crrel
Topics: EPRI Cs5112
Fossil fuel power plants Project 1266-38
Life extension Final Report
Maintenance April 1987
Operation
‘Shutdown
Guidelines: Long-Term Layup of
Fossil Plants
Prepared by
Florida Power & Light Company
Miami, Florida ‘SUBJECTS
ToPics
AUDIENCE
BACKGROUND
OBJECTIVE
‘APPROACH
RESULTS
REPORT SUMMARY
Plant systems and performance assessment / Boilers and related auxiliaries /
‘Steam turbines and related auxiliaries
Fossil fuel power plants Operation
Life extension Shutdown
Maintenance
Generation managers and engineers
Guidelines: Long-Term Layup of Fossil Plants
Placing fossil units into long-term layup for several years requires.
protective measures beyond those commonly used for short peri-
ods. Guidelines developed and demonstrated by Florida Power &
Light Company show how to prevent equipment deterioration dur-
ing long shutdown periods and how to subsequently reactivate
the units.
Many utilities develop excess generating-capacity problems during low peri-
ods of system load growth, particularly with new generation units coming
‘on-ine. System load studies may indicate that the situation Is temporary
and that higher generation capacity will be needed within a few years.
Florida Power & Light Company (FP&L) was faced with this situation in
1976. It put seven older fossil units into long-term layup. Four of these units
were subsequently reactivated after a sixyear layup.
To develop guidelines for the long-term layup and future reactivation of fossi
plant equipment.
FP&L had gained much experience from the extended layup of its Cutler,
Riviera, and Palatka fossil-fueled generating stations. On the basis of that
experience, the utility developed a program that would prevent or reduce
the deterioration of plant equipment and structures during exterded shut-
downs. FP&L also included plans for reactivating the equipment when sys-
tem load-growth demands increased generating capacity. The objective of
the program was to provide protection with minimal manpower and cost.
The resulting guidelines address the methods used to protect plant systems
and equipment during layup and reactivation. They also summarize the
problems and successes of the FP&L program. Key areas include
+ Preservation methods Corrosion is the most serious form of deterioration
Using dehumidification equipment and painting metal surfaces with coats of
preservative primer can reduce or eliminate corrosion by controling the
‘amount of moisture available to support chemical reactions,
+ Operation and maintenance during layup A routine monitoring program, in-
cluding readings of the dehumidification equipment and manual rotation of
equipment with large bearings and shafts, can check the effectiveness
EPRI OS.51128 EPRI PERSPECTIVE
PROJECT
of a layup program. Annual inspections should include visually inspect-
ing the condition of the boiler and turbine and recording electrical re-
sistance readings for the large motors, generators, and exciters.
+ Plant reactivation Reactivating a plant required approximately three
‘months. However, considerably more time may be needed to assign
staff, train operators, and complete any deferred maintenance and over-
haul work,
Layup of older, more-costly fossil plants is a decision based on the eval:
uation of alternative generation options and future load demand. The
layup of a plant effectively extends its life if adequate measures are
taken to preserve equipment. Future load-growth changes may econom-
‘cally justify the reactivation of the plant. Such plants are often candi-
dates for equipment upgrades to improve heat rate or cycling capability.
Fuel conversions and retrofitted fluidized beds are also possibilities.
EPRI report CS-4778 addresses the economic evaluation of life extension
options. Also, EPRI report CS-4629 contains guidelines for short-term
layup practices.
RP1266-38
EPRI Project Manager: J. R. Scheibel
Coal Combustion Systems Division
Contractor: Florida Power & Light Company
For further information on EPRI research programs, call
EPRI Technical Information Specialists’ (415) 855-2411 Guidelines: Longerm Layup of Fossil Plants
cs.5t2
Research Project 1266-38
Final Report, April 1987
Prepared by
FLORIDA POWER & LIGHT COMPANY
Power Resources Department
Post Office Box 029100
Miami, Florida 33102
Principal investigator
RS. Abraham
Prepared for
Electric Power Research Institute
3412 Hillview Avenue
Palo Alto, California 94304
EPRI Project Manager
JR. Scheibel
Performance and Advanced Technology Program
Coal Combustion Systems Division ORDERING INFORMATION
lequests for copies of this report should be directed to Research Reports Center
(FRC), Box 50490, Palo Ao, CA 94303, (418) 965-4081. There is no charge for reports
equested by EPRI member utities and afflates, US. ullty associations, US. government
agencies (federal, sate, and local), media, and foreign organizations with which EPRI has
4n information exchange agreement. On request, RAC will send a catalog of EPRI reports.
"eric Power Reseach lative and EPRI are registered sence marks of Elec Power Resse IB, Ie
Coppi 1987 Eecic Power Resour na In. A vg veered
NOTICE
Ts repo was prepared bythe etgarizaon() named below aban sccourt ol work sporsood by the Electic
Poner Resse inte (EPRI Nether EPR, mersbore cf EPA. he orgenatont) arn Wen, nt ry
eran acting on Beale ary of tam} makes any waranty, exes ciple, wh espe! oth Use any
‘rlormation, apparatus method. of process cedozoa ots Yeo or ht seh use may nee ply
‘nes gs or) assures any Hatiies wih respec 10 he eo or x darsanee resting ar he use
‘any information spparatu, mated, or process daclosed in ie rapon.
Prepared by
ona Power & Light Company
Mam. Foes ABSTRACT
Many utilities have been faced with the problem of what to do with excess generating
capacity. This situation was due, in part, to an unexpected change in the system load
growth predictions coupled with new generation coming on-line. In many cases system
oad studies have indicated this situation would only be temporary and the excess
generation would be needed again in the future, Florida Power & Light Co. was faced
with this situation in 1976 when it put seven (7) older gas/oil fired fossil units into long
term lay-up for use in the future. Four of these units were subsequently reactivated
and put back on-line after a six (6) year lay-up.
This guideline addresses the methods used to protect the systems and equipment on
these units during the lay-up period. Included will be a discussion on the operation and
maintenance requirements needed to (1) prepare the units for lay-up, (2) maintain the
units during the lay-up period and (3) reactivate and make them operational. A
summary of the problems encountered and the success of the program is ako
discussed. CONTENTS
Section page
1 INTRODUCTION 1
2 SCOPE 2a
3 DESIGN CONSIDERATIONS 3-1
Prevention Of Deterioration Options 3
Preservation by Dehumidification 33
Dehumidification System Design Objectives 37
Preservation Methods Selected For Plant Equipment 3-10
4 DESIGN GUIDELINES FOR LAY-UP a1
Dehumidified (0/H) Protected Equipment 41
Water/Steam Cycles 41
Furnace Air/Gas Cycle “7
Generators/Exciters 410
5 OPERATIONS & MAINTENANCE 51
Implementation 5-1
Operations & Maintenance During Lay-up 5-3
6 REACTIVATING THE PLANT 61
Operation & Maintenance 6-1
Problems Encountered 6-2
7 REFERENCES 7
8 — APPENDIXES
Appendix A Guidelines for Long Term Lay-Up Al
Appendix B Preventive Maintenance Program BL TLLUSTRATIONS
Figure
3-1
al
4-2
4-3
4-4
45
5-1
Regenerative Type Dehumidifier
Water Steamside Cycle Dehumidi fication
Boiler Feed Pump and Fan Motor Oehumidification Connection
Furnace Air/Gas Cycle Dehunidi fication
Boiler Feed Pump and Fan Motor Dehumidification Connection
Generator/Exciter Dehumidification Connection
Typical Plot of Humidity Readings
vii
Page
39
a4
4-6
48
49
412
55 TABLES
Table
1.
Bd
5-1
5-2
61
Extended Cold Standby Units at FPL
Preservation Methods for Plant Equipment
Manpower Required to Implement Long Term Lay-up
Annual Manpower Required to Maintain Long Term Lay-up
Manpower Required to Reactivate Units
ix
1-2
3-1
5-2
5-6
6-1 SUMMARY
Of the seven oil/gas fired fossil units deactivated and put into long term
storage by Florida Power & Light Company in 1976 four have been returned to
service. To preserve these units during an anticipated five to ten year shutdown
Florida Power & Light Company developed the Extended Cold Standby (ECS) program.
The ECS program which utilized dehumidified air proved its effectiveness by the
relatively low cost of maintaining these units during the shutdown and
reactivating them later. No significant maintenance work was required to
start-up the units as a result of this progran. The cost savings in the
reduction of the plant work force during the long shutdown more than compensated
for the cost of reactivation.
The most difficult problem to deal with during start-up was obtaining a new plant
staff. Each of the plants’ work force had been reduced to the minimum.
Rebuilding and training the work force from the plant manager to the helper was
‘time consuming effort. An Operator Training program had to be implemented be‘ore
start-up. Obtaining experienced mechanics and training operators at all levels,
turned out to be more difficult than reactivating the plant systems and
equipment. However, this situation was not unexpected and time was built into
the start-up schedule to accomplish this task.
Overall the "Extended Cold Standby" program at Florida Power & Light Company was
considered a success. The program met, and in some cases, exceeded expectations.
sl Section 1
INTRODUCTION
Putting units into cold standby operational status for short periods of time wien
5
the generation is not needed has been a common practice for most utilities.
the most part this is a simple process. In this type of inactive status a1] the
equipment is immediately available and the unit can be placed back into service
in a matter of hours. For the comparatively short period of time the units are
inactive no serious problems are expected to occur.
In 1976 the load forecast at Florida Power and Light Company showed that seven
(7) oil/gas Fired generating units could be inactive for five (5) years or
Tonger. After this period the generation would again be required to meet the
joad growth. FPL realized that these units would have to be maintained in a more
protective and extensive way than during the normal cold standby mode. The term
“Extended Cold Standby" (ECS) was used to apply to this type of inactive status.
For the purpose of this guideline the term “Long Term Lay-up" will be used.
FPL developed a progran that would prevent or reduce the deterioration of plant
equipment and structures during the long shutdown period. The objective of this
progran was to provide this protection with minimal manpower and cost during the
Tay-up and to minimize the cost to reactivate at a future date. Since this time
Four units have been reactivated and made operational. (Refer to Table 1.1)
11 Table 1-1
EXTENDED COLD STANDBY UNITS AT FPL
Plant MW Start-up Date Into ECS Date Out of ECS Rereat
Cutler 4 80 1982 10/15/76 2 ves
Cutler 5 80 1954 11/01/76 o4ya7/e2 No
Cutler 6 140 1955 uyoi/76 06/15/82 Yes.
Riviera 1 35 1946 12/06/76 12/29/78 No
Riviera 2 80 1953 12/06/76 12/29/78 No
Palatka 1 30 1951 12/06/76 - No
Palatka 2 80 1956 12/06/76 - Yes Section 2
scope
The guidelines and procedures are based on information gained from experience at
Florida Power & Light Company. Actual Long Term Lay-up Procedures, data and
results obtained from seven (7) oil/gas fired fossil units located at three (3)
different sites will be used.
a1 Section 3
DESIGN CONSIDERATIONS
The period of Long Term Lay-up used in this guideline is from one (1)to ten (10)
years or more. During this period the unit must be protected fron corrosion,
decay, mildew, mold, etc., which are the main causes for deterioration of
equipment.
The objective of this guideline is to provide this protection at minimim capital
and maintenance cost to implement, and to maintain and reactivate in the future.
The initial engineering and guidelines developed for use during the inactivation
period took into consideration minimum maintenance cost.
To inactivate a power plant unit for “Long Term Lay-up" is a complex operation
requiring a concerted effort by everyone involved to complete the necessary work
in the time allotted. Inactivation will require the use of unfamiliar equipment,
materials and techniques. At the completion of this work, the inactivated unit
can be economically maintained in the “as left" condition for the lay-up period
and can be reactivated for service in a comparatively short period of time in the
future.
At the end of the period, the unit is expected to be put back in service. The
time that it should take to get the unit operational can be anywhere from six (6)
months to a year. The time will depend on how much work needs to be done and how
well the procedures are followed. There is no way to predict the exact condition
the unit will be in five (5) to ten (10) years after it is layed-up. However,
the plant will be maintained by a small work force to make sure chat
deterioration does not begin or become so severe that the systems cannot be
economically put back into service.
PREVENTION OF DETERIORATION OPTIONS
Corrosion and rot are the most serious forms of deterioration. There are several
acceptable methods that the utility industry can use to protect equipment and
systems from corroding or rotting. Four of these were studied by FPL for use in
Bd ‘the long term shutdown program. The four methods are discussed in the folloving
text.
Wet lay-up can be used for vessels such as feedwater heaters and boilers. This
method usually requires that the equipment be filled with demineralized water
which has been “doped with a corrosion inhibitor such as ammonia or hydrazine.
Nitrogen gas may also be added to protect the void spaces where the water may not
come in contact with the surfaces, such as the top of a feedwater heater. The
main advantage of wet lay-up is that ft provides a more positive method for
protect ing equipment than sone others.
The main disadvantages of this method is that it requires more work by the
operations and maintenance personnel to assure the nitrogen cap is not lost and
that the chemical concentrations renain at the proper level. This method would
be optimum for some of the equipment if the lay-up period was for a short period
of time, (i.e. six months or less) and a full operating and maintenance crew were
available. Since this method does not meet the "Long Term Lay-up" objective it
was not used.
The use of primers, paints or preservative coatings are methods that can be used
to protect most surfaces. Proper coatings can offer protection from corrosion,
rot and deterioration from causes such as corrosive vapors, sunlight (ultra
violet radiation), marine growth and galvanic action. These methods were used
during the lay-up period to protect external surfaces such as boiler structures
and other equipment that were exposed to the elements of the weather.
The main disadvantage of this method it that is requires extensive manhours in
preparing the surfaces and applying the proper coatings. The maintenance crew
must periodically monitor the condition of the coatings during the lay-up period
and recoat as necessary. However, this was the only practical method for
protecting exteriors of equipment exposed to the weather. Keeping up with this
activity requires the most maintenance manhours during the shutdown.
Keeping selected equipment and systems in operation, instead of shutting them
down, was another method used. Such systems like the turbine lube oi] and fuel
oil transfer systems contain fluids that provide a natural protection such as
lubricating oi1 or fuel ofl, The plant closed cooling water system is another
system that can be left in operation since the cooling water has been “dopped”
32 with a corrosion inhibitor to give it protection. This system is also used
during the lay-up period.
Many systems were left running during the lay-up period. The only disadvantage
was the energy cost and the minor maintenance required to keep them operating.
However, these cost were considered minor when compared to the expensive
alternatives to protect the same equipment for several years while shutdown.
Dry lay-up is also an alternative for protecting "closed-in" equipment such as
pressure vessels, piping, etc. This is an especially effective method when the
equipment being protected needs to be opened and inspected periodically.
There are two options that can be used for dry lay-up. One is the use of
nitrogen gas for blanketing the internals of equipment. The other is using dry
air, Nitrogen blanketing was not used for long term lay-up due to maintenance
and operational requirements needed to keep the gas in the systems. This method
is more effective when protecting an air tight vessel for short periods.
Dry or dehumidified (D/H) air offers the same advantages as nitrogen gas plus
many more. The dry condition can he maintained even while the equipment is
opened for routine inspections. This allows for routine inspections and repairs
to take place without the loss of costly gas or possible corrosion to take place
during the inspection or repair. D/H air systems are also less costly to
maintain over the long term.
Dehumidified air was selected as the primary method of protecting the most
critical components of the plant. Critical components are defined as those that
would be too costly to repair or replace if they deteriorated significantly.
They would most likely be so costly that it would not be economical to reactivate
the unit. These systems are: turbine, generator, exciter, condensate and
feedwater piping, feedwater heaters, boiler steam/waterside and furnace air/gas
side. Details on how these systems and their auxiliaries were layed-up will be
presented later. Since the use of D/H air is so important to the success of the
Jong term lay-up program more detail on how and why it works will be explained in
detail.
PRESERVATION BY DEHUMIDIFICATION
It is well known that the process of removing the anount of moisture in the air
(dehumidif ication) is the single most important factor affecting the condition of
33 metal surfaces and equipment. By limiting the anount of moisture present, the
most serious forms of deterioration can be halted, even without preservatives.
Even the best paints, greases and other protective coatings cannot be totally
affective in preventing corrosion, mildew or rot if moisture is present. Other
forms of deterioration that are caused by dust, corrosive vapors and gases,
sunlight (ultra violet radiation), marine growth and galvanic action are
controlled to sone extent by placing equipment in a dehumidified zone. This is
mainly due to the D/H zones being sealed from outside elenents.
In addition to prevention of deterioration there are other advantages to the
dehumidified atmosphere. Electrical windings, cables, etc., stay dry and show
higher ground resistance. Sulfur deposits in the boiler furnace, rust on metal
surfaces, corrosion products on the inside of boiler tubes or on turbine bladings
will dry out and becone harmless inert powders that will not cause deterioration.
Since the dehumidification zones used are airtight; dust and vapor contamination
are greatly reduced thus reducing or eliminating any damage they may cause.
With the development of the industrial type desiccant dehumidification (O/H)
machine, dehumidification became a practical means of preserving materials by
continuously removing moisture, The D/H machine is similar in construction to
the regenerative type air preheater, although on a much smaller scale. The wheel
is a non-metallic, inert structure that is impregnated with an inorganic solid
desiccant which absorbs moisture from the air. As the wheel turns (approx. 6-20
RPH) humid air passing through the flutes in the wheel is dried. At the same
time a counter flowing hot reactivation air stream, passing through the
reactivation sector of the wheel, removes the moisture picked up by the
desiccant. This allows for continuous controlled drying. The dried process air
leaving the D/H machine is circulated by a blower fan.
If an enclosure, with the exception of wood, is kept at a relative humidity of
30% at any ambient temperature, the equipment -and material inside will be
retained in good condition. The low humidity prevents the growth of mold and
mildew and inhibits the corrosion of ferrous metals.
‘The effectiveness of D/H depends on maintaining a low relative humidity of not
more than 30% at any given temperature. This means that extreme care must be
taken to prevent moisture from getting inside the enclosure. The sources of
moisture are: (1) rain water, (2) water vapor in the air and (3) moisture in the
34 materials. In the initial D/H drying period air moisture and material moisture
content are in constant exchange with each other until the material is dry.
After the initial D/H period, some moisture will enter the enclosure by
infiltration through cracks, faulty seals, valve packing etc, Moisture can also
enter by "breathing" and diffusion of outside air which can be caused by changes
in the air temperatures inside and outside of the enclosure.
Infiltration of moisture is caused by the wind creating a positive pressure on
one side of an enclosure and negative pressure on the other or downwind side.
"Breathing" is caused by temperature changes which increase (or decrease) the
pressure of air volume inside the enclosure. Breathing will be greater in sunmer
than in winter because of the sharp day and night tenperature change.
D/H air circulation is important to the removal of moisture in the enclosure.
The air from the dehumidifier, with a very low moisture content, is generally at
a slightly higher temperature after contact with the warm surface of the
desiccant wheel. The temperature and pressure differences created by the dry
process air will allow sufficient air circulation in the enclosure, provides it
can be recirculated back to the O/H machine.
Aside from air circulation, the vapor pressure differential of air at varfous
parts of the enclosure also assists in equalizing the moisture content of air in
the D/H zone. The water vapor in the air with high relative humidity (high vapor
pressure) will migrate to the section with loner relative humidity by diffusion.
Any part of the enclosure which is inconvenient or impractical to have dry air
circulate through it will eventually dry by diffusion as long as it is in contact
with the dry air.
The diffusion principle is very important and useful in making the D/H process
work. It is relied upon to dry out very complex piping systems where a good air
flow through them would be almost impossible to obtain. As long as a systen is
in contact with the airflow somewhere and does riot have any blockages, such as
closed valves, diffusion will draw out the moisture.
Relative hunidity (R/H) is the amount of moisture in the air as compared with the
maximum amount that the air could contain at the same temperature. It is
important to understand that this is the R/H of the atmosphere in which the
equipment is being preserved and not the ambient R/H. The R/H in the process
must always be less than anbient, in this case 30%. This difference is important
35 to assure that moisture does not accumulate on the surfaces of the equipment and
cause deterioration. The thermodynanic properties of moist air will help assure
that the moisture does not accumulate if the difference in R/H is maintained.
By referring to a Psychronetric Chart we can see the effect of these differences.
For example at 80° F the air becomes saturated or 100% R/H when it contains
approximately 158 grains of moisture per 1b. of dry air. The vapor pressure at
this point is 1.05 in. of Hg. To maintain 30% R/H at this tenperature the grains
of moisture must be reduced to 46 which gives an approximate .3 inches of vapor
Pressure. To get this reduction the D/H machine must produce dry process air
with a lower moisture content and subsequent vapor pressure than the 30k level.
Initially the machine would be working harder due to the large difference in
moisture that needs to be removed. After a certain period of drying time the
system will reach an equilibrium where 30% will be maintained easily, provided
moisture is not introduced back into the systen.
Nore important is the fact that the dry process air always has a lower moisture
content and vapor pressure. Since the vapor pressure is lower than the vapor
Pressure of the air in the protected atmosphere, moisture will not accumulate on
‘the surfaces thus causing corrosion. Instead due to the difference in vapor
Pressure the moisture will go from the surface to the incoming process air. This
moisture is then removed from the protected area and recirculated through the D/H
machine to be removed before it returns back to the protected area to repeat the
Process. The D/H machine should be used in a closed loop type cycle to be most
effective.
Although the example used 80°F saturated air for comparison the principle
applies at other non-saturated or lower R/H anbient conditions. From experience
at FPL, if the equipment being protected is kept at a 30% R/H or lower at any
ambient tenperature it can be maintained in good condition. During actual
operations, values below 30% are often maintained. The key factor to success
depends on maintaining the air tight integrity of the systens being protected,
There are two common industrial types of dehunidification machines that can be
used to remove moisture from the air. One is the refrigeration type and the
other is the desiccant type. hich type to use is a function of the dew point of
the process air that is being maintained. Above 50° F dew point, refrigeration
has some advantages in capital and operating cost. The disadvantages of chis
equipment is the complexity of the machinery itself. If a dew point of Tess than
36 50° F is required, refrigeration type systems do not perform well. They become
more costly to maintain and operate than the desiccant type, which is primarily
due to icing problems. Below 50°F the desiccant type offers the major
advantages of lower capital and operating cost. The equipment is mechanically
simpler, smaller in size, and is easily connected electrically.
At a temperature of 86° F and 30% R/H the dew point is 50°F. As the temperature
decreases the dew point will be below 50°F, Since most of the operating time
will be at a temperature below 86° F the system will be operating below 50° F dew
point. For this reason plus the equipment and installation advantages and lower
operations and maintenance cost; the regenerative desiccant type machine was
selected for use during the Tong term lay-up. From now on when the O/H machine
is referred to it is this type machine.
DEHUMIDIFICATION O/H SYSTEM DESIGN OBJECTIVES
The primary objective of the Long Term Lay-Up program is to prevent deterioration
of systems and equipment so that they can be reactivated economically in the
future when required. The D/H process assures this for interiors of the mst
critical components. The program also considers other objectives that will make
protecting the other systems in the plant successful
The D/H process allows for the system and equipment being protected to be
preserved in an "as is" condition. No special or complicated procedures are
necessary. No special coatings or preservatives are needed or any major
disassembly of the equipment required. The D/H air and a tight system are all
that is needed. Therefore, the equipment is left intact and ready for simple
reactivation in the future. This makes the process economical in deactivating as
well as maintaining during the lay-up and subsequent reactivation.
Entering the 0/H areas for inspections is easily done by opening the normal
accesses and entering. The 0/H equipment can be kept operational during the
inspection since the atmosphere, which is warm-dry air, does not propose any
hazard for personnel. Afterwards the systens can be closed-up and the drying
process cont inued.
The initial drying is accomplished in a fairly short time. In addition to the
moisture vapor in the air, all surfaces, and material in the space has moisture.
37 ‘As the R/H of the atmosphere increases or decreases the amount of this moisture
also increases and decreases respectively. When the D/H process is first started
the water vapor in the air reduces rapidly. This evaporation process continses
until an equilibrium is obtained between the air vapor and surface vapor. The
system is designed so that this equilibrium occurs at or below the set-point of
30% R/H.
The D/H machine selected for use at the power plant is of the rotary wheel
continuous regeneration desiccant type. Lithium chloride is used as the
desiccant which is impregnated on the rotary drum. The major benefit of this
‘type machine is that the desiccant is reactivated simultaneously with the removal
of moisture from the process air. The machine operates similar to the air
preheater on a boiler. As the wheel continuously rotates the process return air
supply passes through the reactivated desiccant and removes the moisture. The
wheel then rotates the moisture ladden desiccant in a stream of hot reactivation
air that dries it out. The dry desiccant then rotates into the process air and
the cycle repeats. Figure 3-1 shows the basic components of this type 0/H
machine, Several types of D/H equipment were evaluated for use at the plants.
This particular type of equipment was evaluated best when compared to the other
desiccant type machines and also the refrigeration type dehumidifiers. This has
been proven to be true by the success of the program in achieving the objectives.
38 REACTIVATION
AIR OUTLET
REACTIVATION a
nt DESICCANT |
; Esra O
64) WHEEL
4 REACTIVATION
DRY 4 AIR HEATER - i‘
PROCESS
AIR Le >_> +
OUTLET F] REACTIVATION
; AIR BLOWER
REACTIVATION ~~ ,
| ‘SECTOR
L\@Qyrrrre = How
PROCESS AIR
PROCESS INLET
SECTOR
PROCESS BLOWER
@)
Figure 3-1. Regenerative Type Dehumidifier
Desiccant treated contactor wheel rotating through two air streams separated
by Floating contact seals. The contactor is impregnated with desiccant and
allows easy passage of air.
Process air blower moving air to be dried through the contactor. As the air
is dried, the desiccant reaction also heats the process air causing the
‘temperature to rise.
Reactivation air blower moving regeneration air through a reactivation air
through a reactivation heater, through a contactor, and out through a vent.
As the reactivation air passes through the* contactor it picks up moisture
from the contactor and is cooled.
Reactivation air heater, using steam, electric, or gas energy to heat
reactivation air hot enough to drive moisture out of the contactor. There
must be enough heat in the air leaving the contactor to hold all the
moisture collected.
39 PRESERVATION METHODS SELECTED FOR PLANT EQUIPMENT
Dry air is delivered to various selected parts of the systems and components in
the plant that are to be protected by this process. The systems are divided into
several enclosed dehunidification zones. A closed circuit of air flow is used to
protect the enclosures. The dry air leaving the machine will circulate through
the enclosures or zones picking up moisture and returning to the suction of the
O/H machine where the moisture is removed and the dry air is returned to the
process.
In order to have effective dehumidification the boiler water side, gas side,
turbine, generator, steam piping, water piping, electrical, mechanical auxiliary
equipment, etc., are divided into practical zones for dehumidification. The
volume of each dehumidification zone is calculated in order to determine the
required capacity of the dehumidification equipment. Each of the zones must de
made as air tight as possible as the quantity of water that can enter a small
leak can easily be greater than the capacity of the O/H machine.
Aside from air circulation, the vapor pressure differential of air at various
parts of the enclosure also assists in removing the moisture content of air in
the D/H zone. The water vapor on the surfaces has a high relative humidity and
will migrate to the process air with lower relative humidity by diffusion. Any
part of the enclosure which is inconvenient or impractical to arrange for dry air
to circulate through it will dry by diffusion providing it comes in contact with
the air.
The dehunidification process was selected as the method of protecting the most
critical components in the plant from deterioration due to corrosion. However,
sone other areas of the plant are left “as is" with no formal protective methods
used. This was done for various reasons. The equipment was either still
required for operations during the long term lay-up or too remote from the O/H
equipment for practical hook-up. In some cases it was considered less expensive
to repair or replace the equipment during the future start-up than is the cost to
protect it during the lay-up.
Table 3-1 lists the major conponents and systems in the plant and the method used
for their protection during the lay-up.
310 Il.
I.
Table 3-1
PRESERVATION METHODS FOR PLANT EQUIPMENT
PROTECTED BY DEHUMIDIFIED AIR
Boiler (steam & waterside, furnace, gas side, ductwork and breechings)
Generator and Exciter
Turbine (HP, IP & LP)
Desuperheater
Pneumatic Controls (protected by leaving instrument air system in service)
Condensate and Feedwater System (include FW heaters)
Condenser (steam side)
1D & FD fans including motors
Boiler Feed Pump (include motor), Cond. Pump, Heater Drain Pump
Control Room (portable O/H machines)
EQUIPMENT AND SYSTEMS LEFT IN SERVICE
Service and Instrument Air
Open and Closed Cooling Water
Station Batteries
Turbine Lube Of1
switchyard and Auxiliary Switchgear
Water Plant
PRESERVATION OF OTHER SYSTEMS AND EQUIPMENT
Other systems and equipment were treated on a case by case basis depending
on their uniqueness and ability to be protected. Some of these are
described as follows:
Intake and Circulating Water Lines
Special treatment is required for plants that use seawater for their
circulating water systems. A four inch concrete partition can be placed in
front of the traveling screens to keep out mud and debris. Fresh water Should be continuously added to the intake well to reduce the concentration
of saltwater. Chlorine is also added to prevent marine growth.
Boiler and Other Structures
The structures that are exposed to anbient weather conditions are protected
with primers and paint. Protecting these areas from rust and deterioration
Will require a good preventive maintenance progran during the lay-up period.
The majority of manpower should be dedicated to this activity.
Fuel 011 Storage Tanks and Associated Equipment
The fuel oi1 tanks are emptied and left “as is". The heavy of] residue left
fon the inside of the tanks provide a good protective coating. Freshwater
can be added to prevent the enpty tanks from "floating" due to the flooding
in the dike area that could possibly occur during a hurricane. A check
valve can be installed in the side of each tank to allow water to enter the
tank if flooding did occur. Tie down cables can also be installed on each
tank for additional security.
Small Motors, Pumps and Piping
Most of the small motors and pumps are left “as is". This is one of the
areas that can be more costly to preserve and maintain during the lay-up
than to repair or replace later. However, where motor heaters were
installed they should be used.
Turbine/Generator Lube Oi] System
The turbine/generator is maintained so that it can be periodically put on
turning gear with the lube oi1 and seal of1 system in service. This will
provide adequate protection for the lube of] and seal oil system. This *s
another area that would be more costly to preserve and maintain during
shutdown than to leave it operational. Section 4
DESIGN GUIDELINES FOR LAY-UP
As was discussed in the last section, dehumidified air was used to protect the
most critical components and systems in the plant (Refer to Table 2). These are
the itens that if allowed to deteriorate excessively would be to costly to repair
and would make reactivation impractical and too costly. Some systems were
protected by other methods such as use of primers and paints while others were
left "as is". This section will describe the design guidelines for each of these
methods.
OEHUMIDIFIED (D/H) PROTECTED EQUIPMENT
‘The systems and equipment protected by D/H air are divided into major seczions
with each utilizing one 0/H machine. It takes three (3) O/H machines to protect
all the sections adequately on one unit. The sections are divided under the
general categories of, (1) water/steam cycle, (2) furnace air/gas cycle, (3) and
generator /exciters. Since the air space volume of each of these categories is
not the same, different sized D/H machines are used. The largest machine is used
for the furnace air/gas side section, the second largest machine is used for the
water/steam section and the smallest used for protecting the generator/exciter.
WATER/STEAM CYCLES
The water/steam cycle includes all the equipment and systems that are used to
produce steam. It begins on the steam side of the condenser and goes through the
turbine to the steam drum of the boiler. From there it goes through the boiler
tubes and feedwater system then through the condensate system back to the
condenser. The process is a closed loop cycle: Below is a list of equipment
protected in this section.
© Condenser Steam Side and Hotwel1
© Turbine LP, IP, and HP Sections
Main Steam Stop and Control Valve Internals
© Main Steam and Reheat Steam Lines
© Boiler Drum
a1 Boiler Superheater, Reheater, Economizer and Waterwall Tubes
Feedwater Lines
All Feedwater Heaters Both Tube and Shell Side
Boiler Feed Pumps and Drives (Motor or Turbine)
Heater Drain Tanks and Pump
Deareator
Steam Seal Lines
Condensate Pumps
Boiler Drain Header and Blowdown Tank
One D/H machine is used to protect this equipment. A typical size machine needed
is 2000 CFM for a 150MM unit. It is operated in a closed cycle. Figure 4-1
shows how the machine is connected into the cycle. The regenerated dry process
air begins its path by going into the condenser hotwell. This is one of the few
external connections required for the machine. This can be done by connecting
the discharge of the O/H machine to the hotwell through the condensate punp
suction line or into an inspection manway. From the hotwell the dry air flows up
through the LP, IP, and HP turbine. With the turbine and control valves blocked
open the dry air will travel up through the main steam line through the boiler
superheater and into the drum. Then it proceeds down the waterwall tubes and
doxncomers to the boiler drain header where it is returned to the D/H machine.
At the turbine the reheater stop valves are also blocked open. This allows the
dry air to move up through the boiler reheat lines to the reheater keeping it dry
and protected. The difference in sizes between the hot and cold reheat lines is
sufficient to cause a small differential pressure to exist which allows a flow
through the reheater. For the process to work only a small flow through an open
system is required. The principle of diffusion, as discussed earlier, will
assure the system is dry when a large flow is not possible. The most important
criteria is that the system is opened so that water is not trapped in any loop.
Assuring that water is not left in the loops of the superheater and reheater
tubes are addressed in the procedures in Appendix A.
By leaving the extraction and non-return valves open dry air is allowed to travel
through the feedwater heater shell sides. There it casades through each
feedwater heater and is returned to the D/H machine through the heater drain
systen.
42 In the boiler the dry air in the drum proceeds into the economizer and out the
feedwater line. The air follows the feedwater system through all its associated
equipment. This is how the high pressure feedwater heater tube side and boiler
feed pumps are protected. From here it continues on through the low pressure
feedwater heaters tube side, through the condensate pump where the dry air is
returned to the D/H machine. At this point the connection between the suction
line of the condensate pump and condenser hotwell must be blanked off. If not it
will short circuit the supply air into the condenser with the return air fron the
condensate pump. (Refer to Figure 4-1.) A key factor to remenber for the above
Process to be effective is that all valves in the system must be open,
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44 NOTE: Other components can be protected that may be unique to the plant by
simply running a supply line to that component and returning one back to the
machine for regeneration. Keep in mind this is a closed cycle so all the air
that leaves the machine must be returned to it for drying. By keeping the entire
system as air tight as possible the systems and equipment will remain at the
desired controlled point of 30% relative humidity.
The boiler feed pumps motors are protected by this means. A supply line from the
steam/waterside D/H machine is connected to the vents on the boiler feec pump
motors in a casade fashion. (Refer to Figure 4-2.) A return line from the last
motor is connected to the return on the D/H machine. The motors must be sealed
from ambient air for proper protection to take place and also prevent outside
moisture from getting into the day process air. uo39@uu09 uoLze915LPsuNYag 40J0H UE puE dung
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002> WBIIGINDH30 BTOAD SvO/aiv ‘BOwNaNS| cursez HOLOW NS av (f-¥ “914) | gous Nous Nunisa HOLOW Nvs aig 4-6 FURNACE AIR/GAS CYCLE The furnace air/gas cycle includes all the systems and equipment that are required to produce combustion in the boiler. It begins at the FD and ID fans then goes up through the boiler economizer into the reheat and superheat section and into the furnace. Again this cycle is a closed loop the same as the water/steam cycle. The equipment protected in this cycle is listed below: © Forced and Induced Draft Fans and Motors © Ductwork and Breeching © Air Preheater © Reheater, Superheater, Economizer Tube Gas Side © Furnace and Waterwall Tubes © Boiler Penthouse One D/H machine is used to protect this equipment. It's the largest of the three machines used on a unit. A typical size is 4000 CFM for a 150 MW boiler. Figure 4-3 shows how the machine is connected into the cycle. The regenerated dry air begins its path by going into the FO fan discharge and ID fan suction ductwork. The intake to the FD fan is sealed off as well as the discharge from ‘the ID fan to the stack. The dry air rises up through the air preheater, through ‘the economizer. reheater and superheater sections, and then into the furnace. At the same time, it travels through the windbox and enters the furnace through the air registers. The process air is returned to the D/H through a line connected at the bottom of the furnace. AIT the dampers are left opened except those used to keep anbient air out. This allows protection of the FO and ID fans. The FD and 1D fan motors are protected by this same machine by running a separate supply line from the D/H machine to one of the motors and then casading on to the others. After it reaches the last motor a return line brings it back to the D/H machine for regeneration. (See Figure 4-4.) ‘The boiler penthouse is protected by either opening the seals between it and the furnace, or by running a separate air line from the dry air in the furnace to an access in the penthouse. A good process air flow circulation is difficult to achieve in the penthouse therefore, diffusion will be relied on to keep it dry. However, the penthouse must be sealed tightly from outside air. 47 A i y ‘SH FURNACE FROM FD AND ID FAN MOTORS ——B>} RETURN (FIG 4-2) \ \ RH! = ECONOMIZER JocHumorreR| TO FD AND 1D FAN MOTORS (FIG 4-2) Figure 4-3, ‘SUPPLY FD FAN 4-8 NOTE: ID FAN DUCTWORK ‘SEALED FROM THE STACK TO PREVENT LOSS OF PROCESS AIR ID FAN Furnace Air/Gas Cycle Dehumidi fication wo}z0aUU09 UOL3POLJ LPJuNYag 40Z0H UY puR dung paey vaL}og “p-y aunBLy Lr MOLOW Nv aiv (e- ‘oly BOVNYNS OL Alddns eee HOLOW Nv aig MOLOW Nv4 av |; Cd) ’ cpp : , — & N f-y “Ol4) 2 | _aisiciwanza | 8 < 4 8 |< s0vNuns Wous 31040 S¥o/ulv 3 BOWNENS 3 et s a 4 Lr HOLOW Nw ag . = 49 Before the dry air is connected to the system the furnace is washed with a soda ash solution, This not only removes any excessive deposits but helps neutralize Corrosive sulfur deposits that might be remaining. As much of the corrosive deposits as practical should be removed. The process still works very effectively even if some remains. As the furnace dries out the remaining deposits will also dry out. They become inert and turn into a harmless powder like substance. The principle that corrosion is greatly reduced or eliminated in the absence of moisture becomes apparent in this case. After washing, the furnace is dried by firing the boiler until operating pressure is achieved. The heat will dry the insulation before the D/H machine is connected. The fires are shut down and the furnace is drained hot. This will help assure moisture is also removed from the steanside of the boiler components. After drying and draining the boiler, any water remaining in the superheater and reheater tubes can be removed by dry firing the boiler. This can be done by using the ignitors and allowing the heat to evaporate the excess water out of the ‘tubes. By opening the superheater and reheater vents and boiler drains during the firing the water vapor is allowed to escape. Care must be taken not to damage the enpty tubes by applying too mich heat. Just enough heat to evaporate the water inside the tubes is all that should be applied. Thermocouples are used to monitor the heat input so that no damage will result. After dry firing is completed, any water or moisture remaining in the superheater or reheater tubes will be removed by diffusion once the D/H air flow begins. This principle gives the assurance that water will not remain in the loops which can cause damage. Therefore, with the exception of the initial drying of the boiler after washing no special effort needs to be done to drain these sections. More details on drying is presented in the procedures in Appendix A. GENERATORS /EXCITERS The generator /exciter cycle includes the main electrical generation equipment and auxiliaries. Its also a closed cycle. The equipment that is protected in this cycle is listed below: Generator Exciter Generator field Hydrogen coolers gas side Exciter cooling system One O/H machine is used to protect this equipment. It is the smallest m used. A typical size is 600 CFM for a 150 MW generator. Figure 7 shows how the machine is connected into the cycle. The regenerated dry air is brought into the generator through an inspection access on one end and is returned back to the suction side of the D/H machine from the opposite end of the generator. This is one connection. The second is to connect a supply line from the D/H machine to the exciter and back again. For best results the connection should be made into ‘the ductwork of the exciter cooling system and returned from an inspection port ine on the exciter house. This will help assure that the cooling coils are being protected as well as the exciter itself and all other components. Keeping dust and foreign matter out of the generator is a prime concern in this cycle. Therefore, a high efficiency particulate filter is used to filter the dry air before it enters the generator. This is the only cycle where a special filter is used in addition to the normal filter provided at the O/H machine. luo}328uu09 uoLze9L5 {psuNYag ta2}49x3/J03049Uag *G-y a4nBLy 43LIOIWNH30 SOLVYSN | YOLVYANZO YSLIOXa MALIOX3 OL 4-12 Section 5 OPERATIONS AND MAINTENANCE IMPLEMENTATION The plant maintenance personnel can do all of the preparation work for the long term lay-up. This includes painting, boiler washing, connecting D/H air lines and all other work described in the following procedures. The maintenance work files need to be updated as to the status and condition of all major equipment prior to the shutdown. Since no major overhaul work will be performed until the unit is reactivated, these detailed files will be required for future maintenance crews. The importance of these files cannot be overemphasized since an all new maintenance crew, unfamilar with the plant, can be expected when it comes tine to reactivate the unit. The plant operators need to update all the start-up and operational procedures. This includes procedures and drawings that show the various valve line-ups that. were made to accommodate the lay-up procedures and how to return then to their normal operating position. Again this documentation is important in assisting the anticipated all new future operating crew in starting up the plant. (Refer to Table 5-1.) 51 Table 5-1 MANPOWER REQUIRED TO IMPLEMENT LONG TERM LAY-UP Supy Mech = Elect’ «= T&CS Clerk Less Than 400 Mw Gne unit with others Operating 5 2 ah 8 2 Unit with others Operat ing 8 3 1 12 2 Unit with no other Operat ing 1 8 3 1 1 14 Est. Preparation time is 8 to 10 weeks. Manpower requirements are estimated based on FPL experience. 5-2 Typical records that should be maintained on file: © Unit instruction manuals © Operating Letters of Instruction © List of al] major equipment with proper valve positions indicated for normal operations © Complete list of all non return valves, check valves, steam traps, and Safety valves that were altered to allow the flow of D/H air through the systems Copy of Long Term Lay-up Procedures Manual Copy of all manufacturer's equipment manuals Copy of all start-up and shutdown check sheets Copy of pre long term reserve shutdown turbine tests Copy of al1 equipment check sheets and test procedures Long term reserve shutdown equipment rotation check sheets List of all maintenance work that was deferred Routine D/H readings and inspections reports Start-up and shutdown procedures Procedures for reversing long term lay-up process OPERATION AND MAINTENANCE DURING LAY-UP The maintenance and operating crews are reduced to a minimum. Their work is primarily preventive maintenance and inspections. Structure maintenance will require the most effort with some periodic trouble repair on the equipment that is still operating. The maintenance work can be done during a typical five day, forty hour work week. One operator per shift, seven days per week, three shifts per day is required. His job is to act as a watchman plus monitoring whatever equipment is still t to operating. He also takes periodic relative humidity readings of the equipmer make sure the D/H process is working. A routine monitoring program must be established to check the effectiveness of the lay-up progran. This includes periodic humidity readings of the D/H machine's process air (in and out) plus all the equipment that is being protected. These readings should be plotted on a graph each month for compa on of how the process is working over time. (Refer to Figure 5-1 for typical plot.) Equipment with large bearings can be manually rotated weekly to protect the bearings. (Refer to Appendix B for typical preventive maintenance program.) 5:3 A routine annual inspection of a11 equipment plus general condition of the plant should be conducted. This inspection will require personnel to go into the process controlled areas (e.g., boiler, turbine) and visually inspect the surfaces for signs of corrosion and deterioration. Annual electrical resistance readings of the large electrical equipment (e.g., large motors, generators, exciters) should also be taken to make sure this equipment is being properly protected. The annual inspection plus routine D/H readings should show the process is effectively protecting the plant equipment at 30% or less relative humidity. (Refer to Table 5-2.) Initially @ more frequent. inspection progran should be established to make sure the D/H process was set-up correctly and nothing was missed in the line-up. 54 s6ulpeay ALpLUNY Jo Fold LeLaey “T-g aanbI4 BIOAO MBLIOXS/YOLVYSNAO ewan — BTIOAD SVO/MIV SOVNYNS am LNZIGINY me SONIGVSY AIMSSM il SS3Z00Nd ONIANG NIO3E 1 1 1 1 1 1 ° OL me XS OS Ov OS o9 OL os 06 OOoL TDS-a0-+> aweowZe HdVuD BWIL / ALIGINGH BAILV13E8 Table 5-2 ANNUAL MANPOWER REQUIRED TO MAINTAIN LONG TERM LAY-UP Supy Oper. Mech Elect Helper Clerk Total Less Than 400 Mit One unit with others Operating 3 1 1 5 2 Units with others Operating 7 2 1 10 2 Units with no others Operat ing 1 5 7 2 1 1 v Manpower requirements may vary depending on specific plant needs and equipmert left operational. 5-6 section 6 REACTIVATING THE PLANT OPERATION AND MAINTENANCE Reactivating the plant is primarily a function of reversing the deactivation process. The actual time that it takes to make the plant operational will depend greatly on the amount of deferred maintenance and overhaul work that is required. Each unit will vary widely on this effort which will not be discussed here since the work is plant specific and not as a result of the lay-up program. Considerably more time will be required to staff, train operators, and complete the deferred maintenance and overhaul work than it takes to reverse the the work done to initially lay-up the plant. (Refer to Table 6-1.) Table 6-1 MANPOWER REQUIRED TO REACTIVATE UNITS Total Supy Mech Elect Clerk Personnel iB Less than 400 Mi One unit with others Operating 7 2 1 le 2 units with others Operat ing ae 4 4 2 26 2 units with no others Operating 1 14 4 4 Estimated time to reactivate is three (3) months. The manpower requirements are to reverse what was done for lay-up preparation plus inspection and general maintenance of plant and equipment. Does not include any major overhaul, backfit, or repair work that may have been required before shutdown. PROBLEMS ENCOUNTERED No major problem is expected to occur as the result of the lay-up program. The O/H process has proven to be very effective in protecting the systems and equipment to which it was applied during the long lay-up period at FPL. Any Significant repair work that was required on the equipment protected during the program had been identified prior to the shutdown. At FPL, most of the work was done on the equipment and systems that were not protected by dry air. This was primarily corrosion of the areas exposed to the weather. The most significant maintenance problem was with external corrosion of the piping that was covered with non-weatherproof insulation. The insulation absorbed moisture which facilitated corrosion of the piping on the outsideYou might also like
