Professional Documents
Culture Documents
CORPORATION LIMITED
PANCHKULA, HARYANA
DEVELOPMENT CONSULTANTS
PRIVATE LIMITED
CONSULTING ENGINEERS
24B PARK STREET, KOLKATA - 700 016, INDIA
HTPC
HUNAN PROVINCIALTHERMALPOWER CONSTRUCTION CO.
湖南省火电建设公司
99 Jianshe Zhonglu,Zhuzhou,China
2x600MW THERMAL POWER
Operation Manual for 600MW Unit PLANT HISARHARYANA-INDIA
DOCUMENT TITLE:
REV. NO. :0
ENDORSEMENTS
CONTENTS
EMERGENCY SPRAY.................................................................................................................. 4
1.5.1 INITIAL STATE BEFORE START-UP (ENTIRE COLD WORKING CONDITION) .......... 23
1.8.4 MFT.................................................................................................................................... 40
1.8.5 RB ...................................................................................................................................... 40
1.8.6 PRESSURE OF MAIN STEAM AND REHEATING STEAM IN INCORRECT SCOPE ... 41
SITUATIONS: ............................................................................................................................. 82
3.4.2 MAIN PARAMETER AND LIMITATION OF TURBINE NORMAL OPERATION ........... 104
4.1.6 MAIN AND BFP OIL PUMP TECHNICAL SPECIFICATION ......................................... 125
4.2.4 TURBINE JACKING OIL PUMP AND TURNING GEAR ............................................... 128
4.3.1 THE PREPARATION BEFORE START WATER SIDE VACUUM PUMP ...................... 130
4.5.8 THE SHUTDOWN OF HP HEATER DURING UNIT OPERATING NORMALLY ........... 135
4.5.12 LP HEATER AND DRAIN SYSTEM MAIN INTERLOCK PROTECTION .................... 137
4.8.1 SET PROTECTION VALVE FOR OPEN COOLING SYSTEM ...................................... 148
4.9.5 SEALING OIL SOURCE OF AIR SIDE AND HYDROGEN SIDE .................................. 149
4.10.2 PUT STATOR COOLING WATER SYSTEM INTO OPERATION ................................ 152
5.3.2 ASK DEPUTY MANAGER OR CHIEF ENGINEER TO STOP GENERATOR WHEN ONE
5.3.4 WHEN TROUBLESOME OR SWITCH REFUSE TO ACT AMONG G-T ...................... 167
5.3.10 BRUSH OF SLIP RING HEAT HEAVILY OR CATCH A FIRE ..................................... 169
5.3.23 OUTLET AIR TEMPERATURE OF RECTIFIER CABINET HIGH AND ALARM ........ 174
6.3.1 INSPECTION BEFORE FUEL OIL HANDLING SYSTEM START UP.......................... 178
6.4.1 THE INSPECTION BEFORE FUEL OIL HANDLING SYSTEM START-UP.................. 180
.................................................................................................................................................. 192
7.3.6 COMMON PROBLEMS AND DISPOSAL FOR MIXED BED OPERATION.................. 222
7.3.7 PRECAUTIONS FOR ENSURING MIXED BED AMMONIA OPERATION ................... 223
Notice: boiler max continuous evaporation capacity (B—MCR)is accordance with steam inlet
capacity when turbine is on VWO condition.
1.2.2 Main performance index of boiler
Designed coal variety Checked coal
Load Name Unit B-MCR TMCR 80%ECR 60%ECR BMCR
Setting Setting sliding sliding Setting
1. turbine load
pressure pressure pressure pressure pressure
2. steam flow
Economizer inlet t/h 2068 1855 1336 946 2058
SH outlet t/h 2076 1906 1458 1079 2076
RH outlet t/h 1761 1624 1261 948 1761
SH primary water
t/h 8.80 51.10 122.10 133.40 18.00
ejector
SH secondary water
t/h 0.0 0.0 0.0 0.0 0.0
ejector
RH water ejector t/h 0 0 0 0 0
3. steam pressure
SH outlet MPa.g 17.47 17.33 17.14 16.82 17.47
drum MPa.g 18.84 18.50 18.02 17.20 18.84
Economizer inlet MPa.g 19.24 18.86 18.35 17.46 19.24
RH inlet MPa.g 3.938 3.703 3.817 2.133 3.938
RH outlet MPa.g 3.733 3.510 3.618 2.020 3.733
4. steam
temperature
SH outlet ℃ 540 540 540 540 540
RH inlet ℃ 330 323 299 281 330
RH outlet ℃ 540 540 540 540 540
Desuperheater water ℃ 179 179 169 158 179
Feed water ℃ 280 276 259 242 280
Drum ℃ 361 360 356 354 361
5. boiler design
efficiency (calculate
% 92.77 92.86 92.50 93.23 91.64
as per low heat
productivity)
boiler design
efficiency (calculate
87.11 87.22 85.61
as per high heat
productivity)
6. heat loss of
mechanical % 1.05 1.05 1.3 1.3 1.8
un-combustion
7. actual fuel
t/h 366.8 341.2 275.1 210.7 473.9
consumption rate
8. air temperature
Primary air of air
℃ 37 37 37 37 37
preheater inlet
secondary air of air
℃ 30 30 30 30 30
preheater inlet
Primary air of air
℃ 309 306 299 277 312
preheater outlet
secondary air of air
℃ 320 317 306 283 325
preheater outlet
9. flue gas
temperature
Flue gas
temperature of
℃ 1028 1020 985 936 1024
furnace rear platen
outlet
Flue gas of platen
℃ 1329 1341 1351 1317 1316
bottom
Gas exhaust (before
℃ 142.5 141.0 141.5 120.5 148.5
revised)
Gas exhaust (after
℃ 138.0 136.5 136.5 115.0 144.5
revised)
10. air quantity
Primary air of air
kg/h 687074 660424 574661 513407 821761
preheater inlet
Secondary air of air
kg/h 1669169 1520028 1127434 1056542 1559102
preheater inlet
Primary air of air
kg/h 520034 494104 408341 346727 654721
preheater outlet
Secondary air of air
kg/h 1660529 1511748 1123474 1052222 1550822
preheater outlet
Bypass primary air of
kg/h 204696 212976 172800 112608 222696
air preheater
Primary air leakage
kg/h 32040 32040 33480 33120 32400
to secondary air
Primary air leakage
kg/h 135000 134280 132840 133560 134640
to flue gas
Secondary air
kg/h 40680 40320 37440 37440 40680
leakage to flue gas
11. flue gas quantity
Air preheater inlet kg/h 2724645.6 2534547.6 2076411.6 1712192.4 2782069.2
Air preheater outlet kg/h 2900326 2709148 2246692 1883192 2957389
12. excess air
number
Furnace outlet - 1.25 1.25 1.274 1.381 1.25
secondary desuperheater
water
6 Designed flow of secondary
desuperheater water t/h 40
III Economizer inlet pressure Mpa 19.24 18.86 18.39 18.05 14.62 11.16
RH flow speed t/h 1740.2 1605.3 1638.1 1261.5 948.3 728.5
IV Emergency spray water
1 Design pressure of
emergency spray water Mpa 4.35 — — — — —
2 Design temperature of
emergency spray water ℃ 343 — — — — —
3 Pressure of emergency
water spray point Mpa 3.882 3.651 3.820 2.865 2.132 1.617
4 Temperature of spray water ℃ 177 174 178 165 154 144
5 Calculation flow of
emergency spray water t/h 0 0 0 0 0 0
6 Design flow of emergency 82
spray water t/h
1.2.4 Coal performance analysis table
No. Particulars Units Performance Coal Worst Coal for ESP & MILL
A Proximate Analysis
1 Moisture % 15.0 15.0
2 Ash % 34.0 46.0
3 Fixed Carbon % 21.0 19.73
4 Volatile matter % 30 19.27
B Ultimate Analysis
1 Carbon % 41.22 31.88
2 Hydrogen % 2.81 2.13
3 Sulphur % 0.35 0.28
4 Nitrogen % 0.71 0.59
5 Oxygen (by difference) % 5.90 4.12
6 Moisture % 15.0 15.0
7 Gross calorific value Kcal/kg 4000 3150
C Grindability Index HGI 50 50
D t1 ℃ 1100 1100
t2 ℃ 1300 1250
t3 ℃ 1400 1400
1.2.5 Set value of boiler safety valve
Bearing lubricate
8 Lube oil grease
mode
9 Manufacture Shanghai Fan Co. Shanghai Fan Co. Shanghai Fan Co.
Induced air fan Primary air fan
Draft air fan motor
motor motor
10 Model YKK900-8 YKK630-6 YKK630-4
11 Rated power KW 4200 1400 3650
12 Rated voltage KV 11 11 11
13 Rated current A
14 Rotation speed r/min 745 991 1488
Shanghai Electric Shanghai Electric Shanghai Electric
15 Manufacture
Motor Co. Motor Co. Motor Co.
1.2.7.3 Regulation of pulverized coal system devices
1.2.7.3.1 Mill
Designed Worst coal
No Item Unit
coal variety variety
Mill model HP1103
1 Mill output
Max. output(grind output) t/h 75.3 75.3
Guaranteed output(dry output, consider abrasion) t/h 60.2 60.2
Calculated output t/h 60.76 67.34
Guaranteed output(grind output, consider abrasion) t/h 67.8 67.8
Min. output t/h 18.8 18.8
Mill load rate % 81 89.4
2 Mill air rate
Max. air rate t/h 130.8 130.8
Calculated air rate t/h 120.7 125.3
Ensure air rate on output condition (dry output) t/h 125.6 125.6
Min. air rate t/h 91.6 91.6
Temperature of dry medium on mill inlet (calculated
3 ℃ 244 255
output)
Outlet temperature ℃ 77 77
Moisture of pulverized coal % 4.5 4.5
r/mi
4 Mill rotation speed 30.3 30.3
n
Mill ventilation resistance (include separator,
5
pulverized coal classifier)
Max. air flow resistance KPa 4.5 4.5
Air flow resistance (guaranteed output) KPa 4.2 4.2
Calculated air flow resistance(BMCR) KPa 3.83 4.13
6 Mill seal air system
m3/
Wind capacity of mill airproof 70.75
min
Seal air pressure of mill (tolerance of primary air
Pa 2000
pressure)
KW
7 Mill unit power
h/t
KW
Guaranteed unit power when output 10.3
h/t
8 Mill unit abrasion rate g/t 1.8
9 Lifespan of main components
Grind role h ≥12000
No Item Unit
Model
1 Separator model Static separator model
2 Grind role loading mode Spring variable load
3 Foundation model Fixed integral
Input dimension of primary air (inner
4 mm×mm 1020x3068
wall)
Dimension/ wall thickness of center
5 mm/ mm Ф610x10
coal chute
Ф724x16(designed powder
Dimension/ wall thickness of
6 mm/ mm supply pipe Ф710x13, weld the
pulverized coal pipe junction
groove before leaving factory
Volume of Carpolite coal ash
7 m3 0.8
discharge tank
fire control steam capacity/
8 t/h 3~4
Temperature/ pressure
9 Weight of single mill t 180
1.2.7.3.3 Parameter table sheet of motor mill which matched with mill
No. Parameter name Unit Value
1 Manufacture Shanghai Electric Motor Co.
2 Electromotor type squirrel-cage type asynchronous
--
motor
3 Electromotor model -- YHP560-6
4 Rated power kW 750
5 Rated voltage kV 3.3
6 Rated current A 174
7 Rated frequency Hz 50
8 Rated rotation speed rpm 978
9 Number of pole -- 6
10 Protection grade -- IP54
signal of target load, and can take part in grid primary FM. Its advantage is that unit operation is
stable, pressure fluctuation is small, and disadvantage is that peak load regulation is a little
weak.
d. When unit is normally operated, try best to adopt coordinated BF coordination control mode.
C) The conditions of CCS in service
Furnace pressure is automatic controlled.
Air pressure of secondary air is automatic controlled.
Air pressure of primary air is automatic controlled.
Oxygen content revising is automatic controlled.
Air rate of secondary air baffle is automatic controlled.
Primary air rate of mill is automatic controlled.
Rotate speed of coal feeder is automatic controlled.
Fuel oil flow is automatic controlled.
Fuel oil pressure is automatic controlled.
Feedwater main control is automatic controlled.
Coal-water ratio is automatic controlled.
D) When meet the following conditions, the unit works at CCS mode.
Circuit breaker at outlet of generator is closed.
HP bypass is closed.
Turbine main control is automatic.
Boiler main control is automatic.
Unit has no RB dictate.
E) Under CCS mode, when turbine main control or boiler main control switches to manual
operation, quit CCS operation mode.
F) The operation of CCS in service
On unit control graph, make boiler and turbine main control automatic.
On unit control graph, make adjusting mode automatic.
1.3.3 FSSS introduction (Furnace Safety Supervision System)
Boiler safety and supervision for normal operation is becoming more complex when the
capacity of unit is increased, which makes general operator difficult to treat the abnormal
phenomenon’s endangered to boiler. Finance safety supervision system, short for FSSS, is
composed of burner control system and fuel safety system during boiler startup, operation and
shut up condition, FSSS can continuously supervise the parameter and condition of burner
system, and calculate and estimate logically. It reacts sharply and makes the complex safety
interlock process automatically run by the efforts of the inputted process, which can ensure the
safety of boiler furnace and burner system so as to increase safety of the boiler. It also has the
important role for preventing explosion caused by operation accident and equipment accident.
1.3.5.1.3 MFT has no action condition and coal feeder C doesn’t put into operation delayed 50s.
1.3.5.1.4 MFT has no action condition and coal feeder D doesn’t put into operation delayed 50s.
1.3.5.1.5 MFT has no action condition and coal feeder E doesn’t put into operation delayed 50s.
1.3.5.1.6 MFT has no action condition and coal feeder F doesn’t put into operation delayed 50s.
1.3.5.1.7 MFT has no action condition and coal feeder G doesn’t put into operation delayed 50s.
1.3.5.1.8 MFT has no action condition and coal feeder H doesn’t put into operation delayed 50s.
1.3.5.2 Control of auxiliary secondary air damp
1.3.5.2.1 When meet the following conditions, put AB secondary air baffle at flame position.
a) Boiler load is more than or equal to 30%, and there is one angle oil gun in service at least
at AB, moreover delays 75s.
1.3.5.2.2 When meet one of the following conditions, secondary air damper at AB layer shall
automatically close.
a) Boiler load is less than or equal to 30%, and there is one angle oil gun for light-up at least,
moreover isn’t in service.
b) Boiler load is more than 30%, delaying 50s. Without MFT condition, mill A, B halt, oil guns
at AB floor aren’t in service.
1.3.5.2.3 When meet all the following conditions, secondary air baffle at AA and auxiliary air
baffle at AI shall automatically close.
a) Boiler load is more than 30%.
b) Mill A has been halted.
c) No MFT action condition.
1.3.5.2.4 When meet all conditions as follow, auxiliary air baffle at BⅠ floor shall automatically
close.
a) Boiler load is more than 30%.
b) Mill B has been halted.
c) No MFT action condition.
1.3.5.2.5 When meet all conditions as follow, auxiliary air baffle at BC floor shall automatically
close.
a) Boiler load is less than or equal to 30%, and there is one angle oil gun for light-up at least,
moreover isn’t in service.
b) Boiler load is more than 30%, delaying 50s. Without MFT condition, mill A, B halt, oil guns
at AB floor aren’t in service.
c) Delay 40s when boiler load is over 30%.
d) No MFT action.
1.3.5.2.6 When meet all conditions as follow, secondary air baffle at CD floor is on light up
position.
a) Boiler load is lower than 30% and there is at least one angle oil gun in service for light-up,
1.3.6.3.8 Mill A, C, D, F is put into operation, RB action program; oil guns at CD are in service,
switching off mill A.
1.3.6.3.9 Mill A, D, E, F is put into operation, RB action program; oil guns at EF are in service,
switching off mill A.
1.3.6.3.10 Mill B, C, D and E are put into operation, RB action program; oil guns at CD are in
service, switching off mill B.
1.3.6.3.11 Mill B, C, D and F are put into operation, RB action program; oil guns at CD are in
service, switching off mill B.
1.3.6.3.12 Mill B, C, E and F are put into operation, RB action program; oil guns at EF are in
service, switching off mill B.
1.3.6.3.13 Mill C, D, E and F are put into operation, RB action program; oil guns at CD are in
service, switching off mill F.
1.3.6.3.14 Mill A, C, E, F are put into operation, RB action program; oil guns at EF are in service,
switching off mill A.
1.4 Test before boiler start-up
1.4.1 Tests before boiler start-up
1.4.1.1 Test for remote control valve, air and flue baffle.
1.4.1.2 Single logic protection test and emergency push button test for auxiliary.
1.4.1.3 Actuation test of MFT.
1.4.1.4 Fuel oil leakage test.
1.4.1.5 Test for ignition devices.
1.4.1.6 Boiler overall interlocking test.
1.4.1.7 Bypass valve turning on test and interlock closure test.
1.4.2 Boiler overall interlock test
1.4.2.1 Usually after boiler other tests are finished, start up two IDF, two FDF, two primary air
fans, any flame checking cooling air fan.
1.4.2.2 Artificially satisfy furnace blowing condition, after 5 minutes blowing, recover MFT.
1.4.2.3 Open oil trip valve and primary air baffle of mill outlet.
1.4.2.4 In simulation potion, program-control starts up 16 heavy oil guns.
1.4.2.5 Start up 8 mills and 8 coal feeders.
1.4.2.6 Artificially satisfy the condition of load >60%, switch off one IDF, shunt trip relevant
FDF and PAF, switch off relevant mills, emergency loudspeaker sounds, turn into RB state.
1.4.2.7 Switch off another IDF, shunt trip relevant FDF and PAF, and send MFT. All mills and
coal feeder trip, automatically close primary air damper at outlet of mill, close all oil angle quick
action valves and oil tripping valve.
1.4.2.8 Eliminate the single of “Permission of oil start-up” and “permission of mill ignition”.
1.4.2.9 After tests, resume the equipments.
1.5.2.5.2 After water filled into water pump, fill water into drum by condenser pump through
boiler upper valve, the water is chemically desalted and used when drum wall temperature is
low; also can fill water by electromotor feedwater pump or steam booster pump through bypass
control valve, the water is deoxidized and used when temperature of drum wall is high, and
guarantee water quality during filling course. Stop filling when water level in drum is over +
200mm. Fill water slowly and feedwater valve shall be opened and closed lightly. Water filling
speed: winter ≤50t/h, filling time ≥4h, other season ≤100t/h, filling time ≥2h. Filling water
temperature is ≥21℃ & <104℃ and max 50℃ higher than boiler wall temperature. When
temperature tolerance of water and water wall is more 50℃, filling time shall be prolonged
properly. At initial stage of water filling, fill water through boiler shutdown water filling valve and
close it after 15min.
1.5.2.5.3 Check if the expansion indicator is on good condition before filling water to boiler.
1.5.2.5.4 First start A or C boiler water circulating pump, fill water to reach normal elevation (if
water elevation on drum decreased to -300mm, shut down boiler water circulating pump and
check it) when water elevation on drum is drawdown; then start C or A boiler water circulating
pump, stop filling water into boiler when water level is -100mm and keep lighting at low water
elevation (as so to avoid pressure increasing and water level expansion), and later open
economizer recycle valve. When boiler started, again start B boiler water circulating pump.
Every boiler water circulating pump should rotate for 5s, then stop for 15s, and later rotate for
another 5s, perform this 3 times so as to thoroughly discharge the air in the motor cavity.
1.5.3 Boiler blowing conditions
1.5.3.1 Start up two APH.
1.5.3.2 Start up IDF, FDF.
1.5.3.3 Adjust output of IDF, FDF, keep furnace pressure at about -100Pa, and control air rate
between 30%-40% of total air rate.
1.5.3.4 Start up one flame check probe cooling air fan.
(1)IDF is in service.
(2)FDF is in service.
(3)Close all oil angle quick action valves.
(4)Close fuel trip valve.
(5)No MFT dictate.
(6)All coal feeders are out of service.
(7)All mills are out of service.
(8)Water elevation on drum is normal.
(9)No fire is dictated by any flame checking.
1.5.9.15 after load reaches 210MW and is stable; power for factory is changed from standby
power into working power. Pay attention that every electric current of auxiliary equipment is
normal.
1.5.10 Load from 35% of BMCR to 100%
1.5.10.1 Set target load 100% of BMCR on DEH graph(600MW), lift load as 6MW/ min for
unit.
1.5.10.2 After load reaches 300MW and is kept stable, finish warming the second feedwater
pump turbine with low speed, then speed rises to 2500rpm.
1.5.10.3 Slowly adjust rotation speed of the second driven turbine pump, pay attention to
variation of water flow. When speed of two driven turbine pumps is similar, put rotate speed of
the second driven turbine pump into automatic operation. Make sure feedwater automatic
adjustment is normal.
1.5.10.4 Start up the fourth, fifth mill. Gradually raise load to 540MW, and check unit change
into constant pressure operation mode.
1.5.10.5 Load comes to 600MW; entirely check whether every parameter of unit is normal.
1.5.11 Precaution for cold start
1.5.11.1 In whole start process, intensify supervision for metal temperature of every heating
surface (especially water wall), to avoid exceed temperature.
1.5.11.2 In whole cold start process, ignition, pressure raise, flushing, synchronization and
operation with load at each stage of unit, should be carried out and controlled as per unit cold
start curve.
1.5.11.3 Put oil gun into operation properly and use big diagonal.
1.5.11.4 Mill is reasonably put into operation.
1.5.11.5 When electric feedwater pump is working, pay attention to adjust its rotation speed
during lifting pressure, to ensure feedwater flow is normal.
1.5.11.6 Use desuperheated water on time as per steam temperature of superheat and reheat
water.
1.5.11.7 When load is low, discreetly use desuperheated water. If it’s required, warm its drain
pipe to prevent steam temperature from falling down.
1.5.11.8 During start process, open all relative drain of SH, RH system, and make steam
temperature increased equally to avoid too hot of some parts.
1.5.11.9 After all oil guns are out of service, continuous blowing of air preheater can be stopped.
1.5.11.10 when load is above 300MW, carry out entire blowing for boiler, put gap control system
of air preheater into operation.
1.5.11.11 after normal operation of unit, close relevant drain.
1.5.11.12 during load increase process, decide load increasing rate as per turbine expansion.
When abnormal status such as vibration etc happens, stabilize load and extend warm time in
the unit is operated on the condition that every parameter is under the best working condition.
1.6.2 Feedwater adjustment
1.6.2.1 When feedwater flow is low, feedwater adjusting valve is made to adjust feedwater flow,
and feedwater pump is made to maintain pressure difference of adjusting valve. When
feedwater adjusting valve is opened to be 80%, feedwater pump starts to control feedwater flow,
and feedwater adjusting valve is fully opened.
1.6.2.2 When speed of turbine driven feedwater pump is above 3000r/min, two steam driven
feed water pumps can be put into operation parallelly with flow deviation less than 100t/h..
When one motor driven water pump and steam driven water pump operate parallelly, steam
driven feedwater pump is automatically controlled and motor driven feedwater pump is
economical output.
1.6.2.3 During the course of adjusting feedwater, keep water flow rate be stable so as to keep
balance of boiler negative load and coal-water ratio and avoid large fluctuation of parameter
caused by maladjustment of coal-water ratio.
1.6.3 Boiler combustion adjustment
1.6.3.1 Boiler combustion adjustment purpose: ensure combustion stable, improve combustion
economy, make heating load in combustion chamber uniformly distributed, reduce heating
deviation, prevent boiler from clinkering, clogging etc, and ensure each parameter is normal
during boiler operation.
1.6.3.2 When boiler is in service, variety and chemistry analysis of coal, fuel should be known
so as to adjust working condition of operation according to fuel property. During normal
operation, operating staff should frequently comprehensively inspect combustion system, if any
bad combustion is found, adjust it on time.
1.6.3.3 During boiler combustion, color of flame is golden. When fuel oil is burning, flame is
white and bright, flame should be equally filled in furnace and doesn’t scourer water wall and
platen SH. Flame center at the same elevation should be at the same height. Firing point of fuel
should be well situated. Short distance will be easy to cause coke around nozzle. Far distance
will make flame center moved up and cause coke around the top of furnace, even it will result in
unstable combustion.
1.6.3.4 During normal operation, negative pressure of furnace should be kept between -50~
-100Pa. No smoke goes out from boiler upside.
1.6.3.5 During boiler normal operation, air leakage should be furthest reduced. Every access
door and manhole should be closed. Plug on time wherever there is air leakage.
1.6.3.6 Oxygen content at furnace outlet should be decided by the character of coal variety and
load, if oxygen content is manually controlled, adjust it according to the set value, if oxygen is
automatically controlled, it is automatically adjusted by changing oxygen set value. When the
melting point of fired coal and fuel is low, in order to avoid coking on furnce, the fuel is fired by
burner can’t adjust temperature very well, reheat desuperheated water can be used for
accessorial adjustment.
1.6.4.4 During the operation of boiler, carry out combustion adjustment, load increase and
decrease, start-up and close of burner, feedwater, fan, soot blowing, and lancing etc, which all
make the temperature of main steam and reheat steam change. At this time, especially intensify
supervision and adjustment of steam temperature on time.
1.6.4.5 When HP heater is going to be in service and out of service, feedwater temperature is
going to change greatly, and the working temperature also changes correspondingly at every
course. Sickly supervise feedwater and economizer outlet temperature.
1.6.5 Limitation value of boiler operating parameter
Adjust and monitor boiler operation to ensure each parameter within scope, also to use program
control and auto-adjust to maintain operation situation and quality.
Main parameter value:
Normal value Max. Min.
Item Unit Trip value
(range) value value
Steam pressure on SH outlet MPa 17.47 17.99
Steam temperature on SH outlet ℃ 540 545 530 565
Steam pressure on RH outlet MPa 3.73
Steam temperature on RH outlet ℃ 540 545 530 565
Wall temperature of LPSH vertical
℃ <470 472
outlet
Wall temperature on division platen
℃ <480 482
outlet
Wall temperature on rear platen SH
℃ <560 566
outlet
Wall temperature on final SH outlet ℃ <580 580
Wall temperature on platen RH
℃ <570 571
outlet
Wall temperature on final RH outlet ℃ <580 580
Furnace negative pressure Pa -50~-100 +996 -996 +13240-2490
of main steam.
c) When the load is decreased to 500MW, shut down the first mill according to the order.
(Generally shut down G or H first in order to keep stable combustion on furnace.)
Decrease negative load from 80% to 50%
a) Pay attention to the stability of temperature of main steam & reheat steam and water level of
HP heater & LP heater in the course of load decreasing.
b) Shut down second and third mill during the course of load decreasing.
c) Shift the water load to another steam pump and keep the other pump in recycle operation
when the load is decreased to 50%.
d) Switch water handling to AVT style.
(3) Load from 50% to 35%
b) While reducing load, assure the condition of ignition energy. Put into plasma ignition when
load to 210MW and stop third mill. The coal level should be not lower than 60T/H.
c) Pay attention to air control to prevent air flow lower than 25% and MFT because of stopping
mill, the manual control is needed.
d) Steam resource of feed water pump will switch to cool section of reheat steam automatically
during load reducing period. Before switching, switch the first steam-pump after motor pump be
checked operated normally.
e) Pay more attention to supervision of air flow rate, temperature of intermediate point & main
steam. If the automatism is failure, adjust air flow rate and temperature of desuperheated water
manually.
(3) Load from 35%to 0
a) Put motor driven water pump into operation when load is 180MW, stop second turbine driven
feedwater pump, and monitor water flow and water level in drum.
b) Check high-pressure by-pass system when steam pressure near to 8.6MPa, switch DEH to
power mode, and reduce load by reducing power value of turbine.
c) Stop the sixth mill in the right time. Reduce boiler fuel to 15% or a little smaller if opening of
HP by-pass valve is too large, and ignite oil gun if needed.
d) Check steam resource of deaerator to see if it can switch normally, and deaerator can
operate correctly.
e) Report chief supervisor when 0 load, now generator-transformer can trip.
1.7.1.5 Operation of boiler after oilier trip
1.7.1.5.1 After trip turbine, stop the final mill, control steam temperature in 5℃/min, stop primary
fans and tight fans.
1.7.1.5.2 After shut down mill, shut off all oil gun and plasma and boiler flame out.
1.7.1.5.3 Maintain IDF and FDF in operation after boiler flame out, adjust air flow to 30%BMCR,
maintain negative pressure of boiler in scope of -50Pa~-100Pa, and sootblower boiler for 5 min.
After sootblowing, shut down FDF and IDF as per requirement, unlock related interlocks and
shut off related dampers.
1.7.1.5.4 Shut down all isolating valves after flame out.
1.7.1.5.5 Shut down motor driven feedwater pump.
1.7.1.5.6 After 6h, open all dampers of flue air system to ensure ventilation of boiler.
1.7.1.5.7 Shut down flame checking air cooling fan when boiler temperature is lower than
150℃.
1.7.1.5.8 Stop air preheated A/B when its inlet temperature is lower than 120℃ .
1.7.1.5.9 When boiler is required to cool rapidly, start IDF and FDF to maintain air flow in
30%MCR after boiler is shut-off for 18h.
1.7.2 Emergence stop
1.7.2.1 Shut down boiler rapidly in following situations.
1.7.2.1.1 In operation condition, MFT refuse to work in emergence condition.
1.7.2.1.1 There is serious blasting on boiler heating surface, steam pipe and etc. and can’t
maintain normal operation.
1.7.2.1.2 Boiler rear flue duct is returned and exhaust smoke abnormally and can’t maintain
normal operation.
1.7.2.1.3 Steam pressure surpasses limited actuation value and all safety valves are refused to
work.
1.7.2.1.4 Safety valve could not resume after actuated, steam pressure is decreased and
temperature reached to the condition can’t operate continuously.
1.7.2.1.5 There is blasting abruptly happened in furnace or flue duct, and destroy the equipment
seriously.
1.7.2.1.6 Feed water pipe break or leak heavily and have risk to operation and human safety.
1.7.2.1.7 There is leakage in SH, RH, economizer, and water wall, and make water flow lower
heavily.
1.7.2.1.8There is fire in boiler scope and affects operation of boiler directly.
1.7.2.1.9 There are defects in DAS system or power of thermal control gauge is off and could
not monitor or regulate operation parameter.
1.7.2.1.10 Plant power is totally or partly cut off and can’t maintain normal operation of unit.
1.7.2.2 Ask for shut-off of the boiler from the chief supervisor in following conditions.
1.7.2.2.1 Water quality and steam quality is becoming worse and could not resume.
1.7.2.2.2 There is leakage in pressure part of boiler which will destroy other heating surface or
have damage to human safety.
1.7.2.2.3 Cinder and ash is heavily collected in boiler and can’t maintain normal operation after
process.
1.7.2.2.4 Shortage in PCV valve and safety valve.
boiler pipeline);
1.8.2.1.3 When it is acute shortage of water, the main steam temperature rises;
1.8.2.1.4 Water level is lower than III,MFT happened and delay 2 seconds;
1.8.2.2 Reasons:
1.8.2.2.1 The feed water automation device is out of order,feedwater pump speed reduces
abnormally or feedwater pump break down;
1.8.2.2.2 The operator misjudge due to improper manual operation, incorrect indication of water
level & water steam flow rate;
1.8.2.2.3 Water level is not adjusted timely when load and the steam pressure changed a lot;
1.8.2.2.4 Low pressure of feed water, or serious leakage of lower water drum, water wall,
economizer;
1.8.2.3 Handle:
1.8.2.3.1 When water level is lower than I: If the feed water automation is out of order,
immediately shift atomization into manual mode and at the same time increase rotation speed of
feed water pump;If speed adjustor of motor driven feedwater pump is out of order, turn on
motor driven feedwater pump and adjust water level;
1.8.2.3.2 Stop periodic blow down flash tank and continuous blow down flash tank;
1.8.2.3.3 When water level height is lower than III, delay 2 seconds and MFT,and handle as per
related rules after MFT;
1.8.2.3.4 When boiler water level does not show in any water gauges more than 10 minutes,
strictly prohibit to fill water into boiler. If fill water into boiler,it should be approved by chief
engineer.
1.8.3 Priming of steam & water
1.8.3.1 Phenomenon
1.8.3.1.1 Steam drum water level undulates rapidly,water level indicator inside water level is
vague;
1.8.3.1.2 The main steam temperature decreases,steam conductivity increases,water strike in
the main steam inside of pipeline.
1.8.3.1.3 Reasons:
1.8.3.1.4 Quality of feed water or the boiler water is unqualified;
1.8.3.1.5 Boiler load decreases rapidly or steam pressure comes down rapidly;
1.8.3.1.6 Oil enters into the steam and water system
1.8.3.2 Handle
1.8.3.2.1 Report to chief supervisor, decrease and steady boiler load;
1.8.3.2.2 Open big continuous blow down flash tank,strengthen periodic blow down flash tank,
1.8.6.3 Handle
1) In case of PCV valve tripped by accident, force it return to position by hand, if failed, ask to
stop boiler.
2) In case of safety valve is opened by accident, find out reason. Ask to shut down boiler if it
can’t close or leak heavily.
3) In case of by-pass valve is opened by accident, close it by hand. Ask to shut down boiler if it
can’t close or leak heavily.
4) When main steam valve or regulating valve open up or shut down abnormally, contact
respective staff to repair. If the steam pressure is still too high to cause safety valve trip under
normal load or rated load, ask to shut down boiler.
5) Dispose main steam system refers to “SH destroyed” when it leaks heavily.
6) Dispose main steam system refers to “RH destroyed” when it leaks heavily.
7) Dispose steam exhaust system refers to “heating failure” when it is abnormal.
1.8.7 Abnormal of main steam temperature
1.8.7.1 Appearance
1) Temperature of main steam is higher than 576℃ or lowers than 566℃, temperature of
reheating steam higher than 574℃ or lower than 564℃, the parameter on control panel will turn
to red color.
2) It will alarm when main steam & RH steam temperature is too high or too low.
3) Adjusting valve of first and second stage desuperheating water of main steam, or emergence
desuperheating water of reheating steam is open or close thoroughly.
1.8.7.2 Reasons
1) There are coordinate defects in system or manual adjusting is not timely, then cause
proportion of coal and water is imbalanced.
2) Boiler working condition fluctuates too much, but the tracing quality is not qualified and
manual adjusting is not on time.
3) Feedwater system breaks down, and the tracing quality is not qualified and manual adjusting
is not on time.
4) Cinder and ash is heavily assembled on furnace.
5) Sootblowing boiler whenever there is hunk cinder and ash in furnace.
6) Coal quality is much worse than designed value.
7) Break down of desuperheating water valve, or desuperheating water could not be adjusted
well.
8) There is serious leakage on heating surface and pipe of steam system.
9) Blast nozzle, air throttle destroyed or air proportion in boiler is unreasonable.
1.8.7.3 Handle
1) Remove coordination control if there is troublesome in coordinate system, adjust fuel and
water quantity according to current load. In order to prevent system fluctuating too much, try not
to adjusting coal and water at same time when proportion of coal and water is incorrect. Adjust
load after their proportion is comparatively stable.
2) If boiler condition fluctuate largely (like RB or more than one mill system trip), control system
under coordination status and main steam in auto-control status, shift staff should pay more
attention to coordination and auto control condition. Don’t operate manually as much as
possible. If they work incorrectly, shift staff should switch them to manual mode immediately.
3) If there is defect in water system (such as one water pump trip, high-pressure heater trip),
control system under coordination status and main steam temperature in auto control status,
shift staff should pay more attention to coordination and auto control condition, and don’t
operate them manually. If they work incorrectly, shift staff should switch them to manual
immediately.
4) If cinder or ash is heavily assembled in boiler, which cause temperature of main steam
abnormal. When sootblower could not put into operation rightly or cinder and ash are still
heavily assembled after sootblowing, repair middle point temperature of water system or adjust
it manually, ask to shut down boiler in case steam temperature is still high.
5) When sootblowing boiler when there is heavy cinder and ash on furnace, pay more attention
to change of water wall temperature and auto tracing system Decrease set value of steam
temperature a little if it is required. Switch auto tracing system to manual mode if it works
abnormally.
6) Notice shift staff in advance if coal quality changes. Take some measures to make different
kinds of coal mixed together to flame and adjust it.
7) If there is defect in desuperheating water valve, switch it to manual mode and decrease main
steam temperature properly. Repair middle point temperature of water system or switch it to
manual mode. Decrease load changing ratio properly to prevent too high temperature of main
steam. Repair desuperheating water valve immediately.
8) Shut down boiler immediately if main steam system heating surface or tube leak heavily. On
operation period, if coordination control or auto control for main steam could not work correctly,
switch them to manual mode, and decrease temperature of main steam properly. Shut down
boiler after adjustment but have no effect when over temperature of main steam and metal
heating surface caused by serious leakage of heating surface and pipe.
9) If there is defect on burner swing equipment or emergence desuperheating water valve,
switch reheating steam temperature to manual mode and decrease reheating steam
temperature properly, decrease load changing ratio to prevent too high temperature of reheating
steam, repair the swing equipment and valve on time.
10) If blast nozzle or throttle destroyed, or air proportion is unreasonable, properly decrease RH
steam temperature before the defect is removed. Decrease temperature of reheating steam,
load change ratio and avoid too high temperature of RH steam temperature.
11) Adjust air proportion if it is unreasonable.
12) Ask to shut down turbine if parameter could not be controlled.
1.8.8 Water flow for boiler is low
A phenomenon
1) Water flow decreases in control panel, and water pressure decreases.
2) Unit load decreases or main steam flow decreases.
3) Media temperature of boiler heating surface increases.
4) Alarm when feedwater flow and main steam temperature are beyond limitation, water feed
pump trip or failure of adjusting system
B Reasons
1) Steam pump trip, tracing system doesn’t work properly, or output of operating steam pump
cannot satisfy water flow requirement.
2) Feedwater pipe or HP heater leak.
3) There is defect on HP heater, feedwater valve.
4) Auto control for water supply system is out of control.
5) Unit load decrease abruptly, or steam source of steam driven feedwater pump decrease or
intermit. .
C Handle
1) Feedwater pump trip when load is higher than 60%, pay more attention to auto control
system Try the best to not interfere manually, but if the control system works abnormally, switch
it to manual mode immediately. Increase output of operating feedwater pump to max., and
decrease output of coal system or stop some mills. Start motor driven feedwater pump. Try best
to meet requirement of load for grid. When feedwater pump trip under the condition load is
lower than 50%, and auto control system work incorrectly, cut off it immediately, increase water
supply rate of feed water the same before tripped.
2) If water pipe leak but can still maintain normal operation, decrease load properly, and adjust
proportion of water and coal to its normal value, then ask to shut down boiler. For leakage in HP
heater, shut it down immediately, decrease water flow according to water temperature. If
leakage of feedwater pipe and HP heater may lead to equipment destroy or human safety. Shut
down boiler immediately.
3) If there is defect on HP heater or feedwater valve and water flow is larger than tripped value,
decrease load matched to water flow, repair them when unit operate stably. If valve could not be
repaired in operation condition, ask to shut down boiler.
4) If auto control system of feedwater devices work abnormally, switch it to manual. Adjust
rotation speed of feedwater pump and contact thermal control engineer to deal with auto control
system after water flow is controlled stable.
5) If load decrease abruptly, or steam pressure of steam driven feedwater pump is decreased or
intermitted, start motor driven feedwater pump to resume steam pressure when water supply
rate is lower than protection value, adjust water flow or decrease fuel rapidly to ensure boiler
temperature stable. When water flow is lower than protection value or middle point temperature
reach to trip value, but protection equipment refuse to trip, or temperature of water wall surpass
heavily, MFT by hand.
1.8.9 ECO Destroyed
A Phenomenon
1) Four pipes leak, test equipment alarm.
2) Leakage can be heard if inspected on site. Steam and water would emit in heavily.
3) There will be some ash in economizer, air preheater, ESP hoper, bunker pump or ash
handling pipe, air preheater and abnormal operation of ESP.
4) Water flow is abnormally larger than steam flow, and unit load decrease.
5) Temperature increase after leak point, and regulating valve of desuperheating water open
wider abnormally.
B Reasons
1) There is defect on material of economizer pipe, or some damage exists.
2) Friction bar of Eco. is installed incorrectly, or drop off then tube wall thickness decrease, so
blow up.
3) Water quality is worse for a long period, material corrosion, so blow up.
4) Re-flame in eco and make tube temperature higher enough to destroy.
5) Sootblower of eco installed incorrectly, there is water in it then destroy tube.
C) Handle
1) If leakage of economizer is not so much heavy, and water flow can maintain operation, as
well as temperature of water wall material is normal, pay more attention to wall temperature,
report and close watch to leakage.
2) Install enclosure around manhole, ash hoper and hang mark plate.
3) If leakage heavy, and media temperature increases abruptly, MFT by hand.
4) Take close watch to work condition of ash system and economizer, inspect and patrol. If there
is heavy ash in ash system or preheater, or ESP work incorrectly, ask to shut down boiler.
5) maintain forced and IDF running after boiler shut down, stop them when no steam or water
emit out.
1.8.10 Destroy of SH
A Phenomenon
1) Leakage inspection equipment alarm.
2) Leakage can be found if inspect on site
3) ESP may work incorrectly; heavily ash is in ash handling system or preheater.
4)Water flow is abnormally larger than steam flow, and unit load decrease.
5) Temperature behind leakage increase and regulating valve for desuperheating water open
incorrectly.
B reason
1) There is defect remaining in material or damage during manufacture and installation.
2) Friction bar is installed incorrectly, or drop down too many, or no repairing in a long time then
tube wore, wall thickness thinner and lead to blow.
3) Steam quality doesn’t conform to request, salt accumulated heavily make tube temperature
surpass.
4) Mode of coal system is incorrect, so heat load unevenly, mistaken design, or sootblower
destroy, ash accumulate heavily on tube, or support to panel or clamp destroy, and superheater
partly in excess temperature condition, lead to blow up.
5) Some sundries remain in tube or stagger welding makes flow in tube decreasing,
6) Coordination system or auto tracing system of SH could not trace regularly, or it operates in
excess temperature for long time which leads to blow up.
7) Operation incorrectly leads to water entering into SH lead to excess temperature and blow up
of pipe.
8) Position of sootblower is incorrect, water remaining in it and blowing tube to destroy.
C handle
1) Leakage is not so heavy that normal running can maintain, now pay more attention to
leakage and report it on time. Decrease load if needed. In order to prevent leakage destroy
other tube or near tube in low flow or excess temperature, stop boiler as early as possible.
2) If SH heater blows up, temperature behind leakage increase abruptly, normal operation could
not remain, or near tube in excess temperature, stop boiler.
3) For operation in light leakage, install enclose around manhole, inspection hole and hang
mark plate.
4) Pay more attention to ash system and preheater, inspect and patrol. In case of heavy ash in
ash system or preheater, or ESP work incorrectly, ask to stop boiler.
5) After stop boiler, remain FDF and IDF running stop them after no steam or water emit out.
1.8.11 Leakage of reheater
A Phenomenon
1) Leakage inspection equipment alarm
2) Leakage can be found if inspect in site
3) ESP may work incorrectly, and heavily ash is in ash system or preheater.
4)Water flow larger than steam flow, and load decrease.
5) Temperature behind leakage increase.
B Reasons
6) Hole around re-flame like manhole, inspection hole and sootblow hole are not seal, and gas
or fire emit out from them. Fume duct, eco, preheater hoper, preheater outcaste may be burned
red, heat radiation heavy around re-flame.
B reason
1) Coal powder is too coarse, coal powder is not even, air proportion is not correct, blast nozzle
is destroyed, oxygen in boiler is low, block in eco and preheater could not be found in time, take
no sootblowing measure for eco and air preheater for long time, so ash or coal power
accumulates in rear fume duct.
2)Fuel ignite for too long and pulverization is not so good, air proportion of oil gun is
unreasonable, take no sootblowing measure for eco and air preheater for a long time and lead
to rear furnace oil waste accumulated heavily.
3) Boiler flame in mixture of oil and coal, gun control valve leaks.
4) Not so seal around manhole, inspection hole of rear fume duct.
5) Take no sootblowing measure before stop boiler.
7) There is air flowing in fume duct because of air door or damper unseal.
C Handle
1) Shut down boiler when find flame in rear fume duct, and stop forced and IDF, close all fume
dampers.
2) Put sootblower around re-flame into operation to put out fire.
3) If re-flame around eco, start MBFP and make water flow in speed of 150t/h to cool.
4) If re-flame around preheater, but preheater can work normally, lift sector panel by hand and
maintain it running. If preheater blocked, and main driven motor or assist-driven motor trip, lift
sector plane by hand and start pneumatic motor, if pneumatic motor trip again, driving rotor of
preheater by hand, and repair motor immediately. Put sootblower into operation to put out fire,
use hydrant if needed.
5) If outlet water temperature of eco is near to inlet water temperature, there is re-flame around
eco, and inlet fume temperature, outlet fume temperature, hot air temperature decreases to
lower than 80℃, no fume or fire star emitted out from manhole or inspection hole, stop
sootblowing or hydrant. Open manhole and inspection hole to inspect fire put out. Open
drainage door to drain water in fume duct and dry it by opening damper.
6) Cool furnace thoroughly, make sure no equipment is destroyed, clear waste on furnace tube
and start boiler again.
1.8.13 Coking boiler
A Phenomenon
1) There is cinder around water wall, blast nozzle and cooler hoper.
2) Temperature of middle point, superheater outlet or all, reheater outlet or all is incorrect,
regulating valve of desuperheater for superheater or reheater open incorrectly.
3) Flame would be not stable if block of cinder exist around blast nozzle, heat load distribute
unevenly, or metal temperature. Offset designed value a lot.
4) Slag from slag collector increases and its current surpass normal value.
5) Cool hopper may be blocked.
B Reason
1) Coal quality change.
2) Boiler runs on ex-output status.
3) Air proportion in boiler is unreasonable or blast nozzle destroyed, so fire comes nearly to
wall.
4) Outlet temperature of mill is higher than normal value, primary air flow is too lower, coal
power is tiny than ignite early.
5) Coal system run in irrational mode and heat load is excessive.
6) Oxygen in boiler during operation is thin.
7) Sootblower for water wall could not put into use in a long time or its parameter set incorrectly.
C Handle
1) Notice shift staff in advance to take some measures before coal quality change.
2) Boiler should be run in rated output. If boiler coking heavily, decrease boiler output when it
can’t be improved after sootblowing and burning adjusting.
3) Adjust and maintain rational proportion of primary and secondary air to maintain air rigidity.
Repair destroyed blast nozzle and coking to prevent fire from going near to wall.
4) Maintain normal outlet temperature of mill, proper coal powder fineness, and primary air
quantity. If coding around blast nozzle is heavy, decrease outlet temperature of mill, increase
primary air or decrease coal powder fineness properly to delay ignition.
5) Maintain coal system running normally, if it needs to run in abnormal mode, like some mills
need to repair and stop, adjust proportion of air and load of each mill. Decrease output of boiler
if sootblowing and adjusting could not solve problem.
6) Increase air proportion of blast nozzle if coking heavily in boiler, decrease air-flamed quantity
and increase ex-air factor of furnace.
7) Put sootblower for furnace into running correctly, increase sootblowing times if needed.
1.8.14 Temperature of superheater tube and reheater tube surpass
A Phenomenon
1) Temperature of tube is higher than normal value.
2) Temperature of tube is different.
B reason
1) Coal system run in irrational mode, heat load distribute unevenly, design incorrectly,
sootblower destroyed partly, coking in tube unevenly, panel support or clamp destroyed, or
coking heavily in furnace, so heat offset of superheater and reheater exist.
2.2.4.2.4 Adjust first fan work condition lower than lowest point of stall line.
2.2.4.2.5 Start second fan, check inlet damper open in 60s, otherwise stop it immediately.
2.2.4.2.6 Monitor furnace suction pressure, open outlet rotary blade of second fan, check outlet
rotary blade of first fan close automatically. When the opening of two outlet rotary blades is
same, switch second fan’s to auto. Take notice that two outputs should be balance.
2.2.5 Shut-down IDF
Shut down IDF by stopping sequence control. Control of air and gas system, or stop it solely.
2.2.5.1Two IDF run parallel, stop one of them normally.
2.2.5.1.1 Close the outlet rotary blade which prepared to stop to manual when load decrease to
300MW.
2.2.5.1.2 Gradually close the outlet moving blade of the IDF which will be shut down, and check
the other one’s opening increase automatically and furnace pressure is normal.
2.2.5.1.3 Ensure system is normal when outlet moving blade is closed fully. Shut down the IDF,
and ensure its inlet damper is closed automatically.
2.2.5.1.4 Ensure the outlet damper is closed automatically.
2.2.5.1.5 2h later after stopping IDF, stop bearing cooling air fan.
2.2.5.2 Stop one IDF.
2.2.5.2.1 The last IDF can only be stopped when all FDF are stopped.
2.2.5.2.2 Switch outlet moving blade to manual, and close the blade gradually.
2.2.5.2.3 When outlet rotary blade is closed fully, check all system is normal, and shut down this
IDF.
2.2.5.2.4 2h later after stopping the IDF, stop bearing cooling air fan.
2.2.6 Handling accidents of IDF
2.2.6.1 Stopping steps of IDF:
a) Stop IDF manually or protection action.
b) Ensure outlet moving blade of IDF is closed, outlet and inlet damper of IDF are closed
automatically delayed.
c) 2h later after stopping fan, stop bearing cooling air fan.
2.2.6.2 Stall of IDF
A Phenomenon
1) Alarm of “IDF stall” is shown on control panel.
2) Furnace pressure and air quantity fluctuate a lot, and boiler is burnt unstable.
3) Current of stalled fan change intensively, abnormal voice would be heard in site.
B reason
1) Ash accumulated on heating surface and air pre-heater or flue gas damper is closed
incorrectly, which cause increasing of resistance and opening of static blade does not match
with flue quantity which causes fan enter into stall area.
2) IDF will enter into stall area when static blade is adjusted too much.
3) The other air fan will enter into stall area when automatic control equipment is broken down.
C Handle
1)Get air fan to manual control mode immediately, turn down the moving blade of the normally
operated air fan, and properly turn down the moving blade of the stalled one, adjust moving
blade at same time, and maintain boiler pressure in allowable scope.
2) If two air fans stall when they operate parallel, stop parallel.
3) If stall is caused by closing system damper and throttle incorrectly, open them immediately,
and adjust opening of static blade. If it is caused by defects of damper or throttle, decrease
boiler load and repair as soon as possible.
4) After taking above measures, stall is disappeared, and the unit is in stable condition.
Gradually increase load after find out further reasons and take some measures. When above
measures is invalidity or it is heavily threatened to equipment safety, stop this air fan
immediately.
2.2.6.3 IDF trip
A Appearance
1) There are alarms of “IDF (A or B) trip” and “RB” shown on control panel.
2) Negative pressure changes intensively.
3) Load decreases abruptly.
4) FDF, which is on the respective side of tripped IDF, trips.
5) Current of tripped fan decreases to 0, outlet moving blade is closed automatically, load of
running fan increases automatically.
6) RB action, and cut off corresponding mill.
B Operation
1) Ensure unit in coordination mode.
2) Ensure boiler load decrease to 50% automatically, in case auto control breaks down or speed
is too slow, decrease it to 50% by hand on time.
3) Ensure moving blade opening on the side of operated IDF increases automatically, and avoid
overload.
4) Ensure boiler pressure control is in auto mode; otherwise switch it to auto after adjusted.
5) Ensure moving blade opening on the side of FDF increases automatically, air quantity and
oxygen quantity is in normal.
6) Notice steam temperature and steam pressure changing during decreasing load, and adjust
desuperheated water to maintain steam temperature stable.
2.2.6.4 Dealing with defects of IDF outlet moving motor actuator.
a) Switch it to manual, maintain load stable.
b) Staff should go to site to check reasons, contact with main control room when operated
2.3.5.3 Adjust moving blade to required opening according to current and furnace negative
pressure. Press auto if possible.
2.3.6 Stop fan
2.3.6.1 shut down moving blade slowly which fan is stopped; monitor the other blade opening
automatically.
2.3.6.2 Close all outlet dampers after moving blades are closed.
2.3.6.3 Check and stop FDF.
2.3.7 Accident handling of FDF
2.3.7.1 Surge
A Phenomenon
1) There is alarm “FDF surging” shown on control panel.
2) Boiler pressure and air flow fluctuate intensively, and fuel in boiler is burnt unstable.
3) Current of surging fan changes intensively, check it on site and find abnormal sound.
B reason
1) Ash is heavily accumulated on heating surface and air preheater or flue gas damper is closed
incorrectly, which cause resistance increase and moving blade opening can’t match with air or
fume quantity and fan enter into stall.
2) When operate moving blade violently, fan will stall.
3) Adjusting performance of moving blade is becoming worse, and two paralleled fan in
unbalanced status, or auto system is out of control so one of them stall.
4) Start sootblower when boiler is overloaded or forced air flow is too large.
C Handle
1) Switch moving blade control to manual, close down the other normal working moving blade
and close down the moving blade of the stall one properly, adjust IDF and FDF to maintain
boiler pressure within allowable scope.
2) When surging occurs during paralleling, stop parallel, shut down moving blade of stalled fan
quickly, find out reason and resolve it then parallel them again.
3) If surging caused by fume damper or incorrectly close of throttle, open them immediately, and
adjust moving blade opening. If there are defects, decrease boiler load, and repair them as
soon as possible. If it is caused by sootblowing, stop it.
4) Unit will run stably if surging is disappeared by taking above measures, and increase load of
fan after reason is found out and resolved. While surging still exists or bring risk to equipment,
stop the fan.
2.3.7.2 FDF trip
A Appearance
1) There is alarm of “FDF (A or B) trip” and “RB” is shown on control panel.
2) Boiler pressure fluctuates intensively.
gradually.
2.4.7.2.3 Close air fan moving blade fully and stop this PAF. Check outlet damper of PAF is
closed automatically.
2.4.7.2.4 10 minutes later of stopping fan, stop hydraulic lubricate oil pump as per requirement.
2.4.7.3 Failure trip of PAF.
2.4.7.3.1 Stop PAF by hand or by protection.
2.4.7.3.2 Moving blade of PAF is closed automatically.
2.4.7.3.3 Outlet damper of PAF is closed automatically.
2.4.7.3.4 10 minutes after stopping fan, stop hydraulic oil pump as per requirement.
2.4.8 Handling accidents of PAF
2.4.8.1 Bearing vibrates intensively.
A Reason
1) Anchor bolt loose or concrete foundation is destroyed.
2) Bearing is broken, bended, or worn. .
3) Coupling loose and its center offset too much.
4) The blade is destroyed or it is grinded with outer case.
5) Air dust is destroyed.
B Operation
1) Monitor vibration, temperature, current or air flow occasionally as per fan vibration.
2) Find out reasons for vibration as soon as possible, contact special staff to resolve problems
when necessary.
3) Decrease load if air fan properly. It will trip automatically when vibration is larger than 11mm/s,
otherwise stop it by hand.
2.4.8.2 High temperature of bearing of PAF
A reason
1) Lubricate oil supplied is incorrectly, oil pump is destroyed or filter is blocked.
2) Cooling water for lubricate oil system is stopped or its quantity is not enough and cause inlet
oil temperature increase.
3) Lubricate oil quality worsen.
4) Bearing is destroyed.
5) Bearing vibrates intensively.
6) Overload of PAF.
B operation
1) Monitor vibration, temperature, current or air flow occasionally as per fan vibration.
2) Check on site whether hydraulic lubricate oil is normal, find out reasons as soon as possible
and contact special staff when required. .
3) While bearing temperature increasing, decrease load of PAF on time.
4) In case bearing temperature increase because of intense vibration, find out reasons as soon
as possible and resolve it.
5) When bearing temperature is higher than 100℃, fan will trip automatically, otherwise stop it
by hand.
2.4.8.3 Surging of PAF
A Appearance
1) There is alarm of “PAF surging” shown on control panel.
2) Current of surging fan changes intensively, check abnormal sound on site.
3) Primary air pressure fluctuates intensively.
4) Fan surges heavily, trip fan 15s delay when reach to trip value.
B reason
1) Fume damper close incorrectly, so resistance increase and moving blade opening doesn’t
match to air quantity, make fan to stall.
2) When operating moving blade too quick, fan will stall.
3) Adjusting performance of moving blade becomes worse, make two paralleled fan in
unbalanced status, or auto system is out of control and cause one of them stall.
C Handle
1) Switch moving blade control to manual, turn down the moving blade of the other air fan, and
properly turn down the moving blade of the stalled one.
2) When surging occurs during paralleling, stop it, shut down moving blade of stalled fan quickly,
find out reason and resolve it then parallel them.
3) If surging caused by incorrect closing of damper or throttle of PAF, open them immediately,
and adjust moving blade opening. If there are defects, decrease boiler load, and adjust mill
system and contact engineer for repairing.
4) Unit will run stably if surging is disappeared by taking above measures, and increase load of
fan after reason is found out and resolved. While surging is still exist or bring risk to equipment,
stop the fan.
2.4.8.4 PAF trip
A Phenomenon
1) There is alarm of “PAF (A or B trip” shown on control panel.
2) RB cut off respective mill.
3) Load is drop down automatically.
B operation
1) Ensure unit in coordination mode.
2) Monitor RB, if load are not decrease by auto control, stop respective mill by hand
immediately.
3) Try best to maintain primary air pressure. Stop all hot and cold air dampers of stopped mill if
outlet damper and moving blade of tripped air fans are closed.
4) According to primary air pressure, put oil gun into stable burning, stop some mills to prevent
MFT.
5) Notice steam temperature and air pressure changing and adjust them when load is
decreased abruptly.
6) Ensure boiler pressure and air flow normally.
2.5 Pulverized coal system
2.5.1 Mill Trips
Mill trips on any of following condition.
2.5.1.1 Lubricate oil pump trip.
2.5.1.2 Lubricate oil pressure is lower than 0.07MPa, 2s delayed.
2.5.1.3 Bearing temperature of mill speed reducer is >80℃.
2.5.1.4 Supplied lubricate oil temperature for mill is >65℃.
2.5.1.5 MFT。
2.5.1.5 MFT.
2.5.1.6 Primary air pressure is lower than 4KPa, inlet air flow is low, last for 5s or longer, two
PAF will both trip.
2.5.1.7 While mill is running, pressure difference of seal and primary air <1.0KPa. (Is it
necessary?)
2.5.1.8 Outlet damper of mill is closed.
2.5.1.9 Winding temperature of mill motor is>145℃.
2.5.1.12 Bearing temperature of motor is>95℃.
2.5.1.13 Outlet temperature of mill is >100℃.
2.5.1.14 Order
2.5.1.15 RB
2.5.1.16 While mill is running, fire detector doesn’t find flame.(Is it necessary?)
2.5.1.17 Coal feeder is stopped, 5minutes delayed. (Is it necessary?)
2.5.2 Coal feeder trips
Coal feeder trips on any of following condition.
2.5.2.1 MFT.
2.5.2.2 Mill trips.
2.5.2.3 Inlet and outlet motor of coal feeder is closed.
2.5.2.4 Defect in coal feeder system
a) Defect in belt driving motor.
b) Defect in cleaning motor.
c) Coal is cut off for coal feeder.
A Phenomenon
1) Outlet temperature of mill increase intensively.
2) Mill or coal chute is burnt or paint skin is disengaged.
3) There is a sound heard if spontaneous combustion in mill, air pressure of coal system
fluctuates a lot, coal power and gas will emit from the unsealed seam.
B Reason
1) Outlet temperature is regulated incorrectly which cause outlet temperature too high.
2) Flammable material enters into mill.
3) Many coal power or stone coal is accumulated on mill baseplate or air inlet side, which
causes spontaneous combustion.
4) Some coal power is accumulated on grinding bowl.
5) When mill is not stooped on time or blew fully and mill outlet valve is not closed, return fire.
C Handle
1) After ensure combustion in mill, switch coal feeder and mill into manual control, stop coal
feeder, close coal outlet valve, and close hot and cold air regulating damper and isolating
damper.
2) Put out fire by steam.
3) After outlet temperature of mill is decreased, close steam valve after all firing signals are
removed.
4) Maintain mill running for several minutes, clean system thoroughly.
5) When mill outlet temperature is<50℃, stop mill, close mill sealing air damper and outlet
damper. Take measures to clean mill.
2.6 CCP (Boiler water control circulating pump)
2.6.1Main parameter of CCP
2.6.1.1Parameters of CCP is shown in the following form.
Parameters of BCCP
No. Item Unit Data
1 model single suck—double discharge
2 design pressure MPa 21
3 design temperature ℃ 359.1
4 suction pressure MPa 18.9
5 Suction temperature ℃ 359
6 flow m3/h 2180
7 difference of head pressure M 31.1
8 hydraulic test pressure MPa 31.5
9 pump efficiency % 82.5
cold conditions 223.5 , hot
10 absorbing power KW
condition 122.7
11 manufactory British Haywood·Taylor Company
motor parameters
1 model wet stator - rat's cage - induction
2 output power kW 210
3 rotate speed r / min 1450
4 power factor 0.70
5 efficiency heat load 0.86,clod load 0.885
6 overall efficiency heat load 0.71,cold load 0.73
7 winding insulators XLP
8 manufactory British Haywood·Taylor Company
2.6.1.2 Feedwater cooler parameters are shown in the following form.
No Item Unit High-pressure side Low-pressure side
1 design pressure Mpa 21.0 1.0
2 design temperature ℃ 359.1 175
3 test pressure Mpa 31.5 1.5
4 running pressure Mpa 20.96 1.0
5 running flow L / min 12 410
6 inlet temperature ℃ 175 40
7 outlet temperature ℃ 54 43.6
8 feedwater flow L / min 2.0 ) ≯2.27
9 temperature ℃ ≯40
Remarks: The feeding water must be desalt water or condensate water, PH value of 7 ~ 9, with
the same quality as the water filled into the boiler, and must be filtered with a 100 mesh
stainless steel filtering screen.
2.6.2 Alarming and value-fixing parameters of CCP
Number Item HH H L
1 motor chamber temperature 60℃ 55 ℃ 9℃
2 cooler outlet water temperature 57 ℃ 9℃
pressure difference 1/2
3 151kPa
between inlet and outlet
4 cooler outlet water temp 54 ℃ 4℃
5 current
2.6.3 Starting and tripping conditions of CCP
2.6.3.1: Starting conditions
a) Steam drum water level is ≥200 mm or any CCP of the boiler is running.
b) Motor inner temperature is>4 ℃ and <55℃.
c) Cold water flow of CCP is ≥8m3 / h.
d) Temperature differences between the boiler shell and water entered into pump is<28 ℃ .
e) Outlet valve 1 and 2 are started.
2.6.3.2 Trip in any of the following conditions:
a) Any outlet valve of CCP is closed.
c) The inner temperature of the motor is proper, the rate of temperature rising of pump shell is≯
1 ℃ / min.
2.6.6 Preparation to start CCP
2.6.6.1 Pump has been filled with water and excluded air.
2.6.6.2 Make sure that the closed cold water pipe is connected and the LP cold water flow is in
line with the value requirements. If the pump is in hot standby mode, open the inlet and outlet
bypass valve.
2.6.6.3 Inspect motor outlet temperature alarm value and tripping values are correct. Check
whether all instruments is in good condition to ensure the absolute temperature difference
between the collecting header and pump shell does not exceed 56 ℃ . Check differential
pressure transmitter of the pump and the pump control system has been in operation and
functioned well.
2.6.6.4 Make sure the electrical insulation satisfies requirements (with a 1000V shake table
measuring insulation resistance, the value is greater than 200 M), the voltage is normal.
2.6.6.5 Drum water level is high.
2.6.7 Operating conditions of CCP
2.6.7.1 Carry out comprehensive inspection as required when the pumps and the boiler has
been filled with water, and get the motor point rotating for 5 seconds, then stopped for 15
minutes, then transfer to 5 second point-rotating, repeat like this for there times to discharge the
accumulate air in the pump body and the cold water LP system, so that the air in boiler spreads
and then disappears at the end. Water should be also filled during the three point rotating
exhausting period.
2.6.7.2 At the point rotating exhausting period, observe the motor current value and the pump
pressure difference value, pressure should immediately increases to 0.27MPa, stop pumps if
the pressure does not rise immediately. It may be caused by motor reversal that has to re-wire
the motor.
2.6.7.3 The start-up time of pump is about one second. Stop and check if the motor fails to start
in 5 seconds, restart 20 minutes later.
2.6.7.4 Three pumps can be started in A,C,B order, generally start pump A, C first, then start
pump B since the drum pressure is activated.
2.6.7.5 Stop water filling to the pump and turn off the duplex isolation valve and LP water valve
when the drum pressure increases to 0.5MPa.
2.6.7.6 Check the following contents after starting operation for 15 min and the pump current
becomes normal:
a) Measure vibration and record the readings. Stop running one CCP (generally open pump A,
C first, open pump B after there is pressure), if it vibrates.
b) Check the sound of pump and the motor is normal.
concerning the inspection. Guard bars and index plates should remain.
(2) The equipment and components are complete and the symbols are clear and correct. Tight
contact surfaces, complete insulation and ample lighting.
(3) The motors are wired. The earth wire is fixedly connected. The safety hood should be
installed and has no collision, as well as contact with the rotation part.
(4) Discharging and collecting rapping devices, ash discharging valve, screw dust discharging
machine and other rotation equipment work normally. The oil quality of the gear box is qualified
and the oil position is normal. Oil should be added to the driving chain so that chains can move
flexibly.
(5) All the instruments, switches, protection devices, regulation devices, temperature test
devices, alarm signals and indicating lamps are intact, complete and normal.
(6) The heating device of high voltage insulation bushing room and hopper heating device are
intact.
(7) The high voltage rectifier device is clean, as well as insulation parts. There’s no oil leakage
in the rectifier transformer and resistor. The oil quality is qualified and the oil position is normal.
The lead wire of the rectifier device has good contact ability and the damp resistance is intact.
The rectifying control cabinet and the automatic regulation device are intact. The adjustment
button or knob is complete and the instruction is correct. High voltage isolating disconnecting
link should have good contact ability. The operation mechanism is flexible and can be earthed
reliably. The disconnecting link is in the earth position.
(8) ESP high voltage cable lead-in cabin is clean. Lead-in wires have good contact ability and
the damp resistance is complete.
(9) All the switches and disconnecting links of the low voltage distributor work normally. All the
power insurance and operation insurance are intact.
(10) When the silicon controlled plates, heating and rapping devices are confirmed to be
switched off, send power to the above equipments.
(11) As for the breakdown or failure, generally, we will inspect the rotation part or the failure
part. After confirming that it is normal, it can be put into use.
2.8.2 Switch on ESP
Before switching on the ESP, we should confirm that there’s no person in the ESP, all manholes
are closed and there’s no person in the high voltage area. High voltage isolating disconnecting
link is put in the operation position. Switch on the heating device 4-8 hours in advance. Heat the
porcelain through insulator, column insulator and electromagnetic shaft so as to prevent dewing
and creeping. Switch on the hopper heating equipment and remove the moisture on the inner
wall of the hopper. Switch on the rapping device of the ESP collection electrode and discharging
electrode. Remove the dust particle attached on the electrode. Switch on the main blower fan to
preheat and dry the electrode system of the field. Switch off the earth device and put
Operation starts
Switch on ESP
Transmit DC HV to ESP. And then it can Transmit DC voltage to ESP set voltage
work automatically. manually
End
2.8.3 Switching off of ESP
When the main engine is switched off, ESP can temporarily stop and the post HV isolating
disconnecting link on the earth position.
After the power is cut off on the plant, the heating device and rapping mechanism will continue
Stop operation
End
vibrates, the hammer and discharging electrode are running and its contacting position will give
rise to electricity corrosion.
Broken electric wire means the collection electrode has burrs. The discharging electrode
vibrates and shortens the electrode distance, which leads to the local field strength increase.
The discharging wire is broken because of the disruptive discharge. Electric corrosion will
happen after ESP is operated for years.
(2) Thickness of the discharging electrode. Outside dust particle thickness of the discharging
wire concerns the property, concentration, vibration force and rapping mechanism of the dust
particle. In the field, positive electricity adheres to the discharging wire and a membrane is
formed. Because of inefficient rapping dust clearing and accumulated dust, the discharging wire
is thick. When collecting high specific resistance dust particle, the corona current will decrease,
corona discharge diminishes and disruptive discharge increases
Based on the above circumstance, we should adjust the rapping force; readjust the rapping time
and rapping period.
If the electrode’s thickness is caused by the flue gas below the dew temperature or frequent
switching on or off the machine, please improve the insulating measures and power supply.
Before the flue temperature falls down to the dew point, clear the dust of the continuous
electrode rapping. Continuous rapping is conducted within several hours of stopping the
machine.
2.8.4.2 Failure of the dust collecting electrode
Failure of the dust collecting electrode mainly includes:
(1) Dust is accumulated on the collecting electrode. Just like the thickness of the discharging
electrode, local dust accumulation of the collecting electrode will reduce the discharging
property and the collection efficiency will be lowered. Local dust accumulation relates to the
nature of smoke, dust concentration, as well as rapping conditions. The major cause is no
enough rapping force or uneven rapping force distribution. Sometimes, it’s because of the
loosing of the connection bolt on the collection plate or inefficient rapping force transmission.
And then we need to enter the field to ascertain the reason.
(2) Deformation of the electrode plate. Deformation of electrode plate makes the electrode
distance have some changes. The reason is that the flue gas temperature is high; the electrode
plate is deformed due to some limitation. Or accumulated high temperature dust cause thermal
storage and then deformation occurs; or the flue gas temperature overpasses regulated
temperature value; or the breakdown arc inside the electrode plate transforms the electrode
plate. If it is due to the redundant polar plate room or erection problem, when the electrode plate
is transformed because of the flue gas, its phenomenon is that the voltage can reach the rated
value, when smoke appears, voltage will drop with the rise of temperature. When we stop
providing flue gas, the voltage will rise little by little. This kind of failure will appear on the ESP
which is newly put into use. If the local deformation is caused by thermal storage and arc, we
need to ascertain the reason and change transformed electrode plates and solve the problem
from adjusting the electrode distance or improve the rapping system.
2.8.4.3 Failure of the rapping device
Use hammer for rapping for ESP, the transmission part is on the outside of ESP, the rapping
hammer is in the field, the failure of the rapping part can be judged according to the change of
the secondary voltage or the decrease of the dust removing efficiency. As for the discharging
electrode rapping, if there’s wrong with the insulation part, the whole field can’t work, this
situation will immediately be detected, but if an individual hammer fails or breaks down, we can’t
find it until it is inspected.
Major failures of the rapping and transmission devices include the following:
(1) Shaft locking. Main causes are: (1) the supporting shaft of the rapping shaft has a serious
abrasion. (2) Rapping shaft bearing is not on the same line and it overpasses the compensation
ability of coupling and affects the concentricity of the rapping shaft.
(2) During the operation, the hammer and rapping anvil is not aligned. Besides the erection
problem, most are caused by the heat inflation of the rapping shaft and ensuing rapping
hammer dislocation
(3) The rapping and transmission porcelain shaft of the discharging electrode is broken. Firstly,
it’s the quality problem of porcelain shaft, before erection, inspect it. If the porcelain shaft has no
test certificate, or has cracks on the surface, it shouldn’t be used. During the trial operation,
timely re-inspect. Secondly, torsion of the rapping shaft is too much, furthermore, there are
other factors concerning excessive leakage current or breaking of the uneven heating of
porcelain shaft caused by the dust accumulation and dewing.
2.9 Soot –blower
The soot-blowing system is equipped with 42 IR-3D furnace soot-blowers of 267mm soot lance
blowing distance, 48 IK-545 long extension soot blowers (left and right each 24,including HT SH,
HT RH, LT SH, LT RH) with 10450 mm soot lance blowing distance,10 IK-525EL of soot lance
blowing distance 5300mm and 10300mm depth, left and right (fuel economizer)each 5, 2 IK-AH
with 1200 mm soot lance blowing distance, one for each air preheater. The radius of all soot
lances is 2200mm, with 360 angles.
The soot-blowing system includes soot-blower, a decompression station, soot-blowing pipe and
their fixtures and guides and so on. The steam source of the soot-blowers is from the right and
left sides of the connecting pipe from the platen SH to the HT SH, The steam pressure is
17.8Mpa and the temperature is 470℃ under the working condition of BMC. After the reduction
of temperature and pressure, the steam pressure falls to 2.5Mpa,the temperature falls to 350℃ .
2.9.1 Soot –blowing system parameters
2.9.1.1 Furnace soot blower parameters
Value
Item Unit
Design coal Check coal
air heater intake in MCR work
kg/h 1024438 975925
condition
inlet calculation of the wind
℃ 0 0
temperature
outlet wind temperature ℃ 40 40
heating steam inlet pressure MPa 1.1 1.1
heating steam inlet temperature ℃ 320 320
design pressure MPa 1.30 1.30
design temperature ℃ 380 380
steam consumption t/h 21.2 20.2
heat exchanging area m2 791 791
design abundance ≥1.25 ≥1.25
4405×4005(inner diameter) (air duct
air heater interface size mm
4400×4000×5 insert to air heater and weld)
height of air heater mm 446
general resistance Pa ≤250
steam interface (amount/ diameter) 6/73
drainage interface (amount/
3/45
diameter)
heat transfer pipe(external diameter
25 mm x2.5 mm x4505 mm x120
×thickness× length ×amount)
weight Kg 3500
mode of Steam and drainage
welding
interfacing
GV GV
3-1 4-1
3 4
GV GV
1-2 喷嘴组 2-3
1 2
TV TV
1 2
Cooling type of unit is condenser surface cooling. Feed-water system comprises one 50%B-MC
duty motor driven and two 50%B-MC duty BFP. Under normal work condition, two TBFP run
and motor pump is standby. Each unit has 60%B—MCR high-low pressure tandem connection
bypass system, so as to quicken startup speed and protect re-heater during malfunction.
Auxiliary steam system supply common steam to the whole plant. Pressure of auxiliary steam
headers is 0.8~1.6MPa, and temperature 362℃. There is connection manifold connecting to
auxiliary steam system of another boiler. The source of auxiliary steam system is from main
steam or auxiliary steam system of adjacent boiler when unit startup or in low load, and be
came from cold reheat under normal operation. Auxiliary steam system supply steam for soot
blow of APH start-up, deaerator start-up, start-up and debugging of TBFP turbine, turbine gland,
heating and trace heating of oil tank, fire protection blowing of pulverized coal system.
3.1.2 Main specification of turbine
3.1.2.1 Main Parameters
No Description Unit Data
1 model N600-16.7/538/538
Type:subcritical, once intermediate reheat, single shaft, three cylinders, four exhaust
2
hoods, condensing
3 Rated power MW 600
Rated pressure/temperature of steam before
4 MPa/℃ 16.67/538
main steam stop valve
5 Rated pressure/temperature of Reheat steam MPa/℃ 3.432/538
6 Main/reheated steam flow with rated power t/h 1883.418/1605.329
7 Designed back pressure KPa 4.4/5.4
unit feed-water control manual or abnormal state. Under this mode, main control of turbine and
boiler are manually by operator.
3.1.3.1.2 Boiler following turbine (BF)
a. Boiler main control regulates main steam pressure automatically; while turbine main control
adjusts unit power.
b. When turbine main control is in manual, unit power shall be adjusted by operator manually or
by DEH automatically, that is BF1 mode.
c. When turbine main control is in auto, boiler main control received feedback signal of target
load synchronously. Unit power is adjusted by turbine, target load is set by operator manually.
That is boiler follow turbine mode BF2.
3.1.3.1.3 Turbine following boiler (TF)
a. Turbine main control adjusts main steam pressure automatically; boiler main control adjusts
unit power.
b. when boiler main control is in manual, unit power depends on output load of boiler only. That
is TF1 mode.
c. when boiler main control is auto, both turbine and boiler main control received feedback
signal of target load. Unit power is adjusted by boiler main control.
3.1.3.1.4 Coordinated control system (CCS)
a. This mode is actually compound of BF and TF modes. Turbine and boiler main control must
set to auto.
b. Co-coordinated control based on BF: boiler main control adjusts main steam pressure,
setting value of main steam pressure is set by unit sliding pressure curve; turbine main control
adjust not only unit power but also main steam pressure, but its power adjustment coefficient is
bigger than pressure adjustment coefficient; that is to say power adjustment is main, pressure
adjustment is auxiliary. Target load is set by operator manually, boiler and turbine main control
receive feedback signal of target load at the same time; and participate in primary frequency
modulation of grid.
c. Coordinated control based on TF: boiler main control adjust unit power, target load is set by
operator manually; turbine main control adjust main steam pressure as well as unit power, but
its pressure adjustment coefficient is bigger than power adjustment coefficient, that is to say
pressure adjustment is main, power adjustment is auxiliary. Boiler and turbine main control
receive feedback signal of target load at the same time; and participate in primary frequency
modulation of grid.
d. While unit normal running, it is better to adopt coordinated control mode.
3.1.3.2 Digital electro-hydraulic control system (DEH)
(1) Main functions of DEH:control the opening of HP, IP main steam stop valves and
regulating valve, so that the unit can increase and reduce speed and load to realize all
requirements of unit operation. DEH device receive the signal of speed, power and primary
steam pressure, closed loop control speed, power and steam flow of unit. Besides, DEH has
other functions such as valve management, rotor stress calculation, parameter monitoring,
over-speed protection, auto startup and stop control, etc.
(2) Operation control mode
a. Operator automatic(OPER AUTO) mode: setting and its change rate are set by operator on
DEH operation board.
b. Automatic Turbine Control (ATC): ATC can complete turbine acceleration, warming, valve
switchover, synchronization and take initial load automatically, then turn to OPER AUTO. During
unit load changing, ATC can be put into running, and the change rate of its setting will be
decided by control software. During normal running, ATC monitors all parameters, show
information and stress calculation of unit automatically.
c. REMOTE: setting is given by external systems such as CCS. Other operation will be
completed by DEH.
d. Automatic synchronization (AUTO SYNC): adjust settings by receiving rise and decline
signal from synchronizer, so as to make turbine generator unit reach synchronized rotate speed,
for the convenience of unit synchronization.
e. Turbine Manual (TM): control turbine by manual operating the opening buttons of all main
steam stop valves and regulating valves. There are primary manual and secondary manual (it is
forbidden while unit speed-up).
3.1.3.3 (TSI)Turbine Supervisory Instrumentation
The device supervises the axial displacement, differential expansion, absolute expansion, shaft
vibration, speed, eccentricity, etc. of turbine rotor; and compares and judges measuring values;
give warning signal and trip signal while exceed limit.
3.1.3.4 (ETS) Emergency Trip System
When the steam turbine operating parameters exceed the safety limits (such as: vacuum low
lube oil pressure low, EH oil pressure low, rotor axial displacement exceed, over-speed and
other trip parameters), ETS will release the pressure oil of hydraulic servomotor to quickly turn
off the HIP main steam stop valve and regulating valve so as to ensure the unit safety operation.
The system uses a dual-channel design, allowing online tests of important signal, it still have
protection function when online tests, and the reliability of the system is improved with no
malfunction and rejection.
3.2 Interlock and test of steam turbine
3.2.1 Contents of interlock
i. After test, report to shift supervisor, and analyze and record the test result of vacuum tightness
test.
3.2.3.3 Valve action test of HP, IP main steam stop and regulating valve
3.2.3.3.1 Conditions of valve action test
a. Get the permission of shift supervisor, contact I&C personnel to site.
b. Load up to 60% and keep stable, boiler combustion is stable, and unit running is normal.
c. Make sure DEH mode is at “OA” and “single valve”, control mode is “bypass cutting”, “power
loop” is put on.
d. Check the position of HP, IP main steam stop valve and governing valve.
3.2.3.3.2 Test method and precautions
(1) HP main steam stop valve action test
a. Click “TV1” window, open sub-page of main steam valve test (TV1 VALVE TEST), then click
“start test”, TV1 will close slowly.
b. When TV1 valve opening is above 60%, press “stop test” button to maintain main steam stop
valve or “cancel test” button to reopen valve.
c. When TV1 valve opening less than 60%, display “CONTINUOUS TV TEST” (continue test).
d. If operator decides to continue test, press “CONTINUOUS TV TEST” button, GV1, GV3 will
close slowly, and GV2, GV4 rise slowly. GV1 and GV2 turn to 0 opening and then 2 seconds
delay; TV1 will close rapidly and then fully open at once. Click “CANCEL TEST” button, GV1,
GV3 and GV2, GV4 return to original opening slowly.
e. Test method of TV2 is the same as that of TV1.
(2) HP regulating valve action test
a. Click GV1 to open sub-page
b. Click “START TEST” button, GV1 will close slowly until completely turn off.
c. Click “STOP TEST” button can stop test, and press “CONTINUOUS TEST” button can
continue.
d. Click “CANCEL TEST” button, GV1 valve open.
e. Test GV2, GV3, and GV4 by the same method.
(3) IP stop valve, IP regulating valve action test
a. Open “VALVE TEST” control sub-page from DEH control menu.
b. Press “RV1” button on valve control window.
c. Click “START TEST” button, IV1 and IV3 will close slowly, then RV1 close.
d. After 2 seconds delay, RV1 open automatically.
e. Click “CANCEL TEST” button, IV1 and IV3 open slowly.
f. Test RV2 and IV2, IV4 by the same method.
Remark:after all tests above completed, put on DEH remote control, coordination and AGC.
3.2.3.4 Steam turbine ETS channel test
3.2.3.4.1 EH oil pressure low (lube oil pressure low, vacuum low, axial displacement, vibration)
ETS system channel test
a. I&C personnel shall attend when ETS channel test start.
b. Check all alarm light on ETS test panel shall be off.
c. Press “START TEST” function button on ETS panel to start test mode, display light of this
button on panel shall be turned on.
d. Press function buttons which need to be tested (such as EH oil pressure low, lube oil
pressure low, vacuum low, axial displacement, vibration, etc.), corresponding display light on
panel shall be turned on.
e. Press “channel 1” or “channel 2”button corresponds to the testing channel, that
corresponding display light on panel shall be turned on.
f. Press “test confirmation” button to start test.
g. Make sure lighting corresponding channel is in action (namely alarm light of corresponding
channel is on).
h. Press “reset test” button to reset corresponding action channel.
i. Make sure testing channel is not in shutoff state any more (namely alarm light of
corresponding channel is off), press “quit test” function button to quit test mode.
j. Test completed, start another channel test as above method.
3.2.3.4.2 Electric over-speed function ETS system channel test
a. I&C personnel shall attend when ETS channel test start.
b. Check all alarm light on ETS test panel shall be off.
c. Press “START TEST” function button on ETS panel to start test mode, display light of this
button on panel shall be on.
d. Press “over-speed 1”over-speed channel, “over-speed 1”channel display light on panel shall
be on.
e. Press “test confirmation” button to start test.
f. Make sure” electric over-speed CH1” channel alarm light shall be light.
g. Press “reset test” button to reset corresponding action channel.
h. Make sure “electric over-speed CH1”channel alarm light is off, press “quit test” function
button to quit test mode.
i. “over-speed 2” “over-speed 3”channel tests are the same as above.
3.2.3.5 Lube oil pressure low shutdown protection test (this test shall be done before turbine
reset start and rolling up)
a. Start turbine A.C. lube-oil pump and HP seal oil stand-by pump.
b. Start EH oil pump.
c. Contact I & C personnel to relieve vacuum low, MFT, etc. protection signal.
d. Make sure no sound & light alarm on ETS panel.
pressure CH4” and “LP (EH oil pressure)”alarm light on ETS panel shall be off.
n. Reset ETS panel.
o. Test completed, back to original operation mode.
3.2.3.7 OPC test
3.2.3.7.1 OPC solenoid valve test (this test shall be done before turbine reset start and rolling
up)
a. Before unit start-up, contact I&C personnel relieve the protection of ETS, boiler MFT, etc.
Reset ETS panel, no alarm light is on.
b. Contact I &C personnel to put DEH system into running.
c. Start turbine A.C. lube-oil pump and HP seal oil stand-by pump into normal running.
d. Start EH oil pump A (or B) into normal running
e. Start compressed air system into normal running
f. Open the non-return Valves of all extractions and HP cylinder exhaust check valve.
g. Check if DEH system is at OA” mode.
h. Turbine latching check and open GV, IV, RV, TV.
i. Set “OPC protection test switch” at “ON” position, OPC solenoid valve action.
j. Check GV1-4, IV1-4 should be closed rapidly, without jamming.
k. At the same time, all extraction non-return valves and HP cylinder exhaust check valve shall
be interlock closed, without jamming.
l. Set “OPC protect test switch” to “Cut” position.
m. Check if GV, IV and extraction non-return valves are open.
n. Recover the released protection during test, check and put in “OPC protection” switch.
3.2.3.7.2 OPC dynamic test (103% over-speed protection function test)
a. unit synchronized to grid with load 60MW, then trip generator when warming for 4 hours.
b. DEH system is at “OA” mode.
c. drop load to 15MW as normal load reduction shutdown steps.
d. Set “OPC protection” switch at “ON” position. Contact electrical operator to disconnect
generator.
e. Set target speed as 3100r/min at DEH speedup control window.
f. Set speed acceleration as 50r/min, press “START” button, light on.
g. When speed rise to 3090r/min, OPC protection shall work, GV1-4, IV1-4 close.
h. Make sure unit speed is declining, record speed while OPC protection act.
i. Check DEH controller and set target speed as 3000r/min.
k. Supervising that when actual speed down to target speed, GV, IV shall open automatically.
l. Maintain unit speed at 3000r/min.
3.2.3.8 Turbine over-speed test
3.2.3.8.1 Test rule and precautions
a. over-speed test must be done under following conditions, e.g. turbine initial startup, after
overhaul or continuous running for 12~24 months or after maintenance of governing system, so
as to ensure correct action of emergency governor
b. Test shall be done after completion of all the following tests and ensure actions are correct.,
that are, tightness test of HIP stop valve and regulating valve, manual “Emergency Shutdown
Button ”test in control room, local manual tripped test and oil filling test,
c. During test, it is necessary to supervise unit speed, vibration, lube oil pressure, lube oil
temperature, beating pad temperature, axial displacement, LP cylinder exhaust temperature ,
etc. parameters.
d. During test, when turbine speed rise to 3360r/min but protection does not act, it is necessary
to trip manually at once, then check that whether turbine steam has been cut and speed has
slowed down.
e. Mechanical over-speed and electrical over-speed test shall be done twice respectively; speed
difference between two tests shall not be more than 18r/min (0.6%).
f. After over-speed trip, turbine speed less than 2900r/min. Latch and startup again, acceleration
rate can be selected at 250~300r/min.
g. During over-speed test, back pressure of turbine shall be less than 12KPa.
h. Before over-speed test, it is necessary to on load 60MW and warming for 4 hours, and then
disconnection.
3.2.3.8.2 Electrical over-speed test
a. Check that DEH system is at “OA” mode.
b. Start turbine A.C. lube-oil pump and HP seal oil stand-by pump into normal running.
c. Drop load to 15MW as normal load reduction shutdown steps.
d. Contact electrical operator to disconnect generator.
e. Check that “electrical over-speed cut” light on ETS panel shall be off.
f. Set OPC over-speed protection switch on “CUT” position.
g. Press “target value” button, light on, set target speed as 3300r/min.
h. Set speedup rate as 300r/min, press “START” button, light on.
i. When speed up to 3300r/min, electrical over-speed protection shall act, TV, RV, GV, IV shall
close rapidly.
j. Make sure unit speed is declining, record the speed of electrical over-speed protection action.
k. When unit speed declines to less than 3000r/min, latch again, maintain unit speed as
3000r/min.
l. Set OPC over-speed protection switch at “IN” position, end test.
3.2.3.8.3 Mechanical over-speed test
a. Carry out preparation work as electric over-speed test steps a-d.
b. Unit speed 3000r/min, main steam parameter:8~10MPa.
c. Check ETS panel, “Electric over-speed cut” light shall be on (When mechanical over-speed
action g speed > electric over-speed action rotating speed).
d. Set “OPC protective switch” of DEH panel at “CUT” position.
e. Set target speed as 3330r/min, set speedup rate as 300r/min, press “Start” button, light is on.
f. Mechanical over-speed protection acts when speed reaches 3330 r/min, TV, GV, IV, RV shall
close rapidly.
g. Record the action speed of emergency governor.
h. If mechanical over-speed protection does not act when rotating speed reaches 3360r/min, it
is necessary to trip and shutdown manually. Do not startup until reasons have been found out.
i. Set OPC protection switch of DEH panel, over-speed protection switch of ETS panel at “IN”
position.
j. Unit comes back to 3000r/min, synchronization after checking. On load as normal startup
procedures.
3.2.3.9 Stop valve, regulating valve tightness test
3.2.3.9.1 Tightness test of stop valve, regulating valve shall be done in the following conditions:
a. Before and after unit overhaul.
b. Before over-speed test
c. Before load dump test
d. Do stop valve, regulating valve tightness test annually during operation.
3.2.3.9.2 HP,IP stop valve tightness test
a. Ensure the starting parameters of unit and all systems meet the requirements of unit rolling
up.
b. Adopt DEH “OA” mode, speed up turbine speed to 3000r/min by HP and IP cylinders
combined rolling up starting mode.
c. Check that operation of all equipments and oil system running is normal.
d. Control main steam pressure and reheating steam pressure is above 1/2 rated pressure by
bypass system.
e. Set DEH control panel to “Manual”.
f. Close HP and IP stop valves at engineer station, fully open regulating valve. Check that
bypass trace governing is normal.
g. Record the stable speed after speed decline.
h. If speed declines to less than 1/3 of rated speed (1000r/min), that means tightness test of
stop valve is accepted.
3.2.3.9.3 Tightness test of HP and IP regulating valves
a. After completion of HP stop valve tightness test, speed up to 3000r/min again at DEH “AUTO”
mode.
b. Check that operation of all equipments is normal, oil system running is normal
c. control main steam pressure and reheating steam pressure above 1/2 of rated pressure by
bypass system.
d. Set DEH control panel as “Manual”.
e. Close HP and IP regulating valves at engineer station, fully open stop valve. Check that
bypass trace governing is normal.
f. Record the stable speed value after speed decline. if speed declines to less than 1/3 of rated
speed (1000r/min), that means tightness test of regulating valve is accepted.
g. Speed can be calculated by following formula: test pressure × rated speed/ rated pressure =
stable speed under test pressure
3.3 startup of turbine
3.3.1 Preparation before turbine startup
3.3.1.1 When the unit start instructions are sent, all the operators must be ready for all the
preparation before start.
3.3.1.2 Ensure that all the maintenance work has completed and the work ticket have been
taken back.
3.3.1.3 Ensure that all interlocks tests of unit are accepted.
3.3.1.4 Check that control power supply, motor power supply, signal power supply of all auxiliary
systems is o.k.
3.3.2 Basic rules for turbine start
3.3.2.1 Definition of turbine start modes
Cold start means the metal temperature of HP inner casing governing stage and blade carrier of
IP casing first stage is below 204 Celsius degree, while hot start represents the temperature
above 240 Celsius degree.
3.3.2.2 No starting conditions
a. any unit trip protection is abnormal.
b. DEH is abnormal which affect unit startup, shutdown, normal operation and the control can
only in manual mode..
c. DEH device cannot maintain idling of turbine, or rotating speed increasing rapidly to exceed
actuation speed of emergency safety governor after load dumping.
d. Oil filling test or over-speed test of safety governor is not accepted.
e. TSI turbine supervisory instrument is abnormal.
f. Turbine protection of water induction system is abnormal.
g. Action of safety governor is abnormal; and action of main stop valve, governing valve, HP
exhaust check valve, extraction check valve is abnormal.
h. Expansion of unit is abnormal.
i. Eccentricity of rotor is abnormal; rotor eccentricity is over 0.076mm (duplex deviation) before
rotor running.
j. Oil quality is rejected or oil temperature is lower than set value. AC lubricant pump cannot be
started when it is lower than 10℃ ; turning gear cannot be used when it is lower than 20℃.
When EH oil temperature is lower than 10℃, it cannot be put into system; when it is lower than
21℃, long term running is not suitable.
k. Oil level in turbine Lube and EH oil tank are lower than stated value.
l. Any one of EH oil pump, AC lubricant pump, DC lubricant pump, turning gear is broken or any
self-starter of them is broken.
m. CCS coordinated control system is abnormal, which effect the operation of unit and it cannot
be restored in a short time.
n. Main instruments (rotating speed, vacuum, pressure and temperature of main/reheat steam,
EH oil pressure, lubricant oil pressure, sealing oil pressure, axial displacement, rotor eccentricity,
vibration, cylinder expansion and differential expansion of cylinder, etc.) are missing or failure
with no other supervisory methods.
o. Compressed air system is abnormal
p. Bypass regulating system is abnormal.
q. Temperature difference of HIP upper and lower casing is more than 42℃ .
r. Rotating part of T/G unit has obvious frictional noise or turning gear current sway large
amplitude with value over normal obviously, and the reason is not motor after checking.
s. HIP differential expansion exceeds.
t. Steam/water quality is rejected.
3.3.2.4 Selection of turbine starting control mode
a. Generally, DEH “OA” mode is adopted for unit cold start; while DEH “OA” mode or “ATC”
mode is adopted for hot start.
b. After unit synchronization with 26% rated load, put DEH “remote control” to operation after its
conditions are met.
c. CCS adopts “TF” mode. When load increase to 28% rated load, “CCS” mode was selected.
3.3.2.5 Starting bypass rules
Starting without bypass mode is HP cylinder starting mode. Rotating speed and load are
controlled by main stop valve (before valve switchover) or HP governing valve (after valve
switchover and on load stage); IP governing valve shall be fully open after latching, and only be
actuated when protection.
Starting with bypass mode is HP and IP cylinder combined starting mode. In this mode, IP
governing valve play a role as controlling rotating speed and load, and it shall be fully open at
about 35%~40% rated load. After unit latching, reheat main stop valve shall be fully open,
operator open IP governing valve fully and totally close main stop valve by valve position limiter.
rotating speed can be controlled to 600 r/min by IP governing valve and maintain for some time;
then switched to main stop valve/IP governing valve control; at last to turn to valve change while
main stop valve/HP governing valve transition. After unit synchronization and the load reaches
35%~40% rated load, IP governing valve shall be fully open, and bypass operation mode can
be cut when IP governing valve is full open.
3.3.3 Cold start
3.3.3.1 Before auxiliary equipment and system being put into operation, relevant preparation,
inspection and operation before starting shall be done.
3.3.3.2Before boiler ignition, confirm startup and operation state of turbine auxiliary equipments
and systems as per the following procedures:
a. Water level of 500m3 water tank is normal, put one condensate transfer pump in operation
and other two pumps as standby.
b. Put closed cooling water system into operation, and water filling and vent of all coolers are
over, and valves state is normal.
c. Ensure that industrial water, potable water for circulation pump cooling water system
operation is normal, put circulating water system into operation.
d. Put open cooling water system into operation, put auto control of open cooling water electric
water purifier into operation.
e. Put closed cooling water pump into operation.
f. Put instrumental compressed air system into operation, check the air pressure.
g. Put main oil system into operation, and start AC lubricant oil pump and HP seal oil standby
pump into operation.
h. Put generator sealing oil system into operation, start either one AC sealing oil pump at air
hydrogen side into operation.
i. Start jacking oil pump, and put turbine turning gear into operation, it is required that
continuous gear turning shall be above 4 hours before turbine running to speed,.
j. Gas substitution inside generator shall be completed, put stator water system into operation
while hydrogen purity above 96% and pressure reaches 0.2MPa.
k. Put auxiliary steam system into operation.
l. Check if the water level in condenser is normal; put condensate water system into operation.
m. When condensate water quality is accepted, fill it into deaerator until the water level is up to
normal.
n. Heat feed-water in tank to 110℃; start electric feed-water pump, fill water from HP heater
water side.
o. Put two BFP oil systems into operation. Continuous turning of BFP turbine shall be more than
3 hours before boiler firing. Steam, drain and shaft seal system of two BFP turbines shall be
available before put into operation.
p. EH oil system is normal and put into operation.
q. Shaft seal system is at standby state, put water side of gland steam condenser into operation.
g. LP heater shall be started in random, open LP heater extraction motor-operated valve, drain
water flow from higher stage to lower one.
h. HP heater shall be started following the unit, open HP heater extraction motor-operated valve,
drain water flow from higher stage to lower one.
3.3.3.5.2 HIP cylinder combined start (turbine startup with bypass)
a. Check that if bypass system auto control is normal.
b. Select “OA” mode on DEH control panel.
c. Turbine latch, ensure GV, RV are fully open and TV, IV are full closed. Pay attention to
turbine rotor speed ascending; check that HP exhaust check valve is closed and HP cylinder
exhaust valve is open.
d. Trip manually then latch again. Set target rotating speed as 600r/min and speedup rate as
100r/min, turbine speedup is controlled by IV, when rotating speed of turbine is faster than that
of turning gear, turning gear shall quit automatically, otherwise trip and shut down. Check the
reasons, and restart until the problems being eliminated.
e. Turning gear quit, unit trip when rotating speed reaches 500r/min, listen friction sound inside.
f. Make sure no abnormal sound inside cylinder and shaft seal, when the speed reducing to
200r/min and unit latch again, set target speed to 2800r/min and rate 100r/min.
h. Speed up to 600r/min, maintain turbine rotating speed at 600r/min for 15~30mins, DEH
record stable flow of IP cylinder as F1, switchover control mode from IV to TV-IV mode, open
TV and IV as the ratio 1: (1+F1) to control rotating speed together, jacking oil pump shall stop
automatically, exhaust valve of HP cylinder inlet pipe shall be closed, put spray governing valve
auto control into operation, LP cylinder water spray valve shall open.
i. When turbine rotating speeds up to 2600r/min, keep 3 mins. DEH record the opening of IV
valve at this time, and then IV opening is frozen, only can be modified as per hot reheat steam
pressure (when reheat steam pressure changes, IV moves so as to maintain constant flow rate
of IP cylinder, ensure cooling of LP cylinder blades and through flow). Control mode is switched
over from TV-IV to TV automatically.
j. Rotating speed reaches 2900r/min, when wall temperature of inlet chamber is higher than the
saturated temperature at main steam pressure, click “valve control mode”, then click “valve
switchover”.
k. Observe valve switchover process by DEH control screen, TV/GV switchover time ≯2 mins,
after completion, check on the spot that TV is full open and GV is in regulating behavior, rotating
speed shall maintain 2900r/min.
l. Set target rotating speed as 3000r/min, speedup rate as 50r/min on DEH control menu, speed
up to 3000r/min.
m. After turbine speed up to 3000r/min, check all bearing temperature, return oil temperature,
vacuum, vibration, differential expansion, axial displacement, etc. shall be normal, boiler shall
displacement and all bearing metal temperature are normal, lube oil pressure, all bearing return
oil temperature, EH oil pressure are normal; temperature difference of cylinder upper and lower
wall is within allowable range.
3.3.3.6.8 Applying HP, IP combined start check if regulating of HP and LP bypass is normal with
the load change.
3.3.3.6.9 Check that operation of stator cooling water system and hydrogen cooling system is
normal, put hydrogen drier into operation.
3.3.3.6.10 Check and prepare one BFP turbine, and make it in ready state.
3.3.3.7 Main operations during load rise
3.3.3.7.1 Increase load at 4~6MW/min load rise rate.
3.3.3.7.2 When unit load is larger than 60MW, check all drain valves before IP main stop valve
shall be closed automatically; while load is larger than 90MW, check LP cylinder water spray
valve shall be auto closed.
3.3.3.7.3As unit load is larger than 90MW; make sure BFP steam source has more than 20℃
degree of superheat.
3.3.3.7.4 As unit load is 120MW, make sure HP drain valve is closed.
3.3.3.7.5 When load is 170MW, make sure bypass is closed, put DEH to remote control when
the preconditions are met.
3.3.3.7.6 When load is 180MW, put BFP and reduce the output of electric pump. Cut “power
loop and pressure loop”, put “TF” co-coordinated control mode. Switch over to station service
power.
3.3.3.7.7 While four section extraction pressure ≥0.2Mpa, heating source of deaerator shall be
supplied by four section extraction steam.
3.3.3.7.8Auxiliary steam header to be supplied by cold reheats steam; close the steam from
startup boiler. Pay attention to the steam source of turbine and feed-water pump turbine
vacuum and shaft seal.
3.3.3.7.9 Check and prepare second turbine driven feed-water pump, and make it in standby
state.
3.3.3.7.10 While load is 210MW, as per unit cold start pressure curve, maintain turbine
governing valve opening at about 90%, and unit to be shift to sliding pressure operation.
3.3.3.7.11 when unit load is 300MW, add second T-BFP, and steam source shall be changed to
fourth extraction steam. Stop motor driven BFP.
3.3.3.7.12 when the fourth extraction steam pressure is higher than 0.8MPa, steam supply of
auxiliary header shall be changed to fourth extraction steam, and cold reheat steam shall be put
into standby.
3.3.3.7.13 When load reaches 450MW, check self-sealing of shaft seal system, shaft seal
header pressure shall be controlled in 22~32KPa by overflow valve.
Moment shall
Main Steam Pressure MPa 24.2 25.4 less than
31.4MPa.
Reheat Steam
MPa 3.73 4.1
Pressure
Governing Stage
MPa 10.13 11.25
Pressure
Main Steam Temp. ℃ 538 545 530 565
Reheat Steam Temp. ℃ 538 545 530 565
Temp. difference of 42℃ less than
℃ 14 28
main & reheat steam 15min
Temp. difference
between inner & outer ℃ 83
wall of steam chest
Temp. difference
between upper &
℃ 42 56
lower HIP outer
cylinder
HP cylinder exhaust
℃ <404 427
temp.
HP differential +10.2/-4.
mm +8~-2 +9.5/-4
expansion 8
LP differential +22.5/-1. +23.3/-2.
mm 0~20
expansion 4 2
Bearing vibration mm <0.076 0.127 0.254
Axial displacement mm ±0.6 ±0.89 ±1.0
121℃
LP cylinder exhaust
℃ <65 79℃ operation <
temp.
15min
Condenser pressure KPa 4.9 16.9 20.3
Lube oil pressure MPa 0.096~0.124 0.082 0.048
Lube oil temp. ℃ 40~45 49 35
Bearing temp. ℃ 90 107 113
Thrust bearing temp. ℃ 80 99 107
Return oil temp. ℃ 65 77 82
EH oil pressure MPa 14±0.5 11.03 9.31
EH oil temp. ℃ 37~60 60 37
438.15/29
EH oil level mm 438.15-558.5 558.5 193.54
5.15
governing stage and
HP cylinder exhaust MPa <1.7
pressure ratio
Gland steam pressure KPa 22~30 32 20
Gland steam temp. ℃ 149 177 121
Unit rotating speed r/min 3000 3300
3.5 Shutdown of turbine
3.5.1 Preparation before shutdown
3.5.1.1 Preparation before load reduction
1. Make sure steam supply of auxiliary steam header has been switched to startup boiler (or
adjacent unit).
2. Commissioning of unit AC, DC lube oil pump, jacking oil pump, turning gear, HP standby
sealing oil pump, etc. are normal.
3. Warming of shaft seal pipeline.
3.5.1.2 Precautious during load reducing
1. Reduce temperature and release pressure as per sliding shutdown curve by boiler.
2. Superheat degree of main steam shall be controlled as higher than 80℃, but not lower than
56℃. Pay close attention to the temperature reducing speed of steam and cylinder wall. When
boiler outlet steam temperature reduction reaches 50℃ and temperature drop rate higher than
10℃/min, shut down unit.
3. Control temperature drop speed of main, reheat steam ≤1℃/min, temperature drop rate of
metal shall be 0.5~1℃ /min.
4. During load reduction, pay close attention to turbine differential expansion, axial displacement,
temperature difference between upper and lower cylinder, all bearing vibration and bearing
bush temperature which shall be within stated range; otherwise shut down unit.
5. Maintain water level of condenser, deaerator and HP & LP heaters, and condenser vacuum
and exhaust temperature is normal.
6. Adjust gland steam pressure to normal in time.
7. Maintain generator seal oil pressure, hydrogen pressure, stator cooling water temperature,
and so on to normal
3.5.1.3 Reduce load to 300MW or so, auxiliary steam and fourth extraction steam to be sourced
by cold reheat. And gland steam can be supplied by auxiliary steam as per requirement.
3.5.1.4 Reduce load to 270MW, start motor driven BFP, stop one TBFP.
3.5.1.5 Reduce load to 180MW, stop another one T-BFP..
3.5.1.6 When load is reduced to 180MW or so, stop HP heater.
3.5.1.7 Reduce load to 120MW, put HP and LP bypass systems into operation.
3.5.1.8 Reduce load to 120MW, check the drain valves which pressure below fourth extraction
steam can be open normally, and switchover of deaerator steam supply is normal.
3.5.1.9 When load reduce to 90MW or exhaust temperature higher than 80℃, check LP cylinder
water spray valve shall be open automatically.
3.5.1.10 when unit load reduce to 60MW, check the drain valves which pressure above fourth
extraction steam can be open normally.
3.5.1.11 When main steam pressure reduce to 4MPa, drop unit load to zero, report to shift
supervisor, ready to shutdown.
3.5.2 Works after splitting
3.5.2.1 Start turbine AC lube oil pump, trip when operation is normal.
3.5.2.2 Check that HP, IP auto main stop valves, governing valves and HP exhaust check
valves, all extraction check valves are closed tightly. HP cylinder exhaust valve shall be open.
3.5.2.3 Water level of deaerator shall be normal; condensate water re-circulating valve shall be
auto open.
3.5.2.4 Pay attention to unit idle condition; listen to the sound from all part of unit. Check unit
vibration, differential expansion, axial displacement, bearing metal temperature, etc. shall be
normal.
3.5.2.5 Turbine EH oil system can be stopped when necessary
3.5.2.6 Rotating speed drop to 2600rpm, check LP cylinder spray water shall be stopped, LP
cylinder exhaust temperature shall be normal.
3.5.2.7 Rotating speed drop to 600rpm, check and start jacking oil pump, jacking oil pressure
shall be within 10~12MPa.
3.5.2.8 Rotating speed drop to 400rpm, break vacuum. Make sure HP and LP bypass valves
are closed.
3.5.2.9 Rotating speed drop to 200rpm, stop hydrogen cooler and generator cooling water.
3.5.3 Works after rotor being still
3.5.3.1 When turbine rotating speed becomes zero, turning gear shall be put automatically,
otherwise put into manually.
3.5.3.2 Record turbine idle time; Record cylinder temperature, turning gear current, shaft
eccentricity, etc. parameters during turning period.
3.5.3.3 Close all oil cooler and cooling water valves in time, stop open water pump as per
request. Main oil cooler temperature shall be adjusted to 30±2℃.
3.5.3.4 Stop gland steam supply when condenser vacuum drop to zero. Close all steam supply
of shaft seal, stop fan of gland steam condenser.
3.5.3.5 After filling water in boiler, stop feed-water pump; exhaust temperature <50℃, other
user of condensate water system have stopped, make sure no steam & water enter condenser;
stop condensate water pump.
3.5.3.6 Pay attention to monitor water level of heater, condenser, maintain low water level.
3.5.3.7 Make sure closed cooling water has no user, then stop closed cooling water pump. Stop
open cooling water pump as per closed cooling water temperature.
3.5.3.8 When exhaust temperature <50℃, make sure no hot water & steam enter condenser.
Stop the running of circulating pump.
3.5.3.9 Stop other auxiliary equipments as per actual situation.
3.5.3.10 when metal temperature of HP cylinder governing stage is lower than 150℃, and metal
temperature differences between upper and lower casing of HP & IP cylinders are lower than
42℃, stop running the turning gear, but jacking oil pump shall keep running to ambient
temperature.
3.5.3.11Stop seal oil system.
3.5.3.12 when metal temperature of HP cylinder governing stage is lower than 100℃ , AC lube
normal.
3.6.4.4 Stop vacuum pump, open vacuum breaker valve, close all drain water valves leading to
condenser.
3.6.4.5 When vacuum become 0, stop gland steam supply.
3.6.4.6 Rotating speed drop to 0, check that turning gear auto running shall be normal. Start
turning gear manually if it is failed in auto running. Record the following data that is rotor idle
time, eccentricity, motor current of turning gear, cylinder temperature, etc.
3.6.4.7 During shut down process, attention shall be paid to unit vibration, lube oil pressure,
lube oil temperature, pressure difference between sealing oil & hydrogen.
3.6.4.8 Operators shall come to site and listen to unit inner sound very carefully, if there is clear
metal knock or rotor idle time is shortened obviously, start unit again at once is strictly forbidden.
3.6.4.9 Other operations are same as normal shutdown.
3.6.5 Turbine trip conditions
a. Over-speed: electric over-speed 3300rpm; mechanical over-speed: 3330rpm.
b. Turbine lubes oil pressure ≤0.06MPa.
c. Main turbine vacuum ≤-68.7KPa.
d. HP cylinder exhaust temp. >427℃
e. Pressure ratio of HP cylinder <1.7.
f. X & Y direction vibration of bearing is greater than 254um
g. Water pressure difference between inlet & outlet of generator stator winding ≤0.1MPa.
h. Conductivity of generator stator outlet water >9.5us/cm; outlet water temperature 85℃.
i. Pressure difference of oil & hydrogen ≤0.02MPa.
j. Turbine axial displacement is ±1.0mm.
k. Oil level of turbine lube oil tank drop to -417mm.
l. Differential expansion of turbine HP cylinder reaches +10.2 or -4.5mm; differential expansion
of turbine LP cylinder reaches +16 or -1mm.
m. Return oil temperature of turbine radial bearing, thrust bearing are 82℃ higher; metal
temperature of turbine radial bearing is 113℃; metal temperature of turbine thrust bearing is
107℃.
n. Turbine LP cylinder exhaust temperature is 121℃, 15min delay.
o. Temperature difference between upper and lower casing of HIP cylinder >56℃.
p. Main steam temperature <482℃.
q. Main steam temperature >565℃.
r. HP exhaust pressure is 4.8MPa higher.
s. DEH trip.
t. Generator protection action.
u. Boiler MFT.
v. Turbine EH oil pressure is 9.31MPa lower.
3.6.6 Typical turbine failure disposal
3.6.6.1 Condenser vacuum decline
3.6.6.1.1 Phenomenon
a. Indicated value of all vacuum gauges is down.
b. Indicated value on all exhaust temperature gauges are going up.
c. Condensate water temperature is increasing.
d. Under the same load, when main steam flow increases, pressure of governing stage and all
monitoring sections shall rise.
e. CRT “Low vacuum” visual and sound alarm, standby vacuum pump interaction.
3.6.6.1.2 Reasons
a. Circulating water is cut or short.
b. Gland feeding steam is in low pressure or cut, and water seal of gland steam condenser
malfunction.
c. Vacuum pump malefaction and trip, but standby vacuum pump does not interlock or run
abnormally, efficiency is lowing.
d. Water level regulation of condenser is failure, copper tubes of condenser leak badly leading
to full water of condenser.
e. Vacuum system pipeline is broken or valves of vacuum system are opened by mistake, which
result in lost of air entering into condenser.
f. Safety valves of main and BFP turbine have crack.
g. Water level in chemical feed water tank is too low; water level in auxiliary steam drain flash
tank is too low, but the drain valve from auxiliary steam drain to turbine flash tank is open.
h. Hot well drain valve is not tight or opened by mistake
3.6.6.1.3 Disposal
a. Once find vacuum is declining, rapidly check other vacuum gauges and CRT vacuum
indicated value as well as change of turbine exhaust temperature; none but vacuum gauge
indication is declining, meanwhile turbine exhaust temperature is increasing accordingly, we can
say that condenser vacuum is really declined.
b. When vacuum is declining, find out causes rapidly and try to recover vacuum. If vacuum
drop to 87KPa, put standby vacuum pump into operation; maintain parallel operation of HP
condenser A, B and LP condenser A, B vacuum pumps.
c. When vacuum is declining, much attention shall be paid to the vibration of LP rotor last
stage blade, if turbine vibration is increasing, eliminate vibration by reducing load; if load
reducing is ineffectively and vibration keep on increasing, failure shutdown at once while
vibration >0.254mm or vibration has the change trend of over limitation.
temperature declines rapidly for over 50℃, temperature drop rate 10℃/min, it is necessary to
failure shutdown at once.
3.6.6.2.6 When steam pressure and temperature change abnormally, pay attention to monitor
change trend of turbine expansion difference, axial displacement, bearing vibration, monitoring
section pressure and all control index, failure shutdown as soon as exceed limitation.
3.6.6.2.7 When left and right main stop valves, reheat steam valves have steam temperature
difference, please dispose as per following rules:
a. Heat deviation normal value of left & right main stop valves steam temperature <14℃.
b. When heat deviation is running exceed limit, running exceeding limit within 42℃ for 15min in
4 hours for once is allowed.
c. When steam temperature deviation is large, it is necessary to inform boiler to adjust in time.
d. Steam temperature deviation of two sides exceed limit for 42℃, please shutdown in time.
3.6.6.3 Main lube oil pressure decline abnormally
3.6.6.3.1 Phenomenon during oil declining
a. Indicated value of CRT and local pressure gauge is declining.
b. Lube oil pressure drop to 0.082MPa, “Low Lube oil Pressure” visual and sound alarm.
c. Lube oil pressure drop to 0.082MPa, auxiliary oil pump and AC standby sealing oil pump
start automatically.
d. Lube oil pressure drop to 0.075MPa, DC lube oil pump start automatically.
e. Bearing temperature and return oil temperature have ascending trend.
3.6.6.3.2 Reasons for decline of oil pressure
a. Main oil Pump failure during running.
b. Main oil Pump inlet oil injector failure.
c. Oil system pipeline cracking, mass oil leak.
d. Oil system valve is open by mistake, mass oil leak.
e. Turbine oil cooler leak badly.
3.6.6.3.3 Disposal for lube oil pressure decline
a. When lube oil pressure declines abnormally, find out causes as soon as possible. Start
auxiliary oil pump and AC sealing oil standby pump to maintain oil pressure when oil pressure
drop to lower than 0.082MPa. If oil pressure continue dropping and cannot be recovered, failure
shutdown and break vacuum at once.
b. Oil pressure declines due to leakage of lube oil pipe, and the trouble cannot be eliminated,
failure shutdown at once.
c. Lube oil pressure decline, pay close attention to the temperature of all bearing and return
oil, if its temperature (of thrust bearing and support bearing, etc) are high to limit value,
shutdown the unit and break vacuum at once.
d. During unit starting speedup, if lubricant oil pressure declines due to auxiliary oil pump
failure, disposal shall be decided as per unit speed and failure character: if rotating speed is
close to 2700r/min and failure cannot be solved in short time, speed up to rated speed and
dispose auxiliary lubricant oil pump; if rotating speed is lower than 2700r/min, but auxiliary
lubricant oil pump is broken and failure cannot be solved in short time, it is necessary to break
vacuum and shutdown at once.
3.6.6.4 Support bearing or thrust bearing temperature rise abnormally
3.6.6.4.1 Reasons
a. Bearing is damaged.
b. Cooling water in oil cooler is short or interrupted, or cooling water temperature increases, oil
temperature increases abnormally.
c. Oil film is broken due to abnormal change of oil pressure and temperature.
d. Bearing oil inlet is lacking or interrupted, oil quality is worsened.
e. Unit vibrates violently.
f. Unit load changes rapidly, such as load dump or increase greatly, causes axial thrust force
abnormal increase.
g. When cold steam and cold water come into turbine badly, that thrust bearing exceeds limit.
h. Gland seal of turbine balancing disc is badly worn that balancing axial thrust is out of action.
3.6.6.4.2 When temperature of support bearing and thrust bearing is increasing, operators shall
confirm the following data immediately:
a. CRT display, indication of return oil temperature shall all increase.
b. All bearing temperature increase due to oil cooler outlet oil temperature increase and oil
pressure change or turbine vibration.
c. Listen to bearing inside carefully at site, whether the sound inside thrust bearing and turbine
are normal.
d. Verify if axial displacement has abnormal change.
e. Verify if unit vibration increases abnormally.
3.6.6.4.3 Disposal for abnormal increase of support bearing and thrust bearing temperature
a. Find out reasons, if it is due to cooling water, check regulating if it is normal, manually adjust
if it is abnormal.
b. If oil pressure is fluctuating, please check the running of main oil pump.
c. If it is caused by other reasons, please dispose as per actual situation.
c. Any one of support bearing metal temperature increases to 107℃ or return oil temperature
increases to 77℃, “High bearing temperature” and “High return oil temperature” visual and
sound alarm. When anyone of support bearing metal temperature increases to 113℃, failure
shutdown and break vacuum at once.
e. When thrust bearing metal temperature increase to 99℃ , “High thrust bearing temperature”
visual and sound alarm. No matter any reason, when thrust bearing metal temperature increase
cold steam & water. Whatever the reason, manually open main steam pipe, reheat steam pipe,
drain valves of all stages steam extraction pipes (including feed-water pump turbine) and
turbine generator proper immediately.
b. Strictly monitor thrust bearing metal temperature and return oil temperature, axial
displacement, HP & LP cylinder differential expansion, upper & lower cylinder temperature
difference, unit vibration and listen to unit inner sound, once the control index have tendency of
exceeding limit or over limit and endanger unit safety operation, failure shutdown and break
vacuum at once.
3.6.6.5.4 Disposal for cold steam & water entering different part of turbine
a. If main steam temperature and reheat temperature decline rapidly, disposal shall as per
steam temperature abnormal decline.
b. Water will enter extraction pipeline if heaters are filled with water badly, if temperature
difference of upper & lower cylinders, expansion difference of HP & LP, axial displacement have
obvious variation indicates that water has entered turbine, when temperature of upper and
lower cylinders is bigger than 56℃ , failure shutdown and break vacuum at once.
c. When “High water level of heater” alarms, check water level at local as soon as possible. If
water level is high but protection device failure to operate, close steam inlet motor-operated
valve of fault heater, switch over heater water side to be bypass operation. Close inlet and
outlet valves of heater, open drain valve of steam extraction pipes. Force open guide condenser
emergency drain valve to strengthen water draining.
d. Due to malfunction of gland seal cooling water regulating valve with water entering inside
gland seal, rotor is distorted by cold, when turbine expansion difference and vibration increase
abnormally, it is necessary to close gland seal cooling water valve and strengthen draining of
gland steam system at once. When expansion difference and vibration exceed limits, failure
shutdown.
e. After turbine failure shutdown due to cold steam & water intrusion, confirm current of turning
gear is increases abnormally or not; when rotor is distorted badly or turning gear is blocked due
to friction of rotor & stator, force turning is forbidden.
f. When turbine failure shutdown due to cold steam & water intrusion, it is necessary record idle
time well and truly, listen inner sound of unit carefully, pay attention to thrust bearing
temperature, axial displacement, vibration, expansion difference, etc., confirm that if unit can be
start again. If idle time is shorten obviously and metal rubbing come from unit inner during idle
time or strong vibration occurs before and after turbine trip, then check turbine inner after
shutdown, otherwise no starting.
g. If turbine cold water & steam intrusion is not serious, and variation of turbine axial
displacement, thrust bearing temperature and oil pressure, expansion difference, vibration,
upper & lower temperature difference are not obvious, shutdown is not necessary, but
strengthens draining.
h. After turbine failure shutdown due to cold steam & water intrusion, only above-mentioned
control index and unit inner sound have no abnormal change during idle time, manager can
decide if it is allowed to start again.
3.6.6.6 Abnormal vibration of turbine
3.6.6.6.1 Reasons
a. Oil film surge during starting speedup.
b. Improper warming during turbine startup.
c. Turbine rotating speed is in the sympathetic vibration range of critical speed.
d. Due to rapid change of load or main steam parameter, axial thrust increases abnormally, and
that cause rub between moving and stationary part.
e. Bearing oil film is damaged or oil supply is interrupted due to lube oil pressure declining.
f. Bearing oil film is damaged due to too high or too low lube oil temperature.
g. Bearing bend or differential expansion exceed limit during unit startup or operation.
h. Cold water & steam enter turbine or water hammer.
i. Turbine blade is broken or inner parts are damaged and fell off.
j. Steam excitation occurred during high load operation.
k. LP cylinder center drift or last stage blade vibration due to vacuum variation.
l. Bad quality of bearing erection, bearing fit and gap are improper adjusted.
m. Blade resonance occurred during turbine low cycle operation.
n. Unit vibration due to reasons of generator or exciter.
3.6.6.6.2 Disposal
(1) If vibration increase abnormally during turbine start up rush rolling and speedup process,
dispose as per following principles:
a. Before turbine rolling and during gear turning, shaft eccentricity shall <0.076mm, otherwise
forbid to run to speed.
b. After turbine rolling up, when rotating speed <600r/min, shaft eccentricity>0.076mm,
please trip, put turning gear into running when rotating speed drop to zero, when shaft
eccentricity<0.076mm, start the unit again.
c. During turbine speedup process, it is forbidden to maintain rotating speed or warming around
critical speed.
d. During turbine cold start speedup process, if any shaft vibration>0.127mm but <0.254mm,
pause until shaft vibration <0.125mm, carry out holding speed warming for 15~20min, and
carry out sound detection carefully, start speed up again after all control items are normal.
e. During turbine hot or extreme hot start speedup, if any bearing vibration >0.254mm, failure
shutdown at once, record idle time, put turning gear into operation, and analyze vibration
reasons, then start again. It is forbidden to eliminate vibration by reducing speed to maintain
warming or force speedup.
(2) If vibration increase abnormally during normal operation, first reduce vibration by reducing
load until vibration is reduced. Pay much attention to vibration during load up again, if vibration
keeps increasing, it is forbidden to add load, report to leaders.
(3) If vibration decline after eliminating excitation from turbine generator, or unit vibrates during
voltage boosting, it indicates that vibration is caused by short circuit of generator rotor winding.
It is necessary to report to senior leader, and discuss together for disposal.
3.6.6.7 Axial displacement increase
3.6.6.7.1 Reasons
a. Turbine load variation increase.
b. Extraction steam running mode changes, so that pressure difference of extraction steam
increase.
c. Water enters turbine or main & reheat steam temperature drop too fast.
d. Blades are serious scaling, broken.
e. Heater is cut.
f. Condenser vacuum declines.
g. Thrust bearing failure.
h. Cylinder single side admission.
i. Generator rotor axial movement.
j. Lube oil pressure & temperature change greatly.
3.6.6.7.2 Disposal
a. When axial displacement is increasing, check thrust bearing temperature, return oil
temperature, expansion difference, vibration, etc.
b. When load is increasing, stabilize load as soon as possible.
c. If unit axial displacement increases and together with abnormal sound, strong vibration, it
shall be disposed as per emergency shutdown.
d. When unit axial displacement reaches ±1.0mm, turbine shall auto trip. Otherwise shut down
unit manually.
3.6.6.8 Interruption of station service power
3.6.6.8.1 Phenomenon
a. Boiler MFT interlocks turbine, generator trip, and load drop to zero.
b. All AC electromotor of non-protection power source are stopped, ampere meter indicates
zero.
3.6.6.8.2 Disposal for interruption of station service power
(1) When station service power is interrupted, turbine shall auto trip, otherwise trip shutdown
manually at once; make sure BFP turbine is tripped.
(2) When station service power is interrupted, start turbine DC lubricant oil pump, DC lube oil
pump of feed-water pump turbine, DC sealing oil pump at once.
(3) After diesel-engine generator being started and on load, carry out following operations:
a. Make sure oil pumps in relevant oil systems of turbine, auxiliary equipments are self-started
normally, stop DC oil pump.
b. Pay attention to the temperature of turbine lube oil, adjust manually if oil temperature is high.
c. Pay attention to condenser vacuum, before vacuum drops to zero, try to maintain gland
steam supply.
(4) When station service power is interrupted, except necessary operation items as per actual
situation, generally maintain original state of equipments. Restart after station service power
restoration, and put into operation as per following starting procedures:
a. Start circulating water pump.
b. Start open water pump, closed water pump.
c. Start air compressor.
d. Put condensate water, feed water systems into operation.
e. Start land air extractor and gland seal system, vacuum pump.
f. Put deaerator into circulating heating operation.
g. Close all extraction motor driven valves, close feed-water pump outlet motor-operated valve;
put motor driven BFP and feed-water system into operation.
h. Start main and BFP turbine auxiliary oil pump to make oil circulation.
i. Start other auxiliary equipments.
Operating conditions
rated Safety Min flow of Max flow
item units Maximum
(guarantee valve trip single of single
flow
efficiency) conditions pump pump
Connection intake MPa 2.5
flange nominal Off MPa 3.75
pressure take
Connection pipe intake mm φ480×10
specification off mm φ377×10
(φ×S) take
rotation direction Inverse hour(to see from electric motor to booster pump)
Bearing type Sliding bearing + thrust pad
Drive mode Electric motor
Notice: (g) in the table refers to gauge pressure
4.1.2.2 Motor driven FWP technical specification
Operating conditions
rated Safety Min flow Max flow
item units Maximum
(guarantee valve trip of single of single
flow
efficiency) conditions pump pump
type FK4E39(I)M
inlet temperature ℃ 177.6 178.3 178.3 177.6 177.6
inlet flow m3/h 1100 1260 1260 290 1400
outlet flow m3/h 1070 1230 1230 290 1400
head m 2050 2123 2163 2460 1650
efficiency % 84.2 84.2 84.2 41 80
Required NPSH m 47 54 58 22 60
Seal type Mechanical seal
speed r/min 5350 5500 5600 5400 5400
outlet pressure MPa(g) 20.4 20.9 21.45 23.3 18
Shaft output kW 6385 7499 7721 4355 7522
tap pressure MPa(g) 11.2 11.2 11.9 0 0
Tap flow m3/h 30 30 30 0 0
Shaft vibration mm 0.05 0.05 0.05 0.05 0.05
MPa 4 inlet
Connection flange
MPa 16 Tap
nominal pressure
MPa 32 outlet
Connection pipe inlet mm φ377×10
specification Tap mm φ89×7
(φ×S) outlet mm φ355.6×27.76
weight kg 11000
Rotation direction clockwise(to see from turbine to water feed pump)
Bearing type Sliding bearing + thrust bearing
Drive mode Electric motor
(Notice:(g)in the table refers to gage pressure)
4.1.2.3 Feed water pump electric motor technical specification
turbine
jacking oil pump of main turbine PV29-2R1D-CO2 102 l/min 1480rpm
AC lube-oil pump of BFP turbine 80YG-100A(11) 85m 45 m3/h 2950
DC lube-oil pump of BFP turbine 80YG-38(11) 38m 50 m3/h 2950
Oil pump electric motor specification
description model voltage output speed
AC oil pump YB250-4 415 55 KW 1450 rpm
DC oil pump Z2-91 220 55 KW 1500 rpm
hydrogen seal stand-by oil pump YB2-200L-4 415 45 KW 1470 rpm
jacking oil pump YB225M-4 415 45KW 1480 rpm
AC lube-oil pump of BFP turbine YB30KW 415 30 KW 2950 rpm
DC lube-oil pump of BFP turbine Z2-10KWP 220 11 KW 2950 rpm
4.1.7 HP heater
Heater number No. 7 No. 6 No. 5
Feed water
flow t/h 2009.996 2009.996 2009.996
Inlet pressure MPa 30 30 30
Inlet temperature ℃ 248.8 213.8 183
Inlet enthalpy kJ/kg 1081.4 921.6 786.4
Outlet temperature ℃ 280.7 248.8 213.8
Outlet enthalpy kJ/kg 1234.9 1081.4 921.6
Max. resistance losses MPa 0.1 0.1 0.1
Max. allowable pipe side flow m/s 3 3 3
Design pressure MPa(g) 30 30 30
Design temperature ℃ 290 260 230
Test pressure MPa(g) 45 45 45
Extraction steam
Flow t/h 155.419 145.109 83.500
Inlet pressure MPa(a) 6.335 3.901 2.056
Inlet temperature ℃ 392.1 327.6 458.9
Inlet enthalpy kJ/kg 3153.3 3040.6 3376.6
Max. resistance losses MPa 0.069 0.069 0.069
Design pressure MPa(g) 7.44 4.58 2.43
Design temperature.(short/long 420/290 360/260 490/230
section) ℃
Test pressure MPa(a) 11.16 6.87 3.645
Drain water incoming
source No. 7 heater No. 6 heater
Flow t/h 155.419 300.528
Temperature ℃ 254.4 219.3
Enthalpy kJ/kg 1107.5 940.4
Drain out coming (flow from high to low )
Flow t/h 155.419 300.528 384.028
Temperature ℃ 254.4 219.3 188.6
enthalpy kJ/kg 1107.5 940.4 801.3
End temperature difference of drain
5.6 5.6 5.6
(bottom) ℃
End temperature difference of
-1.6 0 0
feed-water (top) ℃
4.1.8 LP heater, Gland steam condenser
4.2.2.3 Start AC lube-oil pump, seal oil stand-by pump and put them into oil pump interlock
control.
4.2.2.4 When oil enters in system, the oil level of tank will lower sharply; it is time to add oil inside
oil tank.
4.2.2.5 When lube oil temperature rise to 35℃ , main oil tank electric heating device shall exit.
When the temperature rise to 40℃, cooling water of oil cooler shall be put into running for make
the oil temperature within 40~45℃.
4.2.2.6 Start jacking oil pump, and put turbine turning gear into operation.
4.2.2.7 During the unit rolling up, rise speed and load, check that lube oil pressure, oil
temperature and return oil temp and flow are O.K. stop jacking oil pump when speed reaches
600r/min.
4.2.2.8 Stop high-pressure start-up oil pump and AC lube-oil pump, when unit speed is above
3000r/min, the outlet oil pressure of main oil pump is range from 1.67 to 1.76MPa and lube-oil
pressure is normal, the lube-oil pressure change must be paid attention to.
4.2.3 Operation and maintenance
4.2.3.1 When unit is working normally, one smoke exhaust fan is running to maintain the lube oil
pressure at minus 100mm water column.
4.2.3.2 When unit is working normally, put AC lube-oil pump, DC lube-oil pump, seal oil stand-by
pump, jacking oil pump and turning gear into automatic - start interlock position.
4.2.3.3 When oil pressure of all turbine bearings is higher than 0.082Mpa and the cooling water of
oil cooler runs well with outlet oil temperature keeps at 40℃ .
4.2.3.4 AC lube-oil pump, seal oil stand-by pump, jacking oil pump and turning gear work well,
and oil pressure is O.K.
4.2.3.5. oil pressure of auto-stop shall maintain at 0.8~1.0MPa when Unit is operating normally.
4.2.4 Turbine jacking oil pump and turning gear
4.2.4.1 Startup:
1)Start one turbine jacking oil pump into operating, and start another one when checking the
system is no leakage. Put stand-by pump into interlock.
2)Check jacking oil pressure of every bearing is within 5.6 to 8.5MPa. And the journal is
lifted at height of 0.050 to 0.076mm.
3)Make sure generator seal oil system is working normally.
4)engaged turning gear manually, Press “startup turning gear” button on the local cabinet or
DCS operation panel.
5)Check turning gear current is normal, eccentricity not greater than 0.076 mm, rotation
speed of turbine 2.38r/min. then listen sound of turbine inside, data such as main shaft bending
value, turning gear current and current changing value shall be recorded.
4.2.4.2 Stop:
1 ensure gland steam supply stops, and HP casing governing stage metal temperature is
lower than 149℃, temperature difference between upper and lower part inside HP/IP casing is
less than 42℃, then stop turning gear operating.
2 turbine jacking oil pump, seal oil pump and AC lube-oil pump can only be stopped when
stator is thoroughly still.
3 when HP casing governing stage metal temperature is lower than 100℃ and every shaft
metal temperature is in normal range, stop AC lube-oil pump, high pressure stand-by seal pump
and smoke exhaust fan.
4.2.5 Lube oil system setting
4.2.5.1 Lube oil pressure ≤0.082MPa, alarm; interlock switch is on, interact AC lube-oil pump.
4.2.5.2 Lube oil pressure ≤0.075MPa, alarm; interlock switch is off , interact DC lube-oil pump.
4.2.5.3 Lube oil pressure ≤0.060MPa, alarm; trip turbine.
4.2.5.4 Lube oil temperature≤21℃, start electrical heating; Lube oil temperature ≥40℃, stop
lubricant electrical heating.
4.2.5.5 Turbine lube-oil tank pressure is -0.35KPa while interlock switch has been put into
operation and Stand-by fan start automatically.
4.2.5.6 While interlock switch has been put into operation, stand-by turbine jacking oil pump
should be started automatically when one of the following conditions reached.
1)Turbine jacking oil pump inlet pressure P>0.021MPa, turbine rotation speed is lower than
600r/min.
2)Turbine jacking oil pump inlet pressure P>0.021MPa, interlock of jacking oil pump, one of
other two jacking oil pumps trip.
3)Turbine jacking oil pump inlet pressure P > 0.021MPa, turbine jacking oil main pipe
pressure P≤10MPa.
4.2.6 Turbine EH oil system setting
4.2.6.1 1When oil pressure of EH manifold P≤11.03MPa, EH oil pumps interlocked start.
4.2.6.2 When oil level of EH oil tank is lower than 195mm, EH oil pump stop automatically.
4.2.6.3 When EH oil pressure is lower than 9.31MPa, turbine trip.
4.2.6.4 When EH oil temperature of oil tank is above 53℃, EH electric heating stop automatically.
4.2.6.5 Shaft seal steam must drain adequately can be operated. After put it into operation, pay
attention to temperature difference between turbine upper and lower casing, differential
expansion etc. important parameters.
4.2.6.6 When switching auxiliary steam source, pay attention to the change of auxiliary steam
pressure and temperature and action of shaft seal pressure and temperature regulator.
4.2.6.7 Pay attention to shaft seal steam temperature must higher than 14℃ degree of superheat.
4.2.6.8 during unit cold start , temperature of HP/IP shaft seal steam is controlled at 150~200℃
4.5.1.3 HP and LP heaters shall be put into operation one by one from LP to HP, and time interval
shall be more than 10min. Shutdown sequence is opposite from starting sequence, that is shut
down as per pressure one by one from high to low. Time interval shall not be less than 10min.
4.5.1.4 During starting and shutdown of HP heater, temperature-rise speed of HP heater must be
strictly controlled to ≤5℃/min, and temperature reducing speed shall ≤2℃/min. Stop operation if
any abnormal condition occurs, find out causes and eliminate.
4.5.1.5 HP and LP heaters can be put into operation if all valves, instruments, level gauges,
protection are normal, otherwise, it is forbidden to be put into system.
4.5.2 HP slide operation
4.5.2.1 Ensure that BFP is running, and HP inlet T valves are at close and outlet T valves at open
position with HP protection being put into operation.
4.5.2.2 Slowly open the start and operation vent valve at HP steam side, pay attention to the
pressure change in deaerator.
4.5.2.3 Open extraction non-return valve of HP heaters No.5, 6, 7.
4.5.2.4 Fully open the motor steam inlet valve of HP heaters No.5, 6, 7 and the HP heaters will be
put into slide operation with the load. Check no knocking inside pipes.
4.5.2.5 Open emergency drain valve of HP heaters No.5 and regulate its water level to normal
position.
4.5.2.6 Close drain valve before and after the Extraction No.5, 6, 7 non-return valves. Check the
drain valve before the HP steam inlet valve is automatically closed when the load reached more
than ten percent.
4.5.2.7 Open the isolation valve from HP heater drain to deaerator and put regulation valve of
them into auto when the pressure at steam side is higher that that in deaerator
4.5.2.8 Close starting vent valve when all the heaters are in normal.
4.5.2.9 Check if the HP heaters and deaerator are normal, then examine and put all the Heaters
protection into operation.
4.5.3 HP heater start during unit normal operation
4.5.3.1 HP heater maintenance work is over, and working ticket have been check out. The
working site is tidy.
4.5.3.2 Check and feed power and air source of HP heater motor valve, regulating valve,
instrument and protection.
4.5.3.3 Check if the entire valves are in right position as per the HP heater system.
4.5.3.4 Do protection and interlock tests if required.
4.5.3.5 open primary and secondary water valve to fill water in HP heater until the pressure at
water side is same as that of FW, then open the outlet and close inlet T valve, at last close
primary and secondary water valve when the water flow meet the requirement.
4.5.3.6 Slowly open the starting and operation vent valve at HP steam side, pay attention to the
all heaters and pipes. If the end temp difference is higher, check vent valves of steam side are
fully open and water level is ok.
4.5.7 HP heater stops with unit load
4.5.7.1 Quit of the HP heaters shall follow the sequence from high pressure to lower.
4.5.7.2 Check water level is ok during load down, and switch the HP drain regulating valve to
manual control.
4.5.7.3 Ensure that the drain valves before the extraction No. 1, 2, and 3 are open when the load
is less than ten percent of MCR.
4.5.7.4 Pay attention to the level are normal when the inside pressure of HP heaters No.3 is
approaching that of deaerator.
4.5.7.5 When the unit trip, check that inlet and extraction non-return valves of the extraction No. 5,
6, and 7 are closed and all the pneumatic drain valves in the extraction pipe lines are open, then
open drain valve after the extraction non-return valve.
4.5.7.6 Isolate water side of HP heater if required, and open inlet T valve of heater, and bypass
water side, then close heaters outlet valve and quit protection, finally open drainage and vent
valve to lower the pressure.
4.5.8 The shutdown of HP heater during unit operating normally
4.5.8.1 During HP heater shutdown, should monitor changes of section pressure and load.
4.5.8.2 Shut #7 motor steam inlet valve of HP heater slowly. After #7 motor steam inlet valve of
HP heater shutdown, shut #6 motor steam inlet valve of HP heater slowly until shut fully. At last,
shut #5 motor steam inlet valve of HP heater slowly until shut fully. Pay attention to control
water feed temperature drop rate in 2~3℃ /min.
4.5.8.3 According to HP heater level changes, put #7)6)5 HP heater drain regulating valve into
manual regulating.
4.5.8.4 When #7 HP heater drain can not transport to deaerator, shut #7 HP heater drain to
deaerator regulating valve and motor valve, start #7)#6)#5HP heater steam side bottom water
drainage valve.
4.5.8.5 Shut extraction non-return valve of HP heaters No.7, 6, 5. Open front or back drain valve
of extraction non-return valve of HP heaters No.7, 6, 5.
4.5.8.6 Isolate water side of HP heater if required, and open inlet T valve of heater, and bypass
water side, then close heaters outlet valve and pay attention to changes of water-feed pressure,
flow. Open inlet T valve of HP heater firstly and then close HP heater outlet valve, which can not
be reversed.
4.5.8.7 Undo the switch of HP heater protection interlock.
4.5.8.8 According to the need, HP heater water side release pressure or drain water. Relevant
motor valves shut down and listed.
motor valve.
4.5.11.10 Extraction non-return valve of HP heaters No.7, 6, 5 shut down condition:
a. HP heater protection requires shut extraction non-return valve.
b. Turbine tripping.
c. OPC oil pressure is low.
d. Generator oil switch is tripping.
e. shut extraction non-return valve on chief operator console.
4.5.12 LP heater and drain system main interlock protection
4.5.12.1 Put LP heater interlock switch into operation. LP heater level highⅠ valve and
highⅡvalve come together. Fully open accidental drain valve.
4.5.12.2 When LP heater water level highⅢ value, open LP heater water side by-pass valve; ;
shut LP heater inlet/outlet valve; shut LP heater steam-feed motor valve; shut LP heater
steam-feed extraction non-return valve; open LP heater steam extraction drain valve; at the same
time shut upper normal drain regulating valve and open upper accidental drain valve.
4.5.12.3 Extraction non-return valves of HP heater No.2, 3 shut down condition:
a. #2,#3 LP heater water level protection shuts extraction non-return valve.
b. Turbine tripping.
c. Generator oil switch is tripping.
d. extraction non-return valve shut on chief operator console.
e. OPC oil pressure is low.
4.6 Deaerator system
4.6.1 Operation of deaerator
4.6.1.1 When maintenance of deaerator is over, work sheet have been checked out, deaerator
checking is finished and valves in every place are in right state.
4.6.1.2 Pressure & temperature of main pipe is checked to be normal.
4.6.1.3 Condensate water recycle system is normal.
4.6.1.4 Water level in condenser is in right level and water quality is qualified.
4.6.1.5 Fill water into deaerator by condenser water pump to normal level, and open re-boiling
heating motor driven valve which connect with auxiliary steam and deaerator.
4.6.1.6 Make sure deaerator pressure is manually controlled, thoroughly open adjusting valve and
rear motor driven valve which connect with auxiliary steam and deaerator.
4.6.1.7 Manually adjust inlet pressure of auxiliary steam to reboil it to 0.138MPa pressure and
hold on for 30minutes.
4.6.1.8 Manually adjust inlet pressure of auxiliary steam to reboil it to 0.138MPa, heat the filled
water up to 108℃ and adjust deaerator to automatic mode.
4.6.1.9 When deaerator flow is found, make deaerator water level adjusting be auto.
4.6.1.10 When the unit is with load and four extraction steam pressure is higher than 0.147MPa,
open motor driven valve which connect with four extraction steam and deaerator, automatically
close motor driven valve which connect with auxiliary steam of deaerator, and close motor driven
valve of reboil heater.
4.6.1.11 When four extraction steam is put into operation, steam of deaerator is supplied by four
extraction steam, operation mode of deaerator changed from constant pressure to slide pressure;
when turbine operates with rated load, change it to constant pressure mode; during slide
pressure course, open motor driven valve which connect with boiler continuous blow down flash
tank and deaerator. Close small oxygen vent valve when oxygen content in water is qualified.
4.6.2 Shut down of deaerator
4.6.2.1 Deaerator decreases along with unit, when the load decrease and deaerator pressure is
lower than 0.147MPa, close motor driven valve and adjusting valve connected with four extractor
and deaerator, and keep deaerator operating under stable pressure of 0.138MPa.
4.6.2.2 After the unit tripped and it is not required to fill water into boiler, close inlet valve of
deaerator and set water level mode to manual from auto, and stop filling water into deaerator.
4.6.2.3 Make sure adjusting valve and its rear manual control valve of #5HP drainage is closed,
and close constant discharge valve which connected with #7, #6, and #5 HP heater to deaerator.
4.6.2.4 Close air-actuated valve and manually operated valve which connected with continuous
blow down flash tank and deaerator.
4.6.2.5 Protect deaerator by filling nitrogen if the deaerator is out of service more than one week,
cut off all steam source, water source, discharge all water in water tank, then close vent valve,
open nitrogen isolate valve and keep certain nitrogen pressure on deaerator.
4.6.2.6 Deaerator will be heating protected when it is out of service within one week, reboil the
water in deaerator by auxiliary steam and keep the pressure at 0.04MPa, and make certain
opening of vent valve.
4.6.3 Control parameter of deaerator under normal operation
4.6.3.1 Pressure of deaerator: normal;1.046MPa,0.147MPa~1.117MPa.
4.6.3.2 Temperature of deaerator: normal: 370.8℃; max 376.2℃; min. 20℃.
4.6.3.3 Water level of deaerator: 2730mm, heightⅠ 2930mm, heightⅡ3030mmheight Ⅲ3330mm,
lowⅠ2530mm, low Ⅱ1030mm.
4.6.3.4 Oxygen content in water of deaerator: ≤7μg/L.
4.6.4 Shut down of deaerator
4.6.4.1 During shut-up period of the unit, pay attention that the deaerator pressure, temperature
and water flow rate should be corresponding with the load. Keep the pressure and water level in
deaerator normal.
4.6.4.2 When load of the unit decrease, the pressure of deaerator also decrease. When the
pressure decrease to 0.147MPa, switch deaerator steam source to auxiliary steam, and shut up
four extractor motor driven valves & return valve. Keep water level normal.
4.6.4.3 When boiler discharge water with load, close adjusting valve, motor driven valve and
manual operated valve which connected with auxiliary steam and deaerator.
4.6.4.4 After the unit shut down, pay attention to the water level in deaerator as so to avoid the
water too full to enter into turbine.
4.6.5 Main interlock protection for deaerator
4.6.5.1 When water level higher thanⅠset value, which is 2930mm, CRT will alarm, while lower
than this value, close its emergence drainage valve and overflow adjusting valve automatically.
4.6.5.2 When water level higher than Ⅱ set value 3030mm, open overflow drainage motor-valve,
while lower than normal level, close it.
4.6.5.3 when water level higher than Ⅲ set value, 3130mm, open its emergence drainage valve,
#5 high-pressure heater drain adjusting valve, drain valve behind forth steam extracting inlet
valve which is a motor-valve, and drain valve behind steam extracting inverted valve. Close #5
high-pressure heater normal drain adjusting valve, inlet motor-valve between forth steam
extracting and deaerator, two inverted valves of forth steam extracting, adjusting valve between
assistant steam and deaerator, water level adjusting valve of deareator.
4.6.5.4 When water level lower than Ⅰ value and alarm, closedown starting booster pump, MBFP ,
TBFP.
4.6.5.5 When water level is lower than Ⅱ value, 1030mm, trip booster pump, MBFP, TBFP.
4.6.5.6 when pressure of forth steam extracting >0.147MPa, open motor-valve between forth
steam extracting and deaerator.
4.6.5.7 When deaerator pressure ≥0.147MPa, close stand-by steam motor-valve.
4.6.5.8 when deaerator pressure <0.147MPa, open stand-by steam motor-valve.
4.6.5.9 when pressure of forth steam extraction <0.147MPa, close motor-valve between forth
steam extracting and deaerator, meanwhile closedown it.
4.6.5.10 when deaerator pressure ≥1.28MPa, deaerator pressure high signal will appear, open
drainage valve automatically, close stand-by steam adjusting valve, meanwhile safety valve
opening.
4.6.5.11 when turbine trips, close steam inlet motor-valve to deaerator, open stand-by steam
adjusting valve.
4.6.5.12 condition to close forth steam extracting inverted valve #1 and #2:
a water level of deaerator water tank higher than Ⅲ value, 3130mm
b turbine trip
c OPC oil pressure is low.
d oil switch of generator trip.
e shut extraction non-return valve on chief operator console.
motor-pump tap valve of TBFP shall be confirmed to open before stop it.
4.7.1.3.2 When unit shutdown and feed water is no need to feed to boiler, MBFP can be stopped.
4.7.1.3.3 Decrease rotating speed of MBFP; switch water flow to other running MBFP, TBFP, and
pay attention to water flow and pressure normal.
4.7.1.3.4 When water flow of motor-pump is lower than regulated value, check recycling adjusting
valve open automatically.
4.7.1.3.5 When rotating speed is lower than 1500rpm, scoop tube to 0, stop MBFP by sequence
control or manually, check current decreasing to 0, record idle time of pump and motor.
4.7.1.3.6 During speed decreasing, check assist ant oil pump start automatically when lube oil
pressure is lower than 0.15MPa; maintain it normal, when temperature of working oil lowers than
35 ℃ , close inlet valve of cooler to standby.
4.7.1.3.7 After stopping motor-pump, close its water outlet valve according to condition, when air
outlet temperature of motor lower than 40℃, stop its air cooler and its inlet valve.
4.7.1.3.8 Stop dose inlet valve of motor-pump
4.7.1.3.9 If motor-pump in hot stand-by state, maintain lube oil system, water sealing and cooling
system, warm pump system running normally.
4.7.1.3.10 If motor-pump is not used for stand-by, stop warm pump valve and intermediate tap
valve, water inlet valve of booster pump, and recycling isolating valve. When its case temperature
lower than 80℃ and metal temperature of each bearing lower than 50℃ , stop its water sealing
and cooling system, lube oil system, motor water cooling system, open drainage valve of pump
proper and tube.
4.7.1.4 Operation and maintenance for MBFP group
a. Check vibration of BFP and hydraulic coupling is not greater than 0.05mm, and that of motor
and booster pump bearing not exceed 0.06mm.
b. when outlet tem of lube oil cooler increase to 45℃, open its water inlet valve, control outlet
temperature of lube oil within 40℃ ~45℃, and not lower than 35℃, or higher than 55℃ . Pressure
difference between filter two sides shall be lower than 0.06MPa, otherwise, switch to stand-by
filter to repair and clean it.
c. when oil outlet temperature of working oil cooler increase to 45℃,open its water inlet valve,
control oil outlet temperature within 40℃ ~70℃ , not lower than 35℃ or higher than 76℃ at
max..
d. Put air cooler into running according to air outlet temperature of motor, control its air outlet
temperature within 40℃~45℃, not higher than 55℃ , and motor winding temperature no higher
than 130℃.
e. Check intermediate tap pressure normal, and motor-pump running in rated work condition, its
pressure shall be about 16.9MPa.
f. Check pressure difference between two sides of booster pump and inlet filter should be lower
than 0.06MPa.
g. Check metal temperature of support bearing and thrust bearing in normal range.
h. Its axial displacement <±0.45mm.
i. in its normal operation range, and its inlet and outlet temperature and flow normal, motor
current in limited range.
j. return water temperature of Mechanical sealing cooler <80℃ .
k. Oil level, quality and flow of hydraulic coupling are normal.
l. lube oil pressure should be about 0.25MPa. Working oil pressure is about 0.2MPa.
m. water level, pressure of deaerator is normal, no vaporization and shock in motor-pump.
n. No leakage in water cooling system, mechanical sealing system, water sealing system, oil
system and water tube.
4.7.1.5 motor-pump trip and in protection
a. lube oil pressure ≤0.08MPa.
b. oil inlet temperature of work oil cooler is 130℃ , oil outlet temperature of coupling is 85℃.
c. oil inlet temperature of lube oil cooler is 75℃, outlet temperature is 60℃.
d. close inlet valve of MBFP
e. inlet pressure lower than 1.25MPa, to trip 30s delay.
f. bearing temperature of booster pump or coupling side high to 90℃.
g. bearing temperature of motor-pump radial and thrusting bearing high to 90℃ .
h. temperature of radial and thrusting bearing of hydraulic coupling is up to 95℃.
i. recycling valve malfunction, then stop motor-pump.
j. deaerator water level is lower than 1030mm.
k. water mechanical sealing temperature for booster pump sucking side or draining side high
90℃, and high- high 95℃ .
l. mechanical sealing water temperature for motor-pump sucking side or draining side high
90℃, and high- high 95℃ .
m. motor winding temperature High-high 145℃
n. radial bearing temperature for booster pump sucking or draining side high 90℃
o. Water sealing temperature for booster pump sucking or draining side high 80℃ and
high-high 95℃.
p. motor-pump electric trip.
4.7.2 TBFP group
4.7.2.1 Forbid to start condition:
a. Speed adjusting system, emergence protection device malfunction, and could not control
rotating speed correctly.
b. Rotating speed of TBFP turbine emergency governor is not accepted.
c. One of main protections for TBFP and its turbine fail.
d. When the turning gear is engaged, there is friction sound inside TBFP and its turbine.
e. Main meters fail.
f. turning gear and oil pump runs abnormally, oil level lower or oil quality is not accepted.
g. Main valve switch fail, rapid closing valve, HP or LP adjusting valve block or could not close
tight.
h. Degree of eccentricity monitors alarm.
4.7.2.2 Startup of TBFP group.
4.7.2.2.1 Ensure maintenance of TBFP is over, work sheet have been checked out,, system pipe
and equipment in good condition.
4.7.2.2.2 Interlock /protection test have been checked normal, booster pump can be ready for
started.
4.7.2.2.3 Single TBFP turbine runs normally. Manual trip test and protection test, over-speed
protection test are normal.
4.7.2.2.4 Water level and pressure of deaerator is normal, OCW and CCW of TBFP system is
normal.
4.7.2.2.5 Check oil system is o.k., oil level is normal, its difference no greater than ±150 mm, oil
temperature Adjusting is put to auto control.
4.7.2.2.6 Put each valve in its correct position according to starting demand.
4.7.2.2.7 Put TBFP turbine oil system into running, start main oil pump, check oil pressure normal,
start oil tank exhaust fan. Put cooling water into running according to oil temperature. Check oil
system no leakage, adjust throttle valve behind lube oil filter, make oil pressure within
0.0981MPa~0.147MPa,temperature 35℃~45℃ .
4.7.2.2.8 Put oil pump and oil tank exhaust fan to interlock.
4.7.2.2.9 Put EH oil system into running, check its inlet and outlet valve are open, adjusting oil
pressure of TBFP turbine is within 10MPa~12MPa, oil pressure of accumulator is o.k. and
emergency governing oil pressure high than 0.65MPa (g).
4.7.2.2.10 Open booster pump water inlet valve, and fill water, injects air, warm pump proper and
pressurizing to booster pump and water feed pump.
4.7.2.2.11 Put water sealing of TBFP into running, water return back to condenser.
4.7.2.2.12 ensure emergency governor valve in disengaging position, HP/LP main steam valve
and adjusting valve in closing position.
4.7.2.2.13 Start booster pump and recycling, inlet pressure of BFP is no lower than 1.4MPa.
4.7.2.2.14 Start jacking oil pump, start stand-by oil pump, put turning gear into running.
4.7.2.2.15 steam is supplied from gland steam condenser, and its temperature is 121℃~177℃,
adjust its steam inlet valve, control its pressure at 0.017MPa~0.038MPa.
4.7.2.2.16 Open steam exhaust butterfly valve slowly, TBFP turbine extraction air, when its
vacuum degree near to that of main turbine, open butterfly valve completely(the vacuum
extraction of TBFP turbine should be simultaneous with main turbine), check steam exhaust
pressure lower than 10KPa, monitor main turbine vacuum normal.
4.7.2.2.17 Open drain valve before and behind HP and LP steam inlet motor-valve, drain
adjusting valve before main steam auto and manual valve, drain valve in T=BFP proper. Control
auxiliary steam or forth extraction steam pressure within 0.15MPa~0.85MPa, when temperature
is higher than that of TBFP turbine casing, Open auxiliary steam or forth extraction steam
motor-valve slowly to warm pipe. After 10~15min., open them completely.
4.7.2.2.18 reset TBFP turbine
4.7.2.2.19 Set target speed, speed rise rate and rotating speed when warm turbine and time
depending on the turbine cold or hot state.
4.7.2.2.30 partly open manual drive valve of TBFP intermediate tap and reheat desuperheating
water and open completely when the air is thoroughly out.
4.7.2.2.31 When TBFP turbine rotating speed excess 3000rpm, check pipe and drain adjusting
valve closed.
4.7.2.2.32 precautions during speed rise:
a. Monitor steam parameter, eccentricity degree, axial direction displacement, and vacuum
changing.
b. Check oil pressure of each bearing, temperature of radial bearing and thrusting bearing, and oil
return temperature are normal. Notice to adjust lube oil temperature in normal when speed is
rising.
c. Steam exhaust temperature of TBFP turbine shall not exceed limited value, and exhaust spray
water control are in auto control.
d. Check TBFP water sealing system running normal, inlet and outlet pressure difference should
be in normal.
e. attention speed rise stable during starting, no heavy fluctuation occurs, pass critical speed
smoothly, and forbid to stay in critical rotating speed scope.
f. Monitor vibration during increasing speed, and shaft vibration of turbine shall not be greater
than 120um, for pump shaft, 40um.
4.7.2.3 Stop TBFP group.
a. Ensure intermediate tap valve of another pump open wide enough.
b. For pump prepared to stop cut off water feeding auto control.
c. Decrease its rotating speed slowly, notice pressure and flow of water feeding, switch water flow
to other running pump, and maintain its flow stable.
d. When pump inlet flow lower than 260t/h, notice recycling adjusting valve open automatically.
e. When stopping pump rotating speed lower to lowest speed 3000rpm, shut off its outlet valve.
f. Shutoff TBFP by manually trip emergency governor, check its rapid closing valve and adjusting
valve closed, when the speed is reduced, open its drain valve.
g. When speed is lower than 500rpm, put turning into running.
h. Stop booster pump.
i. Stop isolating valve of forth extraction steam and HP exhaust inlet.
j. Close steam draining butterfly valve, damage vacuum and close pneumatic drain valve of TBFP
k. When vacuum gets to 0, stop gland seal steam, stop inlet returning valve.
l. Stop EH system of TBFP turbine.
m. continuously turning gear for more than 8h after turbine shut till HP casing temperature is
lower than 200℃
n. if continuous turning gear stop after turbine shut, rotate it manually every 30min for 180 angle
degree in 24hrs..
j. booster pump motor catches a fire or gas emitting, winding temperature greater than 130℃,
bearing temperature greater than 95℃, pre-pump current excess limited value heavily.
k. Booster pump bearing temperature greater than 90℃, water returning temperature of sealing
cooler greater than 95℃ .
l. Oil level of lube oil tank lower than regulated value.
m. Speed adjusting system fluctuates largely.
4.8 Open/close cooling system
4.8.1 Set protection valve for open cooling system
4.8.1.1 Inlet valve close during OCP is running, OCP trip.
4.8.1.2 Fore and rear bearing temperature of motor gets to 80℃ , OCP trip.
4.8.1.3 Motor winding temperature gets to 145℃ , t OCP trip.
4.8.1.4 Pressure difference between electric filter two sides gets to 500mmH2O, open blow down
valve of it automatically.
4.8.1.5 Pressure difference between electric filter two sides lower to 250mmH2O, close blow
down valve of it automatically.
4.8.2 Set protection value for close cooling system
4.8.2.1 Motor bearing temperature Higher than 95℃, CCP stop automatically.
4.8.2.2 CCP Motor fail, its pump stops automatically.
4.8.2.3 CCP electric protection acts, its pump stop automatically.
4.8.2.4 Motor winding temperature gets to 145℃ , CCP stop automatically.
4.8.2.5 Water level of CCP water tank lower than 1000mm, its make-up valve open automatically.
4.8.2.6 Water level of CCP water tank higher than 1500mm, its make-up valve closes
automatically.
4.9 Generator oil sealing system
4.9.1 General regulation
4.9.1.1 Put it into running before turning gearing and generator air replacement is done.
2 Oil sealing system shall maintain running when filling hydrogen or dioxide into generator.
3 Put lube oil system first when generator is full of hydrogen.
4 smoke exhaust fans shall run continually when generator is full of hydrogen.
5 Stop oil sealing system nothing but when generator is stopped and full of air.
4.9.2 Put oil sealing system into running
4.9.2.1 Ensure AC lube oil pump and hydrogen oil sealing pump is running, lube oil system is
running normally, oil level of air side oil tank is normal, no oil level high/lower alarm.
4.9.2.2 ensure main and stand by pressure difference control valve, balance valve, safety valve,
reducing valve are calibrated to realize pressure difference between air side oil sealing and
hydrogen is at 0.084~0.1MPa.
4.9.2.3 Each valve is in its normal position and system inspection finished.
4.9.2.4 Start one of smoke exhaust fan in air side oil tank, put another one to interlock stand by.
4.9.2.5 Start air side DC oil pump, check no leakage in system, stop it when normal.
4.9.2.6 Start one of air side AC oil pumps, after running normally, put same side DC stand by oil
pump to interlock. Check ball float valve in hydrogen side oil returning tank work normally, and
its liquid level normal.
4.9.2.7 Start hydrogen side AC oil pump, switch same side stand by pump to interlock, check
make-up and drain out float valve in oil returning tank work normal.
4.9.2.3 Check oil sealing system overall, no leakage appears, check water level of float water
level detector, oil sealing tank and froth breaking tank changing normally. Prevent generator
from filling oil or water. Trace each balance valve and pressure difference valve normal, and
indicator normal.
4.9.2.9 When oil sealing temperature of two sides increase to 43℃, put oil cooler into running.
4.9.3 Shutdown seal oil system
4.9.3.1 Make sure inner generator fill with air and keep still.
4.9.3.2 Undo seal oil pump interlock.
4.9.3.3 Shut hydrogen side AC seal oil pump. Stop hydrogen side seal oil cooler supplying
water (can stop cooler according to oil temperature).
4.9.3.4 Shut air side AC seal oil pump. Stop to supply water to seal oil cooler at air side (can
stop cooler according to oil temperature).
4.9.3.5 Undo smoke exhaust fan interlock. Shut air side seal oil smoke exhaust fan.
4.9.4 Generator seal oil system operation maintenance
4.9.4.1 During normal operation, must ensure sealing oil pressure. Maintain the sealing oil and
gas inside the machine pressure difference is 84KPa. Air and hydrogen side sealing oil
pressure difference should be lower than ±0.49KPa.
4.9.4.2 Pressure and current of sealing oil pump is normal. Stand-by sealing oil pump and DC
sealing oil pump in good standby condition during normal operation.
4.9.4.3 Examine and maintain oil level of sealing oil tank at air or hydrogen side o.k.
4.9.4.4 Examine and maintain sealing oil cooler at air or hydrogen side are o.k. Outlet oil
temperature should keep in 38~49℃.
4.9.4.5 No oil leakage in the whole system.
4.9.4.6 During normal operation, air side seal oil return tank maintain sub pressure -250~-
500Pa.
4.9.4.7 Scraper oil filter of seal oil unit turns a handle every eight hours to clean to avoid oil
channel blocking. The pressure difference between air and hydrogen side seal oil filter is lower
than 50KPa.
4.9.5 Sealing oil source of air side and hydrogen side
4.9.5.1 Oil source of air side sealing oil
a. main working oil source: normal working oil source of air side sealing oil shall be supplied by
AC sealing oil pump, outlet pressure is 1.0MPa.
b. First standby oil source: it is 2.1~2.3MPa HP oil which comes from turbine main oil pump.
When main working oil source malfunction and oil-hydrogen pressure difference drops to
0.056MPa,the oil source shall be put into operation automatically by the control of standby
pressure difference regulating valve.
c. Secondary standby oil source: it is supplied by the hydrogen seal standby oil pump on turbine
main oil tank. When turbine rotating speed is lower than 2850r/min or goes wrong and
oil-hydrogen pressure difference drops to 0.056MPa, well then sealing oil will be supplied by
hydrogen seal standby oil pump. Outlet pressure is 0.8~1.1MPa..
d. Third standby oil source: it is supplied by DC sealing oil pump. Start DC sealing oil pumps
while hydrogen-oil pressure difference drops to 0.035MPa. This oil pump is allowed to running
for about 1 hour only.
e. Fourth standby oil source: it is supplied by turbine lubricant oil pump, but oil pressure is lower,
normal range is 0.05~0.12MPa. At this time, hydrogen pressure must be reduced to 0.014MPa.
4.9.5.2 Oil source of hydrogen sealing oil: normal working oil source of hydrogen side sealing oil
is supplied by AC sealing oil pump. When AC sealing oil pump is blooey, sealing oil shall be
supplied by standby sealing oil pump.
4.9.6 I & C interlock protection
4.9.6.1 Operating inlet & outlet pressure difference of hydrogen side sealing oil pump is as low
as 0.035MPa, that hydrogen side sealing oil pump shall be started.
4.9.6.2 Oil & hydrogen pressure difference is as low as 0.035MPa; DC oil pump of air side
sealing oil shall be started.
4.9.6.3 Inlet & outlet pressure difference of DC sealing oil pump is as low as 0.035MPa, that air
side sealing oil DC oil pump shall be started.
4.9.6.4 Inlet pressure of generator air side sealing oil is low, start air side sealing oil DC oil
pump.
4.9.6.5 Return oil temperature of air side sealing oil is as low as 40℃, heater shall start
automatically; and it will auto stop when return oil temperature reaches 45℃ .
4.9.6.6 Return oil temperature of hydrogen side sealing oil is as low as 40℃ , heater shall start
automatically; and it will auto stop when return oil temperature reaches 45℃ .
4.9.7 Accident Disposal
4.9.7.1 Reasons for reduction of oil/hydrogen pressure difference and disposal.
a. If air side AC sealing oil pump malfunction, it is necessary to supply oil for HP standby sealing
oil, maintain oil/hydrogen pressure difference as 56KPa.
b. If oil/hydrogen pressure difference cannot be maintained, and keep on reducing to 35KPa,
put DC sealing oil pump into auto operation, otherwise start it manually.
c. After DC sealing oil pump being started, if oil/hydrogen pressure difference cannot be
maintained, emergency hydrogen exhaust shall be done; hydrogen pressure is reduced to
14KPa or below, unit shutdown.
d. If oil/hydrogen pressure difference regulating is failed, contact maintenance men to dispose
as soon as possible.
4.9.7.2 Failure of hydrogen side sealing oil pump or interruption of hydrogen side sealing oil
a. hydrogen side sealing oil pump is shutdown due to failure, strict monitor hydrogen purity of
generator, which shall not be lower than 90%, and ensure the operation of smoke extractor
exhaust fan of main oil tank and air side sealing oil tank.
b. If air/hydrogen side pressure difference balancing valve is failed, please contact maintenance
men to examine & repair in time, and strengthen the monitoring of oil level in defoaming tank.
4.9.7.3 High oil level in defoaming tank:
a. When oil level in defoaming tank is increasing, check the operation of air/hydrogen side
pressure difference balancing valve, contact maintenance men to examine & repair in time.
b. Check the oil level in hydrogen side return oil control tank is normal or not, if high oil level in
defoaming tank is caused by this, when oil level in defoaming tank is increasing to alarming
value, well then manual open hydrogen side return oil high level float valve to control the oil
level in defoaming tank and hydrogen side return oil control tank. If necessary, carefully open oil
drain valve of defoaming tank to drain oil.
4.9.7.4 Hydrogen side sealing oil level is extreme low:
a. Once oil level reduction is discovered and low oil level alarm is sent out, turn down high level
drain floating valve, and open low level filling floating valve to fill in oil tank. Maintain normal oil
level.
b. If oil level cannot be maintained, it is necessary to close high level drain floating valve.
4.10 Stator cooling water system
4.10.1 Stator cooling water system operation rules
4.10.1.1 Generator must pressurize before system is feed water or begin circulation.
4.10.1.2 Water must be inside cooling system before generator loaded or stator coil charged.
4.10.1.3 Generator hydrogen pressure must be 0.035MPa higher than that of stator inlet
cooling.
4.10.1.4 When generator cut excitation, stator cooling water system could shut.
4.10.1.5 Make sure inner cooling water temperature at least higher than hydrogen temperature
1℃ .
4.10.1.6 When generator stator winding inlet and outlet water pressure difference value reduced
to 70% of the rated flow (55t/h), switch differential pressure. According to "three close, take two"
logical principle, this acts as the signal of generator water break protection. When the generator
stator winding appears water break, allow full loaded 100% rated current running 5 seconds and
put stand-by pump within 5 seconds into normal operation. If the standby pump in 5 seconds
can not run normal, generator must stop or every minute in 2 minutes with the rate of 50% of
the stator current will be reduced automatically to 15% of the rated current. At the same time,
electrical conductivity of stator cooling water should be controlled in 1.5 cm/s.
4.10.1.7 When the stator cooling water flow is low and at the same time water conductivity
lower than 1.5μs/cm, generator could operate an hour by 15% rated stator electricity. If stator
cooling water flow is low and conductivity is higher than 1.5μs/cm, generator must stop
immediately. 2.5 minutes later excitation is lost.
4.10.2 Put stator cooling water system into operation
4.10.2.1 Make sure condensate transfer pump put into operation, stator cooling tank feed water
source is normal and
4.10.2.2 Examine generator and make sure inner hydrogen pressure set up.
4.10.2.3 Make sure the level of stator cooling tank is normal, water quality qualified, water
temperature is normal.
4.10.2.4 Put stator cooling ion exchanger into operation; feed the level of stator cooling tank to
normal high level. Water tank water drainage valve blow down, until chemical assay water
quality qualified, close tank water drainage valve.
4.10.2.5 Examine stator cooling tank supply nitrogen automatically to 0.014MPa and its
pressure regulator normal.
4.10.2.6 Shut cooler, filter drain valve, bypass valve. Start air valve, and then start stator cooling
pump, cooler and filter inlet or outlet valve system to feed water to system. Put cooler into
operation, filter air valve leave one circle opening, shut stand-by cooler and filter air valve.
4.10.2.7 Shut stator cooling water pump outlet valve. Shut one group of cooler. Filter inlet valve
on standby.
4.10.2.8 Start stator cooling pump; start outlet valve after checking operation normal; adjust
control pressure of generator inlet valve to 0.25~0.35MPa.Stator cooling water flow is about
90t/h.
4.10.2.9 Put another pump interlock and standby.
4.10.2.10 After generator synchronization, put stator cooler into operation when generator inlet
stator cooling water temperature is over than 45℃ and control generator stator cooling water
temperature between 45~50℃.
4.10.3 Shutdown stator cooling water pump
4.10.3.1 When standby stator cooling water pump switches, firstly manually start stand-by pump;
secondly shut running pump and put stand-by pump into operation. Pay close attention to
cooling water flow is normal or not.
4.10.3.2 When unit shuts, stop the stator cooling system immediately according to demand in
order to prevent generator overcooling.
4.10.3.3 Undo stator cooling water pump interlock. Shut stator cooling water pump. Check
stator cooling water pump shutdown or not.
4.10.4 Stator cooling water system operating maintenance
4.10.4.1 The normal operation should always check the level of stator cooling tank and make
sure stator cooling water pump operate normally.
4.10.4.2 Stator cooling water normal temperature is controlled in 35~50℃. Maintain normal
operation constant value 40±1℃.
4.10.4.3 Stator cooling water pressure is normal. Stator cooling water pump outlet pressure is
about 0.75MPa. Stator cooling water flow is about 90t/h normal.
4.10.4.4 When unit is operating normally, stator cooling water regenerative circuit (ion
exchanger) shall be running. Chemical staff should check water quality regularly and make sure
stator cooling water electric conductivity in 0.5~1.5us/cm.
4.10.4.5 When there is nitrogen in the upper of stator cooling water tank, check its normal
pressure is 0.014MPa.
4.10.4.6 Ion exchanger operating flow is 3~5% of total flow and conductivity indication is within
1.5us/cm.
4.10.5 Main interlock protection
4.10.5.1 When stator cooling water main pipe pressure is low, stator pump starts.
4.10.5.2 When inlet and outlet pressure difference of operating stator cooling water pump is
lower than 0.014MPa, stator pump starts.
4.10.5.3 When stator tank pressure is higher than 0.035MPa, safety valve of tank opens
automatically.
4.10.5.4 When stator water flow is lower than 70% of rated flow(55t/h), time lag 30s, generator
tripping.
4.10.6 Accident disposal
4.10.6.1 The reason of stator cooling water low pressure and disposal:
a. Pressure difference of stator cooling water sieve or stator cooling water cooler is high,
you should switchover sieve or stator cooling water cooler.
b. When the stator cooling pump is overloaded, recycling degree shall be increase and start
stand-by pump if necessary.
c. When the stator cooling pump trip, stand-by pump shall be put into auto operation.
d. When the level of water tank is low; feed water to normal level.
e. When pipes, valves, flanges etc. leaks; isolation measures must be done to not affecting
unit operation.
4.10.6.2 Generator water leaking disposal:
a. When generator level detector high alarm, you should immediately discharge liquid in
situ. If generator contains water more, you should find out reason quickly. Discharging liquid,
you should prevent hydrogen leaking largely.
b. Hydrogen cooler leakage, you should separate broken hydrogen cooler and decrease
load to maintain hydrogen temperature normally. Pay attention to temperature of generator iron
core and coil.
c. You should low stator cooling water temperature if hydrogen pressure is lower than stator
cooling water pressure and generator coil leakage slightly. At the same time, report to
leadership to require failure shutdown.
d. When leakage is too serious to endanger the safety operation of unit, shut stator cooling
water system and separate hydrogen cooler; also start drain valve of generator.
5.2.2.2.2 Bus ring is linked and tighten well, brush can move smoothly up and down, its frame
bottom doesn’t contact with bus ring.
5.2.2.2.3 Slip ring, brush and ground brush of main shaft are installed well and contacted well.
5.2.2.2.4 Each linkage, bond and shim of the generator proper are stable, no condensation in
their part and illumination is enough. Check exciting system and its equipment no break, moist
or dirty and other abnormal situation. Linkage is stable, no loose and broken.
5.2.2.2.5 Running condition of generator-transformer protection, auto –exciting system, NSC,
DCS is possessed; the clamping bars are in their correct position.
5.2.2.2.6 Check auto synchronizing equipment correct.
5.2.2.2.7 Each test before starting unit is conformity.
5.2.2.2.8 Oil sealing system, hydrogen cooling system, and stator inner cooling water system are
put into running normally. Each meter, parameter indicator is correct and agrees with running
regulation of generator cooling system.
5.2.2.2.9 insulating of measuring system conform to regulation.
5.2.2.2.10 put micro-pressure vent equipment into running.
5.2.3 Test before starting
5.2.3.1 According to regulated test list before starting generator, conduct tests like interlock,
protection, and trip and connect test by hand.
5.2.3.2 All tests should be done while the switchgear of 400kv bus (main and assist) is in break
position, work switch of 11kv bus is in test or repair position.
5.2.3.3 Test item
5.2.3.3.1 Main terminal switch trip and close test of generator-transformer.
5.2.3.3.2 De-exciting switch trip and close test and lock to trip main switch test.
5.2.3.3.3 11KV A, B, C work power’s inlet line switches trip and close test.
5.2.3.3.4 Assist to relay staff to do protection test.
5.2.3.3.6 Switch over test of emergence lighting system.
5.2.3.3.5 Signal system test.
5.2.3.3.7 Big interlock test of boiler, turbine and generator.
5.2.4 Basic operation step when start generator-transformer
5.2.4.2 Generator transformer turns to warm stand by:
5.2.4.1.1 All work ticket of G-T have finished, equipment is perfect and can be put into running.
5.2.4.1.2 Check primary and secondary system of G-T wiring correctly and perfectly.
5.2.4.1.3 Measure primary and secondary equipment insulation and conformity.
5.2.4.1.4 According to electric relay protection code, put G-T protection, plant high-voltage
transformer protection and auto equipment. Check NSC, DCS equipment put into running.
5.2.4.1.5 Check 400kv bus differential protection clamping bar to G-T connected.
5.2.1.4.9 Put slip ring cooler into running.
5.2.4.1.6 Put high voltage fuse of generator into its position, push switch into work position, close
secondary switch.
5.2.4.1.7 Check NSC, DCS equipment and monitor meter in running position.
5.2.1.4.8 Check generator bus micro-pressure equipment in running position.
5.2.1.4.11 put rectifier into running.
5.2.1.4.10 Check exciting initiating power, rectifier cabinet, and exciting adjusting equipment
power on.
5.2.4.1.11 change rectifier from cold standby to operation.
5.2.1.4.12 Put exciting system into warm stand-by.
5.2.1.4.13 Put cooling equipment of main transformer into running.
5.2.1.4.14 Put cooling equipment of A, B plant high-voltage transformer into running.
5.2.1.4.15 Check neutral switchgear in closing position.
5.2.1.4.16 Check switches of G-T in broken position.
5.2.1.4.17 Close 400kv bus switchgear according to order.
5.2.1.4.18 put 11kv A, B, C work power switch into warm stand-by.
5.2.1.4.19 Turn the power of plant high voltage t, G-T, de-exciting switch on.
5.2.4.2 Step of put rectifier into running
5.2.4.2.1 Put DC side fuse into position and check it perfect.
5.2.4.2.2 Put AC side fuse into position and check it perfect.
5.2.4.2.3 Turn rectifier power on,
5.2.4.2.4 Turn fan power on.
5.2.4.2.5 Switch fan mode to right fan, check it running correctly.
Note: Steps of stop rectifier are just opposite.
5.2.4.3 Steps of generator synchronize to grid.
5.2.4.3.1 Check condition admitted before synchronizing. And parameter display correctly.
5.2.4.3.2 Start g program control after g‘s speed in 3000r/m stable.
5.2.4.3.3 Watch closely to respective parameter changing, and signal display.
5.2.4.3.4 If synchronize successful, check parameter display correctly, and return main switch on
CRT.
5.2.4.3.5 Check exciting system put into running and its switch close perfectly.
5.2.4.3.6 Check G-T switch close perfectly.
5.2.4.3.7 Adjust neutral running mode of 400kv system according to order.
Note: if synchronizing is done by hand, finish it according to condition and sequence displayed on
diagram.
5.2.5 Inspection after turning (1500r/m or 3000r/m)
5.2.5.1 Temperature, vibration, and oil-back temperature of bearing, bearing pad are normal.
5.2.5.2 Stator cooling water pressure, flow and temperature and outlet water of wire bar and
5.2.8.7 If there is any abnormal found in increasing voltage, stop increasing and decreasing it to 0,
after finding out reason, and approved by deputy manager or chief engineer, increasing can
continue.
5.2.8.8 Synchronizing condition
5.2.8.8.1 The G-T voltage should be equal to grid voltage (difference no larger than ±5%)
5.2.8.8.2 The G-T frequency should be equal to grid’s (difference no larger than 0.1Hz)
5.2.8.8.3 The phase of G-T should be equal to grid’s (difference no larger than 15 degree, max.
no larger than ±20 degree)
5.2.8.9 Check phase rotation after overhaul or synchronizing circuit changed, and false
synchronization test should be done to check its circuit correct.
5.2.8.10 Adjust exciting regulator to lowest voltage before start generator.
5.2.8.11 we regard all equipment have power after generator rotor.
5.2.8.12 for new installed or repaired generator, when start it first, increasing speed slowly and
monitor generator voice, inspects oil flow of bearing and vibration.
5.2.8.13 Inspect brushes on slip ring no jumping, no block, and contact well when generator rotor
speed gets to regulated value.
5.2.8.14 Check generator unit no abnormal signal, after turbine speed stable, can increase its
voltage after foreman’s order.
5.2.8.15 after generator rotating, check display situation, status and alarm on CRT.
5.2.8.16 when rotor current reaches no load rated value while stator voltage doesn’t get to rated
value, or alarm signal appears, stop operation and find out reason.
5.2.8.17 forbidding put exciting system when rotor speed lowers than 2950r/m.
5.2.8.18 when synchronizing, maintain rotor speed in 3000r/m, or adjusting it.
5.2.8.19 If main switch doesn’t close after synchronizing equipment put into running, break it
power and find out reason..
5.2.8.20 Monitor closely three phase current, negative sequence current, active power, wattles
power and other parameter while synchronizing to prevent main switch from closing lack of one
phase.
5.2.8.21 Put AVR into running, close exciting switch, generator will increase voltage from 0v, note:
5.2.8.21.1 Increasing voltage slowly and make three phase voltage balance, current to 0 or nearly.
While rated voltage reached, check rotor voltage and current reaching rated value. Otherwise
stop operation.
5.2.8.21.2 Check three voltage balance after stator voltage get to rated value.
5.2.8.21.3 Check no load rotor voltage and current normal while stator in rated value.
5.2.8.22 Take protect measures if asynchronous parallel.
5.2.8.23 Synchronous parallel when frequency difference in 1HZ.
5.2.8.24 Close watch synchronizing equipment when operation.
5.2.11.1.3 There are some stand-by fans in each cabinet. Switch their power and do interlock test
according to demand.
5.2.11.1.4 In normal condition, power #1 work, power #2 stand-by and right fans work, left fans
stand-by.
5.2.11.2 Regulation of running exciting adjusting equipment
5.2.11.2.1 There are twin auto channel and twin manual channel which is stand-by in exciting
adjusting equipment. And there is manual channel in auto channel also. In normal condition, twin
auto channel work, but impulse of one auto channel is locked. When troublesome in the other
channel appears, switch automatically to this one and block the other’s impulse, if there is
troublesome in this one, switch to stand-by manual channel.
5.2.11.2.2 In normal condition, forbid manual channel mode to run a long time.
5.2.11.2.3 When synchronizing or de-synchronizing, use auto exciting adjusting mode to increase
or decrease voltage. When commissioning or repair, manual mode can be used if needed.
5.2.11.2.4 Forbid to operate any set item on exciting adjusting equipment panel, forbid any
person to clear troublesome message on panel when no order received. Any operation which will
change running mode should be done under dispatch clerk’s order or regulation.
5.2.11.2.5 When return any alarm or troublesome signal, record these message and forbid to
return it again and again.
5.2.11.2.6 Conduct switch test between auto channel and manual channel to inspect stand-by
channel perfect.
5.2.11.2.7 Before conducting switch test, insure signal of ready to channel switch appeared,
otherwise, forbid to conduct this test.
5.2.11.2.8 Exciting system can run continuously when exciting voltage and current no larger than
1.1 times of rated value.
5.2.11.2.9 Exciting winding can withstand following over-voltage in short time when in rated load:
Time(s) 10 30 60 120
Exciting voltage (%) 208 146 125 112
5.2.12 running regulation of stator water cooling system
5.2.12.1 Before put stator water cooling system, rotor and core hydrogen cooling system into use,
forbid to blow rotor, exciting and loading.
5.2.12.2 After de-exciting, stator water cooling system can only be stopped. Hydrogen system
should be stopped according to repairing demand.
5.2.12.3 Control hydrogen pressure higher than water pressure when running, water temperature
higher than hydrogen temperature. When running in low hydrogen pressure, maintain lowest
water pressure no lower than 0.15MPa. Now, admit water pressure higher than hydrogen’s for a
short time.
5.2.12.4 For cooling water entering into stator winding: conductivity no larger than 1.5us/cm,
5.2.13.1.2 Generator rotor rotate normally, vibrate normally, no crack, discharge, overheat, odor
exist in winding terminal, shim fasten, connecting hose of inlet and outlet perfect, no leak and
seep.
5.2.13.1.3 Each part temperature normal, water-hydrogen-hydrogen cooling system and other
equipment normal.
5.2.13.1.4 Check hydrogen leakage detector perfect, no alarm signal.
5.2.13.1.5 Check floater leakage detector perfect.
5.2.13.1.6 Check auto, protection equipment perfect, its power, signal, meter, and display normal.
5.2.13.2 Check in exciting system running
5.2.13.2.1 Sound, vibration, outer case temperature of exciting transformer are all normal, meter,
signal and parameter correct.
5.2.13.2.2 Signal, meter, display and indicator light are all normal, channel trace correct and
ready to switch, fans in cabinet running well, no abnormal sound and odor.
5.2.13.2.3 Check exterior condition and display of de-exciting switch, over connecter,
over-voltage protection perfect, connecting part normal.
5.2.13.2.4 Output of each rectifier cabinet is balance and no heat, loose, odor, abnormal sound in
cabinet. Cooling fan runs well, its signal, meter and display light correct.
5.2.13.2.5 No dirty, ash accumulated, loose and heat in primary and secondary system, otherwise,
notice and repair them.
5.2.14 operate step of de-synchronizing to repair status
5.2.14.1 Decrease load to 180MW before de-synchronizing, switch plant power to start and
stand-by transformer.
5.2.14.2 Check plant system perfect, generator proper perfect.
5.2.14.3 Adjust neutral mode of 400kv system according to foreman’s order.
5.2.14.4 Decrease active and wattles power to 0 gradually.
5.2.14.5 Check de-synchronizing condition reached, start de-synchronizing program.
5.2.14.6 According to program going, close watch parameter changing of stator and rotor, stop
program when abnormal situation found.
5.2.14.7 Check de-synchronizing successfully, return switch.
5.2.14.8 Check exciting system exit well, de-exciting switch break well.
5.2.14.9 Check terminal switch of G-T in break status.
5.2.14.10 Turn the power off for plant high-voltage, G-T, de-exciting switch.
5.2.14.11 Open the 400kv bus side switchgear of G-T terminal switch.
5.2.14.12 Stop cooling equipment of main transformer.
5.2.14.13 Stop cooling equipment of A,B plant high-voltage transformer.
5.2.14.14 Stop micro-pressure equipment of g enclosure bus
5.2.14.15 Stop the slip ring cooler of g.
5.2.14.16 Switch exciting initial equipment and exciting adjusting equipment to cold stand-by if
needed.
5.2.14.17 Turn the rectifier cabinet to cold stand-by if needed, take fuse off.
5.2.14.18 for g outlet, take secondary side fuse off and pull secondary trolley out, and then put it
in isolation position.
5.2.14.19 Stop the protection and auto equipment of G-T.
5.2.14.20 Turn ingoing switch of 11kv A, B, C section work power to cold stand-by.
5.2.14.21 Turn the G-T to repair status if needed. Note: if it is stopped according to provincial
order, steps behind 14th can be omitted.
5.2.14.22 Issue that noticed while stopping g
a receive foreman’s order.
b before de-synchronizing, close neutral ground switchgear of main transformer.
c after active power meter, wattles power meter, electric energy meter indicate to 0, open outlet
switch of G-T.
d notice if outlet switch of G-T open phase.
e when de-synchronizing, put exciting mode to auto to let it turn to inversion de-exciting.
f put rotor into jigger status after stop g. when it need to stop rotor, put its big gear’s centerline to
vertical position, to prevent bend effect.
5.2.15 running regulation of hydrogen system
5.2.15.1 Running condition: installation or repairing have finished, air tightness test has done and
conformity.
5.2.15.2 Use carbon dioxide as middle media when change gas in generator. Charge carbon
dioxide into generator in gaseity.
5.2.15.3 Change generator air whiles its rotor on static state. If needed to do on jigger state,
control gas temperature strictly, but it is forbidden to do during starting or stopping.
5.2.15.4 Prevent carbon dioxide from contacting with inner cooling water of stator, because
carbon dioxide dissolved into water will enlarge water’s conductivity.
5.2.15.5 Before charging hydrogen into generator, insure oil sealing system running normally.
5.2.15.6 Change air with carbon dioxide, only when its contents larger than 98%, can stop
evacuating air.
5.2.15.7 Change carbon dioxide with hydrogen, only when its contents larger than 98%, can stop
operation and make up and increase pressure.
5.2.15.8 When generator running normally, purity of hydrogen should be higher than 96%,
content of oxygen no larger than 2%, humidity 2g/ m 3, otherwise make up or evacuate hydrogen
to make purity, oxygen content and humidity normal.
5.2.15.9 When change hydrogen with carbon dioxide, only when its contents larger than 98%,
operation can stop.
5.2.15.10 Put hydrogen dryer into running when generator running normally, and control
temperature ≤48℃.
5.2.15.11 Hydrogen leakage should be not larger than 11.3 m3/day; otherwise, leakage inspection
should be done.
5.2.15.12 Stop cooling water pump while changing air.
5.2.15.13 when running normally, oil sealing pressure shall be larger than hydrogen’s 0.05MPa;
pressure difference of hydrogen side oil sealing shall not be larger than 0.001MPa.
5.2.15.14 for hydrogen cooler, if one water passage exit in rated hydrogen pressure, load
admitted is 80%, and temperature of each part in limited value.
5.2.15.15 When hydrogen pressure lower than regulated value, control generator load according
to hydrogen- load curve, and temperature of each part in limited value.
5.2.15.16 if stop generator for a short time, or no repair work done on generator or its assist
system, hydrogen evacuating work is admitted to omit. Control each part temperature no lower
than 5℃, and its humidity, purity in regulated value.
5.2.15.17 To prevent generator insulating performance from decreasing, control humidity of
hydrogen in generator to make its dew point in -5℃~-25℃ under 1 standard atmosphere
pressure. Put hydrogen dryer into use while running normally, or make up dry hydrogen which
dew point shall be higher than -35℃.
5.2.15.18 when changing hydrogen, shorten time of carbon dioxide in generator among 24h.
5.2.15.19 after repairing hydrogen system, take some measures like circulating dry air into it to
prevent it damp.
5.2.15.20 Parameter
Normal pressure (MPa) 0.4 Volume of generator (m3) 110
Air quantity replacing CO2 (m3)1.5*110 CO2 quantity replacing H2 2.5*110
3
Leakage <11.3 m /day
5.3 Troublesome of generator
5.3.1 Stop generator emergent
5.3.1.1 If friction sound, clash sound found or vibration going up, and its value excess regulation.
5.3.1.2 There’s explode, smoking or catch a fire in generator.
5.3.1.3 Smoking or catch a fire in exciting transformer, TV or CT.
5.3.1.4 Protection of generator, main transformer, exciting transformer or plant high-voltage
refuse to trip while they have troublesome.
5.3.1.5 Water broken for more than 30s, but protection refuses to operate.
5.3.1.6 Water leakage heavily in generator and stator or rotor grounding.
5.3.1.7 Troublesome in oil sealing system, hydrogen leakage heavily in generator.
5.3.1.8 Slip ring, brush catch fire heavily, could not put out.
5.3.1.9 Other emergence situation which can hurt human or risk to human safety.
5.3.2 Ask deputy manager or chief engineer to stop generator when one of situation
following appears
5.3.2.1 Because of troublesome in oil sealing system, hydrogen pressure could not maintain and
its purity decreases to lowest value.
5.3.2.2 Water leakage in generator stator.
5.3.2.3 Water outlet temperature of generator stator gets to nearly 90℃, or its difference reach to
12K nearly, or temperature difference of stator lamination near to 14K and has trend to increase.
5.3.2.4 Core temperature of generator excess regulated value, and situation maintain after take
some measures.
5.3.2.5 Leakage in hydrogen cooler, its humidity excess regulated value.
5.3.3 General operation rules when generator-transformer protection acts
5.3.3.1 Insure G-T switch, exciting system and its de-exciting switch trip.
5.3.3.2 Check plant power switch over correctly, return power of plant system.
5.3.3.3 Check protection operating correctly, record completely and return switch and signal
normal.
5.3.3.4 Inspect generator and its protection and its electric equipment, find out accident point and
reason, and repair them.
5.3.3.5 If troublesome exist still, contact special repairing person and solve problem.
5.3.3.6 If no troublesome found, report to deputy manager or chief engineer, increase voltage
from 0 after approved by them. During increasing, if there is any abnormal situation found, stop
and inspect in detail.
5.3.3.7 Test G-T and its system insulation conformity after troublesome resolved, and return to
start running.
5.3.4 When troublesome or switch refuse to act among G-T
5.3.4.1 If protection refuse to act, stop generator immediately.
5.3.4.2 If switch refuse to act because of out of control, protection should start and cut off this
400kv line or bus, otherwise open this switch manually.
5.3.4.3 Insure plant power switch over normally.
5.3.5 Generator voltage doesn’t go up while increasing voltage
5.3.5.1 Appearance
5.3.5.1 Stator voltage is abnormal while increasing voltage.
5.3.5.2 Exciting voltage and current abnormal.
5.3.5.2 Handle
5.3.5.2.1 Stop increasing voltage operation, inspect exciting initiate equipment, its power and
output normal.
5.3.5.2.2 Check exciting adjusting equipment normal.
5.3.5.2.3 If meter of stator and rotor indicate none, inspect de-exciting switch close well,
over-connector open completely and rectifier cabinet put into running normally.
5.3.5.2.4 Check exciting circuit perfect.
5.3.5.2.5 If meter in rotor circuit indicates while meter in stator circuit indicates none, check meter
circuit perfect.
5.3.6 Generator loss of exciting
5.3.6.1 Appearance
5.3.6.1.1 Current and voltage of exciting circuit abnormal.
5.3.6.1.2 Terminal voltage of generator and 400kv system voltage decrease.
5.3.6.1.3 Generator change to asynchronous running
5.3.6.1.4 When exciting loss heavily, exciting loss protection operates and trip generator.
5.3.6.2 Handle
5.3.6.2.1If exciting loss protection operates main switch and de-exciting switch trip, check up
reasons and resolves it.
5.3.6.2.2 If exciting loss protection doesn’t operate, main switch and de-exciting switch doesn’t
trip, decrease load to 60% rated value in 60s, to 40% in 90s, and try to increase exciting by best,
control stator and rotor current not to excess 1.1 rated current. Asynchronous running time is not
admitted excess 15m, if exciting current could not resume, notice special repairing person to
repair.
5.3.6.2.3 If protection of exciting loss operate and de-exciting trip, but main switch doesn’t trip,
open main switch by hand.
5.3.6.2.4 If main switch could not be opened, decrease generator load to 0 then adjust running
mode, de-parallel generator by bus connection switch. If situation is urging and vibration is large
enough, open all switch connecting to this 400kv bus.
5.3.7 When generator parallel asynchronously
5.3.7.1 Appearance
5.3.7.1.1 Active power, wattles power and stator current wither heavily after parallel.
5.3.7.1.2 Unit vibrates heavily and big sound heard from inner.
5.3.7.1.3 In worst situation, generator protection operate and G-T switch trip.
5.3.7.2 Handle
5.3.7.2.1 If generator vibrates a little and sound is not so big, and meter swing first but slowly
stop , no need to stop generator, but exterior inspection is needed, and report to deputy manager
and chief engineer to decide if running continuously.
5.3.7.2.2 If shock or heavily vibration occurs, meter pointer swing heavily and no weaken, stop
generator immediately. Inspect and test generator completely, the most important is synchronizing
system After then, conduct false synchronization test, report deputy manager and chief engineer
to decide parallel or not.
5.3.7.2.3 If generator trip because of asynchronous parallel, inspect protection, record, analyze
and report to foreman, inspect and test generator and turbine completely, ask deputy manager
and chief engineer to parallel or not.
5.3.8 Change generator to motor running
5.3.8.1 Appearance
5.3.8.1.1 Active power meter points to minus.
5.3.8.1.2 Reverse power protection operate.
5.3.8.2 Handle
5.3.8.2.1 Synchronous motor running should not be longer than 60s in normal exciting.
5.3.8.2.2 If cross-protection operate because main steam valve close, generator stopping
finished.
5.3.8.2.3 If protection doesn’t operate or main switch doesn’t trip, take some measures
immediately to make generator out of motor running, otherwise de-parallel generator.
5.3.9 Generator vibration heavily
5.3.9.1 Appearance
1) Active power, wattles power, stator current, stator voltage, and other parameter swing
periodically.
2) Unit roaring rhythm.
3) Generator enters into constrained current running.
5.3.9.2 Handle
1) Judge this appearance is caused by generator in common plant or not, if it is, increase exciting
and decrease active power and make generator synchronization. If troublesome last for one
minuet and could not make generator synchronization, de-parallel generator according to
foreman’s order.
2) If it is caused by loss of exciting, de-parallel this generator from system, then report to dispatch
clerk.
3) If it is caused by grid, and frequency swing above 50Hz, decrease output and decrease
frequency to 49.5Hz, otherwise increase output and increase frequency 49.5Hz.
4) If system swing for 2 to 3 minuet, and system could not resume, report dispatch clerk.
5.3.10 Brush of slip ring heat heavily or catch a fire
5.3.10.1 If it is caused by unbalance force put on slip ring and makes current unevenly, check
brush and change shorter or broken brush, adjust spring force, make current evenly.
5.3.10.2 If it is caused by brush blocking in frame or swinging, change them.
5.3.10.3 If caused by different type brush, change them.
5.3.10.4 If cooling system of slip ring, decrease exciting current and find out reason, repair it.
5.3.11 abnormal temperature of generator
5.3.11.1 Appearance
1) Temperature of stator winging or core winding goes to near or excess admitted value.
repair.
5.3.16 when running on phase open
5.3.16.1 Appearance
1) If one phase of main switch close, and other two phases open, two phase currents of three
equal nearly, the other phase equal to 0 nearly.
Phase that close A B C
Stator phase a b c a b c a b c
Current yes 0 yes yes yes 0 0 yes yes
2) if two phases of main switch don’t open, two phase stator current of three shall be equal nearly,
and equal about 1/2 the other one.
Phase that doesn’t open AB BC CA
Phase a b c a b c a b c
Current display big small small small big small small big
5.3.16.2 Handle
1) If G-T switch doesn’t trip which it shall trip, then de-parallel G-T unit from grid.
2) If G-T switch doesn’t trip, report foreman, maintain generator exciting, and notice turbine major
to maintain rated rotor speed, but forbid increasing load and regulating running mode, de-parallel
generator using bus connection switch, and repair.
3) After troublesome removed, check and test generator-transformer unit completely according to
running mode and report to chief engineer, start unit according to approved measure by chief
engineer.
5.3.17. When generator over-exciting
5.3.17.1 Appearance
1) Signal of over-exciting appears.
2) Protection of over-exciting operates and trip.
5.3.17.2 Handle
1) If it is caused by lower system frequency, contact with dispatch clerk to resume frequency,
adjust wattles power and voltage of generator and make V/F in limited scope.
2) After V/F protection operate and trip generator, check and test main transformer, generator,
exciting circuit normal, confirmed by repairing person, approved by chief engineer, then start
generator.
5.3.18 when rotor winding one point grounding
5.3.18.1 Appearance
Rotor winding one point grounding protection acts and trips.
5.3.18.2 Handle
1) If generator trip, operating according to 5.6.1.3 clause.
2) Ask if it is caused by operation mistaken or inspect incorrectly.
3) Check exciting circuit grounding or not, measure insulation of rotor circuit by megger after
change to cold standby, if grounding point is in outside of rotor, eliminate grounding point then
start unit again. If grounding point is inside rotor, change generator to repair.
5.3.19 Hydrogen leakage
5.3.19.1 Appearance
1) Display of hydrogen pressure decreases abruptly, make up hydrogen again and again but
pressure drop heavily, could not maintain running normal.
5.3.19.2 Handle
1) When generator in stand-by status, check oil sealing system running normally while hydrogen
pressure drops, otherwise replace hydrogen, after removing defect of oil seal system, replace
hydrogen again.
2) If generator running when hydrogen leakage lightly, find out reason. If pressure drop is in
normal scope, make up hydrogen; otherwise find out leakage point and repair.
3) If leakage is heavily, decrease active power when hydrogen pressure drops, and check oil
sealing system, hydrogen system immediately, remove defects. Then make up hydrogen. If
leakage heavily and could not remove defects, de-parallel generator. Forbid generator running in
0 hydrogen pressure.
5.3.20 when generator explodes or catches a fire
5.3.20.1 Appearance
1) Smoke or odor smell emitted from outer case or terminal part.
2) Big sounds heard in generator, and oil fume emitted from it.
5.3.20.2 Handle
1) De-parallel generator immediately, and isolate it.
2) Charge in carbon dioxide and drain out hydrogen.
3) Maintain rotor speed in 300~500r/m, to prevent shaft bending.
4) Put out fire with 1211 or dry extinguisher; never use foam, water or sand.
5) Maintain cooling water running normally when taking some measures.
6) Dial 100, report foreman and other leaders.
5.3.21 when troublesome in exciting system and removing
1) If exciting system troublesome caused by parameter excess limited value, adjust parameter to
admitted value, and return signal.
2) If it is caused by its equipment defect, switch it to stand-by channel, in emergent situation,
report to foreman and switch it to manual channel.
3) Analyze and judge troublesome situation according to alarm signal and other troublesome
message, if it is caused by equipment, repair it. Otherwise, remove defects and repair.
5.3.22 Rectifier cabinet defect or alarm
1) Check it in site, find out whom is defect.
2) Analyze and judge reason according to signals or appearances, and adjust running mode of
rectifier cabinet.
3) Isolating defect cabinet if it is need, and repair it as soon as possible.
5.3.23 Outlet air temperature of rectifier cabinet high and alarm
1) Check fans running normally, or start stand-by fans.
2) Check filter of air passage block or not, cooling air flow normal.
3) Contact repairing staff and remove defect.
5.3.24 when generator over-loads by accident
1) Over –load value and time admitted
Stator current(%) 226 154 130 116
Admitted time(S) 10 30 60 120
Rotor current(%) 208 146 125 112
Admitted time(S) 10 30 60 120
2) Formula of stator over-current time and times
(I2-1)t=37.5s I----nominal value of stator over-current
3) If accident occurs outside of generator, admit stator winding over-load running in short time, as
well as rotor, but the times should not excess 2 in a year.
4) When generator over-load, check generator’s power factor and voltage, and check out times of
over-current and last time, control it in value above table.
5) Decrease rotor current, make stator current to limited value, control system voltage not too
lower.
6) If stator current doesn’t decrease to limited value when decrease rotor current, decrease
active power if needed, limit load if dispatch admitted.
7) When generator runs in over-load status, monitor generator, main transformer temperature
closely and cooling system, make their parameter in admitted value.
system in service.
6.3.1.7 Fuel oil tank temperature shall be controlled within 20℃±5℃, when the temperature
below 5℃, start internal heater.
Put the internal heater into operation (as an example with # 3tank)
6.3.1.7.1 Check #3 tank oil temperatures below 5℃.
6.3.1.7.2 Confirm #4 tank internal heater outlet isolation valve is close.
6.3.1.7.3 Open #3 tank inlet air isolation valves.
6.3.1.7.4 Confirm the operation of drain tank is normal, check isolation valve before and after
drain tank are opened, and bypass valve are closed. Open bypass valve when the operation of
drain tank is abnormal.
6.3.1.7.5 Confirm no light oil flow out from drain tank.
6.3.2 Start light oil transfer system
6.3.2.1 Before boiler running, light oil feed pump is running fuel oil circulation, and confirm all oil
gun manual isolation valve are at the closed position.
6.3.2.2 Open fuel oil outlet isolation valve and return oil manual isolation valve of the running
tank.
6.3.2.3Start one light oil feed pump, and confirm the pressure is normal; according to the boiler oil
quantity requirement. Start light oil feed pump, start of the pump can be done in the control room
and local panel.
6.3.2.4 Check the fuel oil pump inlet DP is normal.
6.3.2.5 Confirm boiler light oil system circulation is normal, the temperature below 40℃.
6.3.2.6 Overhauled oil pump, filter mesh, heater, tube should be filled oil and vented before start
up or after start up.
6.3.2.7 Fill oil and vent work should be done carefully and slowly to avoid hot oil hurting.
6.3.2.8 Put a small container at the vent outlet to avoid influence site sanitation, and clean it
immediately.
6.3.3 Light oil pump operation
6.3.3.1 Check oil leakage during operation.
6.3.3.2 Check that outlet oil pressure is normal, if below 15bar, the reasons should be identified
and timely treatment.
6.3.3.3 One pump run and the other spare, and the two pumps switch every week, detailed
regulation see specific provisions of equipment regularly switch and test.
6.3.3.4 Vibration, bearing temperature and current shall be monitored in the operation of fuel oil
pump, if something is wrong, switch the pumps and contact maintenance staff to dispose.
6.3.3.5 It is important to check Light oil pump inlet filter, if DP of filter is high, it should be timely
switched and contact maintenance staff to clean and overhaul.
6.3.3.6 The LFO temp is 20±5℃ and the oil manifold pressure are 16-18bar in normal operation.
6.3.3.7 Check dirty oil tank level are normal every shift
6.3.4 Stop light oil transfer system
6.3.4.1 Stop fuel oil pump operation. Be realized on CCR operation desk, local panel stop button
and emergency button.
6.3.4.2 After fuel oil handling system stop, if light oil system need to be overhauled, purging of
whole line pipes should be done (purge the pipe remaining oil to running fuel oil tank) and make
reliable isolation.
6.3.4.2.1 Fuel oil system by circulating operation before boiler running.
(1)Close #3/4 light oil tank outlet feed oil manual valve
(2)Close A/B feed oil pump inlet isolation valve.
(3)Open A/B feed pump inlet/outlet purge steam isolation valve, open feed oil pipe purge steam
isolation valve, open return oil pipe purge steam isolation valve to purge.
(4)Purge finished, close the opened purge steam isolation valve, close #3/#4 discharge oil valve
before the gate, discharge the remaining oil and confirm the purge finished. Open the return oil
manual valve and #3/4 tank return oil manual valve.
6.3.5 Operation and maintenance
6.3.5.1 Light oil tank switching operation
Two light oil tank, one is operated, another is spare. When operating oil tank level below 3m,
heating(raise) the spare oil tank oil temperature to 20 士 5℃ around, and repairing to switch oil
tank. When operating oil tank level is 2.0~2.5m, switching oil tank should be done, put the spare
oil tank into operation, the procedures according to the following:
(1)Shift supervisor agree, repairing to stop feed oil pump and switch oil tank.
(2)Stop feed oil pump, inform #1/2 unit fuel oil control valve turn to manual.
(3)Close #3tank outlet isolation valves, open #4 tank outlet isolation valve.
(4)Close #3tank return oil isolation valve, open #4 tank return oil isolation valve.
(5)Start feed oil pump and confirm it in normal, the outlet pressure is normal.
6.3.5.2 Oil Pumps level should be Recorded clear between shift, and struck oil benchmark to
confirm the normal oil level which is not correct.
6.3.5.3 Strengthen the inspection and records of oil temperature in oil feeding tank and report
timely when the temperature is abnormal. Standby oil tank oil temp should be maintained
between 10±5℃, while operating oil tank oil temp 20±5℃.
6.4 Heavy oil feed pump
6.4.1 The inspection before Fuel oil handling system start-up
6.4.1.1 Heavy oil system maintenance is completed, all pipes, valves, and equipment state are in
good condition, motor valve and control valve of the system act smooth and correct.
6.4.1.2 Heavy oil system heating steam operation is normal.
6.4.1.3 Heavy oil quality conform to its standard, oil tank level, temperature are normal.
(2)Open the blowing steam valve in the front/back of #1 boiler and # 2 boiler to sweep; open the
blow down valve of return oil pipe in trench in necessary.
(3)Close the steam blowing valve when finishing the blowing of front/back wall of boiler, open the
manual valve of fuel oil feeding in the front/back wall.
6.4.4.3.2The blowing from heater of fuel oil pump outlet to the front of #1 boiler and #2
boiler ,then to fuel oil tank:
(1) Close the manual valve of fuel oil tank outlet; close the manual valve of pump outlet #1/2/3
heater inlet.
(2) Open the steam blowing valve of #1/2/3 heater fuel oil pump outlet; open the blowing valve of
inlet/outlet return oil pipe in trench.
(3)Close the blowing steam valve of heater after the blowing is confirmed to finish.
6.4.4.3.3 The blowing from the manual valve of fuel oil tank outlet to pressure maintaining valve ,
then to fuel oil tank:
(1)Close the manually operated valve of fuel oil tank; close the manually operated valve of fuel oil
pump outlet #1/2/3 heater inlet, and open the by-pass valve of fuel oil pump’s pressure
maintaining valve.
(2)Open the blowing valve of fuel oil tank outlet pipeline.
(3)When the blow is confirmed to finish, open the manually operated inlet valve of fuel oil pump
outlet heater, close the by-pass valve of fuel oil pump pressure maintaining valve. Do two hours
completely blowing to the whole fuel oil system pipeline, then close the blowing valve of fuel oil
tank outlet pipe line.
(4) Close the return oil manually operated valve of running tank.
(5)Blow down after the water deposit in running tank.
6.4.5 Normal running attention
6.4.5.1 The running of heavy fuel:
6.4.5.1.1 One fuel tank is running and the other is standby. when the oil level of running fuel tank
below to 4 meter , then heat the standby one to 65℃ or more ,prepare to switch fuel tank. Heat
the standby one to 68℃ to 70℃ before switching. When the oil level of running fuel tank is 3 to
2.5 meter, switch the standby one .The procedure is(for example ,#1 tank is running ,#2 is
standby, then switch from #1 to #2):
(1)Get the shift supervisor’s permission, prepare to stop running and switching tank.
(2)Shake the filter screen of fuel heater outlet to make pressure difference normal, stop the
running pump, and control the fuel from automation to manual.
(3)Open the outlet isolated valve of #2 fuel tank , put on the lower temperature fuel in outlet pipe
of #2 tank and more moisture fuel at bottom of #2 fuel tank to #1 tank.
(4)When the oil level of #2tank falls down 0.2 to 0.3 meter, close the outlet isolated valve of #1.
(5)Start fuel pump; make sure it runs normal, oil outlet pressure is normal.
tightness
of pump inlet oil line/flange/valve,
(3) Pump inlet cap or intake is blocked. Clear up these sundries.
(4) Oil viscosity is too high. Oil temperature shall be increase in order to decrease oil viscosity.
(5) Water seal line is blocked and air is entered. Water seal line shall be checked and cleaned.
(6) Installation position is too high. Raise feed oil level or lower pump position and difference
height
of oil level.
(7) Motor rotation speed is not enough; check power voltage and frequency decreased.
(8) Motor rotation direction is wrong; wiring shall be changed by electrician.
(9) Impeller of pump/oil outlet blocked. Impeller/oil outlet shall be checked and cleaned.
6.5.2.2.2 Flow is little in operation
(1) Rotation speed reduced. Motor and power supply ought to be checked.
(2) Check oil suction line if air get into it.
(3) Resistances of suction line and out line increased. Valve and line shall be checked whether it
is blocked in valves and pipeline or too small diameter.
(4) Impeller and sealing ring worn. Waste on filter shall be cleaned; impeller and sealing ring
ought to be replaced.
(5) Filter inlet blocked. Filter shall be taken apart and cleaned.
(6) Line and pump leak. The check and handle line and pump, gland packing, flange which is
leakage.
6.5.2.2.3 Pump pressure decrease in running
(1) Rotation speed reduced. Motor and power supply shall be checked. Boiler oil valve shall be
check if opened too large.
(2) Air gets into oil. Suction oil line shall be checked.
(3) Pressure oil line damaged. Pressured oil valve and check pressure oil line.
(4) Impeller and seal worn. They shall be taken apart and maintained or instead.
(5) Vibration and noise occur in pump or motor
a. Improper installation (such as: the center of pump and motor rotor are not in the same line or
bad connection of the coupling) leads to unbalance of pump rotor. In this case, check the
coupling wheel and adjust the center line.
b. Part of impeller is jammed, and impeller should be cleaned.
c. Disassembly or replace the damaged component which have a mechanical defect, for
example, shaft bending, moving part jammed, bearing worn.
d. Fixed set of the aspirate oil pipe and press oil pipe are loosened, it should be fastened.
e. Cavitations happened because oil pump’s erection height is too high; the pump must be
stopped and installed at lower erection height.
f. Some foundation bolts loosen or foundation beneath oil pump units is unstable. In this case,
fasten foundation bolts or strengthen foundation.
6.5.2.2.4 Bearing heating
(1) Maintain and adjust the bearing when it is contact bad or clearance is inappropriate.
(2) Check, maintain and adjust carefully the bearing which has worn or loose.
(3) Oil ring is not moving smartly, oil quantity is small or feed oil interrupted. Check or change oil
ring, make the lube system is free-flowing.
(4) Quality of oil is not good or run short of oil, or there are sundries in the oil, it should be
replaced for filtrated oil after cleaning.
(5) Shaft center is at improper position or shaft bending. Adjust shaft center or change pump
shaft.
(6) Dimension of bearing is wrong, bearing shall be replaced.
(7) Cooling water is interrupted, adjust flow.
(8) If quantity of vibration or axial shaft movement is out of limits, found out the reason and deal
with it.
6.5.2.2.5 Oil line has bumps in side if air is in oil pump and line. Air shall be vented, and the
reason of air getting in shall be handled.
6.5.2.2.6 Pump heating
(1)Stop pump and repair if rubbing is inside pumps.
(2)Pump running within air for long time. After stop pump and vent the air, restart up the pump.
(3)Outlet valve is closed or valve open small range, increase valve open degree (oil is not allowed
to cut when the pump stopped and switch to standby pump to supply oil.)
6.5.3 Common fault of feeding/return oil line
6.5.3.1 Feeding oil line broken
Phenomenon
6.5.3.1.1 Main line pressure decrease immediately, oil pressure reduce, signal bell is loud; visual
lamination light, feeding oil pump current suddenly increase, oil ejecting from point of broken
point.
6.3.1.2 Reasons
Poor pipeline welding; quality of steel is unaccepted or misuse of welding material; incorrect
operation; thickness of pipe become thinner for long term brush and corrosion.
6.5.3.1.3 Method of disposal
Contact with shift supervisor, switch the system according to operation mode; find out the
broken points quickly, and take firefighting measures, and report to department concerned.
6.5.3.2 Return oil line blows up
6.5.3.2.1 Phenomenon
Feeding/return oil pressure decrease, oil pump current suddenly increase, inlet
7.1 introductions
7.1.1 Purpose of condensate polishing
Condensate water will have different level of contamination for the reason of condenser seep or
leakage, thermal system corrosion, load of turbine changing etc. Condensate water is main
supply of feed-water. To improve feed-water quality and meet the strict requirement of sub-critical
high parameter Large Capacity unit, it is required not only to purify and desalt boiler make-up
water or chemical treatment of boiler water, but also to do further treatment to condensate water
for removing of various salt, colloidal silica, metal oxide, suspended matter and some impurity in
the condensate water, thus consequently guarantee the feed-water high purity to ensure the unit
full load operation with small amount leakage and to leave enough time for applying shutdown
with more leakage.
7.1.2 System introduction
The 2 × 600MW sub-critical units has condensate polishing system, which is consists of one
group of deep mixed bed and outer regeneration equipment.
Deep mixed bed can reduce dissolved salt in the condensate water to a very small content,
and can reduce the corrosion products and suspended substances in it. Condensate water of
each unit will apply full flow treatment with flow 1616t /h. running pressure is 3-5Mpa with
temperature 55℃. Each unit consists of three mixed beds; each output is design at 50% of
condensate water volume. Among the 3 mixed beds, 2 mixed beds are running and 1 mixed bed
is standby.
The 2 units share one set of outer regeneration system with design pressure 0.7Mpa.
Regeneration system adopts “complete separation method”. This method consists of three
regeneration towers: “resin separation tower (SPT)”, “cation resin regeneration storage tower
(CRT)”, “anion resin regeneration tower (ART)”.exhausted resin of mixed bed being sent to the
"resin separation tower" do preliminary air scrubbing and then backwashing for layer operation.
The characteristic of “complete separation” regeneration technology is that its separation tower is
designed as large top and small bottom special structure. Firstly, water upon the resin at top
separation tower drains out, secondly, 0-45M3 / H high velocity backwash water is injected in, and
quickly to elevate the entire resin bed to the top of the separation tower, thirdly, the backwash
water flow will be gradually reduced below the cation resin's critical deposition velocities through
a flow-control valve installed on the backwash water, finally at this flow rate, cation resin particles
will sink, while the anion resin is still float upon the top of separation tower. Until backwash flows
are reduced to zero and anion resin is already settled down thus cation and anion resin is
complete separated. Backwash layer flow adjustment is as follows:
(1) inlet condensate water temperature>55℃, inner bypass valve 100% flow adjustment;
(2) Fine treatment bypass pressure difference > 0.35Mpa, inner bypass valve 100% flow
adjustment;
(3) 3 mixed beds of system are at the exit or overhaul state, inner bypass valve 100% flow
adjustment;
(4) 2 mixed bed of system are at the exit or overhaul state (only one mixed bed is running),
inner bypass valve 50% flow adjustment;
7.1.3.3 Fine treatment process Diagram
Bypass system
Condensate water of main condensate pump→high velocity mixed bed→resin trap→Shaft Seal
heater
Outer regeneration system
7.1.4 Main equipment standard of fine treatment
7.1.4.1 Design parameter
Condensate water capacity normal operation 1522 T/h
needed to be disposed peak load 1616 T/h
Condensate water inlet operation pressure 2.9Mpa
pressure design pressure 4.0Mpa
The number of sets of each unit 3 units
mixed bed operation quantity 2 units
Condensate water normal operation temperature 38℃
temperature the largest temperature 55℃
Mixed bed pressure difference when clean resin bed (including resin trap) ≤0.2Mpa
Mixed Bed maximum flow pressure difference of dirty resin bed (including resin trap)
≤0.35Mpa
Total height of mixed bed layer: 1.1m
Anion and cation resin volume proportion:1:1
Reducing valve installed in compressed air main pipe reduce pressure to:0.3-0.4Mpa
7.1.4.2 Vessel
quantity design
name specification
no.1 no.2 common pressure
fine treatment mixed bed dn3200 3 3 4.0MPa
resin trap dn600 3 3 4.0MPa
resin separation tower dn2500/1700 1 0.7MPa
anion regeneration tank dn1500 1 0.7MPa
cation regeneration storage dn2000 1
0.7MPa
tank
wastewater resin trap dn1200 1 normal
compressed air storage 10m3 1
1.0MPa
tank
electric heating water tank dn1800,10m3 1 0.7MPa
acid storage tank dn2000, 20m3 2 normal
alkali storage tank dn2000, 20m3 2 normal
acid metering box dn1100,1.8m3 1
quantity design
name specification
no.1 no.2 common pressure
alkali metering box dn1100,1.6m3 1
acid ejector regenerated acid 1
concentration 4-5%
alkali ejector regenerated alkali 1
concentration
acid fog absorber dn500 1 normal
co2 absorber dn80 1 normal
safety shower 1
resin adding bucket one-time filled resin 1
volume: 0.1 m3
wastewater pool 300m3 1
7.1.4.3 Pump and fan
rated rated linkage
name specification quantity
power(kW) voltage requirement
450m3/h,h= .32mpa,
recycle pump inlet pressure:4.0mpa- 75 415 2
100 percent inspection rate with gap not more than 0.2mm is accepted. Because the
transportation process is likely to cause inner nut loose and make water cap loose;
(b) Inspecting the Internal rubber lining quality, whether there is frost crack or other defects. If so,
repair it. For small cracks deficiency, epoxy resin adhesive can be used, but for large area lining
defects, the problem shall inform the manufacturer to settle.
c) Inspecting interior of equipment whether there is impurities, as well as any loosening of
fasteners;
d) Check nameplate, the installation location and the design drawings equipment of are in line
with;
(2) Machinery equipment:
Confirm that all oil cups are filled full with oil or with suitable lubricants.
Start the motor and check the rotation direction. With regard to pumps and metering pumps,
it should confirm that pump is full of water or liquid before starting motor, start air pump motor in
empty liquid state is prohibited.
Safety valve must be installed in roots blower's vent main pipe to prevent the fan's vent
valve jam and damage fan.
(3) Valve
Isolation system (turn off all manual valves), operates diaphragm valve, pneumatic valve, electric
valve before water filled and check they are flexible, reliable and close tight.
All valves should be maintained in an operable state. In order to revent valve stem jam, lubricant
grease should be added.
7.2.1.4 Rinse and clean
(1)Rinsing system:
Before put stuffing into equipment, the entire system must be thoroughly washed.
The proposed washing procedures are as follows: disconnect equipment inlet pipe flange,
begin to wash at this point to prevent the dirty and trash entering into the equipment and inlet
distribution device. If orifice or flow meter is installed on inlet pipe, this place should be washed
first. All other equipments connected to the pipeline should be washed as similar way.
Then installing inlet pipe and disconnect equipment outlet flange, disconnect any major
external parts from the device. Then washing facilities with water wash any residual dirt away
from drainage device. Then Install outlet flange. Fill water and do pressure test before starting.
(2)Initial backwash
Before the stream passes the empty equipment, equipment should be backwashed. In this
backwash process, the backwash flow rate should be greater than the normal speed of the
backwash. It should be continuous backwash until the drainage turn to be clean.
Backwash may cause blocking and equipment damage, which results in loss of system pressure
difference, is not normal, therefore, pressure difference loss should be carefully observed
Note: pay special attention to resin adding bucket to avoid any impurities entering it and
affecting the usage.
7.2.1.7.3 Pretreatment of resin in transition
The transition of anion and cation resin usually applying double size regeneration liquid for
regeneration with cation resin using not more than 5% of hydrochloric acid and anion resin
utilizing not more than 4% of the sodium hydroxide. outer regeneration system send the first
batch of qualified pretreated resin to the first condensate fine treatment mixed bed, and load the
second batch to the second mixed bed, and then sent the third batch of pretreated resin to third
mixed bed Units, and finally the fourth pretreated and keep in standby state.
Sometimes the manufacturer provides resin ion type of cation H, onion OH. This situation
may not carry out pre-treatment and directly send into the mixed bed for usage.
Notes of resin pre-treatment:
1. Taking into account the mixed resin, transition of the first resin mixture need soak 24 hours in
acid and alkali liquid and then send to the resin separation tank for regeneration stratified
backwash operation. After 6 copies of the remaining resin are in their respective regeneration
tank by 24 hours soaking, directly do in-depth regeneration transformation treatment according to
the step-by-step sequence provided by regeneration program in their regeneration tank. And then
send the anion resin to cation tank for the air mixing and rinse qualified, it can send to the second
mixed bed, and so on.
2. New mixed bed should be put into operation in turn, suggest the time interval of 2 mixed beds
put into operation is more than 24 hours, in order to avoid regeneration system do not have
enough time for regeneration in case both two mixed beds fails simultaneously.
3. The system designed two mixed beds operation, one standby, also permit the 3 mixed beds
parallel work. When one is failed, switch to the other 2 parallel operations.
7.2.2 Pre-inspection and preparation of the normal operation
(1) Checking the compressed air storage tank pressure normal, generally may not be less than
0.5Mpa, and ensure quality of air is clean and it have adequate quantity.
(2) Solenoid valve cabinet whether transmission of electricity and gas is in operating conditions;
(3) All measuring instruments (thermal instrumentation, chemical instrumentation, etc.) are in
good standby situation;
(4) Checking all the valves and related equipment put into operation should be in good standby
situation;
(5) The inlet and outlet manually operated valve of Mixed Bed put into operation is at opening
state;
(6) All the analytical instruments are in good condition. Medicines are all ready;
(7) Inspecting resin trap is not plugged;
(8) Checking the control system is working normally;
CD CD 10LDF11AA002
Vessel Operating
SST-1 SERVICE 10LDF11AA003
CD CD 10LDF11 AA002 Open System Bypass Valve as
1
SST-2 Close Outlet Valve 10LDF01 AA001 CD outlet valve is closed
Inlet stays full open until
CD CD 10LDF11 AA002 operator, (1) reopens outlet, or
1
SST-3 Maintain Pressure 10LDF01 AA001 (2) removes CD from line by
closing inlet.
NOTES: 10LDF11 AA002: mixed bed inlet valve, 10LDF11AA003: mixed bed outlet valve,
10LDF01 AA001: mixed bed bypass valve)
7.2.4.5 Condensate demineralizer—standby to off (total time: 3min)
operation. When bypass valve opens, if we close the bypass, it should start 2 mixed beds to put
into operation first. And then turn off bypass system after it confirms 2 mixed beds put into
operation fully.
7.2.5.3 Due to the high pressure bypass> 0.35Mpa, it illustrates that mixed bed resin is polluted
by corrosion products or suspended matters seriously. Mixed bed resin should be put into
regeneration system to do the air scrubbing and regeneration.
7.2.5.4 If you want to judge the mixed bed high-pressure difference, you can watch the flow value
of mixed bed. When a running mixed bed flow is significantly less than another running mixed bed,
it illustrates that small flow mixed bed resin pressure is higher. It should be regenerative. It should
consider the need of mixed bed regeneration and air scrubbing when the general flow is less than
500 ~ 600M3 / H.
7.2.5.5 When bypass valve is 100% open, it suggests the bypass valve turns off manually. Before
the bypass valve turns off, it must confirm 2 mixed beds have been put into operation, and then
close the bypass valve.
7.2.6 Operation mode of mixed bed
7.2.6.1 When any of the following conditions are met, mixed bed is failed and quit running:
7.2.6.1.1 pressure difference of inlet and outlet main pipe of running mixed bed >0.35Mpa
7.2.6.1.2 Mixed bed flow is less than 500 ~ 600M3 / H
7.2.6.1.3 All the index of mixed bed effluent water is higher than the normal operation value or
close to standard value.
7.2.6.2 When it is in normal operation, two mixed beds are running, one spare. When one mixed
bed is failed, first start standby mixed bed and then trip failed mixed bed.
7.2.6.3 When two mixed beds are in operation, ensure that one mixed bed is in H + / OH-
operation and one bed is NH4 + / OH- operation.
7.2.6.4 When unit is in normal operation, the fine treatment mixed bed is strictly prohibited exiting
(except mixed bed is failed).If there are special reasons, it can quit after the director agrees.
7.2.7 Characteristics of system operation
7.2.7.1 High velocity mixed bed designed according to operation of H / OH-type. And consider the
NH4 + running condition.
7.2.7.2 Outlet water of fine treatment system meets need of the super critical unit’s normal and
non-normal operation and start-up.
7.2.7.3 When happens a small amount of condenser leakage, the design of condensate fine
treatment system could make turbine-generator continuously work in the maximum output
situation by input pre-filters and increase condensate fine treatment’s regeneration frequency;
when the leakage is large, it must ensure necessary run-time of the safety shutdown.
7.2.7.4 When the water conductivity, silicon, sodium, water cycle capacity and any parameter in
depressurization of a high velocity mixed bed exceed the set value, the standby mixed bed put
into operation and recycle resin, then pass into the system after the effluent water qualified. The
failed equipment stops operation. Exhausted resin of out of operation mixed bed was send to
regeneration system to do air scrubbing, separation and regeneration. Standby resin of
regeneration system is delivered to the mixed bed standby.
7.2.7.5 Pre-filter input, outage, washing of fine treatment system and inputs, outage, resin transfer,
regeneration and other steps of mixed bed work according to the control program automatically.
7.2.7.6 Each machine of condensate fine treatment systems has a bypass system, mixed bed
bypass should be the automatic full open when the water temperature is higher than 55 ℃ and
turn off inlet and outlet valves at the same time. When mixed bed inlet and outlet main pipe
pressure difference is greater than the 0.35MPa, the bypass valve 100% open. Before one mixed
bed splits and resin transfer and put into operation, the bypass valve open according the set. It
make bypass flow achieve half of the total flow. The start, stop and regenerative operation of
condensate fine treatment system can work automatically, and operation personnel also can
confirm conditions in the LCD and then give commands for remote operation and handle it at
electromagnetic valve box manually in situ.
7.3 Operation of mixed bed fine treatment regeneration
7.3.1 Preparation of regeneration
7.3.1.1Check the pressure of compressed air is not less than 0.5Mpa
7.3.1.2 Electromagnetic tank have operation condition
7.3.1.3 All detection devices (thermal instrument, chemical instrument, etc.) are in well standby
state
7.3.1.4 Check the valve, pump and fan-motor of regeneration device are in well standby state
7.3.1.5 Acid/alkali system and heating system are in operation
7.3.1.6 Control system is working normally
7.3.1.7 Condensate supplement tank has enough demi water
7.3.1.8 Water in wash pump is enough
7.3.2 Regeneration operation of fine treatment
7.3.2.1“Mixed bed standby from service”. After checking the standby mixed bed has been put into
operation, then exit the failed mixed bed, if exit the failed mixed bed in the situation of the standby
mixed bed couldn’t be put into operation, bypass valve will adjust 50% flow automatically. Inlet
and outlet valve of the failed mixed bed closed, discharge valve turn on, waiting for resin
transferring.
7.3.2.2 “Condensate demineralizer—failed resin transfer to separation”. Start the first step of
regeneration, output of mixed bed resin
7.3.2.3“resin transfer from cation regeneration tank to mixed bed” start the second step of
regeneration, mixed bed could put into operation when the standby resin in cation regeneration
tower have been transferred to mixed bed.
7.3.2.4 “condensate demineralizer—off to standby” put the mixed bed into service.
7.3.2.5“transfer the lose efficacy resin in separation tank” separate the lose efficacy resin, transfer
to the corresponding regeneration tank respectively.
7.3.2.6 “Anion regeneration tank—regeneration”, “cation regeneration tank—regeneration”
regenerate the lose efficacy resin in the corresponding tank.
7.3.2.7“Anion regeneration tank—resin transfer to cation regen”, “cation regeneration storage
tank—air mix/rinse standby” finish the present step in order, the mixed resin can be used as
standby resin.
7.3.3 Operation step and instruction of condensate polishing regeneration
7.3.3.1 Condensate demineralizer—exhausted resin transfer to separation tank (total time: 36min)
10ldf11aa502
10ldf11aa005
cd line flush ,
10ldp01aa401 70ldp21ap001
cd vent 70ldp21
10 10ldf10aa002 or 31m3/h drain cd & fiush transfer line
rto-4 & drain #1#1 cf201
70ldp13aa003 70ldp21ap002
step1
70ldp13aa008
00ldp76aa001
10ldf11aa502
10ldf11aa005
10ldp01aa401
cd line flush , 70ldp21ap001
cd 10ldf10aa002 70ldp21 drain cd & flush transfer line
vent & drain or 31m3/h
rto-5 70ldp13aa003 cf201 from 2 sources
#2 step2 70ldp21ap002
70ldp13aa008
00ldp76aa001
70ldp11aa011
note: 10ldf11aa502:exhaust valve, 10ldf11aa501:mixed bed inlet compressed air valve, 10ldf11aa005:mixed bed recycle valve, 10ldf11aa008:mixed bed
outlet resin valve, 10ldp51aa002:mixed bed total outlet resin valve, 70ldp13aa008:separation tower inlet resin valve, 00ldp76aa001:regeneration
feeding resin main pipe valve, 70ldp13aa003 :separation tower backwash discharge valve), 10ldf11aa007:mixed bed inlet resin valve ,
10ldf10aa001:mixed bed inlet rinse water valve, 10ldp01aa401:mixed bed discharge valve), 10ldf10aa002:mixed bed total resin pipe rinse water valve,
70ldp13aa008:separation tower inlet resin valve), 00ldp76aa001:regeneration resin transportation total valve, 00ldp76aa001::regeneration resin
transportation total valve, 70ldp11aa011:regeneration rinse water total valve
7.3.3.2 Resin transfer from cation regen tank
no. step time valves open/ pump/motors set instruments comments
no. range
70LDP11AA009
70LDP11AA008
CRT Resin 00LDP76AA001
Blowdown Water to
CD Transfer 10LDP51AA001 210m3/h
FS 10LDP61CF201 remove resin. Time
RTI-1 Pressurized 10LDF11AA007
field set
Air 10LDF11AA502
10LDF11AA005
10LDP01AA401
70LDP11AA009
70LDP11AA004
70LDP11AA008
CRT Resin 00LDP76AA001 70LDP21AP001 Bring water into
CD Transfer 10LDP51AA001 OR 13m3/h 70LDP11CF201 bottom of
FS
RTI-2 Press Air/ 10LDF11AA007 70LDP21AP002 210m3/h 10LDP61CF202 vessel-maintain an air
Water 10LDF11AA502 dome at 552KPa
10LDF11AA005
10LDP01
AA401
70LDP11AA001
70LDP11AA004
70LDP11AA008 70LDP21AP001
CRT Resin
CD 10LDP51AA001 OR 13m3/h Bring water into
Transfer FS 70LDP11CF201
RTI-3 10LDF11AA007 70LDP21AP002 31m3/h bottom/top of vessel.
Vessel Flush
10LDF11AA502
10LDF11AA005
10LDP01AA401
NOTE: 70LDP11AA009:cation tower inlet compressed air valve, 70LDP11AA008:cation tower outlet resin tower, 00LDP76AA001:regeneration resin
delivery total valve, 10LDP51AA001:mixed bed inlet resin total valve, 10LDF11AA007:mixed bed inlet resin valve, 10LDF11AA502:mixed bed exhaust
valve, 10LDF11AA005:mixed bed recycle valve, 10LDP01 AA401:mixed bed discharge valve, 70LDP11AA009:cation tower inlet valve,
70LDP11AA004:cation tower backwahing discharge valve, 70LDP11AA008:cation tower outlet resin valve, 10LDP51AA001:mixed bed inlet ,
10LDF11AA007:mixed bed resin-inlet valve, 70LDP11AA001:cation tower rinse admission valve,10LDP51AA001:mixed bed resin-inlet total valve ,
70LDP11AA011:regeneration flush water total valve, 70LDP11AA007:cation tower exhaust valve, 70LDP11AA006 :cation tower forward vent valve
7.3.3.3 Condensate demineralizer—off to standby (total time: 1min)
time valves open/ instruments
no. step comments
(min) valve no. no. range
cd cd off not in service
cd mixed bed boost pressure
cd pressurize 1 10ldf11dp201 <1.5bar pressurizer to pds setting interlock
ost-1 valve 10ldf11aa006
service inlet line & vessel
cd cd mixed bed admission
pressurized .10ldf11aa002 open verifled
ost-2 open service inlet valve 10ldf11aa002
by limit switch action10ldf11aa002
7.3.3.4 Separation and transfer of exhausted resin in separation tank
This step is very important for prolonging the cycle of mixed bed, the resin must inflation as far as possible in the case that it do not run away from
the discharge valve which at the top of the tank, then it must sink gradually under control, so the two kinds of resin can be separated completely by their
different speed of sinking.
Please pay special attention to the waste water trap, if the integrated resin is leak much when operating, you should immediately stop it, then report
to the professional executive, and make necessary adjustment to the valves or the scale time.
70LDP11AA011
70LDP21AP001
70LDP13AA008
SPT-1 SPT Fill FS OR 60m3/h 70LDP13CF201 N/A SPTinitiated by operator
70LDP13AA001
70LDP21AP002
70LDP13AA011
Air to top of resin bed
SPT Pressurized 70LDP13AA002 210 70LDP13AA002 open to
SPT-2 FS 10LDP61CF202
Air Drain 1 70LDP13AA007 m3/h allow bed to compact.
70LDP13AA002
70LDP41AN001
70LDP13AA004 700m3/ 70LDP41CF201
SPT-3 SPT Air Scrub 15 OR
70LDP13AA003 h
70LDP41AN002
70LDP21AP001 Restore water level to
70LDP13AA005 70LDP13CF201
SPT-4 SPT Fill 4 OR 62m3/h bottom of top sight
70LDP13AA003
70LDP21AP002 window.
SPT-5 SPT Drain FS 70LDP13AA002 210 N/A Lower water level to 6”
70LDP41AN001
ART 70LDP12AA005 357 m3/h
ART Air FS OR 70LDP41CF201
R1-2 70LDP12AA007
Scrub 70LDP41AN002
RT Backwash 70LDP12AA004
70LDP21AP001 357 m3/h
ART Air FS 70LDP12AA003 70LDP41CF201
OR 16 m3/h
R1-3 Scrub(Cont’d) 70LDP12AA005 70LDP12CF201
70LDP21AP002
W/Water 70LDP12AA007
ART ART FS Establish Air Dome
70LDP12AA009 128 m3/h 10LDP61CF202
R1-4 Pressurized @552KPA
Flush fines out
70LDP12AA006
ART ART Bottom FS 128 m3/h through underdrain
70LDP12AA009 10LDP61CF202
R1-5 &Side Flush and redenerant
70LDP12AA003
distributor
70LDP12AA001 70LDP21AP001
ART FS 31 m3/h 70LDP12CF201
ART Fill 70LDP12AA007 OR
R-2 10.5 m3/h 70LDP11CF301
70LDP81AA002 70LDP21AP002
70LDP21AP001
ART Dilute 70LDP31AA001
OR
caustic 70LDP12AA002
ART 70LDP21AP002 10.5 m3/h
introduction. 60 70LDP12AA006 70LDP11CF301
R-3 70LDP81BN001 1.4 m3/h
5%NaOH 70LDP81AA001
OR
5%NaOH 70LDP81AA002
70LDP81BN002
ART Caustic 70LDP31AA001
70LDP21AP001
ART displacement 70LDP12AA002
30 OR 10.5 m3/h 70LDP11CF301
R-4 rinse. 70LDP81AA002
70LDP21AP002
70LDP12AA006
70LDP21AP001
ART ART Fast 70LDP12AA001
OR 37m3/h 70LDP12CF201
R-5 rinse 1 15 70LDP12AA006
70LDP21AP002
70LDP12AA001
70LDP21AP001
ART 70LDP12AA007 31 m3/h 70LDP12CF201
ART Fill FS OR
R-6 70LDP12AA002 10.5 m3/h 70LDP11CF301
70LDP21AP002
70LDP81AA002
ART Blowdown water
ART 70LDP12AA007
Draindown FS N/A N/A N/A level to 6” above
R7-1 70LDP12AA003
resin bed.
70LDP41AN001
ART ART Air FS 70LDP12AA005 70LDP41
OR 357m3/h
R7-2 Scrub 70LDP12AA007 CF201
70LDP41AN002
70LDP41AN001
ART
70LDP12AA005 OR
Backwash
ART FS 70LDP12AA003 70LDP41AN002 357m3/h 70LDP41CF201
Air
R7-3 70LDP12AA005 70LDP21AP001 16m3/h 70LDP12CF201
Scrub(Cont’d)
70LDP12AA007 OR
W/Water
70LDP21AP002
ART ART FS Establish Air Dome
70LDP12AA009 128m3/h 10LDP61CF202
R7-4 Pressurized @552KPA
Flush fines out
ART Bottom 70LDP12AA006 through underdrain
ART
&Side Flush FS 70LDP12AA009 128m3/h 10LDP61CF202 and regenerant
R7-5
70LDP12AA003 distributor.
70LDP12AA001 70LDP21AP001
ART ART Fill 31m3/h
FS 70LDP12AA007 OR 70LDP12CF201
R-8 10.5m3/h
70LDP12AA002 70LDP21AP002
Time adjustable by
operstor. Rinse until
25 or
70LDP21AP001 cond. is less than 10
ART ART Final FS 70LDP12AA001
OR 31m3/h 70LDP12CF201 umho/cm. Alam if
R-9 Rinse 2 OR2 70LDP12AA006
70LDP21AP002 time is exceeded
5
cond. Not achieved
time
ART
ART Standby 60
R-10
Notes: 1.Repeat resin cleaning steps (R1-1 TO R1-5 or R7-1 to R7-5) as necessary.
2. 70LDP12AA007:anion tower exhaust valve, 70LDP12AA003:anion tower backwash discharge valve, 70LDP12AA009:anion tower compressed air
inlet valve,70LDP12AA005:anion tower inlet air valve, 70LDP12AA007:anion tower exhaust valve, 70LDP12AA005:anion tower backwash admission
valve, 70LDP12AA003:anion tower reverse vent valve, 70LDP12AA005:anion tower inlet valve, 70LDP12AA006:nion tower forward vent valve,
70LDP12AA001:anion tower forward admission valve, 70LDP81AA002:mixed bed 3-way admission valve, 70LDP31AA001:hot water 3-way adjusting
valve, 70LDP12AA002:anion tower alkali-inlet valve, 70LDP81AA001:mix 3-way alkali-inlet valve
7.3.3.6 CATION REGENERATION TANK—REGENERATION)
time valves open/ pump/ set point/ struments
no. step comments
(min) valve no. motors on valve no. no. range
CRT FS 70LDP11AA007 Blowdown water level to
CRT Draindown N/A N/A
R1-1 70LDP11AA003 6” above resin bed.
CRT FS 70LDP11AA005 70LDP41AN001or
CRT Air Scrub 357 m3/h 70LDP41CF201
R1-2 70LDP11AA007 70LDP41AN002
70LDP11AA004 70LDP21AP001or
CRT Backwash Air
CRT FS 70LDP11AA003 70LDP21AP002 16 m3/h 70LDP11CF201
Scrub
R1-3 70LDP11AA005 70LDP41AN001or 357 m3/h 70LDP41CF201
(Cont’d)W/Water
70LDP11AA007 70LDP41AN002
CRT FS Establish Air Dome
CRT Pressurized 70LDP11AA009 128 m3/h 10LDP61CF202
R1-4 @552KPA
CRT CRT Bottom & FS 70LDP11AA006 128 m3/h 10LDP61CF202 Flush fines out through
70LDP11AA004 70LDP21AP001
CRT Backwash Air 70LDP11CF201
CRT 70LDP11AA003 or70LDP21AP002 16m3/h
Scrub(Cont’d) FS
R7-3 70LDP11AA005 70LDP41AN001 357m3/h
W/Wate 70LDP41CF201
70LDP11AA007 or70LDP41AN002
CRT Establish Air Dome
CRT Pressurized FS 70LDP11AA009 128m3/h 10LDP61CF202
R7-4 @552KPA
70LDP11AA006 Flush fines out through
CRT CRT Bottom &
FS 70LDP11AA009 128m3/h 10LDP61CF202 underdrain and
R7-5 Side Flush
70LDP11AA003 regenerant distributor
70LDP11AA001
70LDP21AP001
CRT 70LDP11AA007 40m3/h 70LDP11CF201
CRT Fill FS or70LDP21AP002
R-8 70LDP11AA002 10.5m3/h 70LDP11CF302
70LDP71AA002
Time adjustable by
operator.
CRT CRT Final Rinse 25 or 70LDP11AA001 70LDP21AP001 70LDP11CF201 Rinse until cond. less than
31m3/h
R-9 2 FS 70LDP11AA006 or70LDP21AP002 10 umho/cm. Alarm if time
is exceeded cond. not
achieved.
CRT
CRT Standby 60
R-10
Notes:
1. Repeat resin cleaning steps (R1-1 to R1-5 ro R7-1 to R7-5) as necessary.Can also function as rinse down
2. 70LDP11AA009:cation tower exhaust valve, 70LDP11AA003:caion tower backwash discharge valve, 70LDP11AA005:cation tower wind-inlet valve),
70LDP11AA007:cation tower exhaust valve, 70LDP11AA004:cation tower backwshing inlet valve,70LDP11AA003:cation tower compressed air inlet
air,70LDP11AA006:cation tower rinse discharge valve, 70LDP11AA009:cation tower air-inlet valve, 70LDP11AA003:cation tower backwash discharge
valve,70LDP11AA001:cation tower rinse admission valve, 70LDP11AA002:cation tower acid-inlet valve, 70LDP71AA002:mix triple inlet valve.
7.3.3.7 ANION REGENERATION TANK—RESIN TRANSFER TO CATION REGEN/RESIN STORAGE TANK (Total time is 20mins)
70LDP11AA010
70LDP11AA006
Comments: 70LDP12AA001:anion tower rinse admission valve, 70LDP12AA006:anion tower rinse discharge valve, 70LDP12AA009:anion tower
air-inlet valve, 70LDP12AA004:anion tower backwash admission valve, 70LDP12AA008:anion tower resin-outlet valve, 70LDP11AA010:cation tower
resin-inlet valve, 70LDP11AA007:cation tower air vent valve), 70LDP11AA006:anion tower rinse admission valve, 70LDP13AA003:separation tower
backwash discharge valve, 70LDP11AA011:regeneration rinse flush total valve
7.3.3.8 CATION REGENERATION/RESIN STORAGE TANK—AIR MIX/RINSE STANDBY
time valves open/ pump/ set point/ instruments
no. step comments
(min) valve no motors on valve no no.
CRT 70LDP11AA007 Drain water level to 6” above resin
CRT Gravity Drain FS
ARS-1 70LDP11AA003 bed by time.
CRT 70LDP11AA005 70LDP41AN001or 629
CRT Air Mix 12 70LDP41CF201
ARS-2 70LDP11AA007 70LDP41AN002 m3/h
70LDP11AA005
CRT CRT Air Mix and 70LDP41AN001or 629 Air mix and draindown to top of
FS 70LDP11AA007 70LDP41CF201
ARS-3 Drain 70LDP41AN002 m3/h bed.
70LDP11AA003
CRT 70LDP11AA001 70LDP21AP001or 40
CRT Fill 8 70LDP11CF201
ARS-4 70LDP11AA007 70LDP21AP002 m3/h
Time adjustable by operator. Rinse
CRT 70LDP11AA001 70LDP21AP001or 52 until cond. is less than
CRT Final rinse 22 70LDP11CF201
ARS-5 70LDP11AA006 70LDP21AP002 m3/h 0.1umho/cm. Alarm if time is
exceeded and cond. not achieved.
CRT
CRT Standby Rinse as required during standby.
ARS-6
Comments: 70LDP11AA007: cation tower exhaust valve, 70LDP11AA003: cation tower backwash discharge valve, 70LDP11AA005: cation tower
wind-inlet valve, 70LDP11AA001: cation tower admission valve, 70LDP11AA006: cation tower rinse discharge valve
7.3.4 Control of electric heating water tank of regeneration system
7.3.4.1 Electric heating water tank is used for heating only 4 to 5 hours before regeneration procedures start.
7.3.4.2 Electric heating water tank is equipped with a water level switch to prevent dry-heating when water level is lower than electric heater. Therefore
level switch and electric heater is interlocked. Thermometer and temperature transmitters are also installed on water tank and they are interlocked.
4-group heaters will work as the temperature is lower than 60°C and just 2-groups heaters heat as temperature within 60-80°C.
7.3.4.3 Electric heater shall be cut off power and be sure in no power state when drain and repairing it, and check that the tank be filled to full, that is
water flow from vent pipe, before putting it into operation again,.
7.3.4.4 A three-way valve is installed at outlet of electric heating water tank and is always in operation during every regeneration process.
7.3.4.5 Method to adjust hot water temperature of three-way valve : firstly, adjust the opening of manual isolate valve of it to make a proper proportion of
hot and cold water, then adjust by three-way combined adjusting valve when the tank is in operation. It can be also adjusted directly by three-way
combined adjusting valve.
7.3.5 Acid-alkali metering tank system
7.3.5.1 It shall be supervised on the site when adding acid/alkali into storage tank in order to prevent acid-alkali overflows accident in case of level
gauge faults.
7.3.5.2 Acid day tank refill
time valves open/ instruments
no. step comments
(min) valve no. no. range
amtr-1 open fill 1 70ldp71aa013 70ldp71cl102 (open fill valve to start filling based on 70ldp71cl102&plc
valve position . Close 70ldp71cl102 and stop70ldp71bn001 or
cmtr-1 open fill valve 1 70ldp81aa013 70ldp81cl102 (open fill valve to start filling based on
70ldp81cl102&plc position . Close 70ldp81cl102
and stop70ldp81bn001 or 70ldp81bn002 on
70ldp81cl102 alarm.)
cmtr-2 close fill valve fs 70ldp81cl102 Close fill valve to stop filling when alkali level
reaches preset point on level transmitter.
7.3.6 Common problems and disposal for mixed bed operation
7.3.6.1 Disposal of over pressure /temperature of mixed bed system
When over pressure /temperature warning device alarms, by-pass valve is started automatically (100% opening). Firstly check whether its action is
reliable, then close mixed bed outlet valve and adjust condensate water temperature. When the temperature is back to normal, operating attendants can
reset opening outlet valve, and close by-pass valve, until the mixed bed work normally.
BY-PASS VALVE OPEN SEQUENCE FOR over pressure/temperature RE
realize continuously operation. Condensate polishing system can not be quit randomly during unit normal operation. If put the bed into operation only
when unit starts or with poor quality condensate water, the resin is impossible to achieve Ammonia operation.
7.3.7.2 Correctly judge and well control mixed bed operation period to avoid regenerating resin too early or too late. During the transition period from
hydrogen-type to ammonia-one, it will appear natrium breakthrough (outlet natrium value is higher than inlet), and present a natrium peak. At last, it
comes to a new balance in ammonia-type, which ammonia content of inlet/outlet water is almost equal to natrium value. For this condition regeneration
can not be done rashly. If condensate leakage or unit frequently start and shutdown has caused an outlet water index pressure difference, it shall
regenerate as earlier as possible as the unit is impossible to achieve Ammonex.
7.3.7.3 Carefully adjust the height of cation and mixed resin during resin separation process. Try to keep water flow stable in delivery of resin, which is
key for regeneration operation, otherwise it will affect mixed bed outlet water quality and make the resin failure in advance or even not able to achieve
ammonia operation
7.3.7.4 it is better to avoid regenerating resin during unit stop period, and ensure resin is put into operation immediately after they are delivered to mixed
bed. However, there are two preconditions for guaranteeing the bed ammonia operation, one is enough resin regeneration degree and the other is no
leakage in condenser.
7.4 Treatment for abnormal condensate polishing
problem cause Advisable treatment
Operation 1)Resin has not been totally 1) Check dilution water quantity, acid-alkali density, regeneration specific
period is short transformed consumption and acid-alkali liquid quality.
1) Adjust resin mixed wind pressure and quantity in mixed resin tower.
Resin layer in mixed bed
2) Adjust flow speed of transferring resin to mixed bed.
1) analyze water quality
3)inlet water quality changed
2)check whether condenser is leaky or not