3,0PERATION MANUAL 3.3. NORMAL OPERATION 3.3.1 Operation management (1) Operator shall always o2serve the boller condition in CCR and local. For the set value and alarm valve ofthe bolle, refer to DWG No.23043-AOFO46 “Alarm List for Boller’ (2) Operation data record for boiler of COR and all ofthe local equipment shall bbe made at every eight hours (8) In the recording report, he measured values, running condition, each ‘supply amount for fuel, water, chemical ee, and operator name (the name who prepared the record) shall be written. (4). File the operation record report of the boiler condition for checking in future. (6) Ensure that all gauges condition is normal at regular intervals, necessary, adjust that gauges. (6) Ensure that control system and alarm system condition is normal at regular Interval. If necessary, ajust that system (7) Check the measure value every day. If trouble is found, investigate the cause of trouble. After that, execute the measures against this trouble, (8) In case of rapidly changng boiler load or boiler low load operation, carefully ‘execute that. f trouble Is occurred, execute the measures against this trouble. (8) About boiler water quality control, refer to section 4.1 “WATER QUALITY ‘CONTROL FOR DRUM BOILER’. © During the boller operation, If show the abnormal value on DCS, LCP or local nstrument, execute efficient measures against trouble. © Dally local patrl of the plant regulary is important. If abnormal Condition is detected, take eficient measure on it ‘Should not open the manhole on boiler, duct and GAH during ‘operation. In this part, be careful about a burn injury When pull the burner gun or samples the exhaust gas, wear a gas mask. Those parts have possibly the poisonous gas (CO, SOx ttc). Peephole, manhole and soot blower penetration part of the 3513.0PERATION MANUAL [Boller mil sysiem and flue gas related system have same] {dangerous situation. Be careful about leaking the poisonous gas. © In case of maintenance or inspection to fan or pump, should tum off those power, Should not touch to those machine during running, (10) Material batance forthe following condition is referred to the OWG No.28043-AON304 "Material Balance Diagram of Bolle’ - BMCR = 105% TMCR - TMCR = 75% TMCR 50% TMCR 40% TMCR ~ Ml 130% / A-Boller 90% TMCR (A-Mill 130% running, B-Mil out of service) Mill Stop / B-Boiler 40% TMCR (Pulverized coal is supplied from A-Ml) = BMCR (Worst Coal) = TMCR (Worst Coal) = Mil 130% / Bolar 90% (Worst Coal) + Mil 80% 1 Boiler 50% TMCR (Oi) (During start-up, bole is running with oil for storing pulverized coal) 40% TMCR (Oil Min. load) BMCR (Minimum Moisture Coal) ~ Mill Stop / Boller 100% TMCR (Putverized coal is supplied from storage bin) «© Wan make sure buring condton in umace by pephole, wear gente and ves orally Pas a maimanance or fepecton the sfey valve and startup Valve, wear eorpuge and gloves aly Aa Ta motor Given ecuprrens uch e fan, pumpe ete, a Stored up by rer operation rom COR oF suomate beck vp operation, be care bout volng or crushing inky. Should not remove the Going cove’ ef moter Given eclpment ding operation, © Be caret about ining or crushing injury end a bum ir at | tte and‘eutonat vontoed dampers " 3.623,0PERATION MANUAL ‘© When pull out the bumer gun, wear leather gloves (This partis high temperature). Should not stand in front of a burner wall box. Should wear a goggle (possibly blow high temperature gas from the bumer part. '© When the door af peep hole on the furnace is opened, there is the possibilty offre gushing out from the door. Should wear a goggle ‘and should not stand infront ofthe door. © In case of maintenance or inspection for the soot blower, tum off the power. Should not touch the machine during running, 33.2. Combustion management (1) Excess air To complete combustion in the boiler, the actual air over theoretical ‘combustion air is supglied in the furnace. The proportion of the actual supplied air inthe furnace to the theoretical combustion air is called as the excess air ratio, For the coal fred boiler, the excess air rato is controlled as per the boiler load from about 1.2 (ful load) to 1.5 (min, load for about 40% load) on the ‘normal operation. Its important to koep the good combustion condition in the furnace. Excess air ratio is roughly calculated with boiler outiet O2 (%) as follows, Excoss Air Ratio for Coal Firing 2 1215 (Boler Outlet 02 = 3.5% ~ 7% dry) Excess Air Ratio for Ol Firing A= 11 ~ 1.4 (Boler Outlet 02 = 1.9% ~ 6% dry) Excess AirRato 1=21/(21- 02%) (2) Coal combustion Boiler operation conciticn is always changed with the ash accumulation on the heating surface during coal fred operation. For example, when ash is accumulated on furnace inside, the furnace outlet flue gas temperature will increase and SH spray water will also increase. When the convection heating surface is accumulated with ash, boiler outlet flue gas temperature will increase. Ash accuriulation trend on the heating surface is depend on the ash property ofthe coal. Therefore the operation trend shall be carefully 3.533,0PERATION MANUAL observed especially when the coal brand is changed and soot blower is property operated, (3) Soot blower operation Basically regular interval soot blower operation is recommended lke as below. = Soot blowers for furnace wall area (Fumace wall ype $B) One (1) cycle operation per each operation shit [Three (3) cycle/Day) = Soot blowers for convection heating area (Long retractable type SB) ‘One (1) cycte operation per each operation shit [Three (3) cycle/Day] Soot blower for Gas Air Heater 40 min, operation per every eight (8) hours [Three (3) cycle/Day) 'frequired, additional sot blower shail be operated respectively. ‘Operator shall aways record the operated soot blower number and interval, the changes for SH spray water amount and ECO outlet flue gas temperature before and after soot blower operation for finding out better ‘soot blower operation tothe firing coal (Note) For the detail soot blower operation, DWG No. 23043-A0F428 yystom Descripton for Soot Blower System” and soot blower O&M shall be referred separately (4) NOx Reduction NOx emission applied forthe bolle is as follows. NOx_<645mgiNms_(341ppm) For the Low NOx Combustion System, following technology is applied on the boll. 1) LowNOx CC CoalBuner —(Fig.5) 2)Two Stage Combustion Air (Fig.6) 353,0PERATION MANUAL Predicted NOx emission and un-burnt carbon is shown in Fig 7 (6) Fuace Clinker Prevention Furnace clinker accumulation shall be paid attention during coal fring, which Is depending on the coal component and the boiler operation ‘condition etc. As for the furnace clinker prevention, folowing items are ‘generally taken account for the measure. Equalizing Flamre and Furnace Temperature = Bumer and Combustion Adjustment Reduction Furnace Outlet Temperature = Fumace Cleaning with Proper Soot Blower Operation Removal of Clinker in Furnace = Fumace Cleaning with Proper Soot Blower Operation = Boiler Load Down and Up Operation (Furnace Wall Temperature Change) Reduction of Slugging Condition of Coal Firing in Furnace '=Moc Fring cf High Slugging Coal with Low Slugging Coal For the reference, the roughly evaluation of slugging condition of coal is shown in Fig8 and Fig3.0PERATION MANUAL 333. Speci operation (1) One mill operation ‘8. On the normal operaton, the coal mill of Unit C supplies the pulverized coal to the PC bin of Unit C through the bag fiter of Unit C, The coal mill Cf Unit D also supplies the pulverized coal to the PC bin of Unit D through the bag fiter of Unit D. Each unit for Unit C and Unit D is operated independently. Both units can be operated with 100% Load. (Gee Fig.10 /Total 200% Load) . When Unit D coal mill Is tipped, Unit D load once becomes runback to {60% Load and continues operation with the remaining pulverized coal in PC bin of Unit D. In the case of coal mil trp, the mil inlet fue gas is shut off and all ofthe fue gas is introduced to directly to the stack, Then Unit D ‘can be operated within the limited capacity of IDF for less than about 70%Load. Therefore Jit C can be operated with 100% Load and Unit D ccan be operated with less than 70% Load. (See Fig.t1 / Total 170% Load) «. Because PC system has the reversible PC Screw Conveyor-2 between Unit C and Unit D, the pulverized coal can be supplied to Unit D PC bin (tip mill Unit side PC bin) from Unit C coal mil (operating coal mill Unit side) though the convayor. As the coal mill capacity is equivalent to 130% Load, the continuous operation of both units, for example 90% Load Unit CC operation and 40% Load Unit D operation, is possible within the range of the coal mil capacity. On that case, the boiler shall be operated not less than 40% Load (Coal Firing Minimum Load) for the stable firing. (See Fig.12 / Total 139% Load) (2) Bag fiter online replacement 2. Bag filter is constructed with two (2) separate rooms and each room has many fier cloths inside and two (2) inlet dampers connected to coal mill outlet coal pipe and two (2) outlet dampers connected fo Vent Gas Fan (VGF) inlet fue gas duct . When bag fiter online replacement, the coal mill load shall be reduced3.0PERATION MANUAL the mill minimum load and bag fiter inet flue gas shall be Kept minimum flow rate of the coal mill. (See Fig.14) «6. Then (2) inlet dampers and (2) outlet dampers on the bag fier room for the bag fiter replacement shall be closed completely. (See Fig.15) The bag fiter cloth is replaced from the upper ceiling ofthe room one by fone. When the bag fier cloth is broken, the dust leakage around the fiter ‘may be detected on the celing area 4d. As the boiler has the indiect firing system, boiler operation load can bbe selected separately independent with the coal mill load. (See Fig.13) ZN caution ‘© During Bag iter online replacement work, be careful for the bumt and the preparation for fe ete (3) ECO bypass operation ‘The boller second-pass is equipped with ECO Bypass System which extracts hot lue gas from upstream of Economizer. The system consists of {wo (2) sets of ECO bypass control damper and one (1) set of ECO outlet ‘control damper. The purpose of the system is to maintain required fue gas temperature to the coal mill for drying coal by throttling the ECO bypass control damper and ECO outlet control damper. Basically OpeniClose of ‘each damper is counter movement. (See Fig.16) (4) Minimum load operation For minimum load operation ofthe boiler, be careful for following points ‘a, Range ability of contrl instrument », Stable combusting of pulverized coal burner ~ As the stable combustion of pulverized coal burner depends on the ‘coal, confirm the burner flame condition and operate the boiler with stable combustion ead range. ¢. Stable combustion of LO burner3,0PERATION MANUAL = LFO burner inlet pressure 0.25MPa is lower limit for stable combustion. 4. LowNOx combustion (NOx <645mg/Nm3_(341ppm)) {As excess air ration increases on the low load operation, thermal NOx ‘may increase on the combustion process. Be careful for the above NOx limitation. . Lowest Temperature for GAH Oullet Five gas = Recommended lowest temperature forthe average value of GAH outlet flue gas and GAH inlet air (Tm) is as follows. (On the condition of sulfur in fuel < 1.2%) Coal fring : Tm > 68 degC LFO firing : Tm > 38 degC {. Stable operation of fun For the low load operation, be careful forthe stable operation of funs. 9. Main steam temperature For the low load operation, be careful for the main steam temperature for steam turbine inlet. ‘© In case of low load operation, be careful for the above points of the ‘operating condition.Fig:1 Boller Start-up and Shut-down Procedure eSFig1 Boller Start-up and Shut-down ProcedureFig Boller Start-up and Shut-down Procedure aFig1 Boiler Start-up and Shut-down ProcedureFig.1 Boiler Start-up and Shut-down Procedure <=“ S|Fig Boiler Start-up and Shut-down Procedure aFig:1 Boller Start-up and Shut-down ProcedureFig.1 Boiler Start-up and Shut-down ProcedureFig:1 Boller Start-up and Shut-down Procedure ee emFig.1 Boiler Start-up and Shut-down ProcedureFig.1 Boiler Start-up and Shut-down Procedure aFig1 Boller Start-up and Shut-down ProcedureFig.1 Boiler Start-up and Shut-down ProcedureFig Boiler Start-up and Shut-down Procedure = SESS ce a ime, | GREEFig.1 Boiler Start-up and Shut-down ProcedureFig:1 Boller Start-up and Shut-down ProcedureFig. Boiler Start-up and Shut-down ProcedureFig Boiler Start-up and Shut-down ProcedureFig Boller Start-up and Shut-down ProcedureFig.1 Boiler Start-up and Shut-down ProcedureFig Boller Start-up and Shut-down ProcedureFig.1 Boiler Star-up and Shut-down Procedure aE 1Fig.1 Boiler Start-up and Shutdown ProcedureFig:1 Boiler Start-up and Shut-down ProcedurePressure(MPa) Fig.3 Boiler Pressure Rising-up Curve Ta Scan ren Sty Va St vaber Fanuc) foroowviod a= ———___—_T Steen Do Sty Va Sat Val: 12) /oaIPEvien! WJ O1PSV 10a) 8 : + i = oxastorRL - ; / = 2 oO [ - ° 1 [Sean Drm Pramas |) s0osMPalG) ‘Time for Boller Pressure Rising-up (h) [we aouPuiaLFO PRESSURE (MPa) 09 08 08 0s 04 03 02 a1 00 Fig4 LFO BURNER PERFORMANCE CURVE (AIR ATOMIZING) SiAIR ATOMIZING PRESSURE 055 MPa CONSTANT BURNER: SET 2000 BURNER? SETS ‘000 LFO FLOW (kG/H) BuRNENS SETS REMARK] unig SETS e—> INCREASING Powt" va» OF BURNER SET -REDUCING POINT THE INCREASING AND REDUCING POINT OF BURNER SET CAN BE CHANGED WATH REAL PROPER LFO PRESSURE, ‘000 5000 e000Fig.5 CC Low NOx Coal Burner Design Concept Basic Concept ‘Stable combustion of high concentrated pulverized coal in outward swirl air zone generated with primary stabilizer ring (Outward ignition flame) First generated NOx Control in first ignition zone (devolatiisation zone) and Effective mixing staged air, which is Low NOx Firing split with secondary and tertiary air, into coal fring flame olin ae @ c Stable Core Flame WHE Kawasakiig-6 Low NOx Combustion System ‘Two Staged Air KawasakiFig.7 Predicted NOx] Reduction Curve ise Moret Goal & Beslan \ cd NT 00750 C 2 S160 1s (yo tage Ale a UBC 11.5% KawasakiFig.8 Ash Property in Coal Component A= Sils + Alas B= Fors + Cad + MgO + NaaO + Ke S.FEA/Bx S BE KawasakiFig.9 Slugging Factor for Furnace \ Slugging Factor Levee} B= Feats + Ca + MgO + NasO + KeO) ARE] | A/B x S Slugging Condition Sevier KawasakiFig 10 NORMAL OPERATION (TOTAL 200% LOAD) re Ts fel Os J{-| j= Fig11 MAX. OPERATION at COAL MILL TRIP. (TOTAL 170% LOAD) go ee i Fig12 ONE MLL OUT OF SERVICE (TOTA. 130% LOAD)i Fig19. NORMAL OPERATION (TOTAL 200% LOAD) Fig:14 Coal Mil Load VS Bag Fiter Gas Flow BEREREES 3E00 BYPASS: STACK, CONTROL DAMPER “| (7 Isa 7 BURNER, 500 OUTLET, ‘CONTROL DAMPER wt Jee Fig.16 ECO BYPASS OPERATION