep damage rate "c and
drop in hardness #Hv (difference in hardness between a material with a load applied and another with no load
applied), and the creep damage rate is obtained from the measurement of hardness making use of the figure.
CrMoV forged iron
Figure 3.4.3-11: Relation between Creep Damage Rate and Drop in Hardness
(ii) A method of using hardness measurement together with analytical calculations (1)
This method assesses the creep damage rate by means of creep rupture characteristics after deterioration that
are obtained from hardness measured in an area that received thermal aging (an area exposed to high temperature
but only to low stress), as well as by means of the analytical calculations. Figure 3.4.3-12 shows the summarized
test results of creep rupture characteristics represented by hardness and temperature time parameters. And creep
rupture characteristics after aged deterioration are obtained from measurement of hardness on actual steam
turbines and the calculation result of temperature and stress by Formula (1) that is induced from the figure.
T(C+logtr)={ ai$(log%)i-1$Hv+ bi$(log%)i-1 ........................................................................... (1)
where tr: Creep rapture time
T: Absolute temperature
C: Material constant
Hv: Vickers hardness
%: Working stress
ai$bi: Approximation constants
289
Stress % (kg/mm2)
(Estimation according
to the formula (1))
Values obtained by
experiments
Figure 3.4.3-12: Comparison between Data on Creep Rupture Characteristics Obtained from Experiments and its
Estimation Based on Measured Hardness
Figure 3.4.3-13: Relation between Creep Damage Rate and Dropped Amount of Electric Resistivity Ratio
(3) The structure-observing method
The structure-observing method is where a metal structure is observed by means of a replica, and the extent of
damage is assessed by the degree of structural change. Since the change in the structure due to creep damage
itself can possibly be grasped, it is an important technique. Concretely speaking, the structure is transferred to a
replica film after the portion of metal to be assessed is polished and etched. The vapor deposition of gold is
applied to the replica, and the replica is observed by a scanning electron microscope.
Figure 3.4.3-14 and Photo 3.4.3-5 show the procedure for picking up of the replica and an example of
observation of a creep void (a cavity), respectively.
290
A crack or a void
The replica
Loading condition
A material used for 140,000 hours
A virgin material
Figure 3.4.3-15: Relation between the Fatigue Damage Rate and the Maximum Microscopic Crack Length
291
3.2.3 Embrittlement
(1) The polarization method (1)(12)(15)(16)
The polarization method assesses the degree of embrittlement by means of the relationship between the voltage
and the current (polarization curve) appearing when electrolysis is caused in the electrolysis solution using a part
whose embrittlement is to be calculated as the anode, as well as by means of the phenomenon where the natural
electric potential varies according to advancement of embrittlement.
(2) The chemical etching method (17)
The chemical etching method detects advancement of embrittlement by means of measurement of the depth of
the grain boundary corroded groove (roughness and width of the grain boundary groove) to know the amount of
segregation at the phosphorus grain boundary following selective corroding of a certain grain boundary by picric
acid.
Photo 3.4.3-6: A Device for Remaining Life Assessment of the Rotor Center Hole [MACH-I]
Figure 3.4.3-17(1)(18) shows the result of remaining life assessment of a high- and medium-pressure outer wheel
casing. (The cumulative operation hours is about 160,000 hours, the number of starts and stops is 370, and the
temperature of the part to be assessed is 538 C.)
292
[1]Operation history
Number of starts and stops: 370 Operated time: 161,000 hours Steam temperature: 538 C
Fatigue damage "f
The part to
be assessed
[2] Result of
the life assessment
Safe zone
Symbol Mark
Figure 3.4.3-17:
An Example of Actual
Application of Remaining
Life Assessment of a Highand Medium-pressure Outside
Wheel Casing
Observation result by a scanning
electron microscope (SEM)
(&1000)
Inspection Item
Electric resistance
measurement
Hardness measurement
Microscopic crack
measurement
Electric resistance
measurement
Hardness
measurement
Microscopic crack
measurement
The data of
the R portion of
the steam chest
Formation of a void in the steam
chest
(Combined voids)
(The initial
stage)
The creep
damage rate and
A void is
the creep strain
formed
(an image
on the
replica).
Figure 3.4.3-18: Situation of the Creep Damage Rate, the Creep Strain, and the Void
293
3.4.3.2
Heat Exchangers
1. Outline
Various kinds of heat exchangers are used in thermal power plants. In this chapter, we discuss measures for
improvement including a new technology to enhance future reliability of the major types of heat exchangers.
Table 3.4.3-3 shows the main failures that occurred to the condensers, the feed water heaters, the cooling water
coolers, the oil cooler and the gland steam condensers due to their aged deterioration, as well as the content of
improvement and countermeasures. For typical examples among them, causes and their countermeasures are
explained below.
Table 3.4.3-3: Improvements of the Plant Equipment and Countermeasures against Malfunctions
Improvements of such major heat exchanging equipment as the condenser, the feed water heater, the oil cooler, the
cooling water cooler, and the gland steam condenser and countermeasures against major malfunctions
Name of
Equipment
1. Condenser
2. Lowpressure Feed
water Heater
Purpose
Method of
Inspection
ET
Reinforcement of temperature-proof
capability (To prevent cracking due to aged
deterioration)
PT
PT
DI
VI
PT
HT
VI
ET
VI
UT
PT
PT
VI
VI
4. Oil Cooler
ET
VI
5. Cooling
Water Cooler
ET
VI
6. Gland
Steam
Condenser
VI
3. Highpressure Feed
water Heater
Meaning of the acronyms: ET (Eddy Current Flaw Detection Test) PT (Penetrate test) DI (Dimension Inspection) VI (Visual Inspection) HT
(Hardness Test) UT (Ultrasonic Flaw Detection Test)
2.
Plant
Output
(at the
opening of
the plant)
250 MW
(1967)
250 MW
(1974)
350 MW
(1970)
600 MW
(1973)
Name of the
Base
Time of
Damage
Occurrence
Damage Situation
DSS
High-pressure Seventeen
Drain
years after
Manifold
the operation
(150 A)
started
A crack of 105 mm in
the body and another
crack of 30 mm in the
nozzle
DSS
MediumTwelve
pressure Drain years after
Manifold
the operation
(100 A)
started
A crack of 115 mm in
the body and another
crack of 70 mm in the
nozzle
At a constant
load
(entered in an
emergency)
At a medium
load
SSR steam
inlet
(150 A)
Turbine Lead
Pipe Drain
Inlet
(50 A)
Nineteen
years after A crack of 178 mm in
the operation the body
started
Ten years
after the
operation
started
Three cracks of 80
mm max. length in the
peripheral direction
occurred on the
welded part of the
thermal sleeve and the
body
Original Shape
Countermeasures
Cracks
(hatched area)
Fillet welding
Cracks
(hatched area)
The thermal sleeve
Fillet welding
Cracks
(hatched area)
Groove
welding
Fillet welding
Cracks
Cracking can be prevented by the countermeasure where the hot side, the nozzle, and the cold side, the body,
are connected through the thermal sleeve and the point of injection is chosen so that the hot fluid does not point
the body to relieve steepness of the temperature gradient between the nozzle and the body.
295
3.
Feed water
Leakage
An inserted pipe
(SUS304TB)
A flow-smoothing bell mouth
(1.25Cr0.5Mo Steel plate)
An inserted pipe
(SUS304TB)
A flow-smoothing bell mouth
(1.25Cr0.5Mo Steel plate)
3.6 Damage to the Diaphragm in the Cylindrical Water Chamber of the High-pressure Feed Water
Heater
There is a structure where a diaphragm is used to obtain water tightness of the water chamber of the highpressure feed water heater (Figure 3.4.3-20). In this structure, the high pressure in the water chamber is
supported by a water chamber cover made of a thick plate and is sealed by the diaphragm. The diaphragm is not
often damaged.
The outlet for the feedwater
The body
The partition
cover
The diaphragm
The heating pipe
297
= Countermeasures =
It is required to replaced the diaphragm every two years taking the DSS mode of operation into consideration.
The old one should not be used but should be replaced it with a new one at such an opportunity as opening of the
water chamber when the old one is broken.
3.7 Erosion of the Inside of the Low-pressure Feed water Heater Body
Reduction in the wall thickness of the parts located inside the heater such as the body plate and the pipesupporting plate due to aged deterioration has often been experienced recently.
A study revealed that the places where reduction in wall thickness had been experienced are those where the
flow of steam is relatively fast in the heater or places where there was movement of wastewater and where erosion
is liable to be induced. This attack is a phenomenon due to erosion and corrosion occurring in a specific
temperature range.
The corrosion speed of an iron or steel material is greatly influenced by the environmental temperature, and
there is a tendency for a material to increase its corrosion speed at a specific temperature. The number of cases
of the phenomenon where plates inside the body of the low-pressure feed water heater are corroded and their wall
thickness is reduced around the above-mentioned temperature range has increased.
= Countermeasures =
Such measures as padding by welding on the area whose wall thickness has been reduced, backing the area by
a metal stripe and/or partially replacing with a newly fabricated part made of SUS material are effected.
4.
The nozzle
5.
298
3.4.3.3
Pump
1.
Inspection Items
Abnormal noise and vibration/Leakage from the piping, the gland and the coupling/Vibration of the small-size
piping/Opening angle of the sealing water control valve/Differential pressure of the strainers
Operation Record
Inspection Items
Abnormal noise and vibration/Leakage from the piping/Abnormal noise and vibration/Leakage from the
gland/Differential pressure of the strainer/Abnormality in the bearing lubricating water
Table 3.4.3-6: The Content of the Inspection on the Periodic Inspection of BFP
Item
The sliding ring
The main shaft
Rotating
Component
The impeller
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
Others
)
)
)
)
)
)
299
Table 3.4.3-7: The Content of the Inspection on the Periodic Inspection of CWP
Item
(1)
(2)
(3)
(4)
The impeller
1. The bearing
1. The pumping-up
pipe of the
discharging body
Rotating
Component
Bearing
Casing
3.
Table 3.4.3-8: Measures Taken to Strengthen the Deterioration-proof Capability of the Boiler Feed water Pump at
Hitachi, Ltd.
No.
Phenomenon that
Occurred
Cause
"
Cavitation erosion
Increased vibration
Increased vibration
&
'
Corrosion damage
to the chrome
plating
301
Table 3.4.3-9: Measures Taken to Strengthen the Deterioration-proof Capability of the Circulating Water Pump at
Hitachi, Ltd.
No.
Phenomenon that
Occurred
Cause
"
Reduction in wall
thickness of the
loose flange due to
corrosion
Corrosion of the
mating surface of
the intermediate
coupling
A malfunction of
feeding of the seal
water
Abrasion of the
shaft-sealing device
Corrosion of the
flange surfaces of
the bearing bracket
and the column pipe
&
Corrosion of the
bolts, the nuts, and
some others
'
Reduction in wall
thickness due to
corrosion of such
parts as the casing,
the column pipe, etc.
302
Figure 3.4.3-22: A Structural Drawing of the Feed water Pump of the Mitsubishi MDG 267 Boiler
This life assessment method(Figure 3.4.3-23) is an analytical method, and they are studying the replacement of
the component when cracking due to fatigue has occurred, development afterwards, and when the maximum
allowable depth of a crack has been reached.
FEM
Stress analysis
(Cracking in NDI)
Development of a crack
Max. allowable crack
depth according to the
crack development
curve for stainless steel
Number of Occurrences
of Cracking N
Depth of a Crack
Life assessment
Stress S
The max.
allowable depth
Remaining Life
Number of Starts
and Stops N
Predicted future
operation mode
Remaining life
assessment
Part Name
Consumed
Fatigue Life
Remaining Life
4.0%
More than
30 years
2.5%
More than
30 years
2.4%
More than
30 years
Name of Portion
304
Parts
The rotor
1Cr-1Mo-1/4V steel
12Cr-Mo-V-Ta-N steel
12Cr-Mo-V-Nb-N steel
12Cr-Mo-V-W-Nb-N steel
The blade
The nozzle
12Cr-Mo-V-W steel
12Cr-Mo-V-Nb-N steel
12Cr steel
Ni-based superalloy
The casing
The steam valve
1Cr-1Mo-V steel
1Cr-0.5~1Mo steel
11/4~21/4Cr-0.5~1Mo steel
12Cr steel
1Cr-1Mo-V steel
12Cr-Mo-V-W steel
12Cr-Mo-V- Nb-N steel
Ni-based superalloy
The rotor
3~3.5Ni-Cr-Mo-V steel
The blade
The nozzle
12Cr steel
12Cr-Mo-V steel
12Cr-Ni-Mo-V-N steel
17-4PH
Titanium
The casing
Carbon steel
3.4.4.1
Corrosion in the High Temperature Zone and its Countermeasures
For corrosion in the high temperature zone exceeding 400 C, it is usually only a question of an oxidation
reaction of the target substance with a gas phase substance, and there is no involvement of a liquid phase. In a
thermal power plant, especially for the boiler, this countermeasures for the high temperature corrosion is an
important issue. This phenomenon is related to the decrease of thickness in many cases, therefore, the selection
of materials and setting of corrosion control such as coating are decided from this perspective.
As for the materials for the components of a turbine, problems directly related to the high temperature
corrosion have not often occurred. However, issues to be considered such as sticking of the major valves like the
main steam stop valve caused by products of corrosion deposited on the valves and erosion occurring due to the
flowing in of oxide particles still remain.
High chromium steel such as 12Cr steel is effective to improve corrosion resistance. And hardening of a
material by applying nitride treatment to the material surface and cladding welding of stelite that is a cobalt base
alloy are effective measures to strengthen corrosion resistance too.
305
Erosion is a phenomenon where decrease of thickness occurs due to high speed fluid and the reduction is
accelerated when solid substances included in the fluid abrade the wall. For example, we experienced a
phenomenon whereby the nozzle plate in the control stage at the turbine inlet is eroded by oxide particles. This
phenomenon mainly occurs at the start-up of a turbine, damaging the end part of the steam outlet of the nozzle
finally resulting in lowered turbine efficiency. Boronizaion treatment is one measure to prevent this erosion from
occurring. This treatment diffuses boron(B) applying its vapor deposition to the surface of the material to harden
it.
Figure 3.4.4-1(2) shows the effect of the treatment. This is the data of effectiveness of the boronization
treatment applied to an actual turbine unit. We obtained the result whereby the nozzle plate with a thickness of
80 !m of the treated layer could realize such durability that almost no erosion occurred in an operation even
exceeding 15000 hours. And also another measure is one in which the shape of the nozzle is structurally
changed to enhance erosion resistance.
With no treatment
With boronization
treatment (thickness of
the surface layer: 80!m)
Time (h)
Figure 3.4.4-1: Erosion Resistance of the Nozzle Plate with Boronization Treatment
3.4.4.2
Corrosion in a Low Temperature Zone and its Countermeasures
Corrosion in a turbine usually means corrosion under a wet steam environment at 200 C or lower. Corrosion
in this temperature zone includes stress corrosion cracking (SCC), corrosion fatigue, and erosion corrosion. The
SCC and the corrosion fatigue are generally considered to be caused by condensed water in the space between
turbine components where impurities such as Cl- and SO42- contained in steam are dissolved and condensed. In
fact, these types of corrosion often occur around the boundary zone between dry steam and wet steam in a low
pressure turbine.
The SCC is cracking that occurs in a material when corrosion happens under a static tensile stress. This
cracking suddenly causes a brittle fracture, therefore, it presents a serious problem for a structural component.
On the other hand, corrosion fatigue is a rupture of a material when an alternate stress is imposed on a material,
being caused by a phenomenon whereby the fatigue strength is lowered in a corrosive environment. For a low
pressure turbine, it occurs at the base of the blade and in the tenon in some cases.
And in the wet steam zone, erosion occurs in some cases. The erosion is caused in a process such that a water
film formed on the surface of the stationary blade is carried away by steam flow to become droplets and they
crash onto the rearmost rotating blades. Stelite welding or some other measures are applied to the rearmost
rotating blades to prevent this from happening.
3.4.4.2.1 SCC Sensitivity of a Material Used in a Thermal Power Plant
Here, some recent studies on the influence of impurities ions and dissolved oxygen on the SCC of materials
used in a thermal power plant are introduced.
The influence of impurities ions on SCC under an AVT (Volatile Matter Treatment) environment is being
studied. The test conditions were 90 C and pH 9.5 with deairing (7 ppb or lower O2) achieved. Figure 3.4.42(11) shows the results of investigation on the influence of Cl- concentration on the depth of the maximum crack
that occurred in a constant strain SCC test.
306
3.5NiCrMoV steel
12Cr steel
17-4PH steel
Figure 3.4.4-2: Influence of Cl- Concentration on Behavior of Various Types of Steel Related to SCC
For the 3.5 NiCrMoV steel, pitting occurs at 100 ppm of a Cl- concentration and SCC with 1000 ppm of a Clconcentration. While, for 12Cr steel and 17-4PH steel, no SCC occurs when Cl- is increased up to 1000 ppm.
SO42- has so little acceleration function compared with Cl- that no SCC occurs when the Cl- concentration is
increased up to 1000 ppm though pitting occurs at the same Cl- concentration. And for Na+, neither pitting nor
SCC occurs up to 1000 ppm of Cl- concentration. However, the SCC occurs both in 12Cr steel and 17-4PH steel
where the concentration is as high as 10% at a temperature of 200 C or higher.
Thus, we show the influence of dissolved oxygen. Figure 3.4.4-3(12) shows the situation in the case of
3.5NiCrMoV steel. This test was conducted in conditions such as a temperature of 90 C, a Cl- concentration of
10 ppm and range of dissolved oxygen concentration between 7 ppb or less and 1.63 ppm. The test results show
that the SCC occurs when the dissolved oxygen concentration exceeds 10 ppb and 10 ppm Cl- concentration.
Our results showed that the SCC sensitivity to the dissolved oxygen has the same tendency as that of the low alloy
steel as shown in Fig. 3.4.4-4(12) in the case of 12Cr steel used in the material for blade, but the speed of crack
development is slow. And the SCC resistance of the 17-4PH steel is more superior than the two types of steel
mentioned above as shown in Fig. 3.4.4-5(12).
Figure 3.4.4-3: Influence of Dissolved Oxygen Concentration on Behavior of 3.5NiCrMoV Steel Related to SCC
Figure 3.4.4-4: Influence of Dissolved Oxygen Concentration on Behavior of 12Cr Steel Related to SCC
307
Figure 3.4.4-5: Influence of Dissolved Oxygen Concentration on Behavior of 17-4PH Steel Related to SCC
Temperature ( C)
3.5%NiCrMoV steel
3.4.4.3
Properties of Steam
All the types of corrosion damage explained above are greatly influenced by impurities contained in the steam.
Therefore, it has become a very important issue to completely grasp the properties of the steam quantitatively.
308
3.4.5 Corrosion of Heat Exchangers and Piping of Turbine Systems and its Countermeasures
3.4.5.1
Introduction
The system configuration of a thermal power plant using steam turbines has become more complicated due to
improvement in the steam condition and increase in the capacity of a single unit. Figure 3.4.5-1 shows as an
example the main system diagram(1) of a power plant having steam turbines of the 1000 MW class. The main
facilities of the power plant are classified as follows.
(1) The turbines and generators
(2) The water treatment unit for water for the condenser and feedwater
(3) The condenser unit
(4) The feedwater heater unit
(5) The feedwater pump
(6) The piping unit for each component system
Approximately
3000 tons/h
The boiler
The generator
The high
pressure
turbine
The medium
pressure turbine
The condenser
The make-up water
The
condenser
pump
The turbine
The
demineralizer
for the
condenser
The
deaerator
Approximately
280 C
The drain
pump
Gland steam
condenser
The condensate
booster pump
Among these main facilities, equipment and components, of which corrosion is one of the main concerns, are
the low pressure turbines, the condenser in the condensing and water feeding system, the deaerator, the feedwater
heater and the piping, all of which are placed under wet conditions during operation of the turbine, is well as other
components and piping that utilize seawater for cooling fluid, all of which handle or use water. In this chapter,
we discuss corrosion occurring in the heat exchanger and the piping for the turbine system and also its
countermeasures.
3.4.5.2
Examples of Corrosion Occurring in the Heat Exchangers and the Piping used in the
Turbine System and its Countermeasures
1
The Heat Exchangers Used in a Power Plant Using Steam Turbines
1.1 The Condenser
Figure 3.4.5-2 shows types of corrosion occurring in the condenser cooling pipes and protective measures
against it(2).
309
The inside
of a pipe
Protective measures
Inlet attack
An electrochemical protection
device
Deposit attack
Sand erosion
Abnormal
impingement damage
Corrosion by polluted
seawater
A shell remover
Corrosion of and
leakage from a
copper alloy pipe
The outside
of a pipe
Ammonium attack
Erosion by
drain
Protective measures
Galvanic
corrosion
The inside
of a pipe
Full-titanium pipes
Hydrogen
absorption
Corrosion of/
leakage from
a titanium pipe
The outside
of a pipe
Erosion by drain
Figure 3.4.5-2: Corrosion and Leakage of Condenser Cooling Tube and Its Countermeasures
Here in this chapter, we introduce the types of corrosion occurring in the cooling pipes facing the outside
(steam side) and the protective measures.
(1) Ammonium attack of the copper alloy pipes.
Part of the ammonium that is used as a feedwater treatment agent is discharged in the form of non-condensed
gas to the outside of the circulating system through the condenser cooler unit by the air extraction device. The
air cooler and the surrounding area are always exposed to ammonium concentrated in the condensed water and
especially the pipes near the supporting plate along which the condensed water drips down suffer from corrosion.
Photo 3.4.5-1 shows an example of the above mentioned corrosion. The countermeasure is replacement of
the existing pipes by titanium types that have superior corrosion resistance.
310
A group of the
cooling pipes
Eroded
portion
The connecting
body
Eroded portion
Eroded portion
Eroded portion
Figure 3.4.5-3: Erosion of the Outer Surface of a Condenser Cooling Pipe (at a place where erosion occurs)
311
A bundle of pipes
A bundle of pipes
The protection pipes
The supporting plate
Figure 3.4.5-5: Prevention of Droplet Erosion by Installation of Pipes to Protect the Peripheral Portion of the
Bundle of Pipes
1.2 Deaerator
In some cases, the inner surface of the deairing chamber body is partly damaged in a plant where the pH of the
boiler feedwater is smaller than 9.0 and the water includes a relatively large amount of dissolved oxygen. The
area receiving the damage is limited to the area on which the feed water drops from the deairing tray or against
which the dropping water is blown by the influence of heating steam. The cause of the damage is erosion
corrosion caused by the feedwater that drops from the deairing tray, is accelerated by heating steam entering from
the bottom center part of the tray which directly collides with the deairing chamber body. And when there is a
certain distance between the deairing tray and the body wall, erosion corrosion is sometimes caused by free fall of
the feedwater regardless of the existence of the heating steam.
Figure 3.4.5-6 shows an example of the damage. The protective plates made of stainless steel having strong
erosion corrosion resistance are attached to the inner surface of the deairing chamber body as shown in Fig. 3.4.57 to prevent erosion corrosion damage of the deairing chamber body.
Deaerating chamber
The tray
Heating steam
Erosion
Figure 3.4.5-6: Example of Corrosion Inside the Main Body of the Deaerating Chamber
312
The tray
Heating steam
Protection plate (SUS304)
Figure 3.4.5-7: An Actual Measure Against Erosion of the Inner Surface of the Deairing Chamber Body
Photo 3.4.5-4: Stress Corrosion Cracking in an Aluminum-brass Pipe Dipped in the Cooling Water.
This is considered to be caused by the following two factors combined.
1) Existence of a corrosive catalyzer in the cooling water (ionized ammonium, ionized sulfur, etc.)
2) Existence of residual stress (those in the raw material itself, generated during the operation or
generated during assembling process)
Prevention of pitting is possible especially for the oil cooler whose operation is suspended (in a stand-by
situation) by providing a fluid speed fast enough (faster than 0.3 m/s) to equalize the difference in the local
concentration of ions that may form a corrosion battery. However, since it is not possible to nullify a corrosive
catalyzer, it is necessary to select and add an appropriate corrosion inhibitor from a practical view point.
As for measures against stress corrosion cracking, firstly, add the most appropriate corrosion inhibitor to
suppress pitting, the starting point of cracking. Secondly, reduce the residual stress in the cooling pipe as much
as possible. For this purpose, improvement of the processing method such as expansion of the cooling pipe and
assembling is important.
313
2
Piping for the Turbine Plant
2.1 The Steam Pipes
The damage to a main steam pipe or a hot reheat steam pipe is creep damage caused by the effect of internal
pressure during the steady operation and erosion and low cycle fatigue damage due to repeated thermal stress
caused by load fluctuation due to start and stop or some other factors.
Places where wall thickness reduction is liable to occur are the main stop valve (MSV), the governing valve
(CV), the lower outlet of the drain valves located before and after the valve seat of the combined stop and control
reheat valve (CRV), the elbows, the caps and the orifices. Leakage due to reduction in the wall thickness was
experienced in these places and components. Figs. 3.4.5-8 and 3.4.5-9 show the location of the damage and the
actual damage to the drain pipe elbows before and after the valve seat of the CRV, and the actual damage to the
main steam lead pipe warming orifice, respectively.
Flow
Figure 3.4.5-8: An Example of Damage to a Drain Pipe Elbow Before and After the Valve Seat of the MSV Valve
From the lead pipe
To the high pressure
casing
To the condenser
Leakage
Figure 3.4.5-9: An Example of Damage to the Main Steam Lead Pipe Warming Orifice
These types of erosion are caused by the collision of the drain jet and flowing- in of the oxidized scale existing
in the main pipe. The countermeasures are periodic measurement of the wall thickness of the places in the
system where reduction in wall thickness is liable to occur and replacement of those components for which
reduction in wall thickness has been advanced.
And the orifice used to be replaced by one that had a shape more favorable in terms of erosion resistance.
Carbon
steel
Ni-Cr-Cu steel
Cr-Mo steel
Temperature: 171 C
Velocity: 200 m/s
O2 concentration: 16 ppm
Carbon steel
Ni-Cr-Cu steel
Cr-Mo steel
Temperature: 150 C
Velocity: 90 m/s
Wetness fraction: 11%
Figure 3.4.5-12: Relation Between Erosion vs. Corrosion Advancing Speed Ratio and Content of Alloy Elements
: Carbon steel
: Cr-Mo steel
Velocity: 90 m/s
Wetness fraction: 11%
O2 concentration:
16 ppm
Steam Temperature ( C)
Photo 3.4.5-5: An Example of Reduction in Wall Thickness of the BFP Booster Pump
Photo 3.4.5-6: An Example of Reduction in Wall Thickness of a Curved Pipe at the Outlet of the Boiler Feedwater
Pump
The short
pipe
The reducer
Figure 3.4.5-14: The Typical Piping Form Around the Heater Drain Pipe Adjusting Valve
316
3.4.6 Corrosion in the Equipment of the Seawater System and the Piping and its Countermeasures
3.4.6.1
Preface
Seawater is considered to be a typical substance that produces a strong corrosive environment since it contains
large amount of strong corrosive chloride ions and has high electric conductivity. Therefore, the equipment and
the piping used in a seawater system and their components often suffer from noticeable corrosion damage unless
they are used based on specific technologies of each component and material. This report explains these
situations of damage, their features, and countermeasures.
3.4.6.2
Corrosivity in a Seawater Environment
Generally, the temperature, pH, and concentration of dissolved oxygen of clean natural seawater are 20C or
colder, approximately 8, and 5 to 10 ppm, respectively. They are approximately the same level as those of
freshwater.
However, the fact that it includes a concentration of 19,000 ppm of chloride ions, which corrodes metal
surfaces, and its electrical conductivity is 27 !cm (both are 100 times or more those of freshwater) has important
meaning.
In other words, since a layer of rust formed on the material surface becomes porous in the presence of a high
concentration of chloride ions, the corrosion rate of carbon steel, cast iron, and niresist cast iron (austenite Ni cast
iron) in seawater increase approximately linearly (3) when the flow speed increases to 5 to 15 m/s although the
gradients of the speed increase are different from each other. This is decisively different from the behavior of
carbon steel in freshwater where the corrosion rate rapidly decreases due to a delicate film forming with a flow
speed of 1 m/s or faster (2)(4). This is one of the strongest reasons why carbon steel cannot be used for seawater
hydraulic machines and equipment without any surface treatment. However, since some niresist cast iron (type
III) and copper alloys (BC2, BC6, AlBC2, etc.) are low in corrosion rate as well as in flow speed dependency,
these materials show superior corrosion resistance unless they are used in high-speed flow or in polluted seawater
(3)
.
The next fact is that highly concentrated chloride ions electrochemically destroy a passive state film. And
this makes the solution in this area acidic by pitting, hydrolysis of metallic ions dissolved inside the structural
crevice, and concentration of chloride ions. As a result, active dissolution occurs to a metal used as a raw
material like stainless steel and copper alloys and continuously advances so that various kinds of local corrosion
such as pitting, crevice corrosion, selective corrosion, intergranular corrosion, stress corrosion crackling, hydrogen
embrittlement, etc. are caused.
Figure 3.4.6-1 shows an example (5) of the relationship between the corrosion of stainless steel and the
environmental conditions. It may be understood that pitting and stress corrosion cracking that do not easily
occur in freshwater (the concentration of chloride ions is 100 ppm or lower) can occur in low-temperature zones
in solution of richly concentrated chloride ions carried by seawater.
Temperature ("C)
Concentration of C1- of
seawater equivalent
Figure 3.4.6-1: Each corrosion damages on SUS304 stainless steel in solution of neutral chloride
317
The next fact is that high electric conductivity of seawater has an important influence on the occurrence and
progression of corrosion damage. In other words, corroding action caused by an electrochemical mutual action
called bimetallic corrosion (also called galvanic corrosion) occurs when component and materials that have
different corrosion potential from each other (for example, a noble metal Cu and a base metal Zn) electrically
make contact and are immersed in a solution. This phenomenon is corrosion damage that a base metal dissolves
at first (as a sacrifice) against noble metal (anodic dissolution). In this case, higher electric conductivity means a
longer distance over which an electrochemical mutual action can occur. In seawater, where the affected area is
simply calculated as the square of 100 times that in freshwater, the speed of corrosion damage is accelerated
according to the increase in the affected area.
Therefore, special care is necessary to prevent this galvanic action (selection of materials and design of parts
configuration) in order to decrease corrosion damage to hydraulic machines and some others that consist of
various components and materials (1).
In certain cases, the corrosivity feature of seawater environment works moderately to the same degree as
freshwater does depending on the material used and the environmental conditions. On the other hand, cautious
observation is required because it is not unusual for a new kind of corrosion phenomenon to appear, greatly
increasing the speed of corrosion propagation and often leading to severe corrosion damage when the
environmental conditions change or a particular material is used(6)(7).
3.4.6.3
Corrosion Damage to Various Parts and its Countermeasures
1
Parts Made of Stainless Steel
Figure 3.4.6-2 shows an example of a configuration and materials of parts of a seawater pump(8).
The casing
(Carbon steel coated heavy corrosion control)
rubber bearing
Level of seawater
shaft casing (SUS316)
shaft (SUS316)
impeller (SUS14)
rubber bearing
bell casing (SCS14)
runner ring (17-4PH)
bell mouth
(Cast iron coated heavy corrosion control)
Figure 3.4.6-2: Structure of a Vertical Shaft-type Seawater Pump and Examples of Materials Used in the
Components
Such local corrosion as indicated below likely occurs in seawater that contains a high concentration of chloride
ions although stainless steel is used for various parts as shown in the figure. We explain the corrosion damage
listed below and countermeasures.
(1) Pitting
(2) Crevice corrosion
(3) Selective corrosion along metallographic structure
(4) Intergranular corrosion
(5) Stress corrosion cracking and hydrogen embrittlement cracking
(6) Cavitation erosion
(7) Corrosion fatigue
318
1 2 3 yr
# type
$ type
Two phase type
304C (color developed)
304HL
Figure 3.4.6-3: Relation between the Pitting Index of Various Stainless Steels Dipped in Actual Seawater and the
Maximum Pitting Depth
However, it is necessary to be careful when seawater is polluted. Figure 3.4.6-4 (a) and (b) show these
examples. Figure 3.4.6-4 (a) shows that the pitting potential (the critical value of the electric potential to cause
pitting) is reduced by some hundreds of mV and makes the material more liable to be corroded when
concentration of hydrogen sulfide in seawater increases. In the result, the average corrosion rate under this
environment is found to rapidly increase with the increase the concentration of hydrogen sulfide.
SUS316
Seawater
Dissolved oxygen:
Open to atmosphere
pH: 4.8
Seawater
50 C
pH: 5.5
Flow speed: 40 m/s
Figure 3.4.6-4: Corrosion Behavior of Stainless Steel in Polluted Seawater Containing Hydrogen Sulfide
Although natural seawater containing such highly concentrated hydrogen sulfide does not actually exist, it
implies that such severe corrosion damage can occur in the event that formation of a local polluting environment
due to attachment and decomposition of marine creatures or a micro-polluting environment due to dissolution of
non-metallic impurities such as MnS in the steel occur.
For parts with thin wall thickness, it is very necessary to use the high-quality steel indicated above. For the
condenser pipes, the two-phase stainless steel SUS329J1 or the recently developed super stainless steel
SUS329J4L is used (12)(13).
319
Crevice corrosion
The
impeller
Crevice
corrosion
Sediment
A bolt
Crevice corrosion
A shaft
Marker paint
Pitting
A shaft
Zone being
washed by
the tide
Figure 3.4.6-5: The places of a Structure Made of Stainless Steel Used for a Seawater Pump Where Pitting
Corrosion Occurred
For the impellers of pumps with a lot of downtime, dust is accumulated at the lower part by the force
of gravity and becomes the starting point of corrosion.
2) For bolts in hollow parts, mats made from marine creatures have accumulated and become the starting
point of corrosion as (1) above.
3) When a part number is written on the shaft by a marker, the ink film becomes a crevice and occurs
crevice corrosion.
4) For pump shafts of pumps with a lot of downtime, corroded pone occurs at the point of a lot of floating
dust floats in the zone of the tide.
In these cases, the degree of corrosion damage is so small as to seldom cause a functional problem even in
long-time operation.
Thus, the occurrence of crevice corrosion strongly depends on the structure of the crevice and existence of
attached substances.
The next matter to be discussed is the influence of environmental conditions on the crevice corrosion shown in
Figure 3.4.6-6. The results indicate that the observed maximum corrosion depth increases according to the
increase in the free surface area as well as the DO concentration, and this increase in the amount of cathode action
around a crevice decides the speed of anode action.
Maximum Crevice Corrosion Depth
(mm)
1)
Concentration of
Dissolved Oxygen
Figure 3.4.6-6: Relation between the Outside Free Surface Area and the Concentration of Dissolved Oxygen
Influencing the Maximum Depth of Crevice with crevice corrosion of SUS304 Dipped in Seawater
320
This phenomenon explains that structures where the area of the crevice working as the anode is small but the
area of the free surface working as the cathode is large are liable to suffer severe corrosion damage.
The next exhibit is Figure 3.4.6-7 (15) that shows the condition of metal materials related to crevice corrosion.
In the same manner as that of Figure 3.4.6-3, it indicates that an alloy element (here, the content of Mo)
considerably increases the critical creive corrosion temperature. And the fact that the critical crevice corrosion
temperature is lower than that causing pitting by about 40C shall be observed.
Crevice corrosion
Pitting
No crevice
corrosion occurred.
No pitting occurred.
Pitting
Crevice corrosion
occurred.
occurred.
Temperature (C)
Figure 3.4.6-7: Relation between Critical Temperature of pitting and Crevice Corrosion and Mo Content in
Various Stainless Steels
Next, it explains measures to prevent crevice corrosion. As described above, since crevice corrosion damage
is basically relatively light two-dimensional damage and change over time in depth is slow, it is not necessary to
be overly concerned. However, in the event that a thin material is used or in the case of a part whose air (water)
tightness is critical, it is recommended to see that the structure to prevent dust from adhering, that the device of
the structure is designed so as to prevent corrosion damage from concentrating in a limited area, and that the
appropriate operation is carried out.
Regarding the selection of materials, Figures 3.4.6-3 and 3.4.6-7 should be referenced and Table 3.4.6-1 can be
referenced when there is much freedom of material selection. In other words, the crevice corrosion resistance of
stainless steel is ranked as the lowest, thus utilization of niresist cast iron, or copper alloy is effective when full
corrosivity can be sacrificed to a certain extent.
Table 3.4.6-1: Crevice corrosivity of various materials to use for seawater structures
Crevice corrosion resistance
Major materials
Hastelloy C
Ti*
Inconel 625
90Cu-10Ni
70Cu-30Ni
Bronze
Inconel 823
Brass
Carpenter 20
Carbon steel
Monel
Copper
A paste containing metal zinc grain to prevent crevice corrosion can be available in the market(18).
Application of the paste to crevices in structures can prevent crevice solutions from becoming acidic and can then
suppress crevice corrosion. Also, welding alloy known as prevention of crevice corrosion ressistance.(19).
321
1.3 Selective Corrosion along the Metal Structure and its Countermeasures
First, Photo 3.4.6-1 shows corrosion damage of the threads of a SUS 304 steel bolt and screw used for
seawater hydraulic devices along the non-metallic inclusion. Corrosion dissolution occurs in the shape of many
tunnels along the longitudinal direction of the bolt and the edge is dissolved along Mns non-metallic inclusion.
The longitudinal direction of the bolt
non-metallic
inclusion
Photo 3.4.6-1: Corrosion Damage on the screw of a SUS 304 Steel Bolt along Non-metallic inclusion
Based on this knowledge, in countermeasures against this kind of damage, it is decided not to use bolt
materials produced through too much rolling and to obsreve the S content where possible. As a result, the
occurrence frequency of damage has been reduced.
Next, we explain the relationship between cutting conditions and corrosion resistance.
The difference in corrosion resistance quality between the best stainless steel and the poorest is a 3-digit
number at maximum even if all of them conform to the JIS standards because the conditions of the formation of
machining-induced martensite phase change greatly depending on the alloy composition and the cutting
conditions.
Figure 3.4.6-8 shows the results of tests where a part of a specimen is dipped in actual seawater for 16 months
in total with the content of Cr as well as the content of Ni changed by a few steps within the JIS standard and also
with the cutting conditions variously changed.
Symbol
Material
Cutting Conditions
Corroded Evaluation
Area Ratio
Fair
Excellent
Good
Figure 3.4.6-8: Advancement of Pitting in SUS 316 Dipped in Seawater with Varying Cutting Conditions
Based on the above-mentioned knowledge and information, it is understood that the corrosion resistance of
stainless steel dipped in seawater cannot always be grasped only by the average chemical composition but is
strongly influenced by minute impurities, metallographic structure, and attached scale (25).
322
Deposited metal
(a) A Hole Made due to Grain Boundary Corrosion of an Area Influenced by Welding Heat and the Surrounding Area
It is basically important to reduce the influence of heat caused by welding to prevent this damage from
occurring, and using a metal of high quality is not always effective.
Next, information on selective dissolution is presented in Figure 3.4.6-9(29)(30). This figure shows the result of
a test where deposited metal and the base metal of SUS 304 stainless steel were tested in a corrosive environment.
It also shows the fact that the deposited metal is inferior to the base metal over wide conditions of heat treatment
in terms of corrosion resistance. As measures to prevent this damage, cancellation of alloy segregation by resolution treatment at 900C or higher, utilization of hyper-low C steel to prevent sensitization, or prevention of
alloy segregation by using 9% Mo- or N-added steel are considered effective (29)(30).
: Deposited metal
: Base metal
As welded
As received
Two-hour hold
One-hour hold
Figure 3.4.6-9: Influence of Heat Treatment on Pitting Corrosion Resistance of the Deposited Metal of SUS 304
Steel
323
1.5 Stress Corrosion Cracking and Hydrogen Embrittlement and Their Prevention
Generally, in our experience, chloride stress corrosion cracking of austenite-group steel does not occur in
seawater at normal temperature.
This material easily cracks due to the rich concentration of magnesium chloride in special seawater
environments where the temperature becomes 60C or higher(33) to (35) or in the event that it is exposed to an
oceanic climate in a dry atmosphere whose relative humidity is as low as 30%(36) to (38).
Next, Figure 3.4.6-10(39) and Figure 3.4.6-11(40) show the hydrogen embrittlement of 17-4 PH steel that is used
for the sliding parts of a seawater pump. According to the information obtained from these figures, cracks occur
to materials whose hardness is more than 320 Hv, and the apparent advancing speed of a crack increases more for
steels of higher hardness.
: Solution treatment at 850C
: Solution treatment at 1050C
Numeral: Cracked specimens/
Total specimens
Figure 3.4.6-10: Behavior of the Sliding Part Material Made of 17-4 PH Steel Dipped in 3% Saltwater at Room
Temperature Related to Hydrogen Embrittlement
Isolated dipping
Figure 3.4.6-11: Behavior of 17-4 PH steel Dipped in the 3% Saltwater at Room Temperature Related to
Hydrogen Embrittlement
Figure 3.4.6-11 shows that a material with higher strength has more crack sensitivity. And crack sensitivity is
higher in the case where the material makes contact with Zn (electrolyted protection) than in the case of isolated
dipping.
Next, Figure 3.4.6-12 shows the influence of environmental conditions on hydrogen embrittlement cracking.
For behavior in this type of cracking, seawater and freshwater are considered to have the same effect. In other
words, pitting at the starting point occurs at first, and then a crack may occur when the dynamic conditions are
satisfied. This point represents a large difference from chloride stress corrosion cracking
Temperature (C)
Austenite steel as
a deposited metal
Martensite steel
Cast iron
cast iron
Nickel equivalent
Figure 3.4.6-13: Relation between the Amount of Damage due to Cavitation Erosion and Hirayamas Nickel
Equivalent
325
Figure 3.4.6-13 shows that each curve representing a hardness value of 2~7Cr steel or 13Cr steel shows a
downhill tendency against the Ni equivalent, while each curve representing a hardness value of 18~30Cr-7~20Ni
steel shows a uphill tendency.
This fact makes us recognize that there is a big difference in cavitation erosion resistance among some types of
steel even belonging to the same standard due to even slight differences in their alloy composition.
Therefore, when you engage in the design of an actual hydraulic machine or selection of a material to be used
for repair of damage, you should calculate the nickel equivalent of the material to be used and check the place to
be repaired in the drawing. In some cases, extension of damage life can be expected by a slight change to the
metal composition.
Figure 3.4.6-14 and Figure 3.4.6.15 indicate that it is preferable to choose a material whose strain energy is as
large as possible among types of steel whose corrosion resistance is almost the same.
Hirayamas Ni equivalent
A zone
C zone
B zone
Figure 3.4.6-14: Relation between Amount of Damage due to Cavitation Erosion of18Cr-6Co Stainless Steel and
Hirayamas Ni Equivalent Using the C Content as a Parameter
C content (weight %)
Figure 3.4.6-15: Relation between Material Hardness Just under the Surface Subjected to a Cavitation Erosion
Test of 18 Cr-8Ni and 18Cr-6Co Stainless Steel
326
Copper Alloy
Photo 3.4.6-3 shows dezincification corrosion of a part made of brass.
Dezincification
corrosion
Material
Copper
Silicone bronze
Admiral brass
Aluminum brass
90/10 cupro nickel
90/30 cupro nickel
Monel 400
316 steel
Incoloy 825/Carpenter20Cb
Inconel 625/Hastelloy C
Titanium
0.9
0.9
1.5
2.4
3.1
3.6
No limitation to the max. flow speed specified
No limitation to the max. flow speed specified
No limitation to the max. flow speed specified
No limitation to the flow speed specified
No limitation to the flow speed specified
On the other hand, in the case of a stainless steel pipe, since a slow flow speed (1 to 2 m/s or slower) allows
marine creatures to easily accumulate causing local corrosion, a faster flow speed is preferable if pressure loss can
be ignored.
Pitting of a copper alloy pipe used for a seawater heat exchanger can occur when the seawater is polluted (67).
Injection of ferric sulfate (Fe2+) into seawater whose concentration is brought to 0.01 ppm is considered
effective. The mechanism according to which this works is explained as follows. FeOOH that is produced by
oxidization of Fe2+ is attached to the inner surface of the pipe, forming a protective film there (68)(69).
However, the industry has recently been restrained from using this method in some cases from an
environmental protection viewpoint because the seawater is slightly colored when this method is used. And this
method is not very effective when the seawater is polluted (70)(71).
327
3
Heavy Corrosion Protection Coating and the Lining Parts
3.1 Steel Plates to Which Heavy Corrosion Protection Coating is Applied
Table 3.4.6-3 shows examples of causes of corrosion that occurred to parts to which heavy corrosion protection
coating was applied. This table reveals that the damage was caused in various production processes such as
assembly operation, painting operation, design, and maintenance operation.
Table 3.4.6-3: Causes of Corrosion Damage to Parts in a Structure Exposed to a Flowing Seawater Environment to
Which Heavy Corrosion Protection Coating Was Applied and the Their Classification
No.
A-1
-2
B-1
Cause of Damage
Separation of a paint film caused by tightening of bolts or nuts
Separation of a paint film caused by contact and/or impact by a wire rope
Assembling operation
-2
-3
-4
C-1
Classification
-2
Improper detailed shape of the base part (corner of the end portion)
D-1
E-1
Painting operation
Design work
Maintenance operation
It is required to choose such a coating material that will not cause problems in each process (for example, a
material with mechanical flexibility) as shown in the Table 3.4.6-3 in the case where the heavy protection coating
under discussion provides a film thickness of hundreds of m. Coal tar epoxy paint that is widely used is
considered to be reasonable from a practical viewpoint (70)(71).
328
Table 3.4.6-4: Examples of Methods of Reducing Galvanic Corrosion Damage in a Structure Used in a Seawater
Environment
No.
Method
Description
Actual Case
b)
A spacer
a)
Coating
A-1
A-2
Methods of relieving
interaction between
the materials
A-3
Carbon steel
b)
a)
A2/A1 = small (wrong)
Stainless steel
Carbon
steel
B-1
B-2
B-3
Methods of relieving
corrosion damage
even if interaction
exists
a)
b)
Paint film
Local corrosion
occurs (wrong)
Even corrosion
occurs (correct)
Paint film
You should understand that the word corrosion potential series that often appears when discussing galvanic
action just means an order and has no relation to the speed of galvanic action. For example, it is a well-known
fact that if the speeds of consumption of a zinc plate are compared between two cases, one where a zinc plate is
made to contact a stainless plate whose area amount is the same as that of the zinc plate (the potential difference is
1.0 V or less) and the other where the zinc plate is made to contact a carbon steel whose area amount is the same
as that of the zinc plate (the potential difference is 0.5 V or less), the speed of consumption of the zinc plate in the
latter case is faster by as much as 30 times at maximum than the former case.
4.2 The Electrochemical Protection Method
The cathode corrosion prevention method where the surface electric potential is made to be the base potential
is the most popular among electrochemical protection methods in the seawater environment. The anode
corrosion protection method where the surface potential is made to be the passive state potential is not practically
used because this method sometimes dangerously accelerates anode dissolution in crevices in a complex structures.
There is the impressed current method and the galvanic anode protection method (the sacrificial anode
method), but the former is relatively rarely used. For the impressed current method, it is necessary to install an
insoluble electrode (graphite or magnetic iron oxide electrode) at the fluid surface and to connect the lead wires
extended from the outside power source with each part. For this method, it is necessary to devise a special fixing
measure so that the fixed parts do not interfere with the fluid flow. And since corrosion damage to parts that are
made of stainless steel sometimes occurs during suspension of operation (installation, periodic inspection, etc.)
when the flow in the equipment also stops, in some cases, unexpected damage occurs because electricity is not
supplied during these periods. And an inappropriate design may cause overprotection in certain cases, resulting
in separation of the paint film or the lining due to the large amount of hydrogen gas generated at the cathode.
Also, in certain cases, severe corrosion damage may occur due to chlorine gas with strong oxidizing power in
equipment whose valve is left completely closed.
On the other hand, this kind of bad effect seldom occurs in the case of the galvanic anode protection method
because the current amount is relatively small. Aluminum (current efficiency: 80%) or zinc (current efficiency:
95%) rather than iron or steel should be used for the anode to be attached because they are cheaper and their selfelectrode potential is lower than iron or steel (71). Mg, when attached, provides too low an open circuit potential
and lower current efficiency (fast consumption), causing overprotection in certain cases.
It is necessary to periodically replace the anode because the anode is consumed when the galvanic anode
protection method under discussion is used. When a replacement period longer than that of the periodic
inspection is desired, it is important to reduce the value of the [protected area/area of the anode]. However, it
becomes important to pay as much attention as possible to the reliability of the heavy corrosion protection coating
when it is difficult to attach many anodes. You should expect very fast consumption of the anode when a carbon
steel part with a large area is exposed to fast-flowing seawater.
329
2.
Concerning dielectric breakdown that is peculiar to electric power generators in particular, active studies are
made including the sampling investigation of actual coils.
331
Inspection
During
operation
Deterioration of
creep strength
Abnormal operation
Asynchronous
operation
Unbalanced operation
High-frequency
operation
Overexcitation
operation
Excessive speed
operation
Short circuit accident
Re-close operation
Hightemperature
tank
Reverse phase
current
High-frequency
current
Deterioration of
low-cycle fatigue
strength
Accumulation
of starts and
stops
Centrifugal
stress during
operation
Electric
corrosion trace
Cracks
Superimposed
start/stop and
high-temperature
creep
Progress of
cracks
Serious
accident
Periodical nondestructive
inspection
Reverse phase magnetic field
Rotor-rotating direction
Polar surface
Cross slot
Teeth
(iron core)
Wedge
Damper ring
Field coil
Retaining ring
Probe
Wedge
Ultrasonic
Shaft
Wedge
Defect
Coil
Coil slot
Wedge ultrasonic
flaw detector
(Continuous operation)
1970s.
In the remaining life evaluation, the presence of thermal influence is checked by confirming wedge hardness.
Defects are detected by ultrasonic flaw detection or magnetic powder flaw detection. The crack size is evaluated
by the superimposed creep and fatigue from the actual stress.
Periodical inspection
Retaining ring
External UT External PT
No defects
Periodical inspection
Retaining ring
Eternal SCC found
Internal SCC defect depth about 10mm
3 years
SCC progress speed 2.5~3.3 mm/year
After removing 6 mm
SCC defects during deletion
333
Retaining ring
Insulation
cylinder
Polar connection
conductor
section
Lead conductor
Rotating span
Rotor shaft
Stopped span
Polar connection conductor
Retaining ring
Insulation cylinder
Retaining ring
(Insulation cylinder side)
#7 coil
#6 coil
Insulation
Centering ring
Polarity crossing
Retaining ring
Rotor coil
Polarity crossing
Flexible section
Shape of polarity crossing
334
No centrifugal force
Movement of
coil in slot during
low-speed
turning
Surface roughness
Copper powder
to the insulator and deformation of the conductor without disassembling the lead wedge.
Coil
Retaining ring
Centering ring
Inspection
Insulation plate
Lead wedge
Lead conductor
(Flexible)
Retaining ring
Centering ring
Fan boss
Inspection
Lead conductor
rise section
Lead conductor
(Solid)
Fiber scope
Terminal stud
3.2 Stator
3.2.1 Transition in insulation method
The capacity of the turbine power generator has been increased and the size has been reduced mainly by
improvement of the cooling method and development of the insulation system. Stator coil insulation of the
rotating electric machines including the turbine generator mainly consists of mica with superior corona resistance
and impregnated resin for holding the mica.
As shown in Fig. 3.5.1-11, the impregnated resin of natural resin (shellac resin, asphalt compound, etc.) was
used. Along with development of synthetic resin with superior heat resistance, polyester resin and epoxy resin
came to be used. Polyester resin has been used from the middle of the 1950s, and epoxy resin has been used
from the late 1950s.
No.
!
"
#
$
Mica base
Flake mica
Flake mica and
laminated mica
Laminated mica
Impregnated resin
Natural resin
Polyester resin
Epoxy resin
Year
1960s. At present, flake mica and laminated mica are used depending on the voltage level, coil dimension, etc.
Because it has become difficult to obtain flake mica of good quality recently, the use of insulation systems with
laminated mica is increasing.
It is necessary to eliminate the void in the insulation layers of the stator coil to the extent for the prevention of
corona. For this purpose, impregnated resin is used. The resin impregnation method is generally classified into
two: the vacuum pressure method (VPI method), and the resin-rich method. The vacuum pressure method of
the coil was used for synthetic resin mica insulation at first. In the middle of the 1960s, the resin-rich method
came into practical use. In this method, semi-cured mica tape is used, and an insulation layer is formed by
pressurization and heating after taping. At present, both the vacuum pressure method and resin-rich method are
used depending on the voltage level, power generator dimension, or the production facilities of the maker.
Mechanical deterioration
Regular voltage
Surge voltage
Regular voltage
Environmental deterioration
Deterioration of insulation
resistance due to moisture
absorption and pollution
wedge.
edge. Inspection of wedge looseness at periodical inspection and re-insertion of the wedge, if necessary, are
also effective measures to prevent these phenomena.
Item
Contents
Megger
AC
Table 3.5.1-3: List of dielectric breakdown judgment standards of wires on high-pressure rotating machine
Company name
Diagnosed rotating
machine
6.6~11 kV
Power generator
#11 kV
Power generator
#11 kV
Power generator
#11 kV
Power generator
#11 kV
Power generator
11 kV
Power generator
11 kV
Power generator
11 kV
Power generator
<12
NG
<12
NG
Insulation resistance R1
(M$)
Polarization index
(PI=R10/R1)
#1.5
OK
#1.5
OK
tan!0 (%) at 2 kV
(6.6 kV: at 1 kV)
#1.5
OK
%10
OK
at 1.25E/ 3
#1.5
at E
#2.0
OK
#2.0
OK
%2.0
0.3~3
OK
%10
OK
%1.0
Caution
needed
NG
#2.5
NG
#2.5
NG
%2.5
OK
Caution
needed
NG
Caution
needed
#6.5
NG
>6.5
NG
at 1.25E/ 3
#5
NG
>5
NG
at E
#12
NG
>12
NG
#10,000
Caution
needed
NG
#6.5
"tan!+"C/C0 (%) at E
<12
#1.5
OK
#0.8
Caution
needed
NG
<10,000
#1.5
OK
#10,000
at E/ 3
OK
#30,000
qmax
(pC)
OK
#2.5
"tan!
(%)
"1
(%)
#1.5
Caution
needed
NG
#10,000
#30,000
Caution
needed
NG
#30,000
<5
OK
<10,000
OK
#10,000
>10,000
at 1.25E/ 3
NG
#30,000
at E
Nq
qmax
#22,000
NG
#2.0
#30,000
at 1.25E/ 3
Insulation resistance
required for operation
2E+1 kV
Caution
needed
NG
2E+3 kV
Surface
discharge is
dominant.
2E+1 kV
2E+1 kV
339
2E+1 kV
2E+1 kV
2E+1 kV
2E+3 kV
Method
Outline
NY map
Obtained from operation hours and number of
start/stop times
Operation condition
Equivalent operation time
Insulation diagnosis method
D map
340
Number of starts/stops X1
((10P3P times)
Fig. 3.5.1-15: Relation between remaining withstand voltage and operation conditions
[3] Remaining life estimation method from equivalent operation hours
Sample coils of epoxy resin insulation are collected from machines, and the destructive voltage test is
performed. From the result, the following formula to estimate the remaining breakdown voltage (% indication,
taking BDV at production to be 100%) using the equivalent operation hours is obtained. The equivalent
operation hours are the operation hours calculated equivalently, regarding that one start/stop is equivalent to 20
operation hours.
BDVav = (-4 ( 10-5)YE + 100
BDV3& = (-6 ( 10-10)YE2 + (-6 ( 10-5)YE + 77.276
Here,
YE: Equivalent operation hours
(Equivalent operation hours) = (Operation hours) + 20 ( (Number of starts/stops)
The relation between the equivalent operation hours and remaining breakdown voltage is shown in Fig. 3.5.116.
Average
Average - 3&
Average
Data range
Average - 3&
341
Discharge parameter
" (="B2B+"B1B) (%)
Remaining breakdown
voltage
Average by least
square
Insulation life control curve
Estimated value of remaining breakdown voltage
Vp (%)
%: Single polyester insulation coil
&: Coil of polyester insulation power generator
: Single epoxy insulation coil
Fig. 3.5.1-18 Relation between estimated value Vp and measured value VR by D map method
[2] Estimation from max. discharge charge amount
The investigation result of the relation between Q max and breakdown voltage VR is reported. Here, Q max
is of the coils sampled from 10 power generators of polyester insulation at the rated voltage. The result is shown
in Fig. 3.5.1-19. Both have a good correlation. Deterioration judgment standard (40% of initial destructive
value) = 22000 pC at the 99% reliability lower limit is proposed.
Remaining breakdown
voltage VBRB (%)
QBmaxB (Coulomb)
342
Withstand
insulation
required for
operation
Model
[3] Estimation by the multiple regression method from nondestructive electric test
In the following formula, the statistical correlation between the destructive voltage collected from the sampling
coil of the epoxy resin insulation and the insulation diagnosis data is calculated, and the remaining breakdown
voltage (% indication, taking BDV at production as 100%) is estimated.
BDV (%) = 91.1 0.767 ' ("I12) 0.151 ' ("tan!12) 1.78(10-6 ' (qmax12)
BDVav (%) = 42 29.2 ' ln((BDV 99.4)/(-56.1))
BDV3& (%) = BDVav ((95.3 0.395 ' Y) ' (57.9 + 0.474Y 0.0405 ' Y2))
Here,
BDVav (%): Average remaining withstand voltage
BDV3& (%): Remaining breakdown voltage of variance 3&
Y: Operating years
The relation between the estimated destructive voltage and measured value is shown in Fig. 3.5.1-21. The
correlation coefficient is as high as 0.61. An example of the relation between the operating years estimated by
this estimation method and the breakdown voltage is shown in Fig. 3.5.1-22. This estimation method uses the
actual insulation diagnosis data and operating years. The remaining life reflecting the actual dielectric
breakdown condition can be estimated.
343
BDV(%)
Batch average
Batch lower limit 3&
Stator core
Wire
Clip
Penetration
Insulation layer
Brazing
section
Absorption
+
Temperature
Hygrothermal aging
Insulation layer
Connection piece
Wire
Ground fault
Fig. 3.5.1-23 Structure of clip section and water penetration to insulation layer
If the cooling water penetrates into the insulation layer, the insulation characteristics drastically lower due to
hygrothermal aging. It is necessary to confirm formation of the water path (leak path) and penetration of the
cooling water into the insulation layer.
Presence of a leak can be confirmed by the coil pressure storage test, vacuum storage test, and tracer gas test,
etc. To judge the absorption degree of the insulation layer, the method of measuring the capacitance of the
insulation layer, which focuses on the difference in the relative permittivity between the water and the insulator, is
put into practical use, and is effective. A schematic diagram of measurement is shown in Fig. 3.5.1-24.
A large difference in relative
permittivity between the wire
insulation layer and water
(1:20) is used.
Coil
Upper coil
Pressing force
3-phase batch short circuit
Electrode
Lower coil
Principle
Capacitance meter
Measurement method:
344
There is another method of estimating the remaining life by obtaining the dielectric breakdown speed by
hygrothermal aging from the capacitance and destructive voltage of the absorbed insulation layer. As shown in
Fig. 3.5.1-25, it is used for examination of the maintenance program. It is important to execute the leak test and
capacitor measurement test periodically. It is important to execute the leak test at each periodical inspection and
to consider the number of years from the initial water supply in the capacitance measurement test.
Aged deterioration by operation
Absorption start point
Capacitance measurement point
Insulation resistance lowering rate = PU/year
Dielectric
breakdown by
hygrothermal
aging
Slide
Ripple spring
Upper coil
Lower coil
Ripple spring
Stator wedge
Ripple spring
Filler
Upper coil
Lower coil
between the coil surface and the slot wall is accelerated, and the insulation layer is damaged. There is a
possibility of a ground fault accident.
Consequently, when the rotor is pulled out, it is necessary to check adhesion of the insulator powder of the
wedge to the iron core visually. It is also necessary to check the hitting sound by the test hammer and the
deformation of the ripple spring under the wedge. If the wedge does not satisfy the judgment standard, proper
measures must be taken.
Power generators are frequently started and stopped recently. The insulators tend to become loose, compared
to the base load machines. It is necessary to inspect and control the machines based on the operation condition.
Flow of hydrogen
gas
Indication,
alarm
radiation
source
Ionization room
3.5.1-30. The search coil output voltage corresponding to the coil with the layer short circuit is lower than usual.
By comparing waveforms, the presence of layer short circuit and coils with short circuit are judged.
Stator core
Rotor
Search coil lead wire
Probe
Search coil
Probe details
Lead wire
Stainless pipe
N pole
Impedance (")
In another method, layer short circuit is detected from the tendency of the changes in the rotor wire impedance
due to the turning speed. If layer short circuit occurs, the inductance of the coil decreases. An small AC
current is supplied to the rotor wire by a constant current generation device. The rotor voltage is measured, and
the rotor impedance at each rpm is measured to judge the presence of layer short circuit. The rotor impedance
characteristics are shown in Fig. 3.5.1-31. The impedance characteristics of the coil with layer short circuit
change drastically. By comparing characteristics, the presence of layer short circuit is judged(18).
347
Detection of phase
difference
Waveform
smoothness
Average stress
Rotation change
unit
Static vibration
ingredient
1st
Detection of strain
amplitude
Peak count method
Damage calculation
(Fatigue life
consumption)
Display request
Display device
Monitor TV
! Oscilloscope
" Digital printer
Power generator
current
Power generator
voltage
Delay unit
5th
Modal conversion
constant
multiplication
Data
recorder
Stress
waveform
Additive
synthesis
Abnormal stress
detection
Alarm
Monitored point
Rotation gap
period
Number of loosened
wedges: f (t)
Initial
[Bathtub curve]
5.
348
3.4.5.2
High-pressure motor
In thermal power plants, high-pressure motors are used for various devices for driving accessories. Highpressure motors are sometimes one of the important devices in a plant. To secure the reliability of the systems of
thermal power stations, preventive maintenance including periodical maintenance, exchange of parts, and
estimation of remaining life by deterioration judgment are performed for the motors of accessories.
Here, the high-pressure basket-type inductive motor is taken as an example, and an outline of preventive
maintenance and remaining life diagnosis is given.
1. Structure and deterioration form of each section
1.1 Structure
A cross-section view of the basket-type motor is shown in Fig. 3.5.1-34. The motor consists of three
sections: the fixed section, rotation section, and bearing section.
Stator frame
Stator core
Rotor core
Stator wire
Rotor wire
Shaft
Internal fan
External fan
Bearing bracket
Bearing
Heat exchanger
Note) The failure is located at the stator and the coil end.
Fig. 3.5.1-35: Transition in cumulative failure rate of each failure of 3 kV basket-type motor
1.3 Control items, deterioration form, and diagnosis method of major sections
Deterioration of major sections of the motor is classified as follows:
[1] Thermal cause
[2] Electric cause
[3] Physical cause
[4] Mechanical cause
[5] Chemical cause
Deterioration is accelerated by a combination of these causes, and failure occurs. The causes of deterioration
are shown in Fig. 3.5.1-36. Examples of control items, deterioration form, and diagnosis method are shown in
Table 3.5.1-5.
349
Electric cause
Physical cause
Thermal cause
Surge
Partial discharge
Heat cycle
Swelling,
Overload
contraction,
Cooling failure deformation,
Thermal
distortion
deterioration
Absorption Degradation of
Dewing
lubrication oil
Dust
Surface
insulation
failure
Deterioration
Start, stop,
vibration,
shock,
overcurrent
Fatigue,
wear,
deformation,
distortion
Mechanical cause
Chemical cause
Control
locations
Appearance
Operation
condition
Related to bearing
No.
Slide
bearing
Roll
bearing
Rotor
Stator
Control items
Deterioration form
Diagnosis method
Pollution
Discoloration
# Visual
# Visual, hitting
Sound
Vibration
Odor
# Odor judgment
Smoke
# Visual
Voltage
# Voltage monitoring
Current
# Current monitoring
Temperature
# Thermometer
Lubrication oil
Oil ring
Deformation
# Visual
Oil scraper
Wear
# Visual
White metal
Vibration
Abnormal noise
# Hearing
# Visual
Grease
Separation, discoloration
# Visual
Duct piece
Loosening
# Visual
Iron core
Loosening
Brazing section
Crack
Short-circuit ring
Deformation
# Visual
Rotor conductor
Loosening
# Visual, hitting
Duct piece
Loosening
# Visual
Iron core
Loosening
Insulation section
Wedge
# Visual
It is understood that daily inspection is very important for early detection and countermeasures against
deterioration. Examples of the standard inspection intervals are shown in Table 3.5.1-6.
Table 3.5.1-6: Standard inspection interval of motor
Initial inspection
350
Continuance inspection
Insulation
method
Rated
voltage
Judgment
II
III
IV
Compound
Compound
Varnish
Resin
Resin
3.3 kV
6.6 kV
3.3 kV
3.3~4.4 kV
6.6~11 kV
3.3~11 kV
OK
OK
OK Caution needed NG
OK
OK
OK
~100~10~
R [M"]
>E+1
RC ["&F]
>10
log (Rd/Rw)
<3
P.I
>1.5
>1.5
tan$0 [%]
%tan$ [%]
>2.0
~20~30~
<10
<0.9
at 1.25E/ 3
at E
~1.5~1.0~
<0.7
<6.5
~0.7~1.1~
<12
%tan$+%C/C0 [%] at E
pi [kV]
% [%]
P11
P12
>6.6
~4.6~3.0~
<2.5
at 1.25E/ 3
at E
Vi [kV]
>E
>3.3
<4.0
<8.5
~4.0~5.9~
q>500 pC
~1.9~1.3~
q>1000 pC
>E
N [Pcs/half cycle]
at E, q>500 pC
~50~100~
<10000
at E/ 3
qm [pC]
at 4.5 kV
at E
<10000
<5000
~1000~1400~
sample is used to obtain some heat analysis values using the heat analysis device.
The correlation between the physical characteristic values and heat analysis value is examined to obtain the
best relation. This is called the master curve. It is obtained for each insulation material. The master curve is
the principle of this test method. An example of a master curve is shown in Fig. 3.5.1-37.
TG 3/1 reduction rate
Chemical
characteristics of
sampled material
Mechanical
strength
Lamination
plate, etc.
Resin
Varnish
Small
Over 75%
Under 2.5%
Under 10%
Medium
50~75%
2.5~5.0%
10~20%
Large
Under 50%
Over 5.0%
Over 20%
3.2 Bearing
3.2.1 Roll bearing diagnosis machine
The bearing is an important part of the rotating machine. As mentioned before, the failure rate is rather high.
It is very important to detect the failure before fatal errors occur.
The life of the roll bearing is particularly short among structural parts of the motor. The life is defined with
99% reliability. The life is mainly judged by the occurrence of flaking. Flaking is fatigue breakdown on the
surface caused by repeated stress on the rolling contact section. Due to this fatigue, the surface peels off in
flakes.
To detect this kind of abnormal phenomena, bearing vibration is detected by acceleration and enveloped. By
this method, according to the enveloped vibration acceleration data, the calculation circuit that is weighed
according to the failure type is passed, and the presence of failure is numerically converted to facilitate judgment.
3.2.2 Diagnosis of slip bearing
The life of the slip bearing is longer compared to the roll bearing. However, due to various causes,
temperature increase, wear, white metal fatigue, peeling, and cracks occur, leading to the life of
the bearing diminishing.
By the thermometer element that is buried in the bearing, the bearing temperature during operation is
monitored throughout the year. The measurement result is used for tendency control. If any temperature out of
the tendency is detected, it must be noted because the lubrication surface might have some errors.
Investigation of the lubrication oil is one of the methods to detect bearing failure. By sampling a small
amount of lubrication oil from the bearing for fluorescent X-ray analysis, the amount of metal materials that form
the white metal ingredients in the lubrication oil can be clarified. If this investigation is performed periodically,
the tendency is controlled to judge the presence of failure.
Afterword
An outline of the preventive maintenance and remaining life diagnosis of the high-pressure motor is introduced
here.
It is desirable to continue a close relationship between makers and users for future development and
improvement of these technologies.
354
3.5.1.3
Electric facilities in the plant
Many thermal power plants in Japan were built between the 1950s and 1970s. More than 70% of units have
been operated for 15 years or more. The number of plants used for 15 years or more will increase in the future.
In addition, for stable supply of electricity and economical merits of extension of life, recent themes of study are
to diagnose the aged facilities properly and effectively execute life control and preventive maintenance based on
the diagnosis result.
From this point of view, as a typical device of the electric facilities of thermal power plants, an outline of
remaining life diagnosis and preventive maintenance of the static devices (including the main transformer,
transformer in the plant) and high-/low-pressure switch gear (including the metal clad, power center, and control
center) is given here.
1.
Transformer
Transformers in thermal power plants include the main transformer for increasing the power generator voltage,
starting transformer for supplying the plant-starting power source, and the transformer in the plant for supplying
the power source during normal operation. Based on the concept in Table 3.5.1-9, daily inspection and
periodical analysis investigation of the insulation oil-dissolved gas are performed for these transformers. In
addition, internal detailed inspection and overhaul are performed at the time of exchange of parts with relatively
short life and at periodical inspection of the plant to secure reliability(1)-(7).
Table 3.5.1-9: Maintenance and overhaul of transformer
Inspection cycle and updating schedule
Remarks
Oil-sealing section
Mechanical
protection relay
Gauges
Oil-cooling device
All devices are replaced if the bearing issues abnormal noise after 5~10
years.
Tap-switching
device for load
Paint
The main body is inspected by gas analysis of the oil once every 6 months
or 1 year. It is decided whether the internal inspection is required
depending on the result.
Along with the increase in the number of devices that have been used for 20~30 years, it is important to
execute deterioration diagnosis of oil-immersed transformers and estimate the remaining life from the view points
of effective use of devices and securing reliability. The oil-immersed gas analysis is widely used to diagnose
device failure. The method is widely known as the Electric Technology Research Association method(1) (5).
Here, we focus on remaining life diagnosis mainly by deterioration.
355
Table 3.5.1-10: Maintenance control value of insulation oil after starting operation
Voltage level
Water
(ppm)
Dielectric
breakdown
voltage
(kV)
Volume
resistivity
("cm)
(80+)
Total
oxidation
(mgKOH/g)
11~77 kV
110~275 kV
Tap switcher
'500 kV
Standard value
Test frequency
Standard value
Test frequency
Standard value
Test frequency
Standard value
Test frequency
<40
Once/3 years
<30
Once/3 years
<20
Once/3 years
40~50
Once/year
30~50
Once/year
20~30
Once/year
"
>50
Countermeasures
>40
Countermeasures
>30
Countermeasures
>30
Once/3 years
>40
Once/3 years
>50
Once/3 years
>20
30~40
Once/6 months
40~50
Once/6 months
"
<30
Countermeasures
<30
Countermeasures
<40
Countermeasures
)20
>1*1012
Once/3 years
>1*1012
Once/3 years
>5*1012
Once/3 years
Once/year
>1*1011~>1*1012
Once/year
>1*1011~>5*1012
Once/year
Once every 3
years or once
every 50,000
times of
operation if a
hot-line washer
is provided; once
every 20,000
times of
switching
operation if it is
not provided.
Take measures if
the voltage is 20
kV or less.
<1*1011
Countermeasures
<1*1011
Countermeasures
<1*1011
Countermeasures
<0.2
Once/3 years
<0.1
Once/3 years
<0.1
Once/3 years
0.2~0.5
Once/year
0.1~0.5
Once/year
0.1~.5
Once/year
"
>0.5
Countermeasures
>0.5
Countermeasures
>0.5
Countermeasures
! >1*1011~>1*1012
"
1.1.2 Insulator
The temperature of the insulating paper that is wound on the wire is the highest. The insulating paper tends
to be affected by degradation of characteristics caused by deterioration. Oil-immersed dielectric breakdown
strength, which is an important characteristic of the insulating paper, is not lowered by deterioration, in the same
way as the insulation oil. No problems normally occur even after the long-term operation of the transformer.
Tensile strength, which is another important characteristic of the insulating paper, is degraded due to deterioration,
and problems might occur when operation is continued. For example, when a system ground fault accident (2wire ground fault, etc.) occurs, external ground-fault or short-circuit current is applied. The tensile stress
functions to the wire coating due to the magnetic mechanical strength that occurs on this occasion. When the
strength of the insulating paper lowers below the strength, the insulating paper is torn or broken. This is the end
of the life of the insulating paper. It is in fact impossible to exchange the wire insulating paper of the transformer.
If the transformer is continuously used, the wire must be exchanged.
According to the above, the life of the transformer depends on the tensile strength of the insulating paper that
is wound on the wire.
Fig. 3.5.1-38: Relation between remaining rate of average degree of polymerization and transformer operation
years
the insulating paper(5) (7). The average degree of polymerization indicates the length of the molecule that
constitutes the insulating paper. If the paper material is deteriorated, the average degree of polymerization
becomes smaller. The initial average degree of polymerization of the insulating paper of the wire is around 1000.
In JEM1463-1993, the following evaluation standards of the average degree of polymerization of the insulating
paper for transformers are defined:
Life level:
450 or less
Dangerous level: 250 or less
Fig. 3.5.1-39: Relation between remaining rate of average degree of polymerization of insulating paper and
CO2+CO generation amount
Condition
No addition
10%
&
Oxygen addition
Water addition
Fig. 3.5.1-40: Relation between remaining rate of average degree of polymerization of insulating paper and
furfural generation amount
2.
Switchgear on switchboard
Switchgears on the switchboard (hereafter called switchgears) are classified into two: the metal-clad
switchgear that has a 6 kV-class magnetic circuit breaker, SF6 gas breaker or vacuum breaker, and the power
center that has a 600 V-class air circuit breaker.
The switchgear consists of structural parts and control accessories. Structural parts include the breaker,
protection relay, measurement transformer, and bus bar. Control accessories include the lamp, fuse, auxiliary
relay, and timer.
For extension of the life of equipment and evaluation of soundness, it is important to take proper measures for
the major devices and insulators by remaining life diagnosis in the appropriate time. Concerning the control
accessories, it is rational to update them in a well-planned manner, referring to the estimated usable years.
Remaining life diagnosis technology and preventive maintenance of major structural devices and parts of the
switchgear are introduced below.
2.1 Remaining life diagnosis technology
Remaining life diagnosis technology (deterioration diagnosis and life evaluation method) of the switchgear can
be classified into two: by the [Soundness evaluation method], it is judged whether the switchgear maintains the
specified performance at each point in time, and by the [Remaining life evaluation method], the remaining life is
evaluated by evaluating the field products quantitatively.
It is practical to use both methods to evaluate the switchgear life. An example of the remaining life
evaluation method of the structural parts of the switchgear is shown in Table 3.5.1-11. Each item is explained
below.
2.1.1 Soundness evaluation
Whether the field switchgear and its structural devices, parts, and accessories function normally is investigated
and evaluated. If there is no failure as a result of diagnosis, it is judged that they can be used without problems.
Lubrication items are added to this judgment method, and this is the periodical inspection that is widely performed.
(1) Visual inspection (VI)
Parts and accessories are inspected visually to see visual defects (damage, pollution, and discoloration).
Dimension measurement might be included.
(2) Operation test
Structural devices are actually operated to check functions. The lubrication condition of the operation
structural sections is also judged at the same time. A characteristics test is performed in some cases.
358
Metal clad
PT, CT
Cause of
deterioration
Temperature
Humidity,
pollution
Dielectric
Humidity,
breakdown
corrosion
Operating failure Wear
VI
Insulation
resistance
measurement
VI
Insulation
resistance
measurement
VI
Measurement of
pollution degree
Material characteristics
investigation
Partial discharge
characteristics
(
Material characteristics
investigation
(
Elevating
structure
Auxiliary switch Operating failure Temperature,
humidity,
pollution
Control line
Operating failure Temperature
VI
Operation test
VI
Conductivity
check
VI
MBB
bushing
Dielectric
breakdown
Temperature,
humidity
Partial discharge
characteristics
MBB
arc shoot
Breaker
malfunction
Humidity, wear
VI
Insulation
resistance
measurement
VI
Insulation
resistance
measurement
VI
Operation test
Insulation
resistance, VI,
operation test
VI
Operating
characteristics
MBB
Operating failure Wear, fatigue
operating
structure
Operating motor Operating failure Wear
Power center
Soundness
evaluation
Contact
resistance
measurement
(
Material characteristics
investigation
Withstand voltage limit
test
Material characteristics
investigation
Actual interrupting test
Main circuit
disconnecting
section
Auxiliary relay
Wear
Heat
deterioration
Operating failure Wear, corrosion
ACB
Pull-out
structure
ACB
Insulation base
Damage
Wear
Operating failure
VI
(
Insulation
resistance
measurement
VI
(
Conductivity
check
VI Conductivity Partial discharge
check/Insulation characteristics
resistance
measurement
VI Operation
Operation test
check
Damage
Temperature,
Operating failure fatigue
VI Operation
check
ACB
Arc shoot
Breaker
malfunction
VI
Insulation
resistance
measurement
VI
Operation test
Damage
Superheating
Humidity, wear
ACB
Operating failure Wear
Overcurrent trip
device
ACB
Operating failure Temperature,
Loading trip coil
humidity,
corrosion
VI
Resistance
measurement
VI: Visual
inspection
Operation
characteristics
test
Layer test
Accelerated deterioration
test
(
Shock life characteristics
Material characteristics
investigation
Actual interrupting test
(
Accelerated deterioration
test
AE amplifier
Coupling
capacitor
AE sensor
RF output
Electrode
Digital oscilloscope or PC
measurement system
Applied voltage
Partial
discharge
measurement
device
18 years 20 years
15 years
(Stress at switching +
Internal stress)
Figure 3.5.1-42 The change of the strength of MBB phenol bushing over time
(3) Accelerated deterioration test
The aged deterioration of insulators is accelerated by the heating conditions, and equivalent evaluation is
360
Temperature
, Break strength
(kg/mmP2P)
performed by the check in a short period of time. An example of the characteristics of tensile strength to the
same insulator is shown in Fig. 3.5.1-43. The parameters are T (heating temperature) and t (heating time).
If the used temperature can be seen from the characteristics, the life of the standard strength can be estimated.
Standard strength
, Time
Contents
Exchange of parts
Only the parts of the magnetic contactors or magnetic relays with relatively short life are
updated.
Exchange of units
The deterioration is in progress generally with devices or wires in the units, for example. It
is necessary to check that bus wires and insulation wires in the panel are in good condition.
Update of panel
The bus wires and insulation wires in the panel are deteriorated, but are planned to be used for
more 5~10 years.
361
To select the range, future operating hours, economic efficiency, and time required for updating need to be
comprehensively compared. In the case of parts exchange, if the control center type is old, it might be difficult
to acquire parts because of model change by makers or it takes a long time for exchange. It might sometimes be
necessary to remodel existing panels to use a new incompatible part. Unit exchange might be more economical
than parts exchange.
Afterword
Many electric facilities in plants have been used for 25 years or more. Reliability has been maintained by
periodical inspection, exchange of parts with short life, or horizontal development of nonconformity. In order to
use these aged facilities for a longer period in the future, it is strongly desirable to establish life diagnosis and
evaluation technology of wires that are the major structural parts, like transformers.
For this purpose, cooperation between the maker and users is effective. We need the understanding and
cooperation of related parties.
362
Stress corrosion of
holding ring
1 . Stator frame
3 . Stator coil
4 . Bushing
5 . Lead box
6 . Rotor
7 . Rotor coil
363
Fig. 3.5.2-2: Relation between dissolving oxygen concentration and corrosion progress speed
The experiment result of the air dissolved condition in Fig. 3.5.2-3 clearly indicates this. The corrosion
amount increases linearly in the case of air of 5 m/s. It saturates in the case of hydrogen or nitrogen.
Concerning the difference in the corrosion amount depending on the speed, the corrosion amount is small in
general if the speed is low. There is no large difference at 1.6 ~ 0.16 m/s.
Dissolved gas: Air
Temperature: 75 C
Water specific resistance:
1 M!or more
Period (year)
364
Copper DC#
0.1 mA/cm2
Copper DC#
0.025 mA
/cm2
SUS27
DC# 1.28 mA/cm2
SUS27
DC# 0.32 mA/cm2
Time (Day)
365
Creep
Fatigue
(including creep
fatigue)
Corrosion
Wear
Cause
Countermeasures
Inspection by replica,
ultrasonic testing,
TOFD method
Restriction on
elongation by heat
Add flexibility
Sliding
R-machining, chamfering,
change of shape
Thermal shock
Change of shape,
improvement of material,
improvement of the shapes
of the seat and piping
Dissimilar metal
welding (SUS/Cr-Mo)
Inconel solvent
Corrosion fatigue
High temperature
fatigue, oxidation
Improvement of the
bearing force of material,
addition of extra welding
Oxidation of steam
(SUS piping)
Superheater, reheater
Corrosion fatigue damage on the inner face of the furnace wall piping occurs when the strength against fatigue
is reduced due to corrosion by the inner fluid. In view of the fact that corrosion fatigue damage also occurs at the
portion where a fixture is mounted on the external side, it is assumed that thermal stress is the major cause. An
effective countermeasure is to reduce the thermal stress by improving the structure of the attached fixture on the
external side.
366
Table 3.6.1-2 Example of measures for improving the bearing force of the boiler equipment
No.
1.
2.
Name of portion
Furnace wall
Wall boxes such as
burners, OAPs,
inside TVs, soot
blowers, etc.
Conventional structure
Chamfering and
R-machining of the
corner portion
Steam type
Steam type
Water cooling type
Current type
3.
367
No.
Name of portion
4.
5.
6.
Dissimilar metal
welded joint under
high temperature
Conventional structure
Honeycomb
Honeycomb
(Flat shape)
(Half-oval
shape)
MT or PT
Half-oval shape of
honeycomb
Tie rod
Sliding
spacer
(Single lag)
Hanging
loop pipe
Portion passing
through the ceiling
(Oval lag)
7.
R-machining
Attached
fixtures
Crown
Ceiling piping
368
Additional
sleeve
Ceiling piping
No.
Name of portion
8.
Conventional structure
Flow nozzle
Venturi pipe
or
The welded portion should
have a flat surface of the
same thickness.
Swing type
nozzle
(single-hole
type)
9.
3-faces joining
corner of the panel
10.
Inner-casing on the
ceiling
Corrugated expansion
Pipe header on
the forepart wall
of the furnace
Pipe header
on the
furnace wall
369
Table 3.6.2-1 Preventive maintenance and technologies for improving the bearing force of steam turbine (outline)
Others
Erosion
Corrosion
Fragility
Damage
by fatigue
Portion subject to
countermeasures
Damage
by creep
Cause of damage
Preventive maintenance and technologies
for improving the bearing force
High/medium
pressure rotor
High/medium
pressure rotating
blade
Low pressure
rotating blade
High/medium
pressure nozzle
Low pressure
stationary blade
High/medium
pressure
internal/external
casing
Main valve casing
Forged valve
Employment of high toughness casing
material
Alteration of valve rod and bushing material
370
3.6.2
Preventive maintenance and technologies for improving the bearing force turbine equipment
Due to continuing operation of aged thermal power generation plants under severe conditions, aged
deterioration of steam turbine equipment has accelerated.
In view of the extension of regular inspection interval and enforcement of self control of the equipment under
the above-mentioned operation conditions, preventive maintenance and measures for improvement of bearing
force have become more important.
Table 3.6.2-1 outlines the preventive maintenance and measures for improvement of bearing force of steam
turbine that have been developed and employed.
(1) Turbine rotor
Measures against creep damage and fragility
As measures against damage caused by high temperature creep or fragility of high/medium pressure rotors,
rotor material is employed that has higher strength against high temperature creep than conventional rotor material,
with low speed fragility and that corresponds to operation changes such as DSS, etc.
Employment of low Si content rotor material
Employment of improved rotor material
371
Medium pressure
shaft
Fig. 3.6.2-1 Expansion of stress softening grooves/flattening of 1st step rotating blade grooves
Conventional blade
(Tenon crimped type)
ISB blade
(Shroud integrated type)
Water drop
Erosion shield
Cover structure
J-type Stellite
Lightening cover
Full arc 1 ring
Without cover
Face contact
Blade rigidity
Tie wire
Tie wire structure
Blade type
Material
Transonic speed
blade type
12Cr-Nb
Stainless steel
12Cr
Stainless steel
Strength increased to
1.1 times
372
(6) Examples of preventive maintenance and technologies for improving the bearing force
Measures against fatigue damage of high/medium pressure rotors
Examples of measures against aged fatigue damage of high/medium pressure turbine rotors are shown in Fig.
3.6.2-1. Its purpose is to improve the bearing force against fatigue by skin-cutting the fatigue deteriorated layer of
stress softening grooves and 1st step rotating blade grooves and further expanding the R of stress softening
grooves and flattening the 1st step rotating blade groove bottom.
Measures against creep damage of high/medium pressure rotating blades
A tenon crimping structure was used for reaction step rotating blades in the past. However, it was found that
creep damage occurred to the tenon portion where the shrouds centrifugal force was applied by high/medium
pressure rotating blades exposed to high temperature steam. As countermeasures, ISB (integral shroud blade) in
which the blade and shroud are integrated together has been employed. ISB has other effects in improving
vibration characteristics by full arc tracing structure and by improving the sealing structure.
373
Casing
Stationary
blade
Drain catcher
Stationary blade ring
Rotating
blade
Trace of
water drop
Rotor
Drain
Slit
Stationary
blade
Drain
374
In addition to the aged erosion of low pressure rotating blades, not only decreased efficiency but also crack
damage may be caused by corrosion or erosion.
In order to prevent such damage, Stellite plates are bonded to the front edge of rotating blades and hardening
treatment is applied. In addition, by employing a hollow stationary blade with a slit and drain catcher and by
promoting drain discharge aggressively, the erosion of low pressure rotating blades can be largely suppressed.
Measures
against erosion
Measures
against erosion
Improvement of
ease of
maintenance
Improvement of
ease of
maintenance
Fig. 3.6.2-5 Measures against erosion of high/medium pressure 1st step nozzles
An example of improvement of drain discharge from low pressure blades is shown in Fig. 3.6.2-4.
Measures against erosion of high/medium pressure 1st step nozzles s! sz!
Erosion phenomenon (SPE: Solid Particle Erosion) caused by oxidized scales flying from boiler, etc. can be
detected on the 1st (initial) step nozzles of high/medium pressure turbines, which creates various issues with
respect to performance, reliability, regular inspection interval, maintenance and control, etc.
Several measures against erosion in this respect are shown in Fig. 3.6.2-5.
In case of high pressure 1st step nozzles, erosion is generated at the outlet end of the nozzle by solid particles
flowing into the steam path. The erosion can be suppressed by such diffusion penetration treatment as boron
treatment (to have B (boron) make diffusion penetration on the metal surface and form a very hard and fine
chemical compound (Fe2B) layer on the nozzle plate), which strongly adheres to the base metal and forms an ultra
hard coat.
The medium pressure initial step nozzle can be damaged when solid particles passing through the nozzle
rebound from the rotating blades. As measures against this, bearing force is improved by forming on the back of
the nozzle a 250 300 !m thick plate hardened coat against high temperature and stable thermal spray metal of
the carbon family mainly composed of chromium carbide by high velocity gas flame metal spraying method
(HVOF).
375
Low-sulfur fuel
Exhaust gas desulfurizer
Nitrogen oxide
Low-nitrogen fuel
Improvement of combustion method
Exhaust gas denitrizer
High-quality fuel
Electric dust collector
Drainage
Hot wastewater
Deep-water intake
Surface/underwater discharge
Oil leakage
Loading arm
Oil fence
Water quality
preservation measure
Land fill
Effective utilization
Coal ash
Waste disposal
measures
- General
Desulfurization
plaster
Effective utilization
Low-noise equipment
Soundproof wall
Optimum arrangement of equipment
Afforestation
Tree plantation
Landscape
In harmony with
ambient surrounding
4.1.1
Major environmental preservation measures of thermal power plants
Major environmental preservation measures planned and employed by Japanese thermal power plants are
classified into two: to deal with global environmental problems and to deal with regional environmental problems.
To cope with global environmental problems, they are currently tackling the prevention of the greenhouse effect
(the most critical issue in the 21st century) through a CO2 reduction scheme. They try to reduce CO2 emission by
improving electric supply and electric usage. To reduce the amount of CO2 from the electric source, they will use
more clean energies such as atomic power, LNG, and natural energy, such as nonfossil energy, and improve the
efficiency of electric power generation, e.g., thermal plants.
To reduce the electric power demand of customers, they try to develop high-efficiency energy-saving
equipment and to promote the use of heat storage systems for load leveling. They also positively support
international CO2 reduction activities to effectively implement the Kyoto Mechanism specified in the Kyoto
Protocol.
To cope with regional environmental problems, they are conducting appropriate environmental assessment
before constructing a thermal power plant, followed by various environmental preservation measures.
Japanese electric power plants had successfully conducted many environmental assessments since the 1977
ministry decision, and the assessment system has been established upon full implementation of the Environmental
Impact Assessment Law" in 1999. These environmental assessments first survey the candidate site, estimate
possible effects of the planned power plant and then begin studying how to preserve the environment.
Japanese thermal power plants provide globally advanced environmental preservation measures according to
the environmental protection agreement conducted between local communities that will be affected (2)(3). The
major environmental preservation measures that a thermal power plant should prepare include: air quality
preservation, water quality preservation, waste disposal, and noise and vibration prevention, as shown in Fig.
4.1.1-1. They should be in harmony with environment. Air quality preservation measures must provide fuel and
equipment that will minimize amounts of sulfur oxide, nitrogen oxide, and ash dust contained in smoke emission;
the measures must also provide coal-handling and storage facilities that prevents coal dust from flying. Water
quality preservation measures must provide a facility that correctly disposes wastewater from the power plant, and
a water intake/discharge facilities that will not affect the sea area from which water is pumped for cooling and
then returned after cooling. The measures also include facilities that prevents leakage of oil being transferred from
oil tankers. Waste disposal measures must provide a facilities that recycle waste. For example, coal ash from a
coal-fired power plant must be used as material for cement or landfill. Desulfurization plaster will be fully
recycled.
Other measures had been taken to reduce noise and vibration emitted outside the power plant site; so that plants
are in harmony with the surrounding environment, greenbelt is created by planting and designing plants that blend
in with the scenery.
Described below are technologies and facilities related to environmental preservation measures taken by
thermal power plants.
4.1.2
Countermeasures against global warming
4.1.2.1 Movement toward preventing global warning
Before the Industrial Revolution, 280 ppm of carbon dioxide (CO2) was contained in the air. Since then, it has
increased year by year and up to 368 ppm today. CO2, together with other greenhouse gases that have also
increased in quantity, has raised the ambient temperature by 0.4-0.8!C over the past 140 years. Observational data
show that the highest ambient temperature was recorded in the 20th century. The Intergovernmental Panel on
Climate Change (IPCC) has simulated future climate change and estimated that the average temperature of the
earth will increase, due to human activity, by 1.4-5.8!C by 2100, resulting in raising sea levels by 9-88 cm
In addition to temperature rise, global warming will have various effects on climate parameters, which in turn
will cause severe hazards to the socioeconomic system, ecological system, and human health. Although many
scientific uncertainties remain as to the prediction of the warming phenomenon and the assessment of associated
impacts, the cause of warming must be immediately reduced because global temperature cannot be reversed once
it is increased.
International undertaking of global warming prevention has proceeded according to the decisions made at the
Framework Convention on Climate Change (COP) founded in 1995.
At COP 3 held in Kyoto in Dec. 1997, the Kyoto Protocol specifying the reduction target of greenhouse gases
such as CO2 was adopted. However, its implementation procedure or rule was not determined. Starting with COP
4, international negotiations have been held where participating countries tried to take advantage regarding
emission quantity. Later, U.S.A. expressed its withdrawal from the Kyoto Protocol. At COP 7 held in Nov. 2001, a
detailed implementation rule of the Kyoto Protocol was agreed, and the countries made efforts towards the
ratification of the protocol. The Kyoto Protocol requires the advanced nations to reduce emission by 5% in total. It
is estimated that this small amount of reduction will not significantly reduce the effects of warming, but the
important thing is that advanced nations will cooperate actively towards the reduction of greenhouse gas.
with other advanced countries, approx. two times as the world average level. Developing countries such as China
and India emitted very small amount of CO2 but they are expected to increase CO2 emission sharply in proportion
to their economic growth rate.
Others
U.S.A.
Australia
South Africa
Total
Approx. 23.2
billion tons
CO2
Poland
Mexico
China
Ukraine
Korea
Canada
India
Russia
Germany
U.K.
Italy
Japan
France
Others
The total emission has increased by 9.0%, and per capita emission, by 6.3%, when compared with the
respective value of 1990 where the reference quantity of emissions was established
(Year)
The Japanese electric industry actively participates the CO2 emission inhibition project shown in Fig. 4.1.2-3 to
achieve the goal specified in the " Environmental Action Program in the electric industry" for the electricity
supply sector and electricity consumption sector. The activity of the electric industry at the electricity supply side
is to advance CO2-free nuclear power generation, to introduce more LNG-fired power generation, and to develop
and propagate natural energy sources such as water, geothermal heat, sunlight, and wind power. The industry's
activities also include improvement of efficiency of power equipment, for example, introduction of combined
power generation, improvement of efficiency of coal-fired power generation, and high-tension transmission with
low power loss. The industry's activities on the electricity consumption side is to save energy by increasing the
efficiency of heat pumps and the like, development and introduction of energy-saving equipment, utilization of
unused energy, and promotion of installation of heat storage systems for load leveling. Among these
countermeasures, an optimum energy mix with nuclear power as a core electric source is said to be more effective
in terms of CO2 reduction.
To further reduce CO2 by way of international cooperation that utilizes the Kyoto Mechanism (emission permit
transactions, joint implementation, and the clean development mechanism), the industry are working on the
thermal efficiency improvement project for existing thermal generation, local electrification projects, tree
plantation projects, etc.
Increased use of
nonfossil energy
Improved efficiency of
electrical equipment
Saving of energy
Countermeasure on
electricity supply side
Countermeasure on the
electricity consumption
side
4.1.3
Air quality prevention measure
4.1.3.1 Sulfur oxide
(1) Sulfur content reduction in fuel
Sulfur oxide (SOx) is produced when the sulfur (S) in fuel reacts with oxygen (O) in air. To reduce SOx, the
use of low-sulfur fuel is the major countermeasure. Therefore, thermal power plants have used light fuels such as
low-sulfur heavy oil, almost sulfur-free naphtha, and NGL (natural gas liquid) to reduce emission of SOx. They
have also positively used crude oil as fuel.
Tokyo Electric Power Co., Inc. was the first user of LNG (liquid natural gas) as the fuel for power generation; it
used LNG at its Minami Yokohama Thermal Power Plant in 1970. Since then, LNG has been recognized as a
clean, environmentally friendly fuel and is used in many power plants. At the end of 1999, the industry had 350
power boilers including 117 LNG power boilers.
Demister
To chimney
Water
Cooling
tower
Gas gas
heater
Calcium
sulfite CaSO3
Oxidation
tower
No.2
absorbing
tower
Plaster
CaSO4
Plaster thickener
Air
Centrifugal
separator
Drainage
Limestone
CaCO3
Limestone slurry
Plaster
Fuel
Fuel
Primary air
Secondary air
Air
Tertiary
air resistor?
Venturi
Exhaust gas
Fuel
Mixer
Fuel
Air
Secondary
air
Exhaust gas
Pulverized coal +
primary air
Exhaust gas
mixing fan
Tertiary air
Exhaust gas
Secondary
air vane
principles. Among them, the exhaust gas denitrification system using the ammonia gas selective catalytic
reduction process, the dry type, is practically used with powerboilers.
Because this type of denitrification system is simple and can decompose NOx into harmless nitrogen and water
with negligible by products, it is suitable for disposing of a large amount of exhaust gas.
The principle of denitration reaction when using ammonia as the reducer is expressed as follows.
Catalyst
4NO + 4NH3 + O2 " 4N2 + 6H2O
This reaction preferentially occurs at gas temperatures between 350 and 400!C, i.e., nitrogen oxide and
ammonia react almost in an equimolar state. When this type of exhaust gas denitrizer is used for a boiler, it is
installed between the economizer and air preheater where the gas temperature is approx. 350!C, assuring at least
80% denitration efficiency.
The exhaust gas denitrizer consists of a NOx removal catalyst, a reactor vessel for storing the catalyst, and a
device that injects ammonia into the exhaust gas, as shown in Fig. 4.1.3-5. There are two arrangements for
installing the exhaust gas denitrizer: the low dust type that removes dust at the previous step of the NOx removal
equipment, and the high dust type that passes the exhaust gas from the boiler directly to the NOx removal
equipment.
The catalyst that has the largest effect on the performance of NOx removal equipment is a porous structure with
many microscopic pores into which the exhaust gas diffusing over the surface of the catalyst flows, promoting
decomposition reaction of NOx. The shape of the catalyst is grain, plate, grid, or cylinder etc.
For heavy/crude oil- and coal-fired power plants, plate- and grid-shape catalysts are preferably used to prevent
clogging. A granular catalyst is used at thermal power plants using gas only. Most catalysts are made from
titanium-type oxide with TiO2 as the catalyst support.
The denitration efficiency is 80% or more for coal-fired power plant exhaust gas.
The denitrification equipment with the ammonia selective catalytic reduction process has been used for more
than 20 years at power plants operating with clean gases such as LNG. It has a reputation for reliability.
Exhaust gas denitrizers for heavy/crude oil and coal had many defects such as deterioration and wear of the
catalyst and clogging of the catalyst layer due to dirty gases (sulfur oxide, nitrogen oxide, soot, and dust). These
problems were corrected, and the denitirizers were modified and put into service several years after denitrification
equipment with the ammonia selective catalytic reduction process (for clean gas) was employed.
Rectifier
Exhaust
gas
Ammonia
injection tube
Catalyst
layer
Catalyst
layer
Exhaust
gas
Catalyst
layer
Fan
NOx analyzer
Catalyst
layer
Catalyst
Buffering agent
(Spare)
Catalyst unit
4.1.3.3 Dust
(1) Dust source and prevention
The boiler outputs ash dust as it fires ash-containing fuel. It does not produce such dust while burning gas fuel,
e.g., LNG. However measures against soot and dust are necessary when using heavy/crude oil or coal as the fuel.
The ash contained in coal is nearly two whole orders of magnitude greater than that in heavy oil. Use of
high-quality fuel and smoke and soot collection devices are common measures to minimize soot and dust. For
power boilers associated with fuel other than gas, high-performance electric dust collectors are used.
(2) Electrostatic precipitator
The world's first electrostatic precipitator for heavy oil-fired power plant was installed at Yokosuka Thermal
Power Plant in 1966. Dry-type electrostatic precipitators as shown in Fig. 4.1.3-6 are now widely used. The
operating principle is that high voltage is applied to the discharge electrode, and corona discharge causes
suspended particulates in the exhaust gas to go to the collect electrode and accumulate on it. The accumulated
particulates are then sent to the dust chamber hopper.
Two types of dust chambers, low temperature and high temperature, are available.
Support
insulator
Discharge
electrode-rapping
device
Porous
plate
Discharge
electrode
Collect
electrode-rap
ping device
Discharge
electrode
frame
Collect
electrode
Hopper
partition
plate
Hopper vibrator
from coal-fired plants contain more sulfur oxides, nitrogen oxides, and particulates than those from oil-fired plants,
comprehensive and unified measures are required. These additional countermeasures become reasonably
expensive as coal-fired power plants grow in size; they must be cost effective.
10 Electric
Power
companies +
Electric Power
Development
Co., Ltd.
Desulfurization
equipment
Dry EP (low
temperature)
Desulfurization
equipment
Desulfurization
equipment
Dry EP
(cold side)
Lowtemperature
EP method
Hightemperature
EP method
Desulfurization
equipment
Denitrification
equipment
Boiler
Denitrification
equipment
Boiler
Boiler
Dry EP (high
temperature)
Dry EP (low
temperature)
Denitrification
equipment
Boiler
Boiler
Denitrification
equipment
Boiler
Boiler
Boiler
Coal fired
Fig. 4.1.3-7 SOx and NOx emission/generated power from thermal power plants
Ultra cold-side
EP method
Wet
EP
Wet
EP method
Fig. 4.1.3-8 shows the exhaust gas treatment systems in coal-fired power plants.
With the low-temperature EP system, the EP is installed after the air preheater and the dust concentration at EP
outlet is kept between 100-200 mg/m3N to prevent the dust from adhering to the heat transfer surface of the
reheater (GGH). The soot separation configuration is employed in the gas-desulfurizing system so that the dust
removal tower is located upstream of the absorbing tower. With this new arrangement, the dust removal tower
reduces soot concentration from approx. 100 mg/m3N to several tens of mg/m3N. With the high-temperature EP
system, the EP is installed upstream of the air preheater to increase the efficiency of the EP. The dust
concentration at the outlet of gas-desulfurizing system is lower than that from the low-temperature EP system.
Recently, coal-fired power plants in suburbs of cities are often required to reduce dust concentration in their
emission from several tens of mg/m3N to below 10 mg/m3N, and that of SO2 to below 50 ppm. To meet these
requirements, they add wet-type electrostatic precipitators to the outlet of absorbing tower of the desulfurization
equipment, to improve the dust removal capacity of the existing low-temperature EP system.
These system components and devices are complex and expensive, and therefore are replaced with more
cost-effective systems: instead of wet type, the dry electrostatic precipitator is used in combination with the
desulfurization equipment and preheater (GGH): this high-performance dust-collecting system is called the
ultra-cold EP system. In this system, the GGH is installed upstream of EP to lower the gas humidity at the inlet of
EP and to increase the performance of EP. At approx. 90C where the dry electrostatic precipitator operates, the
electric resistivity of coal ash drastically drops and back discharge does not occur. This high dust-collecting
method can be applied when using a coal of type whose ash cannot be completely charged and collected. By using
the ultra-cold electrostatic precipitator, dust concentration at the outlet of the chimney can be lowered to several
mg/m3N.
to 1994. Electric Power Development Co., Ltd., based on the result of the pilot test conducted at Takehara
Thermal Power Plant started a field test of the dry-type desulfurization process using activated coal at Matsushima
Thermal Power Plant (gas-processing capacity: 0.3 mega m3N/h, electrical output: 90 MW) in 1980. With this
process, SOx in the exhaust gas is absorbed by activated coal and then recovered as free sulfur. Therefore, the
activated coal maintained high desulfurization performance (95% or more efficiency) and also had high
denitration performance if the concentration of SO2 in the exhaust gas was low. The company tried to further
improve denitration efficiency by passing the exhaust gas through activated carbon layer twice, and designed dry
simultaneous desulfurization and denitrification equipment; they tested this equipment at Matsushima Plant
(gas-processing capacity: 0.15 mega m3N/h, electrical output: 45 MW) by the end of FY 1994. The result showed
the expected achievement: SOx removal efficiency of 95% or more, NOx removal efficiency of 25% or more, and
soot and dust concentration at the outlet of 10 mg/m3N or below.
Following the development of exhaust gas treatment processing for pulverized coal-fired boilers, the company
started developing exhaust gas-processing technology for fluidized bed boilers in 1988 and verified its
performance by installing a 0.1- mega m3N/h demonstrative experimental equipment on the Wakamatsu fluidized
bed boiler field test facility until 1991.
The result showed the expected achievement: NOx removal efficiency of 80% or more, SOx removal efficiency
of 90% or more, and soot and dust concentration at the outlet of 30 mg/m3N or below.
Commercial NOx removal equipment designed based on these tests was installed for use with the No.2 unit
(gas-processing capacity: 1.157 mega m3N/h, electrical output: 350 MW) at Takehara Thermal Power Plant and
put into service in 1995 as the world's largest dry-type active carbon denitration equipment. The operating theory
was almost the same as the conventional denitration equipment using the dry-type selective catalytic reduction
process: allowing NOx in exhaust gas to react with ammonia (put into the denitration tower inlet) with the help of
a catalyst (active coal), decomposing into water and nitrogen. With the fluidized bed boiler, the SO2 concentration
in the exhaust gas is reduced to 100 ppm or below by the incinerator internal desulphurization function. The
combined fluidized bed boiler and active carbon denitration equipment has high NOx removal capability. A
dry-type exhaust gas treatment system utilizing activated carbon will be an appropriate environmental facility for
installation at sites where the volume of water is not available, in suburban power plants where tighter
environmental standards are applied, or in power plants using waste.
4.1.4
Water quality preservation measures
4.1.4.1 Wastewater treatment measures
(1) Types and properties of wastewater
Wastewater from thermal power plants contains steady-state water discharge (during operation) and
unsteady-state water discharge (only during machine maintenance and inspection). Steady-state water discharges
include: water discharged from machinery, containing minute quantities of acids, alkali, suspended matter, oil,
etc.; recycled water from the demineralizer to the boiler and then discharged; water discharged from
desulfurization equipment using the limestone-gypsum process; ash treatment water discharge, and so on; water
discharged from other plant facilities; and domestic wastewater (containing a large amount of organic
components) discharged by workers.
Unsteady-state water discharges include: water used to clean machines and devices during periodic
maintenance of the boiler, and turbine; and rain water from the coal-storage yard and oil tank yard. In the first case,
a large amount of water is discharged in a short period while significantly changing water quality. In the second
case, water contains oil and SS but rarely includes a large amount of other dissolved materials. Table 4.1.4-1
describes the properties of wastewater from thermal power plants.
Others
General wastewater
Type
Wastewater
(Discharge) From service water
pretreatment equipment
(Discharge) From makeup water
demineralizer
(Discharge) From condensate
water demineralizer
From ash-processing equipment
From exhaust gas denitrizer
Air preheater-cleaning water
Dust collector-cleaning water
Flue-cleaning water
Boiler chemical-cleaning water
Domestic wastewater
Quantity
50 m3 /day
Substances treated
Muddy, hydrated aluminum flock
50 to 100 m3 /day
50 to 150
50 to 100
100 to 500
1,500 to 2,000 m3/
Once/unit, year
discharge
3
1,000 to 1,500 m /
Once/unit, year
discharge
100 to 500 m3/
Once/unit, year
discharge
1,000 to 2,000 m3/
Once/unit,
discharge
1-3 years
3
50-100 m /discharge
4.1.5
Emission standards are roughly divided into the general emission standard, special emission standard,
strict standard, total emission control standard, and fuel usage standard.
Over 50
10 ~ 50
Gas-burning boiler 4 ~ 10
1~4
Less than 1
Over 70
50 ~ 70
Solid fuel-burning 20 ~ 50
boiler
4 ~ 20
0.5 ~ 4
Less than 0.5
Over 50
Other boilers (liquid 10 ~ 50
fuel, liquid-gas fuel 4 ~ 10
mixed burning)
1~4
Less than 1
Special waste
Over 4
incinerator
(continuous
Less than 4
furnace.erc.)
Amount of exhaust gas
Facilities
(unit: 10 thousand
m3N/h)
Over 4.5
Gas-burning turbine
Less than 4.5
~ Aug. 9,
1973
April 1, 1987
~
5
5
5
5
5
6
6
6
6
6
6
4
4
4
4
4
130
130
130
150
150
400
420
420
450
450
480
180
190
250
250
250
130
130
130
150
150
300
300
350
350
380
480
180
180
180
250
250
100
100
130
130
150
300
300
300
300
350
480
150
150
150
150
250
60
100
100
130
150
300
300
300
300
350
380
130
150
150
150
250
60
100
100
130
150
300
300
300
300
350
380
130
150
150
150
180
60
100
100
130
150
300
300
300
300
350
350
130
150
150
150
180
60
100
100
130
150
200
250
250
250
350
350
130
150
150
150
180
12
300
300
300
250
250
250
250
12
900
900
900
900
700
700
700
~
Jan. 31, 1988
Feb. 1, 1988
~
July 31, 1989
Aug. 1, 1989
~
Jan. 31, 1991
Feb. 1, 1991
~
Jan. 31, 1994
16
70
70
70
70
16
90
70
70
16
100
100
70
70
16
120
100
100
100
Cylinder I.D.
400 mm or more
13
1,600
1,400
1,200
Cylinder I.D.
below 400 mm
13
950
950
950
On
(%)
Feb. 1, 1994
~
Size
Oil equivalent
combustion
performance 50 L/h or
more and heat transfer
area below 10 m2
On
(%)
4
4
~
Sept. 9, 1986
Not
applicable
for an
undetermin
ed period
300
350
Diesel engine
Facilities
Remarks
950
or before or emergency
facilities, for an
undetermined period.
Remarks
260
N/h
K
:constant specified to a given region (K value = 3.0-17.5: the smaller the value, the stricter the
regulation). A K value of 3.0 is applied to 6 zones: Tokyo special wards, Osaka-Sakai etc., Nagoya etc.,
Yokohama-Kawasaki etc., Kobe-Amagasaki etc., and Yokkaichi etc.
He
corrected exhaust port height (m: chimney height + smoke column height)
Gas-fired boiler
Liquid-fired boiler
Gas-liquid mixture
fuel-fired boiler
Solid fuel-firing
boiler
General
(g/m3N)
0.05
0.10
Main rule
Special
(g/m3N)
0.03
0.05
Small boiler
0.10
0.05
Over 20
4 ~ 20
1~4
0.05
0.15
0.25
0.04
0.05
0.15
Below 1
0.30
0.15
Small boiler
0.30
0.15
Over 20
4 ~ 20
Below 1
0.10
0.20
0.30
0.05
0.10
0.15
Small boiler
0.30
0.15
Gas turbine
Diesel engine
0.05
0.04
0.10
0.08
Additional rule
On
(%)
General
(g/m3N)
5
5
5
Special
(g/m3N)
On
(%)
6
6
6
6
Future
application
16 Not applicable to facilities installed on Jan. 31, 1988 or before or emergency facilities, for an
undetermined period.
13 Not applicable to facilities installed on Jan. 31, 1988 or before or emergency facilities, for an
undetermined period.
Installed on
On
Facilites
Processing capacity
July 1, 1988
(%)
or after
Over 4
0.08
0.04
12
Waste incinerator 2 ~ 4
0.15
0.08
12
Below 2
0.25
0.15
12
* Dust emission standard concerning small boilers (oil-equivalent combustion performance of 50 L/h or more and a heat transfer area below 10 m2)
1. Not applicable to small boilers installed before Sept. 10, 1985, for an undetermined period.
2. Not applicable for an undetermined period to small boilers that burn gas or light liquid fuel (kerosene, light oil or fuel oil A) or gas-light liquid mixture fuel, and were installed on Sept. 10, 1985 and
after
Installed on
June 30, 1988
or before
For gas-fired plants, only denitration equipment is required to be installed as an environmental protection
facility. There are no particular emission-related items to be taken into consideration other than the basic
parameters shown in Table 4.1.5-3 when designing the exhaust gas treatment system.
Table 4.1.5-3 Exhaust gas treatment system layout
Boiler
Boiler
Denitrification
equipment
Boiler
Boiler
Process method
Wet process
High-temperature
EP method
Wet
desulfurization
equipment
Chimney
Dry EP (low
temperature)
Wet process
Low-temperature
EP method
Wet
desulfurization
equipment
Chimney
Denitrification
equipment
Boiler
Dry EP (high
temperature)
Denitrification
equipment
Boiler
Denitrification
equipment
System configuration
Dry EP
(cold side)
Wet process
Ultra cold EP
method
Wet
desulfurization
equipment
Chimney
Dry EP (low
temperature)
Wet
desulfurization
equipment
Wet process
Wet EP method
Wet EP
Chimney
Dry denitration
&
desulfurization
equipment
Dry EP
Denitrification
equipment
Boiler
Boiler
Boiler
Boiler
Coal fired
Boiler
Boiler
Combustion
method
Dry EP
Chimney
Dry process
Denitration &
desulfurization
simultaneous process
(Example of individual
process)
Chimney
Dry process
Denitration &
desulfurization
simultaneous process
(Example: installation of
denitration equipment)
Dry denitration
&
desulfurization
equipment
system, etc.
Desulfurization equipment
Particle diameter 5 m
Boiler
Particle diameter 2 m
Air heater
Visible
from timeto-time
Level of growing
hazy on average,
depending on the
weather
Transparent but
range perceptible
like a heat haze
Electrostatic precipitator
Gas/gas heater
Chimney
Invisible range
Visible range
Suction fan
Bypass damper
Particle
diameter
0.6 m
Particle
diameter
0.4 m
394
Discharge electrode
Collecting electrode
DC high pressure
Ionized area
Fig. 4.2.2-2
separates/collects electrically from the gas through the function of electric field (Coulomb force). In addition, EP
has the following characteristics;
(1) Due to static coagulation effect, collection of fine particles becomes possible, resulting in highefficiency.
(2) The gas speed within EP is 0.5 - 1.5 m/s in general. The pressure loss is as small as 0.1 - 0.2 kPa,
thereby the operation costs can be reduced.
(3) Such nature of the gas/dust as the particle diameter of dust, gas temperature, humidity, etc. can be
broadly utilized.
4.2.2.1.2 Structure of EP
Almost all of the EP presently used for thermal power generation is of the dry-type. A parallel plain type of
collecting electrode is used. The basic structure of a dry-type EP is shown in Fig. 4.2.2-3.
AC high voltage
generator
Motor for hammering the
discharge electrode
4.2.2.2
Characteristics of the dust emitted from a coal fired boiler and points to be noted when
planning
4.2.2.2.1 Comparison with the dust emitted from a heavy oil fired boiler
The nature of the exhaust gas from a boiler varies largely depending on the type of fuel, its nature and its firing
method.
Typical examples of the nature of exhaust gas/dust from heavy oil and coal are shown in Table 4.2.2-1;
Table 4.2.2-1 Comparison of natures of exhaust gas/dust from heavy oil and coal fired boilers
Item
Gas amount
Gas temperature
Gas pressure
Dust content at the inlet
Diameter of dust particle
Components of dust
SiO2
Al2O3
SO3
C
Electric resistance factor
Apparent specific gravity
%
!C
kPa
g/m3
(normal)
m
Wt%
Wt%
Wt%
Wt%
"-cm
g/cm3
Coal firing
About 120
130 to 150
-2.0 to -0.5
(Balanced draft)
10 to 20
1 to 3
20 to 30
Ash content 15 to 20
25 to 35
50 to 60
104 to 108
0.1 to 0.2
60 to 75
15 to 20
0.3 to 0.7
0.4 to 0.8
1010 to 1013
0.6 to 0.8
395
EP inlet
Flying dust
coming from
coal firing
Large
Small
Small
Large
Small
Large
When comparing heavy oil with coal, the ash content in
the coal fuel is larger than that of heavy oil by 100 - 200
times. The dust content in its exhaust gas is 100 times or
more that of heavy oil. In addition, the dust has a
characteristic of very high electric specific resistance.
Current/voltage
Dust collection efficiency
Voltage
Current
Normal Range
396
Function drop
due to back
corona
phenomenon
Fig. 4.2.2-5 Relationship between electric specific resistance of dust and collection efficiency
Collecting
electrode
Negative ion
(2) Volume conduction: More effective
when more alkali metals are
contained in the flying ash and
the gas temperature is high
Fly ash
Gas temperature
397
Discharge
electrode
Particles with
negative charge due to
corona discharge
Ed > Eb
Back corona
Eb: Electric field
strength of
breakdown
caused by dust
Dust layer
Dust
collection
electrode
Discharge electrode
Breakdown
Plus ion
discharged from
dust collection
electrode by a
breakdown
Particle with negative charge due
to corona discharge
Cold side EP
Cold side EP to be installed in the low temperature area at the outlet of boiler AH enjoys the longest operation
record since its adoption for coal fired power plant during the 1950s. This EP exhibits satisfactory reliability as
well.
Hot-side EP system
Gas temperature
350
( C)
NOx removal
equipment
Hot-side EP
Boiler
To chimney
350
GGH
Desulfurization
equipment
GGH
Desulfurization
equipment
A/H
Gas temperature
( C)
350
Boiler
350
NOx removal
equipment
130
130
Cold side EP
A/H
GGH
(Heat
recovery)
To chimney
Desulfurization
equipment
Gas temperature
( C)
Boiler
350
350
NOx removal
equipment
130
A/H
90
GGH
(Heat recovery)
90
Ultra-cold side EP
Ultra-cold side EP
Ultra-cold side EP is a system that utilizes the characteristics of the fly ash, of which electric specific resistance
drops in the temperature area of 100 or lower, which is caused by the relationship between the electric
specific resistance of fly ash and gas temperature, as shown in Fig. 4.2.2-6. In order to lower the gas temperature,
the heat recovery side of GGH, which was used to be installed before the desulfurization equipment, is now
installed between AH and EP.
Next, the advantages of ultra-cold side EP are introduced below;
(1) Improvement of the collection efficiency through the drop in the dust electric specific resistance, caused by
the gas temperature drop
(2) Small-sized EP due to the reduction of the gas amount to be treated
4.2.2.4 New dust collection technology
In order to treat high resistance dust, EP having a far larger capacity than dust with excellent collection
efficiency is required. To that end, various types of technology to cope with high resistance dust have been
developed.
In Table 4.2.2-2, technologies to improve the efficiency against high resistance dust are introduced. The main
items from the table are explained below;
399
(2)
(3)
400
Wheel for
movement
Collecting electrode
driving unit
Rotation
direction
Link chain
Dust collection
area
Roller chain
Collecting
electrode Gas
Discharge electrode
Rotating brush
Guide
Roller chain
Rotating brush driving unit
Particle diameter is
rough resulting in
excellent peeling
off of dust.
Fixed electrode
hammer rapping
method
EP outlet side
Particle diameter is
small resulting in a
difficulty to peel
off the dust
Movable brushing
method
Chinese A-coal
EP inlet side
Canadian A-coal
Australian A-coal
Australian B-coal
This system has been employed mainly in the USA to cope with the efficiency deterioration of hot-side EP over
time and a remarkable improvement effect has been confirmed.
The hot-side EP used in the USA displayed excellent collection efficiency at the start of operation, but its
efficiency deteriorated over time. Although it was operated under high temperature conditions, phenomena of
back corona occurred, which was thought to be because the electric specific resistance had been raised due to the
exhaustion of alkali metals (Na, K, etc.) which should act as an ion carrier inside the fly ash layer.
As a result of injection of Na (Na2SO3, Na2CO3, etc) in order to replenish the Na in the accumulated layer of fly
ash on this electrode, it was confirmed that remarkable efficiency improvement had been attained.
In addition, as a result of injection tests into cold side EP, instead of hot-side EP, for a type of coal with very
poor collection efficiency, excellent efficiency improvement effect has been observed in many test cases.
Outlet of cleaned
air
Artificial distribution
diagram
Artificial smoke duct
Discharge electrode
relation to the requirement for dust collection installation as an exhaust smoke treatment system of high efficiency,
difference in the collection efficiency, etc.
BF is a system for filtering the particles on the surface of the filtering cloth. As a dust collection function,
inertia adsorption, cut off adsorption, etc. are used. As a dust scraping off structure, the scraping off method of the
back wash type and the scraping off method of the pulse jet type are available. The scraping off method of the
pulse jet type has become mainstream in recent years.
Table 4.2.2-3 Comparison of BF (bag filter) for coal fired power plant with EP
No.
1
Item
Collection efficiency
Maintenance
3
4
5
Pressure loss
Running cost
Practical use
BF (Bag filter)
Without being critically affected
by the variation of coals, stable
collection efficiency can be
attained.
Periodical replacement of
filtering cloth is required. (About
once every 2 - 3 years)
High (1.0 - 1.5 kPa)
Large
In America and Australia
No practical use in Japan
EP
Depending on the type of coal,
the collection efficiency varies.
One maintenance/year is
sufficient.
Low (0.2 kPa)
Small
Many practical uses are found in
the world.
Filtering cloth
Discharge electrode
Grounding
electrode
Electrostatic charger
High voltage power source
403
Conventional charging
system
Item
DC charging system
Charging
DC
DC
DC
Even corona
High spark
generating voltage
4
5
Energy
saving
Wave form of
applied voltage
Effect of
collection
efficiency
Structure of
circuit
Serviceability
"
Charging
Suppression of
back corona
Suppression of
back corona
t1: 10 to 100 ms
t2: 20 to 200 !s
t1: 5 to 10 ms
t2: 1 to 100 !s
3
Superimposing
charge
Sudden pulse
Method/principle
Superimposing
charge
DC intermittent charging
system
Characteristics
100
100 to 180
100 to 120
Simple
Complicated
Simple
Good
Pace (Poor collection
efficiency against high
resistance dust)
"
"
Troublesome
Able to apply strong charge to the
dust because the peak voltage is
very high
As the current density is even,
high average current can be
applied and is effective for high
resistance dust
404
"
"
Good
The peak voltage improves
and the collection
efficiency can be improved
for high resistance dust
Large energy saving effect
Therefore, issues to be solved in the future are the reduction of the power source unit, which could determine
the future of the pulse charge and establishment of reliability.
(Microcomputer)
Calculation of required
charge amount
Load responding
control
Setting of required
charge amount
Charging unit
Load signal
Constant dust
concentration control
Dust
concentration
meter at the outlet
(Light
transmission type)
Gas
405
Charged
voltage
(kV)
Section 1
Discharge
current
(mA)
Charged
voltage
(kV)
Section 2
Discharge
current
(mA)
Soot blow
Soot blow
Dust
concentration
at EP outlet
(Manual operation)
(Manual operation)
(Computer controlled) Ws: 60mg/m3 (normal)
The nature of the dust fluctuates largely and the temperature is relatively low when starting/stopping a boiler.
Sparks tend to be generated easily when EP is charged. There is a chance the collected dust may catch fire as a
result of a spark. Therefore, it is necessary to fully understand any and all issues expected to occur at the time of
starting/stopping of the unit and implement measures and actions to minimize the chance of incidents.
Portion to be
inspected
Discharge
electrode
Collecting
Dust
electrode
collecting
chamber
Distribution
plate
Insulator
Description of inspection
Disconnection, looseness
Wear, corrosion
Contamination
Deformation, off-centering
Contamination
Corrosion
Corrosion, falling off
Contamination
Contamination
Breakage
407
Purpose
Prevention Extension of
of accident service life
Handling
Cut off/replacement
Cut off/replacement
Washing by water
Repair
Washing by water
Replacement
Repair/replacement
Washing by water
Cleaning
Replacement
Hammering
unit
Rapping
device
Smoke duct
Ash
discharge
system
Portion to
be inspected
Diaphragm
Hopper
Insulator
shaft
Speed
reducer
Hammer
Rapper shaft
Hammer
drive unit
Hammer
rapper rod
Inlet of
smoke duct
Expansion
Vibrator
motor
Vibrator
Manhole
and gland
Inspection
hole
Each
manhole
Gland seal
Description of inspection
Purpose
Prevention Extension of
of accident service life
Silicon
transformer
Breather
Insulators
High
voltage
protection
resistance
Grounding
switch
High
voltage
circuit
Grounding
FCO
(Film cut
out)
Repair
Close check
Discharge ash, wash by water
Correct plectra clearances
Repair
Cleaning
Replacement
Disassembling, inspection, repair
Replacement and filling up
Repair, replacement
Repair
Repair, replacement
Repair, replacement
Repair, replacement
Breakage, wear
Repair
Corrosion
Corrosion
Loosened fitting
Movement, abnormal noise
Damage to cord
Loosened fastening
Crack on welded portion
Crack on gas sealing plate
Corrosion of stool
Clogging by dust
Corrosion, gas leak
Damaged packing
Corrosion
Closed state
Damaged packing
State of sealing
Electric
system
Handling
Repair, replacement
Additional fastening
Disassembling, inspection, repair
Replacement
Additional fastening
Repair
Replacement
Repair, replacement
Cleaning
Repair, replacement of packing
Replacement
Repair, replacement
Additional packing, correction
Replacement
Additional fastening of gland,
additional packing, replacement
Filtering, replacement,
replenishment
Replacement
Replenishment of oil
Regeneration and replacement
Cleaning
Replacement
Cleaning
Replacement
Burning, disconnection
Tightening of each portion
Roughness of connector
Movement
Deformation
Tightening of each portion
Disconnection, missing
Grounding resistance
Additional fastening
Repair, replacement
Repair, adjustment
Correction
Additional fastening
Repair
Measurement, re-work
Replacement of insulation paper
Movement
408
Wet process
Lime-Gypsum Process
MG-Gypsum Process
Slurry
Solution
Dry process
Nature of
adsorbent
liquid
Slurry
Adsorbent
Material
Byproduct
Calcium
carbonate
Slaked lime
Quick lime
Slaked lime
Calcium
carbonate
Caustic soda
NaOH
Caustic soda
NaOH
Calcium carbonate
CaCO3
Ca(OH)2
CaO
Slaked lime
Quick lime
CaCO3
Ca(OH)2
CaO
Ca(OH)2
CaCO3
Solution
Solution
Slurry
Solution
Calcium
carbonate
Ammonia
Gypsum
Nh4OH
Ammonium
sulfate
Gypsum
Gypsum
Ca(OH)2
Mg(OH)2
Solution
Slaked lime
Magnesium
hydroxide
Activated carbon
Solid
Activated carbon
Ca(OH)2
Na2CO2
Electron beam
Coal ash, gypsum, lime
Slurry
Mg(OH)2
Slaked lime
Ca(OH)2
Sodium carbonate Na2CO3
Electron Beam Process *1
Ammonia
NH4OH
Dry desulfurization method
Solid
Coal ash, plaster,
using coal ash *1
lime
Note: *1 The details of these processes will be introduced in Section 7. New technologies of desulfurization and NOx removal.
409
Mirabilite
Discharge
Sodium
Carbonate Sulfite
Gypsum
CaCO3
Ca(OH)2
CaCO3
Gypsum
Sulfuric acid
Slaked lime
Calcium
carbonate
Magnesium
hydroxide
Magnesium Hydroxide-Gypsum
Process
Gypsum
Discharge of
sulfuric acid
magnesium
Gypsum
Discharge of
sulfuric acid
magnesium
Sulfur, sulfuric
acid
Gypsum
Others
Ammonium salt
Coal ash
Lime, others
Coal
Heavy Oil
6,000 to 7,000
10,500
1.0 to 2.0
10 to 25
0.2 to 2.0
100 to 200
(O2 = 6% base)
0.1 to 0.3
0.1 or less
1 to 2
60 to 100
(O2 = 4% base)
10 to 25
0.1 to 0.2
200 to 1,600
500 to 1,500
Item
Higher heating value
(kcal/kg)
Nitrogen content (%)
Ash content (%)
Sulfur content (%)
Nature of fuel
1)
2)
3)
Dust concentration
(g/m3N)
SOx concentration (ppm)
Considerably large amount of Cl (chlorine) and F (fluorine) is contained, which will affect the
efficiency of desulfurization and waste water treatment and corrode the materials used.
A very large amount of ash is contained. The soot and dust concentration is 100 times or higher that in
heavy oil. As characteristics of the soot and dust, its main components are silica and alumina, which
have strong electric resistance. The dust collection efficiency of the electrostatic precipitator depends
largely on the type of coal.
Depending on the type of coal, the concentration of SO2 becomes high in general.
In view of these characteristics, the points to be noted with flue gas desulfurization equipment and the
countermeasures to be considered in the planning of equipment are summarized in Fig. 4.3.1-1.
Points to be noted
Countermeasures to be
considered in planning
Influence on
desulphurization
Ash-separating system
Ash-mixing system
Selection of adsorbent
Addition of Mg and Na
Corrosion
proofness/wear
resistance of materials
Fig. 4.3.1-1 Points to be considered for flue gas desulfurization equipment for coal thermal power plants
410
Bypass damper
Desulphurization
ventilator
Chimney
Gas heater
(Heat recovery unit)
Limestone silo
Mist eliminator
Dehydrator for gypsum
Absorber
Gypsum
Vacuum pump
Material pit
Waste water
treatment
Filter pit
412
Table 4.3.1-3 Comparison between soot separation system and soot mixture system
Flow
Reheating process
Cooling process
Absorber
Scrubber
ME
Absorber
ME
Absorber
Scrubber
Reheating process
Absorbing process
Gypsum dehydrator
Absorber
ME
Absorbing
process
Gypsum
dehydrator
Limestone
Gypsum
Waste water
treatment
Gypsum
Limestone
Material pit
Material pit
Gypsum-recovering
process
Material-adjusting
process
Item
Gypsum-recovering
process
Material-adjusting
process
Waste water
treatment
Absorption
efficiency
Dust removal
efficiency
Gypsum
quality
Materials of
equipment
Base
Economical
effect
Equipment
cost
Operation
cost
Space
requirement
for
installation
Base
Base
4.3.1.4 Outline of main units/systems composed of wet-type flue gas desulfurization equipment
(1) Cooling, absorbing, and reheating processes
a) Desulfurization ventilator
a. Position to install a desulfurization ventilator
For wet-type desulfurization equipment, a desulfurization ventilator is used as its ventilation source. In general,
the position names for installation of the desulfurization ventilator are identified by the position marks as shown
in Fig. 4.3.1-4. In the past, most of desulfurization ventilators were installed upstream of the untreated gas gas
heater (GGH) called the A-fan. In Table 4.3.1-5, the position to install the desulfurization ventilator and a
characteristics comparison are shown. From the viewpoint of power consumption, the C-fan is most advantageous,
but not advantageous because countermeasures must be prepared against erosion or corrosion by the mist, etc.
downstream of the absorber. In recent years, adoption of the D-position is increasing in view of energy saving and
equipment cost.
413
C-fan
A-fan
B-fan
Desulfurization
equipment
D-fan
S minute
From boiler
Item
Adhered moisture
Purity
pH
Wet tensile strength
Leak
Economical
effect
Item
# Temperature of
gas used
# Wear
# Corrosion
A-fan
100 - 150$C
Negligible
(Depends on fly ash)
Almost none
B-fan
80 - 100$C
Negligible
(Depends on fly ash)
In the corrosive
environment of
sulfuric acid due to
acid dewpoint
# Adhesion of soot
and dust
Negligible
Leak in the
combination of the
rotary-type
regenerative system
GGH
(Non-treatment
Treatment)
Dust leak (%)
Gas leak (%)
Power consumption
Evaluation
Large
Up to 6.0
Up to 3.0
100
(Base)
Has largest
installation records
and high reliability,
but too much power
consumption
C-fan
45 - 55$C
Almost none
D-fan
80 - 100$C
Almost none
Negligible corrosive
environment by
sulfur
Almost none
Small
Small
Large
Up to 4.0
Up to 0.3
Up to 4.0
Up to 0.3
Up to 6.0
Up to 3.0
90
82
95
Has an advantage if
combined with the
rotating regenerative
system GGH, but
careful consideration
must be given to the
materials
Most excellent in
economical effect
with lower power
consumption
The corrosive
environment is
tough, and corrosiveproof materials are
therefore required.
414
Has almost
equivalent
characteristics to Afan
With many
installation records
Fig. 4.3.1-5 Shaft power of ventilators of axial-flow type and centrifugal type
Drive motor
Flexible coupling
Inlet casing
Rotating blade
Bearing-supporting rotating blade
Stationary blade
Servo Support
cylinder blade
b) Structure of absorber
The absorber used for the Lime - Gypsum Process flue gas desulfurization process has a large area in contact
with vapor liquid and its gas absorption reaction is excellent in vapor-liquid solid substances. Its pressure loss in
the exhaust gas is kept low. In addition, an absorber of a type suitable for treating large-volume exhaust gas is
used. Typical types of absorber currently employed as flue gas desulfurization equipment at thermal power
generation plants include the spray tower, filling tower, jet bubbling reactor, and liquid column tower.
a. Spray tower
This is a system to have SO2 gas absorbed by installing several steps of many spray nozzles on the upper part of
415
the absorber, reforming the absorbent into fine liquid tubes, and letting the absorbent come into contact with the
exhaust gas. Because the inner structure is made as simple as possible, it is difficult for solid substances to adhere
and for scaling to be generated, which can minimize the pressure loss. The outlook for the spray absorber is
shown in Fig. 4.3.1-7. No demister is built in in some absorbers.
b. Grid-filling tower
The circulating slurry of the absorbent sprayed evenly from the overflow-type spray header positioned on the
upper part of the absorber changes the entire face of the filling grid to the wet wall state. Here, vapor liquid
composed of exhaust gas and slurry have full contact with each other to have SO2 absorbed. The grid-filling tower
has parallel flow or counterflow. The superficial velocity is high at about 4 - 5 m/s. The unit is more compact than
the counterflow type. The pressure loss varies depending on the grid-filling height, which is, however, 100 mm
H2O or less in general.
Fig. 4.3.1-8 shows the outlook for the grid-filling absorber.
Exhaust gas
Gas
Scrubber
Spray nozzle
Built-in demister Absorber
Mist eliminator
Air blower
Spray pipe
Exhaust gas
Spray pipe
Mist eliminator Spray nozzle
Gas
Scrubber
Agitator
Circulation
pump of
scrubber
Oxidized air
Absorber
Oxidizing air
pipe
Absorber
Circulation pump
of absorber
Limestone slurry
Gas outlet
Gas sparger
Spray pipe
Reaction layer
Gypsum slurry
Air
Gas inlet
Circulation pump of
absorber
c) Gas-reheating system
Because the exhaust gas leaving the absorber is in a saturated state with water, there can be such issues as the
generation of white smoke or corrosion of the smoke duct, if it is discharged without any treatment. In many cases,
it is reheated up to 80 - 100$C. in general.
For reheating of the gas leaving the desulfurization process in the past, supplementary heating (afterburner
method) by firing fuel containing low-level sulfur was usually employed. However, in view of energy saving
since then, a gas heater (GGH) is presently employed that heats up the low-temperature gas at the outlet of the
desulfurization equipment using high-temperature gas at the inlet of the desulfurization equipment. There are 3
types of gas heater available, namely, (1) the rotary-type regenerative system, (2) the media cycle type, and (3) the
heat pipe type. The features of each type are compared in Table 4.3.1-6.
a. Rotary-type regenerative gas heater
Layered wave-shaped plates are contained as a heat accumulator in the rotor having a radial partition wall. Heat
exchange is performed when this rotor rotates in the high-temperature gas and low-temperature gas. Heat is
transferred to low-temperature gas from high-temperature gas via the layered wave-shaped plate heat accumulator.
This type is compact, but due to its structure, the leakage of soot and dust and gas from untreated hightemperature gas to treated low-temperature gas cannot be avoided. Therefore, the general desulfurization
efficiency or dust removal efficiency may drop. However, the level of leakage is currently suppressed by adopting
a scavenging system.
b. Medium recycle-type gas heater
This is a system to exchange heat by forcibly circulating the medium between 2 independent shell and tube heat
exchangers. It has such features that no soot and dust are discharged and that the exhaust gas temperature can be
adjusted by the circulation amount of the heat carrier or the heat carrier heater. The system can be easily enlarged
and has greatest flexibility in installation.
c. Heat pipe-type gas heater
The heat carrier is enclosed in a closed system. The heart carrier receives heat that evaporates in the hightemperature area, discharges the heat, and then condenses it in the low-temperature area. The condensed heat
carrier returns to the high-temperature area to receive heat. Because the heat exchange is carried out in the natural
circulation of the heat carrier, no drive unit is required, and power for operation can be saved.
Table 4.3.1-6 Comparison of gas-reheating systems
GGH-type system
Rotary-type regenerative
system
High-temperature gas
Heat carrier
piping
Medium
steam
Steam
Basic structure
High-temperature
gas
Medium
solution
Lowtemperature
(Evaporator) gas
Heat carrier
Characteristics
No leak
No leak
Most conventional gas heaters were the rotary-type regenerative system. Leakage of soot and dust or gas was
unavoidable. In recent years, the non-leak type of medium circulation system or heat pipe-type gas heater is
adopted when high-level desulfurization efficiency or soot and dust removal efficiency is required.
In particular, the adoption of ultra-cold side EP processes is advancing, and the adoption of medium recycle
systems of the non-leak type is increasing.
(2) Oxidation/ Gypsum-recovering process
a) Oxidation system
With respect to the oxidation system in the flue gas desulfurization equipment, there are 2 types available,
417
namely, a method to oxidize flue gas in a separate oxidation tower, and a method to absorb and oxidize
simultaneously in the absorber. In view of such advantages that the unit itself is simple and utilities can be
reduced, the oxidation system in the absorber has been employed in recent years.
This system feeds air for oxidation into the absorber tank and performs almost 100% oxidation within the
absorber. Absorption of SO2 and oxidation reaction advances at the same time, and sulfuric acid is generated. In
addition, neutralization reaction with existing CaCO3 occurs simultaneously to generate gypsum.
In the oxidation method within the absorber, CaCO31/2H2O does not exist as seen in the separate oxidation
tower. Therefore, the absorbing mechanism is different.
As shown in Table 4.3.1-7, H2SO4 generated by oxidation reaction reacts with CaCO3 in a very quick fashion,
which is characteristic of this method. Therefore, no further sulfuric acid is required to be added. High SOx
removal efficiency can be achieved while keeping excessive CaCO3 at a low level.
The main oxidation equipment that feeds air for oxidation into the absorber tank is shown in Table 4.3.1-8.
There are several methods made available. In each case, air converted into very fine bubbles is fed into the tank.
Table 4.3.1-7 Comparison of oxidation systems
Item
Basic flow
Absorber
Absorber
Sulfuric acid
Oxidation tower
Gas
Gas
Gypsum
Limestone
Air
Gypsum
Limestone
Absorber
tank
Absorber
tank
Air
Chemical reaction
Absorber
Tower
Absorber
Within tank
Oxidation tower
CaSO3!1/2H2O+1/2O2 +3/2H2O
CaSO4!2H2O
CaCO3 + H2SO4 + H2O
CaSO4!2H2O + CO2 "
# Oxidation tower: Required (separate
installation)
# Sulfuric acid: Required
# CaCO3 excess ratio: Large
# Impact of oxidation on absorbing
efficiency: Small
Characteristics
418
#
#
#
#
Multiple-pipe
insertion system
Rotary sparger
system
Air
Air
Air
Characteristics
Air
# Air is converted
into very fine
components
through the rotary
blade of the
propeller-type
agitator.
# The same as on
# Air is converted
the left
into very fine
bubbles by the
fixed-type sparger
ring.
# Air is converted
into very fine
bubbles by the
rotary sparger.
419
Centrifugal filtering/dehydration
Batch operation
Dehydration efficiency
Records of practical use
Advantages
Washing water
Washing water
Pump for feeding
gypsum slurry
Turbofan
Vacuum
tank
Dehydrated
Filtered
cakedehydrator liquid
Centrifugal precipitation/dehydration
Vacuum pump
Suction filtering/dehydration
Continuous operation
Continuous operation
Moisture content of gypsum: 10- 15%
Many
# The moisture content of gypsum is
low.
# Long record of practical use with
high reliability
Characteristics
Belt fan
Dehydrated
cakedehydrator
Mist
separator
Filtered
liquid
Filtered liquid
Dehydration principle
Operation method
Some
# Large treatment capacity
due to continuous
operation
# The unit is made compact,
and the number of
installations can be
lowered.
# Easy maintenance because
no filter cloth is required to
be replaced
# Compared with the baskettype and the filter cloth
traveling type, the moisture
content of gypsum is
higher.
Some
# Large treatment capacity due to
continuous operation
# The number of installations can be
lowered.
# Long record of practical use with
high reliability
Receiving
piping
Receiving
piping
Air slide
Basket-type
centrifugal
d h d
Disadvantages
Decanter-type
centrifugal
dehydrator
Process flow
Decanter-type centrifugal
dehydrator
Air slide
Auto Feeder
To material pit
To material pit
Cone-type silo
Flat-bottom-type silo
and/or limestone concentration at its optimum level. Keep monitoring instruments, etc. under your strict control
by always carrying out the following checks:
#
Whether or not any deviation is present in the value displayed on the instrument
#
Whether or not sufficient cleaning has been performed for the instrument
#
Whether or not the display on the instrument has been kept stable
If the liquid-gas ratio in the absorber (L/G, immersion liquid level, etc.) should drop due to any closed spray
nozzle, accumulation of scale within the spray pipe, etc., it will cause not only a drop in desulfurization efficiency
but also the adherence of scale within the absorber, to which careful attention must be paid.
c) Limestone slurry feed flow rate
If the feed flow rate of limestone cannot be controlled in a successful manner, the pH value in the absorber
cannot be maintained at a stable level, which will have a direct impact on the desulfurization efficiency. Therefore,
it is required to continuously monitor whether or not the feed line of the limestone (including the regulating valve
and instruments) is clogged and for the presence of any abnormal point with the feed pump of the limestone slurry.
d) Air flow rate for oxidation
If the feed flow rate of air for oxidation to the absorber drops, the oxidation efficiency may drop and in addition,
reverse flow of slurry into the air piping may occur, which requires your special attention.
e) Gas temperature at the inlet of absorber
Inside the absorber, plastic parts are used or rubber or resin lining is used, whose heat-resistant temperature is
relatively low. Therefore, in order to monitor whether or not the exhaust gas has been sufficiently cooled down,
a thermometer is sometimes installed at the inlet of the absorber, etc. If the temperature rises, an interlock will be
actuated to apply an emergency stop to let the smoke pass through. The major causes of such high temperature
include an abnormal temperature rise in the gas at inlet, drop in circulating flow rate due to any clogging of the
spray nozzle for cooling water circulation, etc. Daily inspection and monitoring of these points are also required.
f) Control of liquid level
The absorber tanks are controlled in such a manner that their liquid level is kept at a given level by a liquid
level-regulating valve. In the event that the liquid level has dropped too low due to a problem with the liquid
level-regulating valve or clogging in the liquid leveler, the agitator may trip and cause the flue gas desulfurization
equipment to stop. Daily monitoring is required in order to detect any abnormal event at an early stage.
(2) Reheating process
With respect to the gas heater (GGH), any clogging in the element will cause the heat exchange efficiency to
drop and the differential pressure to rise.
In the case of the rotary-type generative GGH, untreated gas (soot and dust) may leak, which will force the
equipment to stop. Therefore, such operation control as capturing aged variation of GGH differential pressure,
monitoring of gas temperature, and inspection of the operation of soot blower becomes important.
(3) Gypsum-recovering process
If the density level of the slurry to be fed to the gypsum dehydrator is too high, the piping may be clogged. If it
is too low, the handling performance of the dehydrator may drop. If the fluctuation of the fed slurry density is too
large, it causes abnormal vibration of the gypsum dehydrator. Therefore, it is required to monitor on a daily basis
the slurry density to be fed to the gypsum dehydrator by adjusting the zero point and checking the span.
(4) Material-adjusting process
The slurry density of the absorbent limestone determines the slurry density within the absorber under operation.
It is required to fully monitor the fluctuation of the density, which causes various problems in the operation of
equipment.
4. Absorber
5. Mist eliminator
6. Limestone silo
7. Various types of tank
8. Various types of agitator
9. Various types of slurry pump
Inspection Item
a)
b)
c)
d)
e)
f)
g)
h)
a)
b)
c)
d)
e)
f)
g)
h)
i)
a)
b)
c)
d)
e)
a)
b)
c)
d)
a)
b)
c)
a)
b)
a)
b)
c)
a)
b)
c)
a)
b)
c)
a)
b)
c)
d)
423
12. Instruments
Inspection Item
a) Corrosion, wear, or damage to basket
b) Damage to bearing, speed reducer, or shaft
c) Wear, looseness, or damage to V-belt
d) Wear of scraper/blade tip of scraper device
e) Damage to damper
f) Clogging or damage to filter cloth
a) Wear of bowl conveyor and scraping blade
b) Damage to shaft
c) Looseness, wear, or corrosion of bearing
d) Damage to rubber support
e) Disassembling inspection of lubrication unit
a) Clogging or damage to filter cloth
b) Looseness, wear, or corrosion of bearing
c) Corrosion within casing
a) Wear, expansion, or damage to lining piping
b) Wear, damage, or off-centering of expansion joint
c) Wear or damage to valve
d) Corrosion or wear of orifice
a) Disassembling inspection of regulating valve
b) Inspection and calibration of all analyzers (SO2 gage, pH gage, etc.)
c) Inspection and calibration of instruments (flow rate gage, pressure gage,
etc.) to be installed on site
d) Movement of security interlock
a) Disassembling inspection of motor
b) Disassembling inspection, checking of movement, and measurement of
insulation resistance of breaker
Inspection Method
Visually inspect all points first. If any problem
is foreseen, check it using a pinhole tester.
2. Blistering
3. Film thickness
4. Hardness
5. Peeling
424
Remarks
Rubber lining: 3,000 V/mm
Resin lining: 2,000 V/mm
Find any portion in which the arc
occurs.
Partial repair, or entire repair if
necessary
Portion with which the spray liquid
collides, etc.
Especially rubber lining
This scale is composed of calcium sulfate (CaSO3!1/2H2O) and gypsum (CaSO4!2H2O) and is generally soft.
Chemical scale, on the other hand, is mainly composed of CaSO4!2H2O, which is precipitated under a partially
super-saturated state of CaSO4 in the absorbent slurry that has absorbed SO2. It grows and becomes solid in the
course of the crystallization of the gypsum. Its removal is not an easy job.
Fig. 4.3.2-1 shows the relationship between the saturated solubility of the pH and CaSO3/CaSO4.
When solid CaSO3!1/2H2O or CaSO4!2H2O is present in the liquid, it has been dissolved to its saturated
solubility depending on its pH level. Chemical scale in such a state is generated because dissolved CaSO3 is
oxidized by dissolved and existing O2, and the CaSO3 reaches a super-saturated state as follows:
CaSO3 + 1/2O2 CaSO4
From Fig. 4.3.2-1, you will understand that when fluctuation of the pH (high low) is large and the pH
becomes as low as possible, the scaling potential rises and scaling is easily generated.
CaSO4(L)
Super-saturated line
Scaling
potential
Saturated
dissolution line of
CaSO4(L)
Saturated
dissolution line of
CaSO3(L)
in these years, the cost required for the equipment has largely dropped. The economical effect of flue gas
desulfurization equipment was discussed in the past because low S-fuel was used. However, it is now positioned
as essential equipment for coal-fired power generation plants or high S-oil-fired power generation plants. The
economical effect is seldom discussed although there is discussion of the flow of cost reduction as seen with other
equipment.
The cost of flue gas desulfurization equipment is affected not only by desulfurization efficiency (SO2 density at
the outlet) but also by dust removal efficiency (soot and dust concentration at the outlet). The desulfurization
efficiency will, as a matter of fact, be reflected in the desulfurization cost within an absorber. Dust removal
efficiency affects the selection of the gas heater. Namely, when dust removal efficiency is sufficient, a gas leak to
some extent is permissible that enables the use of a rotary-type regenerative gas heater. When dust removal
efficiency is very limited, it is required to use a non-leak-type gas heater, which will result in a rise in equipment
cost to some extent.
In these years, we can see an example of rationalization in the installation of dry-type electrostatic
precipitators for coal-fired boilers downstream of the heat-recovering unit of the non-leak-type gas heater, in line
with the reinforcement of environmental regulations. Evaluation of economical effect in this case would not be
enough if you evaluate the same for flue gas desulfurization equipment only. It would also be necessary to make
evaluation as a system including the dry-type electrostatic precipitator. This trend of evaluating the entire exhaust
gas-treating system, not only evaluating the flue gas desulfurization equipment, will become popular in the
discussion of economical effect especially with coal-fired boilers, etc. that remove SO2 together with soot and
dust.
Because the rationalization and simplification of the system of flue gas desulfurization equipment have been
considerably accelerated, the machine cost in the entire equipment cost tends to drop and the weight of controls
tends to become heavier. The cost of controls relates to the operation control. Therefore, it is necessary to make
total evaluation including operation cost.
426
NO ! Ae
E1
RT
[N2IO2] 2
te
427
NO generation volume
0.5 seconds after
reaction
Heavy oil
Gas
4.4.1.2 Fuel NO
No clear conclusion has been so far reached with respect to the generation mechanism of Fuel NO. However, it
is considered in general that there are two generation processes from nitrogen compounds contained in the fuel to
NO as follows:
(1) Nitrogen compounds are thermally decomposed in such intermediate compounds as NH2, NH3, CN,
HCN, etc., and NO is thereby generated.
(2) Nitrogen compound is decomposed and the N atom is discharged. NO is then generated in the
reactions below.
N + O2NO + O
N + OHNO + H
Fig. 4.4.1-2 shows an example of the relationship between O2 = 0% converted NO density and N content by the
percentage in an actual boiler. In the example in Fig 4.4.1-2, NO increases by 53 ppm when the N content
increases by 0.1%. If all of 0.1% N content is converted into NO (conversion rate: 100%), it will correspond to:
"$ Approximately 155 ppm (O2 = 0% conversion) in the case of heavy oil, and
"$ Approximately 200 ppm (O2 = 0% conversion) in the case of coal.
The increase of 53 ppm when the N content is 0.1% corresponds to a conversion rate of 34%. The conversion
rate of the N content contained in the fuel into NO is considered in general to be about 15 - 30%.
4.4.2 Suppression of NOx and combustion-improving technology
4.4.2.1 Suppression of NOx in a boiler and combustion-improving technology
As combustion methods for suppressing NOx in a boiler, the following methods are adopted in general:
(1) To lower the excess air ratio
This is a method of suppressing the generation of NOx by reducing the feed air into a boiler, especially by
reducing excess oxygen in the combustion area. However, most boilers currently used for power generation are
already operated under low excess air ratio. Therefore, it is not considered that any significant NOx reduction
effect can be expected through air ratio adjustment.
(2) To lower the air temperature for combustion
Boilers are operated at combustion air temperature in the range of 250 - 350#C in general. The NOx generation
volume is reduced by lowering this temperature as well as the combustion temperature.
428
Fig. 4.4.2-1 Diagram of low NOx principle from a pulverized coal-fired burner
The characteristics of pulverized coal are utilized in the Mitsubishi PM burner. The NOx generation volume
decreases at the side at which the concentration of pulverized coal is larger at the border where the primary/coal
feed rate corresponds to the value of the theoretical combustion air feed rate of the volatile matter content in the
coal.
In the direct combustion system (a system in which the mill and burner are directly connected via pulverized
coal piping), the primary air/coal feed rate at the mill outlet is 2 - 3. In the case of the PM burner, a distributor is
installed at the burner inlet. The burner nozzle is divided into a nozzle for larger pulverized coal concentration
(Fig. 4.4.2-1) and a nozzle for smaller pulverized coal concentration (Fig. 4.4.2-1). The pulverized coal is fired
generating a smaller amount of NOx (Fig. 4.4.2-1) than the amount of NOx (Fig. 4.4.2-1) generated when fired
through a single nozzle.
429
The A-PM burner shown in Fig. 4.4.2-2 has a built-in distributor and forms a dense mixed-air flame around the
outside circumference of the flame (called Conc) and a thin mixed-air flame (called Weak) within the inside
circumference of the flame.
Primary air
(Pulverized coal +
Air)
Inside
Outside
circumference circumference
Secondary air Secondary air
430
Density
Fig. 4.4.2-4 Principle diagram of NOx reduction by the Hitachi pulverized coal-fired NR burner
In the area, volatilized content burns as shown in Fig. 4.4.2-3 to facilitate pulverized coal to ignite and form
high-temperature reduction with excess fuel in a stable fashion, and heat decomposition is accelerated while
suppressing the initial mixture of the fuel and the inside and outside circumference secondary air. Here, by
maintaining stable ignition and flame holding by consuming the oxygen contained in the primary air, Fuel-NO
generated from volatile organic nitrogen oxide in the coal is discharged at the initial step of combustion (the step
of the combustion of volatilized content occurs first). B in Fig. 4.4.2-3 is the area in which the reducing agent is
generated that generates reducing substances such as intermediate products of the hydrocarbon family ("HC)
through a reaction in the low-oxygen atmosphere of the carbon within the coal discharged by heat decomposition
in the flame center downstream of A and hydrogen. In area C where NOx decomposes, Fuel-NO generated in A
and intermediate products ("HC) generated in B that exist within the flame makes a NOx reduction reaction, where
NOx is reduced to N2 via intermediate products containing nitrogen("NX). D in Fig. 4.4.2-3 is the outside flame
that makes contact with the inside secondary air. Combustion of coal particles advances and, at the same time, a
small amount of NO is generated through the oxidation reaction of the N content (Char-N) existing in the coal
char. This forms a high-temperature flame in a stable state and, at the same time, accelerates char combustion
formed downstream of C by utilizing the strong rotary force of the outside-circumference secondary air. In the
complete combustion area downstream of the flame, combustion of char is accelerated by suppressing the
phenomenon where the N content of char converts to NO. The Hitachi NR burner has the characteristic of
volatizing a large amount of nitrogen compound contained in the coal particles in the gas layer at the initial stage
of combustion and of suppressing the later conversion to NO.
Fig. 4.4.2-5 gives an outline of the structure of the Hitachi NR burner. The pulverized coal nozzle is positioned
at the center of the burner. In the concentric circle of the outside circumference, a cylindrical inside-circumference
secondary air supply nozzle is installed. Outside it, a combustion air-rotating device is installed that adjusts the
outside-circumference secondary air. Pulverized coal is conveyed and supplied by primary air and from its
surrounding area, and inside- and outside-circumference secondary air is supplied in a ring shape.
Pilot torch
Inside
Outside
circumference circumference
Secondary air Secondary air
the volatilized content in the pulverized coal, generating reducing agent, performing NOx reduction, and
completing combustion. In addition, it forms a high-temperature reducing flame through quick ignition, and the
flame becomes short. Because it is a burner able to attain low-NOx combustion and improvement of combustion
efficiency (reduction of non-burnt content in the ash), the minimum load in single coal firing can be reduced.
Therefore, basically, no cooling of the flame by feeding exhaust gas is required. In addition, because an effective
and strong reducing area can be formed in the burner flame when the burner air ratio is relatively high,
combustion at a low excess air ratio becomes possible.
" IHI's low-NOx burner
Although such coal with large volatile content actively generates Volatile-NOx in the ignition area of
pulverized coal, it can be easily reduced by forming a volatile atmosphere through two-step combustion.
Therefore, in order to reduce NOx in pulverized coal combustion effectively, it is recommended to make the
ignition stable, form a reduction atmosphere in the area of pulverized coal ignition, discharge the nitrogen content
in the coal to the extent possible, and reduce it to nitrogen.
In order to realize the above, the DF pulverized coal burner, which is IHI's low-NOx pulverized coal burner,
forms a high-temperature reduction atmosphere using a rotary current and ignites pulverized coal in a stable
fashion.
Fig. 4.4.2-6 shows the structure of the IHI-DF inter-vane pulverized coal burner made by IHI. The secondary
air, which constitutes the major part of the combustion air, is supplied to the burner throat through two routes. The
rotary force of each route can be adjusted independently. The internal secondary air rotary force is adjusted by the
secondary air inter-vane as shown in Fig. 4.4.2-6 so that the flame becomes stable. The flow pattern of the
external secondary air is adjusted by the secondary air vane. As a result, the mixture of secondary air with fuel is
controlled. The fuel is injected from the ring nozzle tip composed of the inner and outer cylinders. The nozzle tip
has been narrowed to a given angle. The fuel injection is so arranged it concentrates on the burner axis, whereby
fuel excess combustion is formed to reduce NOx.
On the other hand, the pulverized coal conveyed in the primary air is injected from the pulverized coal nozzle
after being fed in the circumference direction evenly. The tip of the pulverized coal nozzle has a coned shape by
which the infection of pulverized coal is directed to the center of burner to reduce NOx by performing self-dense
or-thin combustion.
# KHI-CC-type pulverized coal burner
The KHI-CC-type pulverized coal burner made by Kawasaki Heavy Industries is shown in Fig. 4.4.2-7.
This burner aims to stably ignite the flame and reduce NOx in the course of two-step combustion as a
countermeasure against NOx. The air container is a spiral and rotary type for each burner. The flame is stabilized
by the rotation of the combustion air. The air distribution to each burner is simplified. It is designed to attain
excellent combustion under as low an excess air ratio as possible. The burner throat is composed in the sequence
of oil burner, primary air + pulverized coal, secondary air, and tertiary air, starting from the center. With the
functions of a distribution blade and primary/secondary flame holders, this burner has such characteristics as
ignition under a stable condition, high-efficiency combustion, and low-NOx operation without causing any
slugging to the furnace.
Burner inner cylinder
Flow divider
Throat ring
Tertiary air
damper
Oil burner
Primary air + Pulverized coal
Tertiary air
Secondary air
Secondary air
Tertiary air rotation vane
Tertiary air
Tertiary air
Secondary air
Distribution blade
Oil burner
Reduction flame
Primary air +
Pulverized coal
Secondary throat
Primary
throat
Rib
433
Furnace outlet
Area to
complete
combustion
Area to reduce
NOx contained in
unburned fuel
Main burner
combustion
area
Main burner
In-furnace NOx
reduction method
NOx reduction
in-furnace operation
Time
No NOx reduction
in-furnace operation
the fuel, and almost no Fuel NOx is generated. In addition, because the fuel is a type of gas, it becomes easy to
have Thermal NO mix with air in a desirable fashion. Because the time required for complete combustion is
shorter than for liquid or solid fuel, the generation of NOx becomes smaller. In the case of liquid or solid fuel, N
compounds are contained in the fuel. Therefore, the amount of NOx generation become larger in relation to its
time required for combustion and flame temperature. As such, if you use a fuel type with lower N content,
gasified or liquidated solid fuel, it will become possible to make the best use of the technology to reduce NOx in
an effective manner.
In practical boilers for thermal power generation, combinations of the above measures (1) - (7) are used. With
respect to the comprehensive NOx suppression effect through such combinations, it is difficult to expect the total
NOx suppression effect of each measure.
The NOx suppression effect of the boiler has been explained above. The NOx suppression technology of gas
turbines, whose installation has been increasing remarkably these years, is explained below.
435
NH3 nozzle
Boiler
NH3 injection
nozzle
NH3
Cooling water
Fig. 4.4.3-1 Flow diagram of non-catalytic NOx reduction equipment for industrial boilers
436
Gas-fired boiler
Boiler
Denitrification
equipment
Boiler
Dust
Desulphurization Chimney
Denitrification Air
equipment
pre-heater collector equipment
Boiler
Desulphurization Chimney
Denitrification Air
Dust
equipment
pre-heater collector equipment
(Low
temperature)
Air pre-heater
Chimney
Boiler
Dust collector
(High
temperature)
Chimney
Desulphurization
Denitrification Air
pre-heater equipment
equipment
Fuel
Denitrification
equipment
Combined cycle
Gas turbine
Exhausted heat recovering
boiler
Gas turbine
Fuel
Chimney
Denitrification
equipment
Simple cycle
Gas turbine
Exhausted heat
recovering boiler
Chimney
437
To atmospheric air
Boiler
Air pre-heater
Dust collector
Soot blower
Ammonia dilution
device
Denitrification
equipment
Air
NOx
removal
reactor
Chimney
Backfire prevention
device
Accumulator
Liquidated NH3
receiver
Carburetor
NH3 tank
Steam
CATA
CATA
4N2 + 6H2O
(1)
2N2 + 3H2O
(2)
In the case of any possible clogging of the NOx removal reactor caused by gas containing a large amount of
dust, etc., a soot blower is sometimes installed in the upstream side of the NOx removal reactor.
NH3 to be used for reduction is transported by a tank lorry, etc. and stored in a liquidated ammonia tank. The
required amount of NH3 is gasified by an NH3 carburetor and transferred to an accumulator. After being diluted
by some of air from the forced draft fan (hereinafter referred to as "FDF") of the boiler, gasified NH3 is injected
into the exhaust gas evenly from the NH3 injection nozzle. Here, the injection amount of NH3 is determined in
general by judging the amount of NOx flowing into the reactor from the signals representing the exhaust gas
amount such as NOx density at the inlet of the denitrification equipment and the boiler load signal as shown in Fig.
4.4.4-3, and by multiplying the given mole percentage.
Boiler
NOx removal
reactor
Boiler
load signal
Catalyst
FDF air
Compensation
calculator
NOx
gauge
Air pre-heater
Ammonia flow
rate adjustment
Mol ratio-adjusting
station
Ammonia
b)
c)
d)
e)
Minimized side reaction such as the conversion ratio of SO2 into SO3, etc.
High durability
High mechanical strength and heat resistance
Wear-proofness has been taken into consideration when treating exhaust gas containing soot and dust
with high wearing impact
Several types of catalyst satisfying the above conditions are currently in practical use.
As a carrier for such catalysts, porous ceramics that carry various types of metal oxides as an activating
compound such as titan, aluminum, etc. are used.
As the shape of the catalyst, a grid, plate, or particle shape is put to practical use as shown in Fig. 4.4.4-4. Table
4.4.4-1 outlines the points to be considered when selecting the catalyst to use for the denitrification equipment for
a boiler. A NOx removal catalyst is usually contained in a catalyst container (which is called a pack, module,
basket, unit, block, etc.) for use.
2) NOx removal reactor
The NOx removal reactor fills up the NOx removal catalyst and performs NOx removal reaction. In order to
perform NOx removal reaction in an effective fashion, the reactor must be a type not causing clogging or
divagation due to exhaust gas. A guide vane is installed to prevent divagation. To prevent clogging, the following
measures are taken:
a)
Use of a catalyst of the gas parallel flow type
b) Use of the gas longitudinal flow type when the amount of soot and dust is large
c)
Selection of the proper gas flow velocity not causing soot and dust to accumulate
d) Considering the installation of a soot blower if necessary to prevent or remove soot and dust
accumulation
Here, the types of NOx removal reactor are shown in Fig. 4.4.4-5.
Table 4.4.4-1 Points to be considered when selecting
the fuel type for a boiler and catalyst
Particle
Grid
Plate
Gas-fired boiler
Catalyst
Coalfired
boiler
Low-soot
and -dust
NOx
removal
system
High-soot
and -dust
NOx
removal
system
Points to be considered
High activity with thermal
resistance
High activity, thermal resistance,
resistance against SOx, no
poisoning by and resistance
against soot and dust, low SO3
conversion ratio, resistance
against adherence of soot and
dust
Same as above
High-temperature heat
recovery
NOx removal
reactor
Medium-temperature
heat recovery
Low-temperature
heat recovery
Fig. 4.4.4-6 External appearance of the combined cycle exhaust gas boiler
Boiler front
ECO bypass
NOx
removal
reactor
To EP
Here, the types of NOx removal reactor are shown in Fig. 4.4.4-5. In Photo 4.4.4-1 and Fig. 4.4.4-6, a
panoramic view of the gas combined cycle of the gas horizontal flow type and the external appearance of the NOx
removal reactor are shown respectively as an example. In Photo 4.4.4-2 and Fig.4.4.4-7, the overall layout of a
1000-MW boiler plant and external appearance of the NOx removal reactor are shown respectively as an example.
440
SV value: Constant
NH3/NOx mol ratio: Constant
Gas temperature ( C)
Fig. 4.4.4-8 Relationship between gas temperature and NOx removal efficiency (Example)
Coal
Coal
$
$
$
$
High activity
$
$
$
$
Heat resistance
$
$
$
SOx resistance
$
$
$
Poison-proofness against soot and dust
$
$
$
Suppression of SO3 conversion ratio
$
$
$
Resistance against adherence of soot and dust
$
Wear resistance
$ Items to be studied
(b) Selection of suitable amount of catalyst (SV value)
It is required to define the amount of catalyst (SV value: Space Velocity: Amount of gas to be treated/amount
of catalyst) in order to obtain NOx removal efficiency suitable for the design conditions.
NOx removal efficiency tends to drop as the SV value rises, which relationship is shown in Fig. 4.4.4-9. Based
on this relationship, the amount of catalyst should be defined.
SV value (x103h-1)
Fig. 4.4.4-9 Relationship between SV value and NOx removal efficiency (Example)
It is not recommended to fill the catalyst in an amount more than necessary because pressure loss may increase.
Selection of a suitable amount of catalyst is required.
442
SV value: Constant
Gas temperature:
Constant
Therefore, 1 mole of ammonia is required for 1 mole of nitrogen monoxide. NOx removal efficiency largely
varies depending on the injection amount of ammonia. The relationship between the mole percentage and NOx
removal efficiency is shown in Fig. 4.4.4-10.
Fig. 4.4.4-10 Relationship between NH3/NOx mole percentage and NOx removal efficiency (Example)
According to the above relationship, select the correct mole percentage.
The points to be considered when designing denitrification equipment are outlined above. When designing
denitrification equipment, it is most important to plan not only the main body of the denitrification equipment, but
also the best-balanced NOx removal system as an entire plant, synchronized with the boiler or gas turbine to be
installed together.
Points to be considered in designing denitrification equipment are outlined in Fig. 4.4.4-11.
(5) Points to be considered in operation and maintenance
Because moving parts are very limited in the case of NOx removal equipment, it is very rare that any
mechanical issue could occur during operation. However, the activity of the NOx removal catalyst tends to lower
slightly due to the compounds contained in the exhaust gas. It is required to carry out complete inspection and
performance control because NH3 to be used as reduction agent is a poisonous and flammable gas.
Portions to be inspected and points to be considered in the operation of NOx removal equipment are shown in
Table 4.4.4-4.
Control
center
Synchronization
with boilers A, B,
and C
Economizer bypass
NOx
removal
equipment
Air heater
Economizer
Boiler
Electrostatic
precipitator
NOx
removal
fan
Desulphur
-ization
fan
Ammonia/exhaust
gas mixer
Ammonia injection
nozzle
Measures against boiler gas
temperature and its effect
Gas heater
Desulphurization
equipment
Points to be checked
(1) Falling off of thermal insulating materials
(2) Gas leakage
(3) Differential pressure
(1) Clogging of valve and damper
(2) Movement of cutoff valve for ammonia gas injection and regulating valve for
ammonia gas injection
(3) Gland leakage from valve
(4) Leakage of operation air
(5) Leakage from injection flexible tube
(6) Indications on instruments
" Ammonia gas pressure gage
" Ammonia gas thermometer
" Ammonia dilution air pressure gage
(1) Temperature of, vibration of, or abnormal sound from any motor
(2) Oil leakage from gear box
(3) Leakage of gland from head valve or leakage from flange
(4) Rotation of lance tube or any damage to gear
Soot blower
In order to use NOx removal equipment for a long period of time under a stable condition, it is required to
capture any aged efficiency change according to NOx removal efficiency control data, etc., evaluate the life of the
catalyst, and establish a long-term plan for the catalyst.
Fig. 4.4.4-12 shows a flowchart of the method of estimating the life of a NOx removal catalyst. Examples of the
performance test necessary for performance control are shown in Table 4.4.4-5 and Table 4.4.4-6. If the
maintenance inspection and performance control is carried out as shown above, it becomes possible to replace the
catalyst at a desirable timing, whereby NOx removal equipment can be operated under a stable condition and its
economic effects will be improved.
(Customer)
Acquisition of data
from operation of
actual equipment
Analysis of data
obtained from operation
of actual equipment
Change in
efficiency
NOx removal
efficiency
No
Yes
Sampling and
evaluation of
catalyst
To determine
remaining life
Time passed
Not required
Replacement
required?
NOx removal
efficiency
To continue
operation
Required
Time passed
Possible
Possibility
of recycling
Local
performance
test
(Outline for
evaluation)
Implementation
of recycling
Not
possible
Performance
evaluation
To capture the
features of aged
performance change
by evaluating the
sampled catalyst and
local performance
test results
Performance
evaluation matches
Performance does not match.
To study the
amount for
replacement
To study any
issue related to
equipment
Clogging of ammonia injection nozzle,
defective gas sealing in reactor, etc.
Fig. 4.4.4-12 Flowchart of method of estimating the life of a NOx removal catalyst
444
Item
Test load
Frequency
Items to be
recorded
Item
Test item
Frequency
445
Number
Facilities
installed
between
August
10, 1973
and
December
9, 1975
Facilities
installed
between
December
10, 1975
and June
17, 1977
Facilities installed
between June 18,
1977 and August 9,
1979
Liquid fuel-fired
small boilers
installed between
June 18, 1977 and
September 7,
1977
Facilities
installed
between
August 10,
1979 and
September
9, 1983
Facilities installed
between September
10, 1983 and March
31, 1987
Facilities
installed
between
September 10,
1983 and
September 9,
1984
Facilities
installed
after April
1, 1987
onward
(1)
(2)
Solid fuel-fired
boiler
" Furnace heat
release rate
200,000
kcal/m3#h or
more
" Reheating
regenerative
condensing
extraction type
Natural
circulation type
" Emission of
500,000 700,000 m3N/h
or more
" Fuel to be
converted to
solid fuel by
December 31,
1984
130
130
130
150
150
150
130
130
100
130
130
100
130
130
130
150
150
130
150
150
150
150
150
150
Solid fuel [Residual oxygen density 6%]
60
100
100
130
150
150
60
100
100
130
150
150
60
100
100
130
150
150
420
420
200
300
250
300
300
446
(3)
Solid fuel-fired
boiler
70 or more
50 - 70
20 - 50
4 - 20
0.5 - 4
Below 0.5
400
420
420
450
450
480
300
300
300
300
300
300
350
300
300
350
300
300
380
350
350
480
480
380
Liquid fuel [Residual oxygen density 4%]
300
300
300
300
350
380
300
300
300
300
350
350
200
250
250
250
350
350
(4)
Liquid fuel-fired
boiler
50 or more
10 - 50
4 - 10
1-4
0.5 - 1
Below 0.5
180
190
250
250
250
250
180
180
180
250
250
250
130
150
150
150
180
180
130
150
150
150
180
180
130
150
150
150
180
180
150
150
150
150
250
250
130
150
150
150
#250
#250
180
180
No.
(1)
(2)
(3)
(4)
Gas turbine
(Firing gasified fuel
only)
4.5 or more
Below 4.5
Gas turbine
(Firing liquid fuel only
and mixed gasified
and liquid fuel)
4.5 or more
Below 4.5
Diesel engine
Large-sized type
(Cylinder diameter
400 mm or more)
Diesel engine
Medium-sized and
small-sized type
(Cylinder diameter
Below 400 mm)
Application exempted
Application exempted
70
90
Application exempted
100
Application exempted
120
Diesel engine [Residual oxygen density 13%]
70
70
70
70
100
100
70
70
Application exempted
1,600
1,400
1,200
Application exempted
950
950
950
447
Gas system
Main equipment
Wear
Corrosion
Items to be inspected
Thermal
Sliding
deterioration
portion
Others
Scaling
Adherence of dust
Adherence of dust
Scaling
Accumulation of
dust
Bridging
Slurry accumulation
Silo
Tank
Slurry pump
Water pump
Agitator
Blower
Gypsum dehydrator
Conveyor
Piping
Clogging
448
Pinhole inspection:
Use a pinhole tester for inspection. The setting of inspection voltage may be changed depending on the
rubber material or lining coat. However, it should be 2000 4000 V/mm in principle per lining
thickness. In the case of butyl rubber, it should be 2000 v/mm.
c)
d)
Hitting inspection:
Hit the lining face lightly with the hitting rod (a rod on whose edge a small steel ball has been attached)
and check for any floating, blistering, etc. according to the hitting sound. In the case of soft rubber,
check it by finger pressure inspection.
durometer) and hard rubber (Type-D durometer). Because the rubber hardness is likely to be affected by
the temperature, it is desirable if the temperature is measured at the same time. In the case of FGL,
measure the hardness of the lining using a bacall durometer. When using these methods, a hole for the
durometer needle may be made on the lining surface, which needs to be repaired after inspection.
b)
c)
External inspection:
Record the inspection results in a quantitative manner and rank them in a several steps for each item
such as the number of blisters that occurred per unit area, number of cracks, size of blisters, degree of
wear, discoloration, etc.
b)
Pinhole inspection:
There should be no pinhole detected.
c)
d)
Hitting inspection:
Use the results of this inspection together with the results of the external inspection and any other
inspection results as material for judgment of the lining conditions.
e)
Hardness inspection:
Periodically, conduct sampling of the portions under the same conditions for use, put the inspection
results in an aged manner, and assess the remaining life using the time reaching the boundary limit
hardness for use specified in advance by selected materials. In the case of FGL, it is possible to raise the
surface hardness by reinforcement coating after removing the deteriorated portion from the surface
layer.
f)
g)
Comprehensive judgment:
It is important that all inspected items are still within the boundary limit for use. Immediate repair is
required for the items whose assessed life will not last until the next inspection or whose assessed life
will end before the next inspection timing approaches. Those items assessed to have long enough life
until the next inspection must be judged by the results of the next inspection and inspections thereafter.
The accuracy of such judgment can be improved by accumulating as many result data as possible and
putting them in good order.
Gas
Reheating device
the exhaust gas at the heat recovery device in the ultra-low-temperature EP system, there is almost no concern
about corrosion of the heat exchange tube. If the dust removal equipment is a type of steel ball-spraying system, it
is especially required to check for any wear of the heat exchange tube and casing caused by the collision of steel
balls.
(2) Preventive maintenance and technology to assess remaining life
Explanation of such devices generally used for other equipment as pumps, tanks, soot blowers, etc. of the
devices comprising the GGH is not given here. Instead, heat exchange tube and steel ball-spraying-type dust
removal equipment specific to the GGH are explained here.
The thickness of the heat exchange tube becomes smaller due to corrosion and wear occurring in the exhaust
gas atmosphere, which, however, can be captured through thickness measurement during regular inspection.
According to the results obtained from measurement, the remaining life of the heat exchange tube can be
estimated. Because wear caused by steel balls is unavoidable in the case of the steel ball-spraying-type dust
removal equipment, it is required to capture the degree of wear of the heat exchange tube, hopper, casing, etc.
through visual inspection and thickness measurement, repair if necessary and, at the same time, assess the
remaining life.
Table 4.5.2-1 Items for inspection and maintenance of heat medium recycle-type GGH
Device
Heat recovery device
Reheating device
452
4.5.3
Denitration equipment
4.5.3.1 Description of maintenance and inspection
Because the moving parts are very limited in the case of denitration equipment, it is very rare that any
mechanical issue could occur during operation. However, the NOx removal catalyst tends to lower its activity
slightly due to the compounds contained in the exhaust gas. It is required to carry out complete inspection and
performance control because NH3 to be used as a reduction agent is a poisonous and flammable gas.
Portions to be inspected and points to pay attention to in the operation of denitration equipment are shown in
Table 4.5.3-1.
4.5.3.2 Preventive maintenance and technology to assess remaining life
In order to use denitration equipment for a long period of time under a stable condition, it is required to capture
any aged efficiency change according to NOx removal efficiency control data, etc., evaluate the life of the catalyst,
and establish a long-term plan for the catalyst.
It has been confirmed from the records to date and results obtained from actual operation of a gas pilot plant
that aged deterioration of the activity of the catalyst advances very slowly, except for the initial deterioration
occurring within some thousands of hours after the start of operation. It is difficult to quantify the cause of such
deterioration, because crystallized particles of the catalyst grow slowly under the influence of temperature,
resulting in a decrease in specific surface area, and this occurs through the combination of several affecting factors
such as a very small amount of poisoned compound (halogen, alkali metal, etc.) contained in the gas and dust. As
long as the operation conditions are kept constant, the speed of deterioration does not change suddenly.
Under the circumstances, this method of estimating the efficiency until the next regular inspection and for a
longer period of time according to daily operation data, data obtained from regular performance tests, and the data
obtained from aged change investigation of sample catalysts used for actual devices is currently considered the
most adequate. The NOx removal efficiency of actual equipment varies depending on the initial allowable amount
of filled catalyst and practical operation conditions. Therefore, even when the efficiency drops, NOx removal
efficiency can be maintained to some extent by adjusting the mol ratio (NHinjection amount). The degree of
deterioration of the activity of NOx removal only cannot be the basis for assessment of life. Therefore, it is
required to improve the accuracy in life assessment through accumulation of aged data at each plant. Fig. 4.5.3-1
shows an outline of NOx removal efficiency control. A performance test using the actual equipment required for
efficiency control is normally carried out once every other month, and a laboratory test using a sample catalyst is
normally carried out at every regular inspection. Examples of test items in the laboratory test are shown below:
(1) Activity of NOx removal
(2) SO3 conversion ratio
(3) Specific surface area
(4) Pore volume
(5) Strength
(6) Analysis of adhered substances
(7) Observation through microscope
Replacement of the catalyst at the proper timing will be possible if the above maintenance/inspection and
performance control are carried out, whereby denitration equipment can be operated under a stable condition and
in addition, its economic effect will be improved.
453
Table 4.5.3-1 Example of points to be inspected and items for observation of denitration equipment
Ammonia injection
pipe
Soot blower
Acquisition of data
from operation of
actual equipment
Analysis of data
obtained from operation
of actual equipment
Change in
efficiency
No
To determine
remaining life
Yes
Sampling and
evaluation of
catalyst
Not required
Replacement
required?
To continue
operation
NOx removal
efficiency
Observation items
Falling off of thermal insulating materials
Gas leakage
Differential pressure
Opening/closing of valve and damper
Movement of cutoff valve for ammonia gas injection and control valve for
ammonia gas injection
Gland leakage from valve
Leakage of operation air
Leakage from injection flexible tube
Indications on instruments
(Ammonia gas pressure gage, thermometer, ammonia dilution air pressure gage)
Temperature of, vibration of, or abnormal sound from any motor
Oil leakage from gear box
Leakage of gland from head valve or leakage from flange
Rotation of lance tube or any damage to gear
NOx removal
efficiency
Points of inspection
NOx removal reactor
To capture features
of aged performance
change by
evaluating sampled
Performance
catalyst and local
evaluation
performance test
Performance results
evaluation
matches.
Performance does not match.
Impossible
To study amount
for replacement
454
Time passed
Required
Possible
Implementation of
Possibility of
recycling
recycling
Local
performance
test
(Outline for
evaluation)
Time passed
4.5.4
Dust removal equipment
4.5.4.1 Description of maintenance and inspection
Important checkpoints of EP during operation and operation stop are shown below. Basically, if operation of the
equipment once starts, the operation will continue for a long period of time. When operation is stopped, it is
important to always carry out inside inspection and do your utmost in carrying out its preventive maintenance.
(1) During operation
Inspect and check for any abnormal event by observing the charging of the DC power supply, movement of the
rapping device, etc.
(2) During operation stop
The points to be checked are any disconnection of the discharge electrode, movement of the rapping device,
leakage from the casing, and degree of corrosion. In the event that any failure should be detected, never leave it
unattended. It is required to take adequate action on each occasion.
4.5.4.2 Preventive maintenance and technology to assess remaining life
This cannot be explained sweepingly because it varies because there is a difference in the structure and design
concept of such major components as the casing, collecting electrode, and discharge electrode. General examples
are explained below.
According to recent records, the life of the collecting electrode and discharge electrode is 10 15 years in the
case of oil-fired boilers and 15 20 years in the case of coal-fired boilers.
(1) Casing
In the investigation of casing deterioration, it will be determined as follows, and proper actions are to be taken,
by capturing the thickness decrease through measurement of the wall thickness of each portion using an ultrasonic
thickness gage.
1) No action is required to be taken in general if the maximum thickness decrease is kept within the
designed permissible value (within the corrosion allowance).
2)
When the maximum thickness decrease is beyond the designed permissible value, carry out individual
checking through strength calculation, and study what reinforcement action is required.
3)
When the average thickness decrease is beyond the designed permissible value, overall repair is
required in general. Its final judgment should be made through strength calculation.
c)
3rd investigation and thereafter: If it is detected that the degree of thickness decrease is too high as a result
of the 2nd investigation, it is desirable to carry out every regular inspection thereafter. This inspection
should be carried out at least 1 2 years before the assessed life ends as a result of the 2nd investigation in
order to determine the timing of renewal.
456
457
Heavy crude
oil ash:
0.5 %
Living creatures
adhering to the
cooling water
channel:
0.3%
Desulphurized
gypsum:
22.0 %
Gypsum ash:
76.8 %
Fig. 4.6.1-1 Ratio of each byproduct generated by the thermal power generation plant
(Unit: 10,000 tons)
Waste
Description
Cinders
Soot and dust
(Gypsum ash)
Debris
(Waste from construction work)
Bypr
oduct
Metal scrap
Desulphurized limestone
Amount generated
Amount recycled
(Recycling rate)
Amount generated
Amount recycled
(Recycling rate)
Amount generated
Amount recycled
(Recycling rate)
Amount generated
Amount recycled
(Recycling rate)
2005
724
697
(96%)
36
35
(97%)
19
18
(99%)
190
190
(100%)
Fig. 4.6.1-2 Effective usage ratio of byproducts from thermal power generation plant
The effective usage ratio of gypsum is about 96 %, most of which is used in the civil work segment. Unused
gypsum is buried at own ash disposal site, while partially disposed of by industrial waste treating companies.
The ratio of the effective use of each discharged substance is shown in Fig. 4.6.1-2.
458
Meaning
Rough particle ash generated by combustion
Fine particle ash generated by combustion
Ash generated by combustion which becomes a lump
Ash generated by combustion which has dropped down onto the furnace bottom
Location of generation
Coal ash collected by the dust collector from the combustion gas coming from the pulverized coal
Fly ash
fired boiler
Coal ash collected after dropping down while the combustion gas from the pulverized coal fired
Cinder ash
boiler passes through an air pre-heater, economizer, etc.
Clinker ash
Coal ash collected after dropping down on the furnace bottom of the pulverized coal fired boiler
(Note):
1. Fly ash and cinder ash may be collectively called fly ash.
2. Bottom ash is called clinker ash.
Clinker ash
Remarks
These are used as fly ash for
concrete and Class I - IV are
specified by JIS Standards.
Boiler
Economizer
Air
pre-heater
Precipitator
hopper
To chimney
Clinker
hopper
Classification according
to the location of
generation
Clinker
ash
Cinder
ash
Fly
ash
Classifier
Dehydrati
on tank or
sediment
ation tank
Fine
particle
silo
Rough
particle
silo
Fine
particles
Rough
particles
Raw
particle
silo
Classification according
to product type
Clinker ash
Raw
particles
459
460
3Al2O3), magnetite (Fe3O4), etc., while a large amount of non-crystallized glass content also exists.
Although a difference in the chemical compound composition of coal ash is recognized to some extent, silicon
dioxide (SiO2) and aluminum oxide (3Al2O3) occupies 70 to 80 % of the entire chemical compound. In addition, a
small amount of oxides such as Fe2O3, CaO, MgO, SO3, Na2O,. K2O, etc is also contained.
Table 4.6.2-3 Example of the property of fly ash (equivalent to Class II)
Chemical compound
Name of
the power
generation
plant
Moisture content
(%)
Ignition loss
(%)
Silicon dioxide
(%)
Density
(g/cm3)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
0.16
0.00
0.32
0.10
0.20
0.05
0.05
0.00
0.00
0.10
0.00
0.10
0.10
0.10
1.92
2.96
4.00
1.50
2.40
3.70
1.03
0.31
0.60
2.60
0.90
1.50
2.20
2.60
1.90
61.7
61.8
52.0
59.4
57.7
66.7
59.2
55.9
50.8
53.4
62.7
64.0
59.7
60.2
57.0
2.29
2.25
2.25
2.30
2.23
2.24
2.20
2.26
2.29
2.20
2.25
2.23
2.26
2.26
2.26
Physical property
Powder level
Residual content
after sieving
Specific surface
through 45 m
area
mesh
(cm2/g)
(%)
4.5
3,828
5.2
3,644
11.1
4,694
8.3
3,370
17.2
3,465
15.3
3,875
3.9
3,240
4.2
4,590
16.7
3,306
29.3
3,036
3.3
4,074
3.8
4,142
4.2
4,263
18.1
4,483
13.0
3,200
Because the composition is similar to that of soil and clay, much coal ash has been effectively used as a clay
replacement for the raw materials of cement. In Table 4.6.2-4, the chemical ingredients of coal ash are shown.
Table 4.6.2-4 Ingredients of coal ash
Ingredient
Silica
Aluminum
Iron
Calcium
Magnesium
Potassium
Sodium
(SiO2)
(Al2O3)
(Fe2O3)
(CaO)
(MgO)
(K2O)
(Na2O)
Coal type
Domestic coal
Imported coal
(%)
(%)
(%)
(%)
(%)
(%)
(%)
50 to 55
25 to 30
4 to 7
4 to 7
1 to 2
0 to 1
1 to 2
40 to 75
15 to 35
2 to 20
1 to 10
1 to 3
1 to 3
1 to 2
Soil
(example of
mountain soil)
62.8
24.0
1.6
0
0.3
1.4
0
(Information source: Thermal Power Generation Association: Treatment and effective use of waste <old version>)
The ash content in the coal ash is composed of inorganic matter contained in its originated plant and clay and
rocks mixed into the coal during its creation and differs depending on the location in which the coal was produced.
In some cases, minute amounts of all types of mercury, cadmium, lead, and arsenic, etc are also contained.
Generally speaking, the concentration of these ingredients is virtually the same as their concentration in the soil.
As the elusion property of coal ash into water, Ca, Na, OH, CO3 among the chemical compounds are dissolved.
In general, the pH value tends to become higher. In the case of the disposal of ash on the sea, the ash becomes
neutralized by absorbing carbon dioxide in the air over time, due to the seawater buffer action. The coal ash does,
as shown in Table 4.6.2-5, satisfy the judgment criteria pertaining to disposal by reclamation, as provided for by
the Prime Ministers Office, which specifies the judgment criteria of industrial waste, including metals, etc.
Coal ash falls on the recyclable resources as specified in that law (useful substances obtained as byproducts in
the course of energy supply and usable as raw materials or potentially usable as such).
Table 4.6.2-5 Coal ash elusion test results (Example)
(Unit: mg/l)
Type
Alkyl
All types
Organic
Cadmium
Lead
Hexachromium
Arsenic
Solvent
mercury of mercury
phosphate
Type
Domestic
Pure
ND
ND
ND
ND
ND
0.19
ND
coal
water
Seawater
ND
ND
ND
ND
ND
0.19
ND
Chinese
Pure
ND
ND
ND
ND
ND
ND
ND
coal
water
Seawater
ND
ND
ND
ND
ND
ND
ND
South
Pure
ND
ND
ND
ND
ND
0.10
ND
African
water
coal
Seawater
ND
ND
ND
ND
ND
0.15
ND
Australian
Pure
ND
ND
ND
ND
ND
ND
0.06
coal
water
Seawater
ND
ND
ND
ND
ND
ND
0.20
Criteria for the
(Note)
judgment of disposal by
ND
! 0.005
! 0.3
! 0.3
! 1.5
! 0.3
!1
reclamation (*)
ND:
Indicates below detection boundary
(Note): Coal ash is not an item subject to the criteria for judgment of disposal by reclamation.
(*):
The above criteria for judgment are based on the Order of the Prime Ministers Office, notified on June 10, 1998.
Cyanogen
PCB
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
(Note)
!1
(Note)
! 0.003
In addition, the coal ash produced as a byproduct from a power generation enterprise with an annual power
supply capacity of 120 million kWh (about 20 MW) has been specified as a byproduct, of which the effective use
must be especially promoted as recyclable resources.
With respect to the effective use of coal ash, the following statement was made in the Basic policy toward the
promotion of use of recyclable resources (officially announced in October 1991):
Although coal ash being generated in line with the combustion of coal has been used as a raw material for
cement, etc, its use as a recyclable resource must be further expanded in future. To that end, those enterprises
engaged in the electricity related business shall endeavor to develop such technology by arranging for processing
facilities, expanding usage and improving quality in order to promote commercialization in accordance with
related standards and specifications and utilize the material as a recyclable resource in an effective manner.
As such, the above requirement for the effective use of coal ash must be satisfied in a manner far more
aggressively than before in all fields.
Because coal ash has been designated as industrial waste in its use under the Waste Disposal and Public
Cleaning Law, the relationship with the said law must be understood. The said law is not applied to overall coal
ash and its applicability depends on whether or not the coal ash is handled as a valuable item.
The criteria for judgment of whether or not it is a valuable item depends on whether or not it can be sold for
value to a third party, which depends on the law.
Sale for value means the occupant delivers the item to the receiving party and actually receives the payment for
such delivery from the same.
463
Sea
reclamation
(2) Handling of coal ash of the type under control (Waste Disposal Law,
Marine Pollution Prevention Law)
Record of reclamation in the past, elusion test results, river wall
construction costs, image to the local community
Disposal by
reclamation
Ash treatment
method
Preparation of land " Preparation of land for agriculture/housing, Materials for reclamation "
Because handling is of the type under control, the preparatory and reclamation costs increase.
Land/construction materials " Cement mixed materials, replacement of clay for cement, etc.
Others: Man-made gathering place for fish, ocean structures
(1) Development of demand, fluctuation
(2) Commercial value " Many uncertain elements
(3) Competition with related industries
USA " Preparation of vast land for ash disposal sites
Europe " Promotion of effective use, Capacity of ash disposal sites reserved for 10 - 15 years
Effective use
Example in
USA and
European
countries
Table 4.6.2-7 Amount of coal ash being generated and its effective usage
in the electricity related business (history)
(Unit: 10,000 tons)
Item
Year
Amount of coal ash being
generated
Effective usage
(Effective usage ratio %)
Reclamation
Sea
Land
Usage of coal
(Ash generation ratio %)
1994
441.1
1995
513.5
1996
528.7
1997
540.8
1998
502.9
1999
576.6
2000
633.2
240.2
(54.5)
106.6
94.3
3,327.9
(13.3)
310.7
(60.5)
106.7
96.1
3,848.8
(13.3)
337.4
(63.8)
112.1
79.2
4,053.4
(13.0)
351.1
(69.8)
112.5
93.1
4,378.9
(12.5)
351.1
(69.8)
65.0
86.8
4,334.7
(11.6)
444.9
(77.2)
53.2
78.5
4,910.1
(11.7)
493.2
(77.9)
140.0
54,761
(11.6)
Dehydrator
Rough
particles
Fine
particles
Classifying
machine
Storing silo
Storing silo
Storing silo
Storing silo
Bulk
Bulk
Bulk
Bulk
Bulk
Raw
particles
Bulk
Bulk
Bulk
Raw
particles
Raw
particles
Blending
silo
Storing silo
Clinker
Cinder
Bulk
Bulk
NOx
removal
Packer
Flexible
container
Or boat
Boiler
ECO
hopper
AH
hopp
er
Clinker
ash
Air intake
valve
Clinker
hopper
Electrostatic
precipitator
To chimney
Cinder
ash
Fly ash
Crusher
Ash discharge
valve
Clinker
ash
Classification
Bag filter
Dehydration
tank
Ash precipitation
tank
Water storage
tank
Grab crane
To an ash
disposal station
via a dump truck
or boat
Vacuum
pump
Ash treatment
pump
Effective use
JP vehicle
or boat
Overflowing
water
Raw
particles
silo
Dump
truck or
boat
To ash disposal
station by a dump
truck or boat
various types of substances is shown in Table 4.6.2-8. The effect of fly ash when mixed in concrete is shown in
Table 4.6.2-9 while the usage, efficiency, etc. of fly ash according to its quality is shown in Table 4.6.2-10.
Next, an example of classification of the technologies using coal ash is shown in Table 4.6.2-11 with an
explanation.
Table 4.6.2-8 Example composition of various types of substances
Composition
(Note) *Fe2O3,
Al2O3
(%)
23.4
5.1
8.9
14.5
1.5
22.0
-
SiO2
(%)
56.6
22.2
62.4
33.4
10.9
59.6
60 to 75
Substance name
Fly ash
Portland cement
Concrete
Slug from blast furnace
Slug from converter furnace
Mountain soil
Clay (of Japan)
Fe2O3 FeO
(%)
5.8
3.2
*
0.4
20.7
**
5 to 8
CaO
(%)
3.8
65.4
16.5
41.0
42.9
0.4
10 to 25
MgO
(%)
1.7
1.2
1.2
6.0
7.2
0.8
-
**FeO
Improvement of
workability
Ball bearing
effect
Note:
Pozzolanic reaction
effect
Suppression effect of the alkali
aggregate reaction
Delaying effect of the
hydration reaction
Improvement of
airtightness
Enforcement of
long-term strength
Improvement of water
tightness
Improvement of
resistance against
chemicals
Improvement of
durability
Low heat
generation
Prevention of
cracking
Reduction of dry
shrinkage ratio
Note: Pozzolan: A mineral fine particle material that hardens itself by yielding insoluble matter
through a reaction with calcium hydroxide under room temperature where water is
present, although alone it has almost no hydraulic setting characteristics.
466
* Construction materials
Artificial aggregate
Construction materials
* Ocean structure
! Other fields
* Desulphurization materials
* Absorbent
* Others
Replacement of clay
Regular Portland cement (Ash content: 5 % or less)
Fly ash cement (Ash content: 10 to 30 %)
High volume FA concrete (Ash content: 30 % or more)
RCD Method (Concrete for a huge dam)
High liquidity concrete
High performance classified fly ash (fine ash)
Asphalt filler materials
Roadbed materials (Clinker ash)
(The use of newly generated ash)
(Pozzotech)
(Ashroban (Solidified pulverized coal ash))
(Naruton (Solidified liquid ash))
Pozzotech
Non-diffusing high density reclamation
FAC light weight civil work materials (Fly ash with Air and Cement)
Slurry method
Pre-mixing method
FAC light weight civil work materials
Slurry method (Surface layer treatment)
FGC deep layer mixing method (Fly ash + Gypsum + Cement)
SCP materials
Use for the soil generated from construction
Use for the soil dredged from the ocean floor
PC method
CAP method
Slurry method
Lightweight coarse aggregate (FA light)
Ultra lightweight aggregate (specific gravity: 1.25 or less)
High strength aggregate (specific gravity: 1.7 to 1.9)
High pressure steam cured aggregate (Specific gravity: 0.9 to 1.5)
Building materials, (Wall materials, sound insulation materials, blower
materials)
Ceramics (roofing tile)
Cement products (pole, block)
Fertilizer (special fertilizer, potassium silicate fertilizer)
Soil improvement materials
Snow melting materials
Man-made fish gathering structure (FGC, HFA structure, kelp structure, seaweed
structure)
Mound materials for a gushing outflow
Dry type desulphurization agent
Artificial zeolite
Rubber filling materials, corrosion prevention agent, technology to recover valuable items
467
Heavy
oil
Air
blending
tank
Crusher
Mixer
Suspension
pre-heater
Coal
Assisted
combustion
furnace
Shredder
Shredder
Chimney
Exhaust heat
power
generation
Ferrous
materials
Silica
Clay
Limestone
Coal ash
(Clay
replacement)
Electrostatic
precipitator
Rotary kiln
Air separator
Mixer
Cooler
Clinker
Portland cement
Shredder
Shredder
Gypsum
Mixer
Type A: 5 - 10 %
Type B: 10 - 20 %
Type C: 20 - 30 %
Fly ash
(JIS standard
product)
Table 4.6.2-12 Raw materials, fuel and power required to manufacture 1 ton of cement
Material (Unit: kg)
Limestone
Clay
Silica
1,088
210
70
Note:
Ferrous
materials
31
Gypsum
35
Power
(kWh)
98
1. The value of fuel has been converted into that of coal (6,200 kcal/kg).
2. Power is based on actual consumption (including power generated by waste heat).
Materials for
manufacturing cement
Clay replacement
(Limestone can replace up to
50 % of the clay amount.)
Materials mixed in
cement
(Mixture up to about 30 %)
The usage of coal ash in the cement field is roughly divided, as shown in Table 4.6.2-13.
The typical use is as a replacement for clay and the SiO2 and Al2O3 contained in the coal ash are utilized. The
SiO2/ Al2O3 of coal ash is about 3.5, which is lower than that of clay, which is 7 (less SiO2). If a large amount of
coal ash is used as a replacement for clay, the usage of silica (SiO2) also increases, hence the use of coal ash is
limited to some extent and the use of 40 % - 50 % of clay is considered to be the limit.
The next typical use involves mixing a small amount into cement. 5 % (by mass) of a single or combined slug
from a blast furnace, silica mixture, fly ash (JIS) and limestone can be mixed into regular Portland cement. This
468
addition of 5 % can help save 4% of energy during the manufacture of cement, which has a significant effect,
because 80 % of total cement production is from Portland cement.
The third typical use is for fly ash as a mixing material. There are 2 cases, one involving the sale as fly ash
cement by mixing with regular Portland cement during cement production, and the other involving mixing with
Portland cement in the course of concrete manufacturing.
Fly ash and blast furnace forms of cement are collectively known as mixed cement, which is classified into
Types A, B and C, each of which has a designated mixing ratio. The standards for fly ash cement are shown in
Table 4.6.2-14.
Concrete or mortar using fly ash has the characteristics as shown in the above Table 4.6.2-9 and is very suitable
for mass concrete and ocean structures. In particular, the effect of suppressing the alkali aggregate reaction is
drawing attention in these years.
g/cm3 (1)
cm2/g
Start min
Setting
End h
PAT testing
(2)
Stability
Le Chatelie's Principle
3d
Shrinkage
resistance
7d
N/mm2
28d
Magnesium oxide %
Sulfur trioxide %
Ignition loss %
1. Note
mm
Type A
Type B
Type C
2500 or more
60 or more
10 or less
Good
10 or less
12.5 or more
22.5 or more
42.5 or more
5.0 or more
3.0 or more
3.0 or more
2500 or more
60 or more
10 or less
Good
10 or less
10.0 or more
17.5 or more
37.5 or more
5.0 or more
3.0 or more
-
2500 or more
60 or more
10 or less
Good
10 or less
7.5 or more
15.0 or more
32.5 or more
5.0 or more
3.0 or more
-
Type
Type A
Type B
Type C
2. Fly ash: Fly ash as specified in JIS A 6201 (fly ash) shall be used.
3. Method of cement manufacturing: Fly ash cement is manufactured by adding an adequate amount of limestone to clinker and fly ash
and then mixing/crushing or by mixing cement and fly ash evenly.
If any crush facilitating agent is used when crushing, it must be confirmed that the agent has no adverse effect on the cement quality
and the amount used shall be equivalent to 1 % or less of the cement.
With respect to banking materials, testing work and high banking verification work, etc. have been carried out.
Consequently, its usefulness was recognized and it tends to be used in bulk.
Filling materials are used to fill tunnels, etc. In addition, by mixing coal ash with a small amount of cement and
additives and converting it into slurry, it has been used practically in bulk as a river wall water sealing material.
In addition, there are examples of use as a mixing additive for the deep layer mixing work method, where it
functions as a ground improvement material and ocean bank building with soil improvement, via a mixture of coal
ash using the dredged soil/sand disposing method.
ceramic products as clay roofing-tiles, bricks, tiles, etc, taking advantage of the fact that coal ash contains similar
compounds to the chemical structure of conventional building materials. By adding the characteristics of coal ash,
it contributes to reducing the production cost and improving quality.
As potential building materials, heat insulating materials using the physical and chemical properties of coal ash
are expected.
Other industries
Others
Electricity related
businesses
Agriculture
and fishery
Building
field
Civil work
field
Cement
field
Year of 1994
Year of 1995
Year of 1996
Year of 1997
Year of 1998
Year of 1999
Year of 2000
Fig. 4.6.2-7 Historical movement in the effective use of coal ash in each field
With respect to the amount of coal ash to be generated in future, the estimation of demand for electric power
generated by electricity related businesses, of which the coal ash generation ratio is 75 % of total generation, is
470
shown in Table 4.6.2-15, while the plan for power source development is shown in Fig. 4.6.2-8. With respect to
the trend of future demand for electric power, power generation is expected to increase by an average of 1.5 %
each year until 2010. Although the coal supply is maintained at a stable level and coal has economical advantages,
the power supply from thermal power generation by coal will be positioned at mid and peak levels, because of the
high environmental load with prevention of the greenhouse effect in mind.
Table 4.6.2-15 Expected demand (10 electric power companies)
Year
Item
Electric power for sale
(Unit: 100 million kWh)
Maximum electric power
in August
(at transmission end, Unit:
10,000 kWh)
Annual load rate
(%)
1999
(Actual
records)
2005
2010
Annual
increase rate
(%)
11 - 22
8.169
8,937
9,644
1.5
16,567
18,488
19,897
1.7
59.4
58.5
58.6
It is expected that thermal power generation by coal will increase to 201.5 billion kWh in 2010, which
represents an increase by 20 % on the figure for 2000, namely 168.1 billion kWh.
Therefore, a simple calculation demonstrates that the total generation of coal ash in 2010, including the same
from other industries, will approach 10 million tons or so. However, although this may vary with high probability
depending on the economy and trends in greenhouse effect prevention, etc, it is indisputable that the overall
amount of coal ash generated will tend to increase. Against this, the development of technology to utilize coal ash
effectively has become a critical issue, with its bulk use in mind. Points of issue and prospects for expanding the
effective use of coal ash are shown in Table 4.6.2-16.
Table 4.6.2-16 Points of issue and prospects of expanding the effective use of coal ash
Technical issues
Environmental issues
Cooperation among
industry, government
and academy
Balance adjustment
between supply and
demand
471
(1,010.5
billion kWh)
(1,089.35
billion kWh)
Nuclear
Thermal
Coal
Others
Geothermal
heat
Petroleum
2005
2010
(Year end)
2000
(estimated actual record)
(Note 1)
shows the composition rate (%), ( ) shows the generated power (in kWh).
(Note 2) Because the figures have been rounded off, the total is not always correct.
Natural gypsum
Gypsum dihydrate
Anhydrous
gypsum
Byproduct
gypsum
Gypsum
Chemical gypsum
Recovered
gypsum
At 47 thermal power generation plants (owned by 10 electric power companies, J-Power, Joint Electric Power),
79 units of flue gas desulphurization equipment have been installed, of which 78 units employ the process to
produce gypsum as a byproduct (predominantly the wet type Limestone - Gypsum Process). The reaction process
is shown in Fig. 4.6.3-2.
(Limestone slurry)
Absorber/scrubber
Exhaust
gas
Non-reacted
content
Substances generated by
reaction
Reaction tank
Oxidation tower
Centrifugal separator
(Gypsum)
Fig. 4.6.3-2 Reaction process in flue gas desulphurization equipment (Wet type Limestone - Gypsum Process)
Raw material
for cement
869,011
Treatment method
Soil
improvement
Gypsum board
material
593,304
14
Final disposal
5,183
The amount of desulphurized gypsum generated by the thermal power generation plant is as shown in Table
4.6.3-1. The thermal power generation plant has a heavy weight in the gypsum market.
Measured value
cm2/g
kg/cm2
%
%
%
%
%
%
%
%
%
%
473
2.49 2.56
2,020 2,470
40 96
0.7 12.3
18.0 20.9
31.1 32.9
43.1 46.2
4.8 9.3
< 0.01 1.68
< 0.02 5.24
0.01 0.44
< 0.002 0.78
< 0.01 0.08
< 0.005 0.065
Average
value
2.53
2,250
75
6.4
20.1
32.4
45.5
7.2
< 0.17
< 0.50
0.10
< 0.09
< 0.02
< 0.011
(%)
(%)
<1
(%)
(%)
Gypsum dihydrate
(%)
(%)
(%)
(%)
(%)
()
Calcined
gypsum
<1
< 0.03
< 0.01
57
< 90
< 40
> 80
Should be good
> 0.9
1.0
475
2.2
2.3
2.4
FY2004 TNB/JEPIC Seminar (Sep. 2004) Heat Rate Improvement of Thermal Power Plant
V-1. Combustion of Coal, p119 - of Thermal and Nuclear Power Engineering Society Seminar
No.14 Fuel and Combustion by Matsuda, Thermal and Nuclear Power Engineering Society
Chapter 3
3.1
3.2
3.3
3.4
XI. Maintenance of administration of Aged Thermal Power Plant, p287 of Thermal and Nuclear
Power Engineering Society Seminar No.22, Construction, Commissioning and Operation
Maintenance of a Power Plant by shimamoto, et al., Thermal and Nuclear Power Engineering
Society
- VIII. Operation and Maintenance of Boilers, p111 of Thermal and Nuclear Power Engineering
Society Seminar No.32, Boilers by Aoyama, et al., Thermal and Nuclear Power Engineering
Society
1-2. Boiler Main Body (2), p57 of Thermal and Nuclear Power Engineering Society Seminar
No.27, Preventive Maintenance and Remaining Life Assessment of Equipment and Components
used in a Power Plant by Umaki, et al., Thermal and Nuclear Power Engineering Society.
- I. History and Outline of Water Treatment Technology, p2 of Thermal and Nuclear Power
Engineering Society Seminar No.19, Water Quality Control and Water Treatment Facility by
Kawanabe, et al., Thermal and Nuclear Power Engineering Society
- Study on Application of Oxygen Treatment Method at the No. 1 Unit of Chita No.2 Power
Generation Plant, Vol. 45, No.9 (Sept. 1994) p1008 of Thermal and Nuclear Power Generation,
by Wakahara, et al., Thermal and Nuclear Power Engineering Society
- VI. Water Quality Control at a Thermal Power Plant, p128 of Thermal and Nuclear Power
Engineering Society Seminar No.19, Water Quality Control and Water Treatment Facility by
Tsubotani, et al., Thermal and Nuclear Power Engineering Society
- Structure of a Steam Turbine 1. Steam Turbine used at a Thermal Power Plant, p77 of Thermal
and Nuclear Power Engineering Society Seminar No.31, Turbine, Power Generator and Heat
Exchanger by Hamano, Thermal and Nuclear Power Engineering Society
- A Guidance to Open Inspection of a Steam Turbine (Mar. 1987) p332 - by Thermal and Nuclear
Power Engineering Society
- 1. Heat Exchangers used in a Turbine Plant (1), of VIII. Structure and Functions of a Heat
Exchanger, p187 of Thermal and Nuclear Power Engineering Society Seminar No.31 Turbine,
Power Generator and Heat Exchanger by Mochida, Thermal and Nuclear Power Engineering
Society
- 1. Heat Exchangers used in a Turbine Plant (2), of VIII. Structure and Functions of a Heat
Exchanger, p217 of Thermal and Nuclear Power Engineering Society Seminar No.31 Turbine,
Power Generator and Heat Exchanger by Iwata, Thermal and Nuclear Power Engineering Society
- 1. Heat Exchangers used in a Turbine Plant (3), of VIII. Structure and Functions of a Heat
Exchanger, p231 of Thermal and Nuclear Power Engineering Society Seminar No.31 Turbine,
Power Generator and Heat Exchanger by Kawazato, Thermal and Nuclear Power Engineering
Society
- 2-1. Main Body of Steam Turbine, p111 of Thermal and Nuclear Power Engineering Society
Seminar No.27, Preventive Maintenance and Remaining Life Assessment of Equipment and
Components used in a Power Plant by Sobate, et al., Thermal and Nuclear Power Engineering
Society
VI. Corrosion and its Countermeasure of a Steam Turbine, p93 of Thermal and Nuclear Power
3.5
3.6
Engineering Society Seminar No.24 Corrosion and its Prevention of a Thermal Power Plant, by
Muto, et al., Thermal and Nuclear Power Engineering Society
- VII. Corrosion and its Countermeasure of Heat Exchanges used in Steam Systems, p105 of
Thermal and Nuclear Power Engineering Society Seminar No.24 Corrosion and its Prevention of a
Thermal Power Plant, by Muto, et al., Thermal and Nuclear Power Engineering Society
- VIII. Corrosion and its Countermeasure of a Seawater System and its Pipes, p121 of Thermal
and Nuclear Power Engineering Society Seminar No.24 Corrosion and its Prevention of a Thermal
Power Plant, by Ishikawa, et al., Thermal and Nuclear Power Engineering Society
- 4-1. Turbine Generator, p191 of Thermal and Nuclear Power Engineering Society Seminar
No.27, Preventive Maintenance and Remaining Life Assessment of Equipment and Components
used in a Power Plant by Ishizuka, et al., Thermal and Nuclear Power Engineering Society
- X. Corrosion and its Countermeasure of a Power Generator and Power Distribution and
Transformation Systems, p148 of Thermal and Nuclear Power Engineering Society Seminar
No.24 Corrosion and its Prevention of a Thermal Power Plant, by Omachi, et al., Thermal and
Nuclear Power Engineering Society
- 2-1. Main Body of Steam Turbine, p111 of Thermal and Nuclear Power Engineering Society
Seminar No.27, Preventive Maintenance and Remaining Life Assessment of Equipment and
Components used in a Power Plant by Sobate, et al., Thermal and Nuclear Power Engineering
Society
-1-2. Boiler Main Body (2), p57 of Thermal and Nuclear Power Engineering Society Seminar
No.27, Preventive Maintenance and Remaining Life Assessment of Equipment and Components
used in a Power Plant by Umaki, et al., Thermal and Nuclear Power Engineering Society.
Chapter 4
4.1
4.2
4.3
4.4
4.5