600mw Operation Manual

HARYANA POWER GENERATION CORPORATION LIMITED PANCHKULA, HARYANA DESEIN PRIVATE LIMITED CONSULTING ENGINEERS NEW DELHI CENTRAL ELECTRICITY AUTHORITY SEWA BHAWAN, R K PURAM, NEW DELHI 2X600MW THERMAL POWER PLANT HISAR HARYANA-INDIA Operation Manual for 600MW Unit DOCUMENT No: HISAR-ZT-07

RELIANCE ENERGY LIMITED H-146/147, Sector-63 Noida (U.P) – 201301

DEVELOPMENT CONSULTANTS PRIVATE LIMITED CONSULTING ENGINEERS 24B PARK STREET, KOLKATA - 700 016, INDIA

SHANGHAI ELECTRIC CORPORATION No. 8, Xingyi Rd., Shanghai, 200336, China

SHANGHAI ELECTRIC IMP. AND EXP. CORP, No. 22, Lane 376, Yan’An Rd. (West), Shanghai, 200040, China

HTPC 湖南省火电建设公司

HUNAN PROVINCIALTHERMALPOWER CONSTRUCTION CO. 99 Jianshe Zhonglu,Zhuzhou,China

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISARHARYANA-INDIA

DOCUMENT CONTROL SHEET

PROJECT

:

2X600 MW THERMAL POWER PLANT HISAR HARYANA-INDIA

CLIENT LIMITED

:

HARYANA POWER

GENERATION

CORPORATION

DOCUMENT TITLE:

Operation Manual for 600MW Unit

DOCUMENT NO. : HISAR-ZT-07

REV. NO. :0

ENDORSEMENTS

0

2009-02-20

First Issue

Rev No

Date

Description

DOCUMENT NO. : HISAR-ZT-07

Prepared by Sign.( Initials)

Reviewed by Sign. (Initials)

Approved by Sign.( Initials)

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

CONTENTS CHAPTER I BOILER OPERATION REGULATIONS.................................................................. 1 1.1 INTRODUCTION OF BOILER DEVICES .............................................................................. 1 1.2 BOILER MAIN TECHNIQUE REGULATIONS ...................................................................... 1 1.2.1 MAIN PARAMETERS OF BOILER..................................................................................... 1 1.2.2 MAIN PERFORMANCE INDEX OF BOILER ..................................................................... 2 1.2.3 PARAMETER OF SH PRIMARY, SECONDARY WATER SPRAY DESUPERHEATER RH EMERGENCY SPRAY.................................................................................................................. 4 1.2.4 COAL PERFORMANCE ANALYSIS TABLE ..................................................................... 5 1.2.5 SET VALUE OF BOILER SAFETY VALVE ........................................................................ 5 1.2.6 LIMITING VALUE OF HEATING SURFACE ...................................................................... 6 1.2.7 TECHNIQUE REGULATIONS OF BOILER MAIN AUXILIARIES ..................................... 6 1.3 MAIN CONTROL SYSTEM.................................................................................................. 11 1.3.1 SUMMARIZE ..................................................................................................................... 11 1.3.2 INTRODUCTION OF UNIT COORDINATED CONTROL SYSTEM................................. 11 1.3.3 FSSS INTRODUCTION (FURNACE SAFETY SUPERVISION SYSTEM) ...................... 13 1.3.4 BOILER MFT CONDITION ............................................................................................... 14 1.3.5 CONTROL OF SECONDARY AIR DAMPER ................................................................... 15 1.3.6 FUEL CONTROL OF RB ACTION ................................................................................... 19 1.4 TEST BEFORE BOILER START-UP................................................................................... 21 1.4.1 TESTS BEFORE BOILER START-UP ............................................................................. 21 1.4.2 BOILER OVERALL INTERLOCK TEST .......................................................................... 21 1.4.3 FURNACE PRESSURE PROTECTION ........................................................................... 22 1.4.4 OTHER PROTECTION TEST ........................................................................................... 22 1.5 START UP OF BOILER ....................................................................................................... 23 1.5.1 INITIAL STATE BEFORE START-UP (ENTIRE COLD WORKING CONDITION) .......... 23 1.5.2 PREPARATION BEFORE START-UP.............................................................................. 23

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

1.5.3 BOILER BLOWING CONDITIONS................................................................................... 24 1.5.4 INSPECTION OF CONTROL SYSTEM BEFORE START-UP......................................... 26 1.5.5 BOILER IGNITION, TEMPERATURE INCREASE, PRESSURE RAISE......................... 26 1.5.6 INCREASE COMBUSTION RATE.................................................................................... 27 1.5.7 PRECAUTIONS DURING THE COURSE OF BOILER TEMPERATURE INCREASING27 1.5.8 TURBINE TURNING AND SYNCHRONIZATION ............................................................ 28 1.5.9 TURBINE SYNCHRONIZATION WITH MINIMUM LOAD TO 35% OF BMCR (100MW) 28 1.5.10 LOAD FROM 35% OF BMCR TO 100% ........................................................................ 29 1.5.11 PRECAUTION FOR COLD START ................................................................................ 29 1.5.12 HOT START .................................................................................................................... 30 1.6 BOILER OPERATION CONTROL AND ADJUSTMENT .................................................... 30 1.6.1 ADJUSTING WORK OF BOILER OPERATION .............................................................. 30 1.6.2 FEEDWATER ADJUSTMENT........................................................................................... 31 1.6.3 BOILER COMBUSTION ADJUSTMENT.......................................................................... 31 1.6.4 ADJUSTMENT OF BOILER STEAM TEMPERATURE ................................................... 32 1.6.5 LIMITATION VALUE OF BOILER OPERATING PARAMETER....................................... 33 1.7 STOP BOILER TO OPERATION ......................................................................................... 34 1.7.1 STOP OPERATION BY SMOOTH PARAMETER CHANGING ....................................... 34 1.7.2 EMERGENCE STOP......................................................................................................... 36 1.7.3 PRECAUTIONS DURING BOILER SHUT OFF ............................................................... 37 1.8 TYPICAL ACCIDENTS DISPOSAL IN BOILER ................................................................. 38 1.8.1 FULL WATER OF BOILER ............................................................................................... 38 1.8.2 THE BOILER IS SHORT OF WATER............................................................................... 38 1.8.3 PRIMING OF STEAM & WATER ...................................................................................... 39 1.8.4 MFT.................................................................................................................................... 40 1.8.5 RB ...................................................................................................................................... 40 1.8.6 PRESSURE OF MAIN STEAM AND REHEATING STEAM IN INCORRECT SCOPE ... 41 1.8.7 ABNORMAL OF MAIN STEAM TEMPERATURE ........................................................... 42 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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1.8.8 WATER FLOW FOR BOILER IS LOW ............................................................................. 44 1.8.9 ECO DESTROYED ........................................................................................................... 45 1.8.10 DESTROY OF SH ........................................................................................................... 45 1.8.11 LEAKAGE OF REHEATER............................................................................................. 46 1.8.12 REFRAME IN REAR FUME DUCT................................................................................. 47 1.8.13 COKING BOILER............................................................................................................ 48 1.8.14 TEMPERATURE OF SUPERHEATER TUBE AND REHEATER TUBE SURPASS ..... 49 CHAPTER II OPERATION MANUAL FOR BOILER ACCESSORY ......................................... 51 2.1 AIR PREHEATER................................................................................................................. 51 2.1.1 INTERLOCK PROTECTION FOR PREHEATER ............................................................. 51 2.1.2 TRIP CONDITIONS FOR PREHEATER ........................................................................... 51 2.1.3 START PREHEATER ........................................................................................................ 51 2.1.4 STOP PREHEATER .......................................................................................................... 51 2.1.5 HANDLING PREHEATER TROUBLESOME ................................................................... 51 2.2 IDF ........................................................................................................................................ 52 2.2.1 ADMITTED STARTING CONDITIONS ............................................................................. 52 2.2.2 TRIP CONDITIONS ........................................................................................................... 53 2.2.3 INTERLOCK CONDITIONS OF STARTING COOLING FAN: ......................................... 53 2.2.4 START IDF ........................................................................................................................ 53 2.2.5 SHUT-DOWN IDF.............................................................................................................. 54 2.2.6 HANDLING ACCIDENTS OF IDF..................................................................................... 54 2.3 FDF ....................................................................................................................................... 56 2.3.1 ADMITTING START CONDITIONS .................................................................................. 56 2.3.2 TRIP CONDITIONS ........................................................................................................... 56 2.3.3 INTERLOCK OF LUBRICATE OIL PUMP ....................................................................... 56 2.3.4 INTERLOCK OF ELECTRIC HEATER OF LUBRICATE OIL TANK ............................... 56 2.3.5 START FDF ....................................................................................................................... 56 2.3.6 STOP FAN ......................................................................................................................... 57 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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2.3.7 ACCIDENT HANDLING OF FDF ...................................................................................... 57 2.4 PAF ....................................................................................................................................... 58 2.4.1 ADMITTING START CONDITION..................................................................................... 58 2.4.2 TRIP CONDITIONS ........................................................................................................... 58 2.4.3 INTERLOCK OF LUBRICATE OIL PUMP AND HYDRAULIC OIL PUMP...................... 58 2.4.4 INTERLOCK OF MOTOR DRIVEN LUBRICATE OIL PUMP OF PAF. ........................... 59 2.4.5 INTERLOCK OF ELECTRIC HEATER OF LUBRICATE OIL TANK OF PAF. ................ 59 2.4.6 START PAF ....................................................................................................................... 59 2.4.7 STOP OF PAF ................................................................................................................... 59 2.4.8 HANDLING ACCIDENTS OF PAF.................................................................................... 60 2.5 PULVERIZED COAL SYSTEM ............................................................................................ 62 2.5.1 MILL TRIPS....................................................................................................................... 62 2.5.2 COAL FEEDER TRIPS ..................................................................................................... 62 2.5.3 START SEALING AIR FAN............................................................................................... 63 2.5.4 START PULVERIZED COAL SYSTEM ............................................................................ 63 2.5.5 STOP COAL SYSTEM...................................................................................................... 64 2.5.6 PARAMETER OF COAL SYSTEM................................................................................... 64 2.5.7 HANDLING ACCIDENT OF PULVERIZED COAL SYSTEM ........................................... 65 2.6 CCP (BOILER WATER CONTROL CIRCULATING PUMP) ............................................... 68 2.6.1MAIN PARAMETER OF CCP ............................................................................................ 68 2.6.2 ALARMING AND VALUE-FIXING PARAMETERS OF CCP ........................................... 69 2.6.3 STARTING AND TRIPPING CONDITIONS OF CCP ....................................................... 69 2.6.4 PREPARE FOR OPERATION OF CCP............................................................................ 70 2.6.5 CCP WATER FILLING AND AIR EXHAUST .................................................................... 70 2.6.6 PREPARATION TO START CCP ..................................................................................... 71 2.6.7 OPERATING CONDITIONS OF CCP ............................................................................... 71 2.6.8 THE RUNNING OF CCP ................................................................................................... 72 2.6.9 STOP OF CCP................................................................................................................... 72 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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2.6.10 RELEASING WATER OF CCP ....................................................................................... 72 2.6.11 ISOLATION, MAINTENANCE AND REPAIR OF CCP................................................... 73 2.7 FLAME INSPECTION OF COOLING AIR FAN SYSTEM................................................... 73 2.7.1INTERLOCK PROTECTION OF FLAME INSPECTION ................................................... 73 2.7.2 START FLAME INSPECTION .......................................................................................... 73 2.7.3 STOP FLAME INSPECTION SYSTEM ............................................................................ 73 2.8 OPERATION OF ESP .......................................................................................................... 73 2.8.1TEST AND INSPECTION BEFORE COMMISSIONING ................................................... 73 2.8.2 SWITCH ON ESP.............................................................................................................. 74 2.8.3

SWITCHING OFF OF ESP............................................................................................. 75

2.8.4 TYPICAL FAILURE AND ITS ANALYSIS......................................................................... 76 2.9 SOOT –BLOWER................................................................................................................. 78 2.9.1 SOOT –BLOWING SYSTEM PARAMETERS.................................................................. 78 2.9.2 CONDITIONS AND INSPECTION OF SOOT BLOWING ................................................ 80 2.9.3 OPERATION OF SOOTBLOWER .................................................................................... 80 2.9.4 SOOTBLOWER OPERATION PERIOD ........................................................................... 81 2.9.5 SOOTBLOWING STEAM SOURCE OF THE AIR PREHEATER .................................... 81 2.9.6 SOOTBLOWER MAINTENANCE..................................................................................... 81 2.9.7 SOOTBLOWER FAULT TREATMENT............................................................................. 81 2.9.8 STOP SOOTBLOWING OPERATION IN CASE OF ANY OF THE FOLLOWING SITUATIONS: ............................................................................................................................. 82 2.9.9 TREATMENT TO ABNORMITY OF SOOTBLOWER STEAM PRESSURE.................... 82 2.10 SECONDARY AIR HEATER .............................................................................................. 82 2.11SYNOPSIS OF PRESSURE AND TEMPERATURE UNDER SATURATION .................... 83 2.12 BOILER STARTUP CURVE AND LOGIC DIAGRAM ....................................................... 84 CHAPTER III

STEAM TURBINE OPERATION REGULATIONS........................................ 85

3.1 INTRODUCTION OF STEAM TURBINE ............................................................................. 85 3.1.1 MAIN PARAMETERS OF STEAM TURBINE .................................................................. 85 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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3.1.2 MAIN SPECIFICATION OF TURBINE.............................................................................. 86 3.1.3 BRIEF OF MAIN CONTROL SYSTEMS .......................................................................... 87 3.2 INTERLOCK AND TEST OF STEAM TURBINE................................................................. 89 3.2.1 CONTENTS OF INTERLOCK........................................................................................... 89 3.2.2 UNIT INTERLOCK RELATIONSHIP ................................................................................ 90 3.2.3 INTERLOCK TEST ........................................................................................................... 90 3.2.3 CONDENSER VACUUM TIGHTNESS TEST................................................................... 90 3.3 STARTUP OF TURBINE ...................................................................................................... 97 3.3.1 PREPARATION BEFORE TURBINE STARTUP.............................................................. 97 3.3.2 BASIC RULES FOR TURBINE START............................................................................ 97 3.3.3 COLD START.................................................................................................................... 99 3.3.4 HOT STARTUP PRECAUTIONS .................................................................................... 104 3.4 TURBINE NORMAL OPERATION..................................................................................... 104 3.4.1 GENERAL PRINCIPLES ................................................................................................ 104 3.4.2 MAIN PARAMETER AND LIMITATION OF TURBINE NORMAL OPERATION ........... 104 3.5 SHUTDOWN OF TURBINE ............................................................................................... 105 3.5.1 PREPARATION BEFORE SHUTDOWN ........................................................................ 105 3.5.2 WORKS AFTER SPLITTING .......................................................................................... 106 3.5.3 WORKS AFTER ROTOR BEING STILL ........................................................................ 107 3.6 TURBINE ACCIDENT DISPOSAL..................................................................................... 108 3.6.1 PRINCIPLE OF ACCIDENT DISPOSAL ........................................................................ 108 3.6.2 EMERGENCY SHUT DOWN .......................................................................................... 108 3.6.3 FAILURE SHUTDOWN ................................................................................................... 109 3.6.4 DISPOSAL PRINCIPLES FOR TURBINE EMERGENCY STOP .................................. 109 3.6.5 TURBINE TRIP CONDITIONS........................................................................................ 110 3.6.6 TYPICAL TURBINE FAILURE DISPOSAL .....................................................................111 CHAPTER IV TURBINE AUXILIARY EQUIPMENT OPERATION ......................................... 120 4.1 TECHNICAL SPECIFICATIONS OF TURBINE AUXILIARY EQUIPMENT...................... 120 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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4.1.1 CONDENSER.................................................................................................................. 120 4.1.2 MOTOR DRIVEN FEED WATER PUMP GROUP .......................................................... 120 4.1.3 TBFP GROUP ................................................................................................................. 123 4.1.4 DEAERATOR SPECIFICATION ..................................................................................... 124 4.1.5 THE TECHNICAL SPECIFICATION OF CONDENSATE PUMP ................................... 125 4.1.6 MAIN AND BFP OIL PUMP TECHNICAL SPECIFICATION ......................................... 125 4.1.7 HP HEATER .................................................................................................................... 126 4.1.8 LP HEATER, GLAND STEAM CONDENSER................................................................ 126 4.2 TURBINE LUBE AND EH OIL SYSTEM ........................................................................... 127 4.2.1 LUBE OIL SYSTEM OPERATION.................................................................................. 127 4.2.2 STARTUP OF OIL SYSTEM ........................................................................................... 127 4.2.3 OPERATION AND MAINTENANCE ............................................................................... 128 4.2.4 TURBINE JACKING OIL PUMP AND TURNING GEAR ............................................... 128 4.2.5 LUBE OIL SYSTEM SETTING ....................................................................................... 129 4.2.6 TURBINE EH OIL SYSTEM SETTING ........................................................................... 129 4.3 VACUUM AND SHAFT SEAL STEAM SUPPLY SYSTEM............................................... 130 4.3.1 THE PREPARATION BEFORE START WATER SIDE VACUUM PUMP ...................... 130 4.3.2 STARTUP OF WATER COLLAR VACUUM PUMP........................................................ 130 4.3.3 THE STANDARD OPERATION AND MAINTENANCE ................................................. 130 4.3.4 STOP WATER COLLAR VACUUM PUMP ..................................................................... 130 4.3.5 VACUUM PUMP MAIN INTERLOCK PROTECTION .................................................... 131 4.3.6 PRECAUTION OF GLAND STEAM SUPPLY CONTROL ............................................. 131 4.4 CONDENSATE WATER AND WATER-FEED SYSTEM ................................................... 131 4.4.1 START CONDENSATE PUMP ....................................................................................... 131 4.4.2 STOP SYSTEM ............................................................................................................... 131 4.4.3 CONDENSATE SYSTEM PROTECTION....................................................................... 132 4.5 H/LP HEATERS.................................................................................................................. 132 4.5.1 START OR QUIT RULES OF HP/LP HEATERS............................................................ 132 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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4.5.2 HP SLIDE OPERATION .................................................................................................. 133 4.5.3 HP HEATER START DURING UNIT NORMAL OPERATION ....................................... 133 4.5.4 LP HEATER START WITH UNIT LOAD......................................................................... 134 4.5.5 LP HEATER START INDEPENDENTLY ........................................................................ 134 4.5.6 OPERATION AND MAINTENANCE OF HP/LP HEATERS ........................................... 134 4.5.7 HP HEATER STOPS WITH UNIT LOAD ........................................................................ 135 4.5.8 THE SHUTDOWN OF HP HEATER DURING UNIT OPERATING NORMALLY ........... 135 4.5.9 LP HEATER STOPS WITH TURBINE............................................................................ 136 4.5.10 LP HEATER STOPS PARTICULARLY......................................................................... 136 4.5.11 HP HEATER MAIN INTERLOCK PROTECTION ......................................................... 136 4.5.12 LP HEATER AND DRAIN SYSTEM MAIN INTERLOCK PROTECTION .................... 137 4.6 DEAERATOR SYSTEM ..................................................................................................... 137 4.6.1 OPERATION OF DEAERATOR ...................................................................................... 137 4.6.2 SHUT DOWN OF DEAERATOR..................................................................................... 138 4.6.3 CONTROL PARAMETER OF DEAERATOR UNDER NORMAL OPERATION ............ 138 4.6.4 SHUT DOWN OF DEAERATOR..................................................................................... 138 4.6.5 MAIN INTERLOCK PROTECTION FOR DEAERATOR ................................................ 139 4.7 FEED WATER STEAM (MOTOR) PUMP GROUP ............................................................ 140 4.7.1 MOTOR-PUMP GROUP.................................................................................................. 140 4.7.1.4 OPERATION AND MAINTENANCE FOR MBFP GROUP.......................................... 141 4.7.2 TBFP GROUP ................................................................................................................. 142 4.8 OPEN/CLOSE COOLING SYSTEM .................................................................................. 148 4.8.1 SET PROTECTION VALVE FOR OPEN COOLING SYSTEM ...................................... 148 4.8.2 SET PROTECTION VALUE FOR CLOSE COOLING SYSTEM.................................... 148 4.9 GENERATOR OIL SEALING SYSTEM............................................................................. 148 4.9.1 GENERAL REGULATION .............................................................................................. 148 4.9.2 PUT OIL SEALING SYSTEM INTO RUNNING .............................................................. 148 4.9.3 SHUTDOWN SEAL OIL SYSTEM.................................................................................. 149 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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4.9.4 GENERATOR SEAL OIL SYSTEM OPERATION MAINTENANCE .............................. 149 4.9.5 SEALING OIL SOURCE OF AIR SIDE AND HYDROGEN SIDE .................................. 149 4.9.6 I & C INTERLOCK PROTECTION.................................................................................. 150 4.9.7 ACCIDENT DISPOSAL................................................................................................... 150 4.10 STATOR COOLING WATER SYSTEM............................................................................ 151 4.10.1 STATOR COOLING WATER SYSTEM OPERATION RULES ..................................... 151 4.10.2 PUT STATOR COOLING WATER SYSTEM INTO OPERATION ................................ 152 4.10.3 SHUTDOWN STATOR COOLING WATER PUMP....................................................... 152 4.10.4 STATOR COOLING WATER SYSTEM OPERATING MAINTENANCE ...................... 153 4.10.5 MAIN INTERLOCK PROTECTION............................................................................... 153 4.10.6 ACCIDENT DISPOSAL................................................................................................. 153 CHAPTER V ELECTRICAL EQUIPMENT OPERATION REGULATION ............................... 155 5.1 ELECTRICAL EQUIPMENT .............................................................................................. 155 5.1.1 GENERAL INTRODUCTION .......................................................................................... 155 5.1.2 SPECIFICATION ............................................................................................................. 155 5.2 GENERATOR OPERATION REGULATION ...................................................................... 155 5.2.1 START CONDITION........................................................................................................ 155 5.2.2 CHECK BEFORE STARTING GENERATOR................................................................. 156 5.2.3 TEST BEFORE STARTING ............................................................................................ 157 5.2.4 BASIC OPERATION STEP WHEN START GENERATOR-TRANSFORMER .............. 157 5.2.5 INSPECTION AFTER TURNING (1500R/M OR 3000R/M)............................................ 158 5.2.6 CHECK AFTER G SYNCHRONIZING............................................................................ 159 5.2.7 OPERATION REGULATION AFTER G SYNCHRONIZING .......................................... 159 5.2.8 OPERATION WHEN START GENERATOR................................................................... 159 5.2.9 GENERAL REGULATION WHILE UNIT RUNNING ...................................................... 161 5.2.10 GENERATOR CURRENT AND VOLTAGE REGULATION.......................................... 161 5.2.11 EXCITING SYSTEM REGULATION WHILE RUNNING .............................................. 161 5.2.12 RUNNING REGULATION OF STATOR WATER COOLING SYSTEM........................ 162 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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5.2.13 GENERATOR CHECK AND REPAIR ........................................................................... 163 5.2.14 OPERATE STEP OF DE-SYNCHRONIZING TO REPAIR STATUS............................ 164 5.2.15 RUNNING REGULATION OF HYDROGEN SYSTEM ................................................. 165 5.3 TROUBLESOME OF GENERATOR.................................................................................. 166 5.3.1 STOP GENERATOR EMERGENT.................................................................................. 166 5.3.2 ASK DEPUTY MANAGER OR CHIEF ENGINEER TO STOP GENERATOR WHEN ONE OF SITUATION FOLLOWING APPEARS ............................................................................... 167 5.3.3 GENERAL OPERATION RULES WHEN GENERATOR-TRANSFORMER PROTECTION ACTS ........................................................................................................................................ 167 5.3.4 WHEN TROUBLESOME OR SWITCH REFUSE TO ACT AMONG G-T ...................... 167 5.3.5 GENERATOR VOLTAGE DOESN’T GO UP WHILE INCREASING VOLTAGE ........... 167 5.3.6 GENERATOR LOSS OF EXCITING ............................................................................... 168 5.3.7 WHEN GENERATOR PARALLEL ASYNCHRONOUSLY ............................................. 168 5.3.8 CHANGE GENERATOR TO MOTOR RUNNING........................................................... 169 5.3.9 GENERATOR VIBRATION HEAVILY ............................................................................. 169 5.3.10 BRUSH OF SLIP RING HEAT HEAVILY OR CATCH A FIRE ..................................... 169 5.3.11 ABNORMAL TEMPERATURE OF GENERATOR........................................................ 169 5.3.12 TROUBLESOME IN INNER COOLING WATER SYSTEM.......................................... 170 5.3.13 STATOR GROUNDING ................................................................................................. 170 5.3.14 VOLTAGE CIRCUIT WIRING BROKEN....................................................................... 171 5.3.15 WHEN STATOR 3 PHASES CURRENT UNBALANCE............................................... 171 5.3.16 WHEN RUNNING ON PHASE OPEN........................................................................... 172 5.3.17. WHEN GENERATOR OVER-EXCITING ..................................................................... 172 5.3.18 WHEN ROTOR WINDING ONE POINT GROUNDING................................................ 172 5.3.19 HYDROGEN LEAKAGE ............................................................................................... 173 5.3.20 WHEN GENERATOR EXPLODES OR CATCHES A FIRE.......................................... 173 5.3.21 WHEN TROUBLESOME IN EXCITING SYSTEM AND REMOVING .......................... 173 5.3.22 RECTIFIER CABINET DEFECT OR ALARM .............................................................. 173 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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5.3.23 OUTLET AIR TEMPERATURE OF RECTIFIER CABINET HIGH AND ALARM ........ 174 5.3.24 WHEN GENERATOR OVER-LOADS BY ACCIDENT ................................................. 174 CHAPTER VI THE FUEL OIL SYSTEM OPERATION REGULATIONS................................. 175 6.1 FUEL SYSTEM................................................................................................................... 175 6.1.1 EQUIPMENT FUNCTION................................................................................................ 175 6.1.2 THE CONFIGURATION AND PUMP OPERATION MODE............................................ 175 6.1.3. TECHNICAL DATA OF FUEL EQUIPMENT ................................................................. 175 6.2 SHIFT AND EQUIPMENT INSPECTION........................................................................... 177 6.2.1 SPELL PROGRAMS ....................................................................................................... 177 6.2.2 EQUIPMENT INSPECTION ............................................................................................ 178 6.3 LIGHT OIL FEED PUMP .................................................................................................... 178 6.3.1 INSPECTION BEFORE FUEL OIL HANDLING SYSTEM START UP.......................... 178 6.3.2 START LIGHT OIL TRANSFER SYSTEM ..................................................................... 179 6.3.3 LIGHT OIL PUMP OPERATION ..................................................................................... 179 6.3.4 STOP LIGHT OIL TRANSFER SYSTEM ....................................................................... 180 6.3.5 OPERATION AND MAINTENANCE ............................................................................... 180 6.4 HEAVY OIL FEED PUMP................................................................................................... 180 6.4.1 THE INSPECTION BEFORE FUEL OIL HANDLING SYSTEM START-UP.................. 180 6.4.2 FUEL OIL HANDLING SYSTEM STARTUP .................................................................. 181 6.4.3 FUEL OIL PUMPS OPERATION .................................................................................... 182 6.4.4 STOP FUEL OIL HANDLING SYSTEM.......................................................................... 182 6.4.5 NORMAL RUNNING ATTENTION.................................................................................. 183 6.5 PRINCIPLE OF ACCIDENT DISPOSAL ........................................................................... 184 6.5.1 THE CONDITIONS OF EMERGENCY STOP PUMP ..................................................... 184 6.5.2 COMMON TROUBLE AND ITS SOLUTION .................................................................. 184 6.5.3 COMMON FAULT OF FEEDING/RETURN OIL LINE.................................................... 187 6.5.4 APS INTERRUPTION ..................................................................................................... 188 6.5.5 LIGHT PUMP VIBRATION .............................................................................................. 188 DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

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6.5.6 EXPORT PRESSURE OF LIGHT FUEL PUMP ABNORMAL ....................................... 189 6.5.7 HEAVY FUEL PUMP VIBRATION .................................................................................. 189 6.5.8 HEAVY ABNORMAL HYDRAULIC FUEL PUMP EXPORT .......................................... 189 6.5.9 PUMPS FOR VAPORIZATION ....................................................................................... 189 6.5.10

CURRENT SWING ................................................................................................... 190

6.5.11 PRESSURE SWING ...................................................................................................... 190 6.5.12 FEED OIL PUMPS TRIP ............................................................................................... 190 CHAPTER VII CONDENSATE POLISHING OPERATION AND MAINTENANCE REGULATIONS .................................................................................................................................................. 192 7.1 INTRODUCTIONS.............................................................................................................. 192 7.1.1 PURPOSE OF CONDENSATE POLISHING .................................................................. 192 7.1.2 SYSTEM INTRODUCTION ............................................................................................. 192 7.1.3 PROCESS DESCRIPTION ............................................................................................. 193 7.1.4 MAIN EQUIPMENT STANDARD OF FINE TREATMENT ............................................. 194 7.2 OPERATION OF CONDENSATE WATER FINE TREATMENT DEVICE ......................... 196 7.2.1 THE INSPECTION AND PREPARATION OF INITIAL OPERATION............................. 196 7.2.2 PRE-INSPECTION AND PREPARATION OF THE NORMAL OPERATION................. 199 7.2.3 OPERATION OF MIXED BED ........................................................................................ 200 7.2.4 OUTAGE OF MIXED BED .............................................................................................. 201 7.2.5 SYSTEM BYPASSES VALVE MOVEMENT CONDITION ............................................. 201 7.2.6 OPERATION MODE OF MIXED BED ............................................................................ 202 7.2.7 CHARACTERISTICS OF SYSTEM OPERATION.......................................................... 202 7.3 OPERATION OF MIXED BED FINE TREATMENT REGENERATION............................. 203 7.3.1 PREPARATION OF REGENERATION ........................................................................... 203 7.3.2 REGENERATION OPERATION OF FINE TREATMENT ............................................... 203 7.3.3

OPERATION

STEP

AND

INSTRUCTION

OF

CONDENSATE

POLISHING

REGENERATION ..................................................................................................................... 204 7.3.4 CONTROL OF ELECTRIC HEATING WATER TANK OF REGENERATION SYSTEM 221 DOCUMENT NO. : HISAR-ZT-07

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7.3.5 ACID-ALKALI METERING TANK SYSTEM................................................................... 221 7.3.6 COMMON PROBLEMS AND DISPOSAL FOR MIXED BED OPERATION.................. 222 7.3.7 PRECAUTIONS FOR ENSURING MIXED BED AMMONIA OPERATION ................... 223 7.4 TREATMENT FOR ABNORMAL CONDENSATE POLISHING ........................................ 224 7.5 CHEMICAL QUALITY REQUIREMENTS.......................................................................... 228

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Chapter I Boiler Operation Regulations 1.1 Introduction of boiler devices Boiler model: SG2050/17.47- M918, subcritical, Π arrangement, pressure controlled circulation boiler, once intermediate reheat, single furnace, corner tangential firing, balanced draft, dry slag, full steel structure, full suspended structure. Positive pressure straight blow system of medium speed milling primary air fan is adopted for boiler coal pulverized sys temperature Furnace, with width 17830mm, height 17830mm, elevation of water wall lower than 9000mm, and center elevation of furnace top at 80000mm. Boiler inside diameter is 1743mm, 6ps big diameter downcomer are installed along furnace, boiler water is connected to the three LP circulating pump at boiler front side after it is collected by collecting header. There are 2nos outlet valve for each circulating pump, and connect the circulating pump with lower half circular header of water wall by the outlet valve, and install throttle at the inlet of circular header inside water wall. Water wall is composed of furnace wall, nose, bottom & both sides of flue extend side. SH is composed of top pipe, rear HRA, horizontal flue side wall, low temperature SH, division SH, rear division and final SH. Reheater is composed of wall RH, platen RH, final RH. Economizer is below rear HRA. 32ps DC burner is located at furnace four corners with 8 layers, pulverized coal and air is forced from four corner and burn at the center. Temperature of SH is adjusted by two grade ejector. Temperature of RH is adjusted by swing burning (use automatic), install emergency ejector at RH inlet. Bottom of rear HRA is furnished with two sets of primary air fan (Junker’s trisection storehouse). Elevation of boiler Operation floor is 17m. Expansion center and zero position guarantee system are set on boiler, the roof is sealed by big shell, and roof pipe is protected by full-steel, furnace wall is the outer casing made of ladder type light metal structure, and water chamber is set on both sides of drum. Light metal shell is selected to make the roof. The pressure, temperature, flow and other parameters of boiler main steam and RH should match the parameters of turbine. Boiler nameplate, that is max continuous evaporation discharge (B-MCR), is equal to the steam flow when all the adjusting valves of turbine are full open (1.02 times VWO). 1.2 Boiler main technique regulations 1.2.1 Main parameters of boiler Name

Unit

BMCR

BECR

SH steam flow

t/h

2050

1906

Steam pressure on SH outlet

MPa(g)

17.47

17.33

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Operation Manual for 600MW Unit Name

Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

BMCR

BECR

Steam temperature on SH outlet

℃

540

540

RH steam flow

t/h

1761

1624

Steam pressure on RH inlet

MPa(g)

3.94

3.70

Steam pressure on RH outlet

MPa(g)

3.73

3.51

Steam temperature on RH inlet

℃

330

323

Steam temperature on RH outlet

℃

540

540

Water temperature on economizer inlet

℃

280

276

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 Load Name

B-MCR Setting pressure

Unit

1. turbine load 2. steam flow Economizer inlet SH outlet RH outlet SH primary water ejector SH secondary water ejector RH water ejector 3. steam pressure SH outlet drum Economizer inlet RH inlet RH outlet 4. steam temperature SH outlet RH inlet RH outlet Desuperheater water Feed water Drum 5. boiler design efficiency (calculate as per low heat productivity)

Designed coal variety TMCR 80%ECR Setting sliding pressure pressure

Checked coal BMCR Setting pressure

60%ECR sliding pressure

t/h t/h t/h

2068 2076 1761

1855 1906 1624

1336 1458 1261

946 1079 948

2058 2076 1761

t/h

8.80

51.10

122.10

133.40

18.00

t/h

0.0

0.0

0.0

0.0

0.0

t/h

0

0

0

0

0

MPa.g MPa.g MPa.g MPa.g MPa.g

17.47 18.84 19.24 3.938 3.733

17.33 18.50 18.86 3.703 3.510

17.14 18.02 18.35 3.817 3.618

16.82 17.20 17.46 2.133 2.020

17.47 18.84 19.24 3.938 3.733

℃ ℃ ℃ ℃ ℃ ℃

540 330 540 179 280 361

540 323 540 179 276 360

540 299 540 169 259 356

540 281 540 158 242 354

540 330 540 179 280 361

%

92.77

92.86

92.50

93.23

91.64

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Operation Manual for 600MW Unit boiler design efficiency (calculate as per high heat productivity) 6. heat loss of mechanical un-combustion 7. actual fuel consumption rate 8. air temperature Primary air of air preheater inlet secondary air of air preheater inlet Primary air of air preheater outlet secondary air of air preheater outlet 9. flue gas temperature Flue gas temperature of furnace rear platen outlet Flue gas of platen bottom Gas exhaust (before revised) Gas exhaust (after revised) 10. air quantity Primary air of air preheater inlet Secondary air of air preheater inlet Primary air of air preheater outlet Secondary air of air preheater outlet Bypass primary air of air preheater Primary air leakage to secondary air Primary air leakage to flue gas Secondary air leakage to flue gas 11. flue gas quantity Air preheater inlet Air preheater outlet 12. excess air number Furnace outlet

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

87.11

87.22

%

1.05

1.05

1.3

1.3

1.8

t/h

366.8

341.2

275.1

210.7

473.9

℃

37

37

37

37

37

℃

30

30

30

30

30

℃

309

306

299

277

312

℃

320

317

306

283

325

℃

1028

1020

985

936

1024

℃

1329

1341

1351

1317

1316

℃

142.5

141.0

141.5

120.5

148.5

℃

138.0

136.5

136.5

115.0

144.5

kg/h

687074

660424

574661

513407

821761

kg/h

1669169

1520028

1127434

1056542

1559102

kg/h

520034

494104

408341

346727

654721

kg/h

1660529

1511748

1123474

1052222

1550822

kg/h

204696

212976

172800

112608

222696

kg/h

32040

32040

33480

33120

32400

kg/h

135000

134280

132840

133560

134640

kg/h

40680

40320

37440

37440

40680

kg/h kg/h

2724645.6 2900326

2534547.6 2709148

2076411.6 2246692

1712192.4 1883192

2782069.2 2957389

-

1.25

1.25

1.274

1.381

1.25

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Air preheater outlet 1.338 1.344 1.396 1.532 1.337 13. leakage rate furnace % 5 5 5 5 5 Air preheater % 6.45 6.89 8.20 9.99 6.30 14. steam water resistance SH steam water KPa 1373 RH steam water KPa 200 Economizer (include KPa 392 potential difference) 15. burner Single design output kg/h 15283 14217 13754 13166 16925 (coal dust) Devotion quantity PCS 24 24 20 16 28 16. ahs discharge rate Furnace cool hopper % 20 20 20 20 20 Economizer hopper % 5 5 5 5 5 ESP hopper % 85 85 85 85 85 1.2.3 Parameter of SH primary, secondary water spray desuperheater RH emergency spray N O 1 2 3

4 5 6

II 1 2

3

4 5

Boiler load Item Main steam flow Design pressure of Primary desuperheater Design temperature of primary desuperheater pressure of Primary desuperheater water spray point Temperature of primary desuperheatered Flow speed of primary desuperheater water Designed flow speed of primary desuperheater water SH Secondary desuperheater Design pressure of secondary desuperheater Designed temperature of secondary desuperheater water Spray point pressure of secondary desuperheater water Temperature of secondary desuperheater water Flow calculation of

DOCUMENT NO. : HISAR-ZT-07

unit

BMCR

TMCR

t/h

2050

1883

Mpa

19.79

℃

HP exclud ed 1651

80% TMCR

60% TMCR

40% TMCR

1458

1078.5

820

—

—

—

—

458

—

—

—

—

—

18.08

17.85

17.56

17.35

14.04

10.64

181

178

182

169

158

148

t/h

27.1

55.3

169.7

98.5

101.1

58.6

t/h

206

Mpa

19.79

—

—

—

—

—

℃

513

—

—

—

—

—

Mpa

17.72

17.54

17.32

17.16

13.93

10.58

℃ t/h

181 0

178 6

182 10

169 20

158 20

148 10

Mpa ℃

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Operation Manual for 600MW Unit secondary desuperheater water 6 Designed flow of secondary desuperheater water t/h III Economizer inlet pressure Mpa RH flow speed t/h IV Emergency spray water 1 Design pressure of emergency spray water Mpa 2 Design temperature of ℃ emergency spray water 3 Pressure of emergency water spray point Mpa 4 Temperature of spray water ℃ 5 Calculation flow of emergency spray water t/h 6 Design flow of emergency t/h spray water 1.2.4 Coal performance analysis table No. A 1 2 3 4 B 1 2 3 4 5 6 7 C D

Particulars Units Proximate Analysis Moisture % Ash % Fixed Carbon % Volatile matter % Ultimate Analysis Carbon % Hydrogen % Sulphur % Nitrogen % Oxygen (by difference) % Moisture % Gross calorific value Kcal/kg Grindability Index HGI ℃ t1 ℃ t2 ℃ t3 1.2.5 Set value of boiler safety valve

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

40 19.24 1740.2

18.86 1605.3

18.39 1638.1

18.05 1261.5

14.62 948.3

11.16 728.5

4.35

—

—

—

—

—

343

—

—

—

—

—

3.882

3.651

3.820

2.865

2.132

1.617

177

174

178

165

154

144

0 82

0

0

0

0

0

Performance Coal

Worst Coal for ESP & MILL

15.0 34.0 21.0 30

15.0 46.0 19.73 19.27

41.22 2.81 0.35 0.71 5.90 15.0 4000 50 1100 1300 1400

31.88 2.13 0.28 0.59 4.12 15.0 3150 50 1100 1250 1400

NO

Name

P(fixed pressure)

K(return ratio)

Δp(release)

p1=p-Δp

1 2 3 4 5 6 7 8 9 10

Drum

19.79 19.99 20.19 20.19 20.38 20.38 18.35 18.35 18.9 18.9

0.04 0.05 0.06 0.06 0.07 0.07 0.03 0.03 0.03 0.03

0.7916 0.9995 1.2114 1.2114 1.4266 1.4266 0.5505 0.5505 0.567 0.567

18.9984 18.9905 18.9786 18.9786 18.9534 18.9534 17.7995 17.7995 18.333 18.333

Drum SH outlet

SH outlet

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Operation Manual for 600MW Unit 11 EBV 12 13 EBV 14 RH inlet 15 16 17 18 19 RH inlet 20 RH inlet 1.2.6 Limiting value of

17.99 18.17 18.17 4.35 4.35 4.41 4.41 4.48 4.48 4.06 heating surface

0.02 0.02 0.02 0.03 0.03 0.03 0.03 0.03 0.03 0.03

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

0.3598 0.3634 0.3634 0.1305 0.1305 0.1323 0.1323 0.1344 0.1344 0.1218

17.6302 17.8066 17.8066 4.2195 4.2195 4.2777 4.2777 4.3456 4.3456 3.9382

No. Name Unit Alarming temperature 1 No 1 pipe outlet of LP SH vertical part ℃ 472 ℃ 2 No 1 pipe outlet of division platen 482 ℃ 3 No 4 pipe outlet of rear platen SH 566 ℃ 4 No 1 pipe outlet of final SH 580 5 No 5 pipe outlet of platen RH ℃ 571 ℃ 6 No 5 pipe outlet of final RH 580 *Notice: pipe on vertical part is the first one counting from boiler front to rear. **Other heating surface pipes are counted from outer circle to inside. 1.2.7 Technique regulations of boiler main auxiliaries 1.2.7.1 Air preheater system Air preheater driven motor Type

2-32VI（65）-82” SMRC Type

Main motor type Rotation speed

MZQA225S-4B3 model Rated power 1480 r/min Rated current GM160M double out Rated power shaft 1450r/min Rated current

Auxiliary motor type

Rotation speed Rotation rate of Main motor 124.92 reducer Reheating rotation speed when main 11.93 r/min motor runs Air motor INGERSOLL-RAND 1.2.7.2 IDF, FDF, PAF No 1 2 3 4 5 6 7

Name Model Model Air flow rate Full pressure Rotation speed Efficiency Adjusting scope QTY and capacity

Unit

m3/S pa r/min ％

DOCUMENT NO. : HISAR-ZT-07

Air preheater (Junker’s trisection storehouse) 37KW 11kw

Reheating rotation speed when main motor 92RB045/VRSM-330T 7.5 HP 103 r/min

IDF SAF38.5-22.4-1 Axial flow type 651.2 5513 745 88.09 -30°～＋25° 2×50％

FDF FAF25-13.3-1 Axial flow type 261.70 4284 985 83.40 ＋30°～-75° 2×50％

PAF PAF20.2-12.5-2 Axial flow type 172.15 15401 1490 86.35 -30°～＋25 2×50％ Page

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Operation Manual for 600MW Unit

9

Bearing lubricate mode Manufacture

10 11 12 13 14

Model Rated power Rated voltage Rated current Rotation speed

8

Lube oil

KW KV A r/min

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

grease

Shanghai Fan Co. Shanghai Fan Co. Induced air fan Draft air fan motor motor YKK900-8 YKK630-6 4200 1400 11 11

Shanghai Fan Co. Primary air fan motor YKK630-4 3650 11

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 No 1

2

3

4 5

6

7

Item Mill model Mill output Max. output（grind output） Guaranteed output（dry output, consider abrasion） Calculated output Guaranteed output（grind output, consider abrasion） Min. output Mill load rate Mill air rate Max. air rate Calculated air rate Ensure air rate on output condition (dry output) Min. air rate Temperature of dry medium on mill inlet (calculated output) Outlet temperature Moisture of pulverized coal

Worst coal variety

t/h t/h t/h t/h t/h %

75.3 60.2 60.76 67.8 18.8 81

75.3 60.2 67.34 67.8 18.8 89.4

t/h t/h t/h t/h

130.8 120.7 125.6 91.6

130.8 125.3 125.6 91.6

℃

244

255

℃ % r/mi n

77 4.5

77 4.5

30.3

30.3

KPa KPa KPa

4.5 4.2 3.83

4.5 4.2 4.13

Wind capacity of mill airproof

m3/ min

70.75

Seal air pressure of mill (tolerance of primary air pressure)

Pa

2000

Mill rotation speed Mill ventilation resistance (include pulverized coal classifier) Max. air flow resistance Air flow resistance (guaranteed output) Calculated air flow resistance(BMCR) Mill seal air system

Mill unit power Guaranteed unit power when output

8 9

Designed coal variety HP1103

Unit

Mill unit abrasion rate Lifespan of main components Grind role

DOCUMENT NO. : HISAR-ZT-07

separator,

KW h/t KW h/t g/t h

10.3 1.8 ≥12000 Page

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10

11

lining plate Carpolite coal quantity（normal, max.） Carpolite coal granularity Carpolite coal temperature Permissible dimension & quantity of fine coal

Primary air flow rate on mill outlet（include airproof air flow rate） 13 Shaft power(BMCR/TMCR） 1.2.7.3.2 Mill technique datasheet 12

No

Item

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

h kg/h mm ℃ mm, t/h

≥12000 30.7/61.3 ≤50 ≤250

t/h

124.1

128.7

kW

590/557

638/606

34/67.9

No requirement

Unit

Model 1

Separator model

Static separator model

2

Grind role loading mode

Spring variable load

3

Foundation model

Fixed integral

4 5 6 7 8 9

Input dimension of primary air (inner wall) Dimension/ wall thickness of center coal chute Dimension/ wall thickness pulverized coal pipe junction Volume of Carpolite discharge tank fire control steam Temperature/ pressure Weight of single mill

coal

of ash

capacity/

mm×mm

1020x3068

mm/ mm

Ф610x10

mm/ mm

Ф724x16(designed powder supply pipe Ф710x13, weld the groove before leaving factory

m3

0.8

t/h

3~4

t

180

1.2.7.3.3 Parameter table sheet of motor mill which matched with mill No.

Parameter name

1

Manufacture

2

Electromotor type

Unit

Value Shanghai Electric Motor Co.

--

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

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2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

No.

Parameter name

Unit

Value

11

Insulation grade

--

F

12

Cooling type

--

IC611

13

Erection place

--

Near mill

14

Working type

--

S1（continuous）

Efficiency

%

Efficiency under rated load

%

93

Efficiency under 3/4 rated load

%

92

Efficiency under 1/2 rated load

%

91

15

Power factor Power factor under rated load

0.81

Power factor under 3/4 rated load

0.75

16

Power factor under 1/2 rated load

0.65

17

Max.

torque/

locked-rotor

torque

/rated torque 18

Multiple of locked-rotor current

19

Permissible locked-rotor time

20

Accelerate time and startup time (under rated load)

N·M

15376/21966/7322 ≤6

s

2.5

s

1.5

21

Moment of inertia of electromotor

kg.m2

80

22

Noise

dB(A)

85(1meter)

23

Vibration

mm

_____

amplitude

of

bearing

pedestal 24

Shaft vibration speed

mm/s

2.8

25

Stator temperature up

K

80

26

Phase

3

27

temperature measurer element

Platinum resistance

Bearing model

rolling bearing

Bearing oil trademark

3# lithium-base grease

Bearing lubricate type

Oil grease

28

Bearing cooling type

Self cooling

29

Electromotor weight

30

Flow rate of bearing lube oil (m3/s）

DOCUMENT NO. : HISAR-ZT-07

kg

7000 Grease lubricate Page

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Operation Manual for 600MW Unit Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

No.

Parameter name

Value

31

CT model ratio/ precision grade

No

32

Rotation direction

Bidirection

33

Thread pipe junction tank

Supply afterwards

34

Thread pipe inlet

Supply afterwards

35

Equivalent heating time

36

Outline drawing, drawing No.

37

s

Supply afterwards

Startup torque

N·M

21966

38

Min. startup torque

N·M

15376

39

Recommended lube oil

40

Model

of

resistance

3# lithium-base grease temperature

PT100

detector on stator Model

of

resistance

temperature

PT100

detector on bearing 41

Efficiency/ voltage of electric heater

kW/VAC 1(single mill)/415

1.2.7.3.4 Integrated data sheet of other devices matched with mill No. 1

Parameter name Speed reducer (model)

Unit

Transmission mode

1.1

2

Transmission ratio Lube cooling device(model) oil pump flow rate Electromotor power Normal pressure of oil Cooling water quantity Cooling water pressure Quantity of oil tank electric heater Rated voltage Rated power of oil tank heater Quantity of electric heater on oil return pipe Rated voltage Rated power Lube oil trademark/ quantity required for each mill Sealing air fan (model) Rated air flow Rated upgrade squeeze head Sealing air fan motor (model) Rated power Bearing power (BMCR/TMCR)

DOCUMENT NO. : HISAR-ZT-07

l/min kW MPa m3/h MPa V kW

Value JLX-61S Second stage stand-up-drive of helical bevel gear operated gear and planetary gear 32.435 special 250 11 0.15~0.35 20 0.5~0.7 6set/p 415 1.7kW/个 1piece

V kW

220AC 0.1775（35.5W/m） ISO-VG320/1500L

m3/h Pa kW kW

9-26 16D-3 58211 6659 Y355M2-6 185 153.6(BMCR)/TMCR Page

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Parameter name Rated rotation speed Rated voltage Air strainer (model) Chamber number of each set Air quantity of each chamber Resistance Filter ratio(grain≥5μm) 1.3 Main control system

Unit r/min V

m3/h Pa

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Value 960 3300 60M 14 4245 1370 95%

1.3.1 Summarize The control system of this unit is DES of CENTUM CS 3000 R3 manufactured by Henghe Electric Co.; the whole system includes 4 subsystems: data acquisition station (DAS), sequence control system (SCS), simulates control system（MCS）, furnace safety supervision system （FSSS）. 1.3.2 Introduction of unit coordinated control system 1.3.2.1 Boiler is adjusted following turbine (BF) Control strategy is that boiler main control is automatic, adjust main steam pressure, turbine main control manually, and adjust unit power. Set value of main steam pressure accepts setting of sliding pressure curve. Boiler main control performs adjustment based on offset between actual main steam pressure and its setting value. 1. BF when meet the following requirements. a) HP bypass pressure adjusting valve is closed. b) Turbine main control is manual. c) Boiler main control is automatic. d) Generator outlet breaker is shut-up. e) There is no RB dictate of the unit. 2. Operations during BF a) On the air and gas system, make A/B static blade of IDF automatic. b) On the air and gas system, make A/B static blade of FDF automatic c) On the air and gas system, make oxygen content main control automatic. d) Make more than one coal feeder rotation speed automatic. e) Make feedwater main control automatic. f) Make fuel main control automatic. g) Make boiler main control automatic. 3. As following instance happens, unit automatically quit BF mode. a）Boiler main control is switched to be manual. b) HP bypass valve is open. RB happens. 4. Any condition stated following can satisfy boiler main control switch to be manual. DOCUMENT NO. : HISAR-ZT-07

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a) Big offset is between set value and adjusted quantum. b) Signal of main steam pressure is abnormal. c) MFT action. d) Signal of unit power is abnormal. 1.3.2.2 Turbine is adjusted following boiler (TF) Control strategy is turbine main control is automatic; adjust main steam pressure, which accepts setting of unit sliding pressure curve. Boiler main control is manual, adjust unit power. Satisfy following conditions, unit is on TF mode. a) Turbine main control is automatic. Boiler main control, fuel main control or feedwater main control is manual. HP bypass is closed. B) Operations during TF a) On directive set of unit, check indicator light of set pressure. b) Under base modem, make turbine main control automatic on unit control graph. 1.3.2.3 Coordinated control system （CCS） A) Main functions of CCS a) Control boiler steam temperature, pressure and combustion rate. b) Improve control efficiency of the unit, increase adaptive capability to load variation. c) When main auxiliary machine has faults, carry out RUN BACK. d) When unit operation parameter or offset is beyond limitation, carry out load increase and decrease block, load fleet increase & decrease and track etc. e) Cooperating with BMS, ensure safety operation of burning equipments. B) CCS control mode a. CCS control strategy is the compound of BT and TF, and requires turbine and boiler main control is automatic. According to difference control mode, sort two control strategies. b. Under coordination mode of BF, boiler main control adjusts main steam pressure. Set value of main steam pressure adjusts turbine main control as per sliding pressure curve setting, but the pressure adjusting coefficient is more than pressure adjusting coefficient, that is, takes power adjustment as important and pressure adjustment as accessorial. Target load is manually set by operator. Boiler and turbine main control synchronously receive feedforward signal of target load, and can take part in grid primary FM. Our factory use this TF coordination control mode, the advantage is it can quickly meet load variation requirement, disadvantage is adjustment fluctuation is large and require high requirement of boiler dynamic performance. c. Under coordination mode of TF, boiler main control adjusts power, and target load is manually set by operator. Turbine main control adjusts main steam pressure and power, but its pressure adjusting coefficient is more than power, namely pressure adjustment is master, power adjustment is accessorial. Boiler and turbine main control synchronously receive feedforward DOCUMENT NO. : HISAR-ZT-07

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

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. DOCUMENT NO. : HISAR-ZT-07

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The main functions of this system include: (1) Furnace blowing (2) Main fuel trip (MFT) (3) Display trip reason and memory (to DAS) (4) Protection of furnace positive and negative pressure (5) Leakage test (6) Control of burner light-up and flameout (long distance sequence light-up and site light-up) (7) Switching control of burner (8) Return of load (RB) (9) Protection of furnace flameout (10) Flame test (11) Management of cooling air system on flame checking of probe (12) Interlock control of break valve and circle valve (13) Interlock and alarm (14) Control of secondary air damper 1.3.4 Boiler MFT condition 1.3.4.1 When one of the following conditions happens, FSSS immediately shuts off main fuel of boiler, stops unit operation and displays first trip reason. (1) Manually operate MFT (2) IDF trip (3) FDF trip (4) All preheater trip (5) MCS power loss (6) Drum water over max. (7) Boiler light-up failed (8) Drum water below min. (9) Boiler pressure excess max limitation (choose two from the three) (10) Boiler pressure below min limitation (choose two from the three) (11) Whole furnace loses fuel (12) Whole furnace loses flame (13) Loss flame test cooling air (delayed) (choose two from the three) (14) Air flow below min. value (choose two from the three) （15）All boiler water recycle pump trip （16）Reheater loses protection. （17）All water feeder pump trip （18）Air flow of economizer inlet is lower than min set value (choose two from the three)

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（19）Loss FSSS power （20）Temperature of SH outlet is too high （21）Temperature of RH outlet is too high 1.3.4.2 Give dictate to the following devices when MFT trips (1) Close boiler oil main pipe trip valve. (2) Close all coal feeder (3) Close all mills (4) Induced air fan and draft air fan changed from manual to automatic (5) Close automatic soot blower (6) Open all secondary air dampers (7) Close desuperheater water adjusting valve (8) Close main steam valve (9) ESP trip (10) Give signal to SCS & MCS (11) Close all fast valves (12) Cut high-energy igniter (13) Close primary air fan (14) Give signal to bypass control system 1.3.4.3 MFT condition explanation 1.3.4.3.1 When the following conditions occur, protection of RH is losing. a) A or B of LP reheater is too high b) HP bypass is closed c) Turbine is tripped 1.3.5 Control of secondary air damper For each air chamber of the burning devices, it has its own air dampers and drove by single electromotor actuator, and operates as per the dictate of TB coordination control system (CCS) and furnace supervision, and commonly the 4 group burners on the same floor will run synchronously with air damper. Control principle of burner secondary air damper is shown in following table. Control principle of burner secondary air damper Wind chamber code name

Furnace blowing

CCOFA4

Close

CCOFA3

Close

CCOFA2

Close

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Light-up & single oil filling

Mixed burning of coal & oil

Feed pulverized coal only

Backup or confirm burning adjustment Backup or confirm burning adjustment The opening increase from 60% MCR and Page

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CCOFA1

HH H floor coal GH floor heavy oil

G floor coal FG floor light oil

F floor coal EF floor heavy oil

E floor coal DE D floor coal CD floor heavy oil

C floor coal BC floor light oil

B floor coal AB floor heavy oil

A floor coal AA

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

when it is 85% MCR. The opening increase gradually from 60% MCR and full open when it is 85% MCR. Close when H mill is shut up, otherwise post it Post into △P into △P control Function of mill rotation speed of the coal feeder with H floor opening Open When boiler load 30% MCR, post into ΔP control during light-up; load >30% MCR and G/H floor mills are closed, otherwise post into ΔP control Function of mill rotation speed of the coal feeder with G floor opening Open When boiler load 30% MCR, post into ΔP control during light-up; load >30% MCR and F/G floor mills are closed, otherwise post into ΔP control Function of mill rotation speed of the coal feeder with F floor opening Open When boiler load 30% MCR, post into ΔP control during light-up; load >30% MCR and E/F floor mills are closed, otherwise post into ΔP control Function of mill rotation speed of the coal feeder with E floor opening Post into △P control Function of mill rotation speed of the coal feeder with D floor opening Open When boiler load 30% MCR, post into ΔP control during light-up; load >30% MCR and C/D floor mills are closed, otherwise post into ΔP control Function of mill rotation speed of the coal feeder with C floor opening Open When boiler load 30% MCR, post into ΔP control during light-up; load >30% MCR and B/C floor mills are closed, otherwise post into ΔP control Function of mill rotation speed of the coal feeder with B floor opening Open When boiler load 30% MCR, post into ΔP control during light-up; load >30% MCR and A/B floor mills are closed, otherwise post into ΔP control Function of mill rotation speed of the coal feeder with A floor opening Fully open when mill A runs, otherwise post Post into △P control into △P control Close

Notice: (1) When it is manually operated, each floor can be controlled separately. (2) Startup boiler, when light up oil gun on the first floor, the damper shall be opened after the third corner oil gun is lighted. (3) Perimeter air can be used after 50s of powder feeding, and cut it after 0s of powder off. (4) Fully open all the dampers when it is MFT. 1.3.5.1 Control of fuel air damper 1.3.5.1.1 MFT has no action condition and coal feeder A doesn’t put into operation delayed50s. 1.3.5.1.2 MFT has no action condition and coal feeder B doesn’t put into operation delayed 50s. DOCUMENT NO. : HISAR-ZT-07

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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, DOCUMENT NO. : HISAR-ZT-07

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moreover delayed 70s. 1.3.5.2.7 When meet one of following conditions, CD secondary air baffles shall automatically close. a) Boiler load is less than 30%, and there is at least one angle oil gun for light-up at CD floor, and out of service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mill C, D are halted, oil gun at CD are out of service. 1.3.5.2.8 When meet all conditions as follow, CⅠ floor auxiliary air baffle shall automatically close. a) Boiler load is more than 30%. b) Mill C is halted. c) No MFT action. 1.3.5.2.9 When meet all conditions as follow, DⅠ floor auxiliary air baffle shall automatically close. a) Boiler load is more than 30%. b) Mill D is halted. c) No MFT action. 1.3.5.2.10 when meet all conditions as follow, DE floor auxiliary air baffle shall automatically close. a) Mill D is halted. b) Mill E is halted. c) Boiler load is over 30% and delayed 20s. d) No MFT action. 1.3.5.2.11 when meet all conditions as follow, set EF floor secondary air baffle at light position. a) Boiler load is less than 30%, and at least there is one angle oil gun in service at EF, moreover delays 75s. 1.3.5.2.12 when meet one of following conditions, close EF secondary air baffle. a) Boiler load is less than 30%, and there is one angle oil gun for light-up at least at EF and not in service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mills E, F are halted. Oil guns at EF are out of service. 1.3.5.2.13 when meet all conditions as follow, close EI secondary air baffle. a) Boiler burden is more than 30%. b) Mill E has been halted. c) No MFT action condition. 1.3.5.2.14 when meet all conditions as follow, close FI secondary air baffle. a) Boiler load is more than 30%. DOCUMENT NO. : HISAR-ZT-07

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b) Mill F has been halted. c) No MFT action condition. 1.3.5.2.15 when meet all conditions as follow, set FG floor secondary air baffle at firing position. a) Boiler load is less than 30%, and at least there is one angle oil gun in service at EF, moreover delays 75s. 1.3.5.2.16 when meet one of the following conditions, close FG secondary air baffle. a) Boiler load is less than 30%, and there is at least one angle oil gun for light-up at EF floor, and out of service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mill F, G are halted, oil guns at EF floor are out of service. 1.3.5.2.17 when meet all the following conditions, close GI floor secondary air baffle. a) Boiler load is more than 30%. b) Mill G has been halted. c) No MFT action condition. 1.3.5.2.18 When meet all the following conditions, set GH secondary aid damper at lighting position. a) Boiler load is less than 30%, and at least there is one angle oil gun in service at GH, moreover delays 75s 1.3.5.2.19 when meet one of the following conditions, close GH floor secondary air baffle. a) Boiler load is less than 30%, and there is at least one angle oil gun for light-up at EF floor, and out of service. b) Boiler load is more than 30%, delaying 30s. Without MFT condition, mill G, H are halted, oil guns at GH floor are out of service. 1.3.5.2.20 when meet all the following conditions, close HI floor secondary air baffle. a) Boiler load is more than 30%. b) Mill H has been halted. c) No MFT action condition. 1.3.5.2.21 when meet all the following conditions, HH floor auxiliary air damper will close automatically. a) Mill H has been halted. b) Boiler load is more than 30% and delayed 20s. c) No MFT action. 1.3.6 Fuel control of RB action When boiler main auxiliaries broken-down during operation and can’t work with full load, RB logic will cut some burners immediately as per the principle of operation condition of burners and advantageous to steady of burner flame, and decrease fuel burning quantity on furnace to match the degree of main auxiliaries operation. DOCUMENT NO. : HISAR-ZT-07

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(1) There are dictates for decreasing load: (2) Two FDF are running, shut down one. (3) Two IDF are running, shut down one. (4) Two APH are running, shut down one. (5) Only one water pump is left for running. (6) Two primary air fans are running, shut down one. (7) Only one recycle water pump is left for running. 1.3.6.1 Six mills put into operation, RB action program; oil guns at CD are in service, and switch off mill F delaying 2s, and switch off mill A delaying 6s, switch off mill B. 1.3.6.2 Five mills put into operation, RB action 1.3.6.2.1 Mill A, B, C, D, E are put into operation, RB action program; oil guns at CD are in service, switch off mill E, delaying 2s, switch off mill A. 1.3.6.2.2 Mill A, B, C, D, F are put into operation, RB action program; oil guns at CD are in service, switch off mill F, delaying 2s, switch off mill A. 1.3.6.2.3 Mill A, B, D, E, F are put into operation, RB action program; oil guns at EF are in service, switch off mill A, delaying 2s, switch off mill B. 1.3.6.2.4 Mill A, C, D, E, F are put into operation, RB action program; oil guns at EF are in service, switch off mill A, delaying 2s, switch off mill F. 1.3.6.2.5 Mill B, C, D, E, F are put into operation, RB action program; oil guns at CD are in service, switch off mill B, delaying 2s, switch off mill F. 1.3.6.2.6 Mill A, B, C, E, F are put into operation, RB action program; oil guns at EF are in service, switch off mill A, delaying 2s, switch off mill B. 1.3.6.3 Four mills put into operation, RB action. 1.3.6.3.1 Mill A, B, C, D is put into operation, RB action program; oil guns at CD are in service, switching off mill A. 1.3.6.3.2 Mill A, B, C, E is put into operation, RB action program; oil guns at AB are in service, switching off mill E. 1.3.6.3.3 Mill A, B, C, F is put into operation, RB action program; oil guns at AB are in service, switching off mill F. 1.3.6.3.4 Mill A, B, D, E is put into operation, RB action program; oil guns at AB are in service, switching off mill E. 1.3.6.3.5 Mill A, B, D, F is put into operation, RB action program; oil guns at AB are in service, switching off mill F. 1.3.6.3.6 Mill A, B, E, F is put into operation, RB action program; oil guns at EF are in service, switching off mill A. 1.3.6.3.7 Mill A, C, D, E is put into operation, RB action program; oil guns at CD are in service, switching off mill A. DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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1.4.3 Furnace pressure protection 1.4.3.1 keep on adjusting IDF baffle to make furnace pressure reached ＋996Pa, and give high pressure alarm to make furnace pressure reached ＋13240Pa and keep for 5s. Give high-high alarm and MFT action. 1.4.3.2 Keep on adjusting fan baffle to make furnace pressure reached -996Pa, and give low pressure alarm. 1.4.3.3 Adjust air fan baffle to make furnace pressure reached -2490Pa, and give low pressure Alarm, after 5s MFT acts. 1.4.4 Other protection test 1.4.4.1 Alarm when pressure difference of mill’s bowl is over 3.25Kpa and set coal feeder at minimum speed. Mill will trip when pressure difference of sealing air and primary air is less than 1.0Kpa. 1.4.4.2 Alarm when outlet temperature of mill is over 93℃ and it will trip when it is over 100℃. 1.4.4.3 When lube oil quantity of mill is less than 121 L/min, give an alarm after 2s. 1.4.4.4 Alarm when pressure difference of mill’s lubricating strainer is more than 0.2 Mpa. 1.4.4.5 When lube oil pressure of mill’s gear box is less than 0.09 Mpa, give an alarm, and trip after 2s when it is less than 0.07MPa. 1.4.4.6 Alarm when lubricating oil level in tank is lower than 200mm. 1.4.4.7 When oil temperature at outlet of mill lubricating pump is 60℃ higher, give an alarm, and trip when it is 65℃ higher. 1.4.4.8 When temperature of thrusting pad of mill gear box is 75℃ higher, give an alarm, and trip when it is 80℃ higher. 1.4.4.9 When bearing temperature of mill motor is 85℃ higher, give an alarm, and trip when it is 95℃ higher. 1.4.4.10 When thrusting bearing temperature of IDF is higher than 85℃ , give an alarm and shunt start spare cooling air fan; when it is more than 100℃ , shunt trip IDF. 1.4.4.11 When radial bearing temperature of IDF is more 85℃, give an alarm and shunt start spare cooling air fan; when it is more than 100℃ , shunt trip IDF. 1.4.4.12 when horizontal and vertical vibration of bearing of IDF is 0.192 mm, give an alarm. 1.4.12.13 when bearing temperature of motor of IDF is 90℃, give an alarm. 1.4.4.14 when winding temperature of motor of IDF is more than 125℃, give an alarm, and when it is more than 145℃ , IDF trips. 1.4.4.15 When surge of IDF is high (inlet pressure is +2000 Pa when damper is fully closed), delaying 15s, fan trips. 1.4.4.16 When librations of IDF at any side reaches 8mm/s give an alarm, and when it reaches11mm/s, IDF trips. 1.4.4.17 when bearing temperature of IDF is more than 90℃, give an alarm, and when it is DOCUMENT NO. : HISAR-ZT-07

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more than 100℃, IDF trips. 1.4.4.18 when hydraulic oil pressure of IDF is lower than 2.5Mpa, block IDF. 1.4.4.19 when surge of IDF comes to +2000 Pa, IDF trips after 15s delay. 1.4.4.20 When support bearing temperature of PAF is more than or equal to 85℃ , give an alarm, and trips when it is more than or equal to 100℃ . 1.4.4.21 When thrust bearing temperature of PAF is more than or equal to 85℃ , give an alarm, and when it is more than or equal to 100℃, PAF trips. 1.4.4.22 When bearing temperature of motor of PAF is more than or equal to 85℃, give an alarm, and when it is more than or equal to 95℃, PAF trips. 1.4.4.23When bearing vibration of PAF is more than 8mm/s(X/Y coordinates), give an alarm, and when it comes to 11mm/s, PAF trips. 1.4.4.24 when surge of PAF comes to +2000 Pa (inlet pressure when damper is fully closed), delay15s, fan trips. 1.4.4.25 When motor winding temperature of PAF is more than or equal to 110℃, give an alarm, and when it is more than or equal to 120℃, PAF trips. 1.5 Start up of boiler 1.5.1 Initial state before start-up (entire cold working condition) 1.5.1.1 When all maintenance work of the unit is finished and working notice is over, it is ready for start-up. 1.5.1.2 Power isn’t supplied yet and all equipments are out of service. 1.5.1.3 All pneumatic valves are out of gas, and other gates are closed. 1.5.1.4 No water is injected into boiler. 1.5.2 Preparation before start-up 1.5.2.1 Supply power to electric devices. 1.5.2.2 Inspect DCS operating station and filed operating station and confirm that all valves are in correct position. Inspect air vent valve of SH and RH, drain valve of SH and RH, and confirm drain valve of main steam pipe to turbine is open. Economizer, drain valve of water wall, SH, spray adjusting valve of reheater and electric stop valve are closed. 1.5.2.3 Boiler start-up system backup includes atmospheric flash vessel, header tank, drain return pump etc. Motor isolator valve of boiler start-up system is open. Start pipe warming valve of boiler start-up system for standby. Adjusting valve of boiler start-up system is automatically put into operation. 1.5.2.4 Smoke temperature probe is in service. 1.5.2.5 Feed water into boiler 1.5.2.5.1 Before boiler filled with water, fill water into motors of boiler water pump one by one as per the Operation Regulation of Boiler Water Pump, and make sure the pipe is clean enough for filling. DOCUMENT NO. : HISAR-ZT-07

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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.

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（10）Air rate is proper. （11）Cooling air for flame checking is normal. （12）Preheater is in service. （13）ESP is out of service. （14）Secondary air damper is on adjusting position. （15）Oil leakage test is finished. （16）Power of FSSS system is normal. （17）Power of FMCS system is normal. （18）Close SOFA damper. （19）Shut down primary air fan. Furnace blowing steps a) Carry out blowing when the conditions are ready. Blowing time is 5 minutes. b) On operating station, set relevant indicator light to indicate above conditions, and according to working condition, respectively show “blowing allowance” , “blowing process” , “blowing halt” and “blowing completion” c) Blowing for 5 minutes, air rate is between 30%-40%. d) After finishing blowing, confirm MFT relay is reset. e) Check air damper to flame position, keep air flow at 30% of total. 1.5.3.6 Fuel oil leakage test 1.5.3.6.1 Conditions for oil leakage test. a) Blowing is finished b) Fuel angle valves are closed. c) 1.5MPa Oil inlet pressure of fuel header is allowed to be above 1.5Mpa. Procedure of leakage test of boiler front fuel oil system a) Open inlet quick action valve and return valve to perform oil circulation normally. b) Adjust oil pressure of main pipe to be over set value of 1.5Mpa for leakage test. Close return valve, after charging pressure to inlet quick action valve, leakage testing pressure is more than or equal to 1.5Mpa, close oil inlet quick action valve. c) During stated 3 minutes, ensure pressure of inlet quick action valve is higher than 1.45Mpa. d) After opening return valve to relieve pressure to inlet quick action valve, pressure is less than 0.23Mpa pressure switch action, close return valve. e) Check pressure variation inlet quick action valve. During specified 3 minutes, if inlet quick action valve pressure is less than 0.23 Mpa, it means leakage test for tripping valve is accepted. f) If leakage test is aborted, furnace blowing is unsuccessful, and system gives a failure signal. After treatment, restart leakage test.

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1.5.4 Inspection of control system before start-up 1.5.4.1 Furnace pressure is automatically controlled. 1.5.4.2 Air flow is automatically controlled and keeps air rate at about 30% of total. 1.5.4.3 Set up HP/LP bypass automatic control for condenser vacuum and make sure HP/LP bypass desuperheated water is normal. 1.5.4.4 Fuel adjusting valve is automatically controlled. 1.5.4.5 Temperature of SH and RH is automatically controlled and set value of superheat temperature is 50℃ at least. 1.5.5 Boiler ignition, temperature increase, pressure raise 1.5.1.1 After blowing, entirely inspect light-up conditions. Open fuel inlet and oil return quick action valves. Ensure fuel pressure, atomizing steam pressure and temperature is normal. 1.5.5.2 Put boiler front oil system into operation. In order to ensure successfully light-up and combustion, it is required that viscosity of fuel oil is below 3°E and temperature is below 8℃ which are affected by pressure and temperature of control fuel oil. 1.5.5.3Put soot blowing system of air preheater into operation. Start up oil gun at AB layer, check every angle oil gun are orderly put into operation, generally as per order 1, 3, 2, 4 . Conform light-up is normal. After the third oil gun is put into operation, adjust fuel oil recycle valve as per specific condition. Fuel pressure control can switch to flow control, and oil flow is set to 5% of BMCR 1.5.5.5After oil gun at AB layer is working normally, start up PAF by sequence, and check operation of PAF is normal. Primary air/furnace pressure difference is more than 6.0Kpa. Automatically open damper at inlet of primary air of air preheater, interlock of sealing air fan A is normal, sealing air fan B is in service of interlock standby. 1.5.5.6 Inlet steam air preheater of mill A is put into operation (open isolation damper of hot primary air at inlet of mill B, open adjustable damper of hot primary air of mill B, close secondary isolation damper of hot primary air of mill B, open electric damper at inlet of steam air preheater, open electric damper at outlet of steam air preheater, close isolation damper of hot primary air at inlet of mill A, close adjustable damper of hot primary air of mill A). 1.5.5.7 Make sure ion ignition equipment is conform to start –up condition. 1.5.5.8 Start condition of mill A is satisfied, and air temperature at inlet of mill A comes to 180℃. Make start mode of mill A be “plasma mode” to start mill A. After outlet temperature of mill reaches 70℃, turn on every angle ion ignition device after 15minutes, and confirm every angle. 1.5.5.9 Shut down oil gun at AB as per combustion condition, smoke temperature probe indicates temperature is less than 538℃. 1.5.5.10 According to combustion condition, carry out adjustment of fuel oil quantity and oil secondary air rate. 1.5.9.11 Confirm metal wall temperature of water wall, SH and RH is in specified scope. DOCUMENT NO. : HISAR-ZT-07

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1.5.6 Increase combustion rate 1.5.6.1 When superheat temperature of main steam is over 50℃ , burning ratio will increase. However, before turbine is synchronous or steam flow reaches 10%, temperature of furnace smoke temperature probe shall be controlled below 538℃ by burning ratio. 1.5.6.2 Slowly increase burning ratio (make sure temperature of the smoke on furnace outlet is below 538℃) as per start-up curve after mill A has been put into operation for 25minutes, and notice increasing speed of pressure and temperature. 1.5.6.3 Pressure of main steam reaches 8.6MPa and RH reaches 0.8MPa, check pressure control mode of HP/LP bypass. 1.5.6.4 When temperature of air preheater outlet reaches 200℃, mill A inlet steam air preheater can be out of service, and make sure that the temperature on mill A outlet is normal. 1.5.6.5 When the temperature of main steam is 380℃ , open secondary chief valve of desuperheated water and fill up secondary desuperheated water, and ensures water supply speed and temperature is set on 360℃. When RH steam temperature is 340℃, operate RH temperature automatically with fixed value at 320℃. When SH outer pressure reaches 8.4～ 8.9MPa, HP bypass control mode, adjust burning ratio to make steam temperature match with turbine’s. 1.5.7 Precautions during the course of boiler temperature increasing 1.5.7.1 Make sure desuperheated water of condenser HP/LP drain flash tank put into operation normally, and the pressure and temperature is within limitation. 1.5.7.2 Supervise the wall temperature of drum, water wall, SH, RH and control temperature increasing speed. 1.5.7.3 Control fuel feeding speed, emphasize supervision of separator water level, and make sure the drum will not full of water. 1.5.7.4 Confirm HP/LP bypass system operate properly. 1.5.7.5 Make sure feed water is adjusted properly, and keep water level of condenser, deaerator in normal level. 1.5.7.6 Check if ion ignition devices operate properly or not. 1.5.7.7 Keep blowing for air preheater during boiler start-up, and strengthen supervision of hotspot of air preheater. Go to site immediately once there is an alarm and so as to avoid burning of air preheater. 1.5.7.8 When the temperature of smoke on furnace is over 538℃, furnace smoke probe will drop out automatically. 1.5.7.9 Temperature and pressure increasing will carried out as per temperature and pressure increasing curve under cold-start, conform to turbine turning requirement, and keep it. 1.5.7.10 Temperature increasing speed of main and reheat steam can’t exceed 110℃/h.

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1.5.8 Turbine turning and synchronization 1.5.8.1 Make sure quality of steam pressure & temperature satisfy the requirement of speed up and warming of turbine during turbine turning. 1.5.8.2 After turbine is synchronized, close all drain, vent valves of SH & RH. 1.5.8.3 Switchover bypass control of main steam pressure to turbine control. Boiler, turbine control mode is BF mode. 1.5.8.4 By adjusting combustion rate and air rate, control temperature of superheated steam and reheat steam to be stable. 1.5.9 Turbine synchronization with minimum load to 35% of BMCR (100MW) 1.5.9.1 In initial period of load warming, increase speed of main steam is controlled within 1.5～ 2.5℃ /min, and reheat steam’s is controlled between 2.5～3.5℃ /min. Load is increased as per 3MW/ min. 1.5.9.2 Adjust hot air duct pressure of PAF, set pressure difference control between hot air duct and furnace to be automatic state. 1.5.9.3 As unit load increases, add fuel on time. After coal quantity of mill A comes to 35t/h, put coal feeder into automatic operation. After mill is warmed on time, put the second and third mill into operation. Pay attention that overall fuel quantity shall be reposefully increased after it’s in service. 1.5.9.4 According to combustion condition, halt oil gun. Check every angle oil gun quit normally. Smoke temperature probe indicates temperature must be less than 538℃. 1.5.9.5 Adjust speed of all coal feeders which are in service. Load increases to 17% of BMCR. Two turbine driven feedwater pumps are ready for operation. 1.5.9.7 Confirm boiler feedwater, fuel, FDF system are normally automatic operated. Adjusting valves of proportion of fuel and water, primary desuperheated water, secondary desuperheated water, desuperheated water of RH are in automatic standby state. 1.5.9.9 When the load is about 30%, switch motor driven feedwater pump to steam driven pump, and avoid large range fluctuation of flow water and ensure the self-regulation is in good condition. 1.5.9.10 Ｗhen boiler load comes to 28% of BMCR and be stable, unit adopts CCS mode. 1.5.9.11 Increase fuel quantity, when output of working mill is more than 60％ of coal flow, add mill for service. 1.5.9.12 Under DEH control mode, as load increases, opening of HP valve is bigger than 90 ％,change to sliding pressure control mode, slowly increase fuel quantity and load. 1.5.9.13 after coal is fully combusted; electrical precipitator is put into operation. 1.5.9.14 as per the combustion condition, relevant oil gun can be halted (or plasma device). As per mill operating condition, choose oil gun emergency feeding mode

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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 DOCUMENT NO. : HISAR-ZT-07

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time as per turbine requirement. 1.5.11.13 Check whether action of HP, LP bypass system is normal. 1.5.12 hot start 1.5.12.1 The process of hot start is basically the same as cold start-up. Boiler temperature and pressure increasing process takes boiler minimum pressure as initial point after light-up. 1.5.12.2 According to unit’s state, arrange work at every stage properly and reasonably. 1.5.12.3 In entire hot start process, according to different state of the unit, strictly control temperature, pressure and load increase speed as per “ unit warm start curve”, ”unit hot start curve”. 1.5.12.4 When temperature of main steam is 30℃ higher than adjusting metal’s, open the main valve of secondary desuperheated water, and put secondary desuperheated water into operation. When reheat steam is 20℃ higher than metal temperature at inlet area, put reheat steam temperature into automatic. HP bypass is pressure controlled, adjust burning ratio to make steam temperature match with turbine. 1.5.12.5 Set turbine parameter as per cylinder temperature and start curve supplied by manufacture. Ensure the temperature of main & reheat steam is 50～100℃ higher than that of adjusting grade and carrier metal of IP cylinder, and 56℃ of superheat temperature is required at least, but it can not be higher than rated temperature. Dismatch between steam and metal temperature can’t exceed the range of －56～＋110℃. 1.5.12.6 Since load increasing rate is very fast during hot start, it is required to warm mill in advance meet load increasing requirement. 1.5.12.7 Check whether HP, LP bypass actions are normal during temperature increasing and pressure raise. 1.5.12.8 Since temperature of turning main steam is high during hot start, during temperature and pressure increasing course, especially pay attention that the wall temperature of water wall, superheater and reheater can’t exceed the limitation. Steam temperature of RH inlet is controlled ≯400℃, inlet smoke temperature of HP superheater ≤ 538℃ . 1.5.12.9 Sequence of filling warm fuel: AB oil layer－plasma ignitor－A coal layer－B coal layer －C coal layer－D coal layer－E coal layer－F coal layer－G coal layer－H coal layer. 1.6 Boiler operation control and adjustment 1.6.1 Adjusting work of boiler operation 1.6.1.1 Make sure boiler evaporation capacity meet requirement of unit load. 1.6.1.2 Adjust every parameter fluctuating within in allowable scope. 1.6.1.3 Keep working condition of combustion in furnace well, keep optimal air rate to ensure boiler at optimal combustion rate. 1.6.1.4 Adjust boiler working condition on time, improve boiler efficiency. Try best to make sure

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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 DOCUMENT NO. : HISAR-ZT-07

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regular triangle and air is filled by inverted triangular. 1.6.3.7 In order to ensure boiler economy operation, coal fineness should be maintained reasonable. Regularly sample ash and slag to analyse and compare, and adjust combustion in time. 1.6.3.8 When adjust combustion or increase negative pressure of boiler, ensure the steam temperature and pressure is normal, outlet temperature of water wall also should be in normal range. After burner is put into operation, check whether firing condition is good or not, and adjust air rate on time to avoid black smoke emitting from chimney. 1.6.3.9 When improper combustion of boiler is cause by variety of reasons, oil gun should be put into operation on time to stabilize combustion, and find out reasons to eliminate unstable factors of combustion. If burnout happens, fuel supply should be stopped at once to avoid boiler deflagration. 1.6.3.10 when furnace blowing is carried under less than 60% load, supervise working condition of combustion in furnace. If combustion is stable, stop blowing at once. 1.6.3.11 As carrying out normal supervision and adjustment, simultaneously intensify analysis of operation parameter and metal temperature at heating surface, such as when there is big temperature difference of steam temperature, or beterrn both sides of primary and secondary desuperheated water, or large temperature deviation of each heating surface, analyse and find out reasons on time to solve problems. Check whether operating mode of pulverized coal system is reasonable. Output for operating pulverized coal system should be furthest kept the same, so as to avoid continuously stopping the two intermediate pulverized coal systems. Check whether there is any damage to adjustable damper of burner secondary air and auxiliary air, whether the position of adjustable damper is correct. Check whether the coal for every working mill is consistent with the mill and whether actual coal feeding quantity for mills is equal. Check and analyse whether coking and damage exist on the burner. Check whether oxygen content measurement point is correct, whether oxygen value is adapts to relevant load. Regularly check working condition of the burner, if any coking is found, clean it out on time. Carry out blowing as per the coking stage in boiler. When coking is serious, take measures to clean. 1.6.4 Adjustment of boiler steam temperature 1.6.4.1 When boiler runs normally, the temperature of main steam should be controlled within 571±5℃, temperature of reheat steam should be controlled within 569±5℃, and temperature difference at both sides is less than 10℃. At the same time medium temperature at each part and wall temperature should be within set value. 1.6.4.2 Temperature adjusting of main steam is based on adjusting burning, and assisting of desuperheated water and normal temperature of main steam. 1.6.4.3 Reheat steam temperature is mainly adjusted by swing angle of burner. If swing angle of DOCUMENT NO. : HISAR-ZT-07

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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: Item

Unit

Normal value

Max.

Min.

（range）

value

value

Trip 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

℃

＜470

472

℃

＜480

482

℃

＜560

566

℃

＜580

580

℃

＜570

571

Wall temperature on final RH outlet

℃

＜580

580

Furnace negative pressure

Pa

-50～-100

+996

-996

+13240-2490

Pressure of fuel header

MPa

1～1.8

1.8

0.3

0.23

Temperature on mill outlet

℃

77

93

65

100

Feedwater temperature

℃

280

Exhaust smoke temperature

℃

134

Main pipe pressure of primary air

KPa

8～10

Wall temperature of LPSH vertical outlet Wall temperature on division platen outlet Wall temperature on rear platen SH outlet Wall temperature on final SH outlet Wall temperature on platen RH outlet

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1.7 Stop boiler to operation 1.7.1 Stop operation by smooth parameter changing 1.7.1.1 Use this method in follow situation: 1.7.1.1.1 The unit need to repair and short start time; 1.7.1.1.2 Deal with the defects in pipe of boiler proper and turbine proper; 1.7.1.2.1 Prepare to stop boiler 1.7.1.2.1 General regulation a) Chief supervisor should make order and tell aims and mode of boiler halt; b) The special stop should be put forward by operation dept., approved by deputy manager. The chief supervisor should be noticed by paper or oral and the special engineer should come to site to instruct. c) Chief supervisor should give order in advance and contact with chemical, fuel, ash and desulphurization staff to prepare to stop. d) When command is given to every stall, check the whole system, and record every equipment defect. Prepare to remove defects after stopping. e) If stop boiler before maintenance, the fuel in coal feeder and bunker should be exhausted. To maintain flame in stable situation, reduce coal level smoothly; pay more attention to flame when the bunker will be empty. Special engineer should arrange in site to empty the bunker. 1.7.1.3 Prepare to reduce load 1.7.1.3.1 Check plant steam system; 1.7.1.3.2 Soot blow totally when load is more than 300MW; 1.7.1.3.3 Check if there is enough oil in thin oil house, oil circling system is normal, and oil gun can be put into operation normally. 1.7.1.3.4 Check if plasma ignition apparatus is in spare condition. 1.7.1.3.5 HP and LP by-pass warming pipe is in spare condition. 1.7.1.3.6 Ensure all auto adjusting equipments are in good condition. 1.7.1.3.7 Prepare operation notice for unit shut up. 1.7.1.4 Operation 1.7.1.4.1 Reduce load Reduce load according to chief supervisor order and operate unit by coordinate-control before lower load. The speed of load reducing should be within 5MW/min. Reduce negative load from 100% to 80% a) Operation staff reduces load set value from 600MW to 540MW by coordinate-control mode. And the decreasing ratio is 5MW/min, in this condition, don’t reduce mill quantity. b) Reduce coal of every mill gradually, in this condition, the load decreasing ratio can be quicker but not excess 10MW/min. From load the decreased to 90%, the unit goes into smooth pressure mode. Ensure opening of adjusting valve is between 88%~90%, and reduce pressure DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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1.7.2.2.5 Temperature of steam and furnace wall surpass largely. 1.7.2.3 Emergency shut off of boiler 1.7.2.3.1 MFT trip, stop boiler by lock function, otherwise, stops locked equipment manually. 1.7.2.3.2 Equipment should be tripped after MFT: 1) All mills, coal feeder trip. 2) Two primary air fans trip. 3) All outlet dampers of mill are closed. 4) Close fuel trip-valve, oil angle quick valve and blowing oil gun. 5) Stop all high energy igniter. 6) Switch secondary air damper to blowing position. 7) For FD and IDF, switch their auto-control mode to MFT. 8) Closedown stop valve of primary, secondary desuperheated water and RH emergency desuperheated water. 9) When boiler is blowing during MFT, close steam blowing and soot blower will exit automatically. 10) Turbine trips. Tow steam driven pumps trip and motor driven pumps interlock. k) ESP trips. 1.7.2.3.3 If FD and IDF not trip after MFT, blow furnace automatically. Air flow should be larger than 30%BMCR on furnace, make all secondary air dampers open. While air flow is smaller than 30%BMCR during MFT, 5min later, all secondary air dampers will on blowing position, and air flow would be adjusted to 30-40%BMCR automatically, and blowing for 5minutes. 1.7.2.3.4 Due to MFT cause by FDF and IDF, or FDF and IDF trip after MFT, open secondary air damper after 1minute, 15m later, check and ensure all mill outlet dampers, fuel closing valves and fuel quick action valves are closed correctly. Ensure there is no flame in furnace by watching TV and checking by fire inspecting probe, open damper of FD and IDF slowly after all interlocked equipment tripped for 5 min at least. Sootblowing as per normal procedure after FDF and IDF resume. 1.7.2.3.5 When SH pressure is reached to 26.7MPa, pressure of PVC valve should be reduced. 1.7.2.3.6 Other operations should be carried according to the normal regulation. 1.7.3 Precautions during boiler shut off 1.7.3.1 Pay more attention to temperature difference of outer and inner wall of outlet header of separator and SH, decrease cooling speed if temperature difference is larger than normal scope. 1.7.3.3 Decrease opening of main feedwater adjusting valve properly if there is not enough desuperheated water supplied for main steam. 1.7.3.4 To prevent steam temperature changing too much, desuperheating water can’t be increased or decreased rapidly in low load condition. DOCUMENT NO. : HISAR-ZT-07

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1.7.3.5 Sootblowing preheater continuously blow during all stopping time. 1.7.3.6 Monitor fumes temperature of air preheater after stopping boiler; check overall if there is any troublesome. Ensure there is no flame in furnace. 1.8 Typical accidents disposal in boiler 1.8.1 Full water of boiler 1.8.1.1 Phenomenon 1.8.1.1.1 All water level indicators exceed regular indicated value, gives an alarm when “water level in steam drum is high”; 1.8.1.1.2 Flow rate of supplied water is larger than that of steam； 1.8.1.1.3 When water level height is III，delay 2s and MFT； 1.8.1.1.4 When the water is too full，main steam temperature suddenly drop，water hammer may happen in the main steam pipeline and the pipeline vibrates acutely； 1.8.1.2 Reasons: 1.8.1.2.1 The feed water automation device is out of order, and

rotation speed of feedwater

pump rises abnormally； 1.8.1.2.2 It is manually operated improperly, or misjudged by operator because of incorrect indication of water level & water steam flow rate; 1.8.1.2.3 Water level is not adjusted timely when load and the steam pressure change a lot; 1.8.1.3 Handle: 1.8.1.3.1 When water level height is I: If the automation of feed water is out of order, transfer automation to manually control immediately, and reduce rotation speed of motor driven feedwater pump at the same time；If the speed adjustor of motor driven feedwater pump is out of order，stop turbine driven feedwater pump immediately and adjust water supply quantity by turning on motor driven pump； 1.8.1.3.2 When water level height is III，delay 2 seconds and MFT，and handle as per related rules after MFT； 1.8.1.3.3 During handling process，pay attention to the change of steam temperature； 1.8.1.3.4

Fill water to normal level after boiler shut-up, and light again after eliminate the

reasons； 1.8.1.3.5 It is forbidden to filling water by offset valve. 1.8.2 The boiler is short of water 1.8.2.1 Phenomenon 1.8.2.1.1 All water level indicators exceed regular indicated value, gives an alarm when “steam drum water level is low”; 1.8.2.1.2 Flow rate of water supply is much smaller than that of steam（exclusive of blowup of

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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， DOCUMENT NO. : HISAR-ZT-07

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and lower steam drum water level to- 50mm； 1.8.3.2.3 Close desuperheated water，open superheater drainage when it is necessary，and keep close watch to the variation of steam temperature； 1.8.3.2.4 Notice the chemistry special field，stop adding medicine，and reinforce boiler water chemical examination. 1.8.4 MFT 1.8.4.1 Phenomenon 1) Alarm accident by voice and light, FSSS will display reason. 2) Related equipment and valves trip. 3) Unit load get to 0 4) Flame is extinguished in boiler, no flame on flame monitor. 1.8.4.2 Reason 1) MFT by hand. 2) Main protection equipment trip because of unit or equipment breakdown. 3) Protection equipment trip incorrectly or thermal element failure. 1.8.4.3 Handle 1) Check if all mill and coal feeder, primary air fan and seal fan tripped, fuel closing valve and oil valve shut off, the first and second stage desuperheating water valve shut off, accident desuperheating water valve for reheater shut off, steam sootblow closedown. Sootblower should be exit automatically if sootblowing when MFT, ensure operation by auto or manually. 2) Check auto tracing for furnace negative pressure is normal, unchain auto if the tracing is abnormal. Regulate it manually to avoid trip of ID, FDF caused by excessive negative pressure. 3) When PCV valve is not open and pressure of SH gets to 17.99MPa, PVC relief valve should be opened manually. 4) After sootblowing is finished, resume all tripped equipments. 5) Monitor fumes temperature and hot air temperature; prevent rear heating surface of boiler re-flame. 6) Find out reasons of MFT, and remove shortage, and then prepare to start again. 1.8.5 RB a) Appearance 1) Alarm accidents by voice and light, CRT will display reason. 2) For equipment tripped, monitors flash. 3) Coal powder system trip partly. 4) Load decreases to 300MW rapidly. B Reasons 1) Trip one steam pump, don’t put motor pump into operation.

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2) Trip one of the two FDF. 3) Trip one of the two IDF. 4) Trip one of the two PAF. 5) Trip one of the two APH C Handle 1) Check if auto tracing equipment works normally, don’t remove it. On condition that if it works incorrectly, switch it to manual mode and stop some mills, but remain 4 mills operating at least. Adjust coal feeder output to match with 300MW, and regulate water flow to ensure normal temperature of main steam and reheating steam. 2) Increase the operating steam pump output to max if the other one trips. Switch to assistance steam if pressure on the fourth exhaust is not enough. 3) One FDF output will increase to max if the other one trips. Check the tightness of its outlet damper of the tripped FDF. 4) One FDF output will increase to max. if the other one trips. Check the tightness of its inlet and outlet damper of the tripped FDF. 5) Increase the operation primary fan output to max if the other one trips. Check the tightness of the tripped primary air outlet damper and cool air damper. 6) Adjust coal powder, water flow and air flow to ensure the unit operates stable under max output. Find out reasons of RB and resume to normal operation after eliminating the defects. 1.8.6 Pressure of main steam and reheating steam in incorrect scope 1.8.6.1 Appearance 1) Pressure of main steam and reheating steam offset with normal value. 2) Temperature along main steam pipe and reheating steam pipe may be abnormal. 3) Load may be decreased. 4) Some leakage in main steam safety valve, reheating steam safety valve, HP by-pass, LP by-pass, or high temperature of desuperheater and its valve is open. 5) Some leakage is in main steam and reheating steam pipe, and alarm when the four pipes leak. 6) It is abnormal that water supply rate is even larger than main steam flow rate. 1.8.6.2 Reasons 1) Safety valve or PCV valve trip by accident, or leak heavily and cause pressure of main steam and reheating steam lower. 2) Open by-pass valve by accident, or serious leakage which cause pressure of main steam and reheating steam being abnormal. 3) Auto-valve of main steam or regulating valve is opened up or turned down abnormally. 4) Main and reheat steam system leak heavily. 5) Exhaust system is abnormal. DOCUMENT NO. : HISAR-ZT-07

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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 DOCUMENT NO. : HISAR-ZT-07

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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, DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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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 DOCUMENT NO. : HISAR-ZT-07

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1) There is defect remaining in material or destroy during manufacture and installation. 2) Friction bar 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 non-conformity welding makes flow in tube decreasing, 6) Coordination system or auto tracing system of superheater could not trace in time, or it operates in excess temperature situation long time, lead to blow up. 7) Water entering into reheater because of false operates emergence desuperheating water or reheater operates in excess temperature condition lead to tube temperature excess and blow up. 8) No water in tube during start boiler, fume temperature surpass designed value to destroy. 9) Sootblower is incorrect position and water remaining in it to destroy tube. C Handle 1) Leakage is not so heavy that normal running can maintain, now pay more attention to leakage and report in time. Decrease load if needed. To prevent leakage destroy other tube or near tube in low flow or excess temperature, stop boiler as early as possible. 2) For tube blow 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. 1.8.12 Reframe in rear fume duct A Phenomenon 1) Inlet fumes temperature or outlet temperature of preheater increase abruptly and surpass normal value. 2) Temperature of hot air increases abruptly and surpasses normal value. 3) Heat inspection for preheater alarm and its temperature difference of inlet fume and outlet hot air is lower, even minus. 4) Suction pressure of furnace fluctuates abruptly. 5) Re-flame around eco, outlet water temperature on eco increases abnormally, rear fume temperature increases abnormally. DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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2) Tube temperature is higher than designed value because of deposit heavily. . 3) Blocked by sundries or mistaken welding, so water flow decreased. 4) Auto control or auto tracing system could not trace very well, so temperature of tube wall surpass. C handles 1) 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 to make heat load going to even. By adjusting, metal temperature is still high, decrease steam temperature of main steam and reheating steam. 2) Sootblowing water wall and superheater more times. Repair destroyed sootblower. 3) Monitor chemical dosing more and if boiler maintain running for a long time, so salt accumulate in superheater and reheater, their steam temperature should be decreased. The boiler needs acid cleansing soon. 4) Decrease steam temperature of superheater and reheater to run if their tube temperature surpass. And cut tube to inspect in repairing time. 5) Adjust and set parameter if tracing system work incorrectly, lower load changing speed or switch auto mode too manually before it repaired.

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Chapter II Operation Manual for Boiler Accessory 2.1 Air preheater 2.1.1 Interlock protection for preheater 2.1.1.1 Signal of direct bearing temperature high occurs if bearing temperature higher than 70℃, and preheater trip when temperature is higher than 85℃. 2.1.1.2 Signal of pressure difference of filter high occurs if its guide and supporting bearing pressure difference higher than 0.35Mpa. 2.1.1.3 Put preheater interlock switch into use, if main driven motor of preheater trip when start, then interlock starts assist-driven motor, and vice verse. 2.1.1.4 When main motor and assist motor of preheater running, open primary air and secondary air damper respectively. 2.1.1.5 When both main motor and assist motor trip, close primary air and secondary air damper respectively. 2.1.2 Trip conditions for preheater 2.1.2.1 Preheater stall. 2.1.2.2 Main motor trip, but assist motor doesn’t start jointly. 2.1.2.3 Temperature of supporting and guide bearing of air preheater is higher than 85℃. 2.1.3 Start preheater Air preheater may be auto-controlled or manually starts. Steps as follow: 2.1.3.1 Start oil pump of guide and support bearing. 2.1.3.2 Start main motor. 2.1.3.3 Open outlet dampers of secondary air, primary air and fume inlet damper. 2.1.3.4 Put sealing adjusting device “automatically” when boiler load is larger than 50％MCR and running continuously for more than 4 hours. 2.1.4 Stop preheater Preheater can be stopped by auto-control or manually. Steps as follow: 2.1.4.1 Switch sealing adjusting equipment to “manual” when boiler load decrease to 300MW, and lift section plate to upper-limited position by hand. 2.1.1.2 Close fume inlet damper, primary air and secondary air outlet damper after boiler is flameout and fume inlet temperature of preheater lower than 120℃. 2.1.4.3 Stop main motor running. 2.1.5 Handling preheater troublesome 2.1.5.1 Failure of running main motor or AC power off A Treatment a) Monitor suction pressure of furnace, temperature change of primary air and secondary air, and flame combustion in boiler. b) Decrease boiler load if needed, and put oil gun into use, increase sootblowing frequency. DOCUMENT NO. : HISAR-ZT-07

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c) Monitor temperature of primary air, secondary air, and fume. d) Maintain normal load if assist-motor starts automatically and air leakage system has normal power. When main motor repaired, return to normal running gradually. e) If rotor of preheater stops, assist-motor auto-start fails, or all AC power is off, preheater stops, take measures as follow: 1) Stop respective forced and induced air fan, and boiler runs in half side. And close all dampers of other side. 2) Monitor alarm of fire monitoring system 3) Lift sector plate of air leakage system 4) Jigger when needed. 5) Put preheater into running after power resume and running condition reached, and sootblowing continuously. 2.1.5.2 Preheater trip A Appearance 1) Current of preheater weaken to 0, assist-motor auto start and voice and light signal alarm. 2) When assist-motor could not auto start, stop signal alarm, fume temperature of respective side will increase. B reason 1) Current of preheater weakens to 0, assist-motor automatically start, voice and light signal alarm. 2) Electric protection trip. 3) Assist-motor auto start fails. C Handle 1) If no ex-current appearance exists before trip, connect it once by force. Continue to run if success. 2) If fail to connecting by force, or ex-current exists when start, stop it immediately, and check if assist-motor run normally. 3) If assist-motor running incorrectly, stop preheater, then close outlet and inlet damper respectively, isolate primary and secondary air, decrease load. If trouble could not be solved shortly, boiler would be stopped. When temperature increase to 250℃, MFT should be by hand. 2.2 IDF 2.2.1 Admitted starting conditions 2.2.1.1 Bearing temperature of fan ≤85℃ 2.2.1.2 Bearing temperature of motor ≤75℃ 2.2.1.3 Any bearing cooling fan running. 2.2.1.4 Inlet rotary blade closed. 2.2.1.5 Inlet motor-damper closed. DOCUMENT NO. : HISAR-ZT-07

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2.2.1.6 Outlet motor-damper opening. 2.2.1.7 The other preheater running. 2.2.2 Trip conditions 2.2.2.1 opposite preheater trip. 2.2.2.2 Opposite FDF trip. 2.2.2.3 2preheater trip. 2.2.2.4 Bearing temperature of fan ≥100℃. 2.2.2.5 Bearing temperature of motor ≥85℃ 2.2.2.6 Winding temperature of motor ≥145℃ 2.2.2.7 Bearing vibration ≥7.1mm/s. 2.2.2.8 After MFT, furnace pressure lower than ≥-2290Pa, and FSSS issues trip signal. 2.2.2.9 Press site trip button. 2.2.2.10 IDF surges and trips later 15s. 2.2.3 Interlock conditions of starting cooling fan: 2.2.3.1 Put interlock switch into running 2.2.3.2 The other cooling fan trips. 2.2.3.3 Bearing temperature higher than 85℃ 2.2.4 Start IDF Start IDF automatically by sequence control. or start it solely, 2.2.4.1 Start first IDF. 2.2.4.1.1 Insure electric protection, thermal protection put into running. 2.2.4.1.2 Start condition reached. 2.2.4.1.3 Turn on power, check inlet damper closed, inlet stationary blade closed, and outlet damper opened. 2.2.4.1.4 Start one bearing cooling fan. 2.2.4.1.5 Start fan, and monitor current and voltage of 11kV bus bar, and monitor starting current and returning time. 2.2.4.1.6 Check inlet damper opened in 60s after starting fan, if it could not open fully, stop fan. 2.2.4.1.7 If the opposite preheater running, check inlet damper auto-start. 2.2.4.1.8 open outlet rotary blade slowly, monitor and adjust furnace suction pressure in scope of -50～-100Pa, switch the inlet stationary blade to auto. 2.2.4.1.9 Check IDF running normally. 2.2.4.2 Start the other one. 2.2.4.2.1 When start the second fan, the other one should be running. 2.2.4.2.2 Open outlet damper, close inlet damper and outlet rotary blade before start the second fan. 2.2.4.2.3 Start first bearing cooling fan. DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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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 DOCUMENT NO. : HISAR-ZT-07

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manually, and monitor boiler negative pressure. c) Open and close in correct direction d) Operate slowly. e) When abnormal sound is heard or machine is blocked, stop operation. 2.3 FDF 2.3.1 Admitting start conditions 2.3.1.1 Thrust bearing temperature ＜85℃. 2.3.1.2 Support bearing temperature ＜85℃ 2.3.1.3 Motor bearing temperature ＜85℃ 2.3.1.4 Winding temperature of motor ＜110℃ 2.3.1.5 Rotary blade closed 2.3.1.6 Motor outlet damper closed 2.3.1.7 Hydraulic liquid pressure >2.5Mpa. 2.3.1.8 One IDF running at least. 2.3.1.9 Lubricate liquid flow of bearing ≥3L/min 2.3.2 Trip conditions 2.3.2.1 Respective side IDF trip. 2.3.2.2 FSSS order. 2.3.2.3 FDF bearing temperature is higher than 100℃. 2.3.2.4 Motor bearing of FDF temperature is higher than 100℃. 2.3.2.5 Motor winding temperature of FDF is higher than 120℃. 2.3.2.6 Bearing vibration(X or Y) of FDF is larger than 11mm/s. 2.3.2.7 Field trip button. 2.3.2.8 Failure trip of FDF 2.3.2.9 Surging in FDF, 15s delayed. 2.3.3 Interlock of lubricate oil pump 2.3.3.1 Start FDF by sequence control, interlock starts the chose lubricated oil pump. 2.3.3.2 If one lubricated oil pump is in operation and oil pressure is low, interlock start the other one. 2.3.3.3 Lubricate oil pump trip, interlock start the standby oil pump. 2.3.4 Interlock of electric heater of lubricate oil tank 2.3.4.1 Temperature on oil tank is lower than 25℃, interlock to start another one; while temperature is higher than 35℃, interlock to stop. 2.3.5 Start FDF 2.3.5.1 Close outlet damper of FDF, as well as moving blade totally. 2.3.5.2 Press FDF “start” button, and outlet damper is open automatically.

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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. DOCUMENT NO. : HISAR-ZT-07

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3) Load drop intensively. B operation 1) Ensure unit is in coordination mode. 2) Ensure boiler load decrease to 50% automatically, in case auto control is out of control or speed is too slow, decrease it to 50% manually. 3) Ensure boiler negative pressure is in auto control mode; otherwise switch it to auto after adjustment. 4) Ensure output of running side fan increase automatically, air and oxygen is in normal quantity so as to avoid overload of running side air fan. 5) Notice changing of steam temperature and steam pressure during load decreasing, adjust quantity of desuperheated water and maintain steam temperature stable. 2.4 PAF 2.4.1 Admitting start condition 2.4.1.1 Temperature of PAF bearing is＜85℃ 2.4.1.2 Temperature of PAF motor bearing is＜85℃ 2.4.1.3 Lubricate oil flow of PAF bearing is larger than 3L/min. 2.4.1.4 Close moving blade of PAF. 2.4.1.5 Motor blade of motor driven damper of PAF outlet is closed. 2.4.1.6 Hydraulic oil pressure of PAF is normal and＞2.5MPa. 2.4.1.7 The corresponding side IDF is running. 2.4.1.8 Boiler MFT resumes. 2.4.2 Trip conditions 2.4.2.1 MFT. 2.4.2.2 The corresponding side FDF is tripped. 2.4.2.3 Temperature of PAF bearing is≥100℃. 2.4.2.4 Temperature of motor driven bearing of PAF is≥100℃. 2.4.2.5 Temperature of motor driven winding of PAF is≥120℃. 2.4.2.6 PAF is failure tripped. 2.4.2.7 Bearing vibration (X/Y) of PAF is larger than 11mm/s. 2.4.2.8 Surge of PAF is larger than +2000Pa, 15s delayed. 2.4.2.9 Press field trip button. 2.4.3 Interlock of lubricate oil pump and hydraulic oil pump 2.4.3.1 Oil level of tank is normal and the pump is allowed to start. 2.4.3.2 Hydraulic oil pressure under normal condition is ≤0.8Mpa and start spare oil pumps interlock. 2.4.3.3 Lubricate oil pressure under normal condition is ≤0.2Mpa and spare oil pumps interlock. 2.4.3.4 The spare oil pumps interlock while the operated oil pump is tripped. DOCUMENT NO. : HISAR-ZT-07

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2.4.4 Interlock of motor driven lubricate oil pump of PAF. 2.4.4.1 Oil level in tank is normal and oil pump is allowed to start. 2.4.4.2 Lubricate oil pressure under normal operation is ≤0.075pa and spare oil pumps will interlock. 2.4.4.3 Operated oil pump is tripped while spare oil pumps interlock. 2.4.5 Interlock of electric heater of lubricate oil tank of PAF. 2.4.5.1 Temperature on oil tank is lower than 25℃, put it into operation, while temperature is higher than 35℃, and stop automatically. 2.4.6 Start PAF 2.4.6.1 Start the first PAF. 2.4.6.1.1 Put hydraulic lube oil station and motor lube oil station into operation. 2.4.6.1.2 Ensure permissive conditions for starting PAF is achieved. 2.4.6.1.3 Stop moving blade and outlet damper of PAF. 2.4.6.1.4 Start PAF, check outlet damper can be opened automatically, and otherwise open it by hand. 2.4.6.1.5 Open moving blade of PAF slowly, adjust primary air pressure to be normal, and put moving blade control of this PAF into auto. 2.4.6.2 Start the second PAF. 2.4.6.2.1 Check outlet damper and moving blade of PAF are closed. 2.4.6.2.2 Put hydraulic lube oil station and motor lube oil station into operation. 2.4.6.2.3start the second PAF, check its outlet damper can be opened automatically, otherwise open it by hand. 2.4.6.2.4 Start moving blade adjusting damper of the second PAF and adjust moving blade of the first FDF, make the moving blade opening of the two PAF be the same, switch moving blade of the second air fan into auto, pay attention that output of the two PAF should probably be the same. 2.4.7 Stop of PAF 2.4.7.1 Two PAF are running on parallel, stop one of them. 2.4.7.1.1 Switch moving blade of PAF be auto which is going to stop. 2.4.7.1.2 Gradually shut down the moving blade of the hauled PAF; check opening other the one is increasing more automatically. 2.4.7.1.3 Close its moving blade fully and outlet damper. 2.4.7.1.4 Stop this PAF, check running side air fan running normally. 2.4.7.1.5 10 minutes after PAF stopped, stop hydraulic lubricate oil pump as per requirement. 2.4.7.2 Stop one of the PAF. 2.4.7.2.1 The last PAF can only be stopped after all mills are stopped. 2.4.7.2.2 Switch the moving blade of PAF to be manual, and shut down its moving blade DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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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 DOCUMENT NO. : HISAR-ZT-07

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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 2kPa, start sealing air auto. 2.5.3.7 Interlock another sealing air fan. 2.5.4 Start pulverized coal system 2.5.4.1start by hand 1) Start mill, check the current is normal. 2) Check sealing air damper is interlocked. 3)Open hot and cool primary air isolating valve, adjust their regulating valve of mill cool and hot primary air, and warm coal in the speed of 3℃ / min for about 15m, control outlet temperature of mill in scope of 65～93℃ . 4) Set rotation speed of coal feeder at lowest output condition, start coal feeder, inspect it running normally. 5) Notice rotation speed of other feeder. (Switch operated coal feeder to auto) 6) Ensure belt of coal feeder of mill is put into normal operation automatically. 7) Fuel quantity can be increased after outlet temperature of mill reaches set value. 8) After coal feeder and mill are running normally, switch cool and hot air regulating valve of mill into auto. 2.5.4.2 Start coal system by sequence control A Conditions for sequence control 1) Admit ignited by coal. 2) Any of sealing air fan is operating. 3) No trip order of the mill. 4) No sequence control is executed. 5) Put sequence control into operation by hand or by auto. B Procedures of sequence control 1) Start mill lubricate oil pump by sequence control. 2) Start mill’s sealing air damper and outlet closing valve by sequence control. DOCUMENT NO. : HISAR-ZT-07

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3) Start mill’s cool primary air closing valve by sequence control. 4) Put mill’s damper to start position by sequence control. 5) Start mill by sequence control. 6) Start mill’s hot primary air closing valve sequence control. 7) Put mill’s air flow, temperature control to auto. 8) Open outlet coal valve of coal feeder by sequence control. 9) Open outlet coal valve of coal hoper by sequence control. 10) Set rotation speed of coal feeder to lowest by sequence control. 11) Start coal feeder by sequence control. 12) Put coal feeder control to auto by sequence control. (two mill running at least). 13) Resume sequence control. 14) Finish sequence control. 2.5.5 Stop coal system 2.5.5.1 Stop by hand 1) Switch coal feeder control to manual, decrease coal quantity gradually. 2) Maintain normal temperature of mill outlet when decrease coal quantity. 3) Stop coal feeder after coal feeding ratio drop to 0. 4) Maintain mill running for 10min at least under rated air flow after coal feeder is stopped. 5) When mill outlet temperature is lower than 50℃ and no coal in mill, stop mill. 2.5.5.2 Stop coal feeding by sequence control. 1) Start sequence control of stopping coal feeding. 2) Set coal feeder rotation speed to lowest by sequence control. 3) Stop hot primary air closing valve by sequence control. 4) Stop outlet valve of coal hoper by sequence control. (when outlet temperature of mill is≤70℃). 5) Stop coal feeder by sequence control. 6) Stop outlet valve of coal feeder by sequence control. 7) Stop mill by sequence control. 8) Stop mill outlet closing valve and cool primary air closing valve by sequence control. (Stop mill for 5min, outlet temperature of mill is lower than 65℃ ). 9) Stop mill sealing air valve by sequence control. 10) Resume sequence control. 11) Finish sequence control. 2.5.6 Parameter of coal system 2.5.6.1 Parameter

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2

Description Pressure difference of mill grinding bowl is high Pressure difference of seal air and primary air is low

unit

alarm

trip

KPa 1.25

remarks Adjust coal feeder’s

KPa 3.25

output to 25% 1.0

＜1.25 alarm and lock to start spare fan

3 Mill output temperature is high

℃

4 Mill lubricate oil flow is low

L/min 121

Mill lubricate oil pressure is low

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

93

100

MPa

>0.15

5 Pressure difference of lubricate oil filter is high MPa 0.2 6 Lube oil pressure in mill gear box is low

MPa 0.09

7 Oil level in lubricate oil tank of mill is low

mm

200

8 temperature of mill lubricate oil is high

℃

60

65

75

80

85

95

9 temperature of thrust pad of gear box is high 10 temperature of motor bearing of mill is high

℃

0.07

Trip mill 2s delayed

2.5.6.2 Maintain fineness of coal power when coal system is running. 2.5.6.3 Control coal feeder’s rotation speed in scope of 40%~80%. Put another mill into running when average output excess 80%; stop one mill when average output is lower than 40%. 2.5.6.4 Maintenance of lubricate oil station a) When oil temperature of lube oil tank is higher than 15℃, start lubricate oil pump. b) Oil temperature of tank is lower than 35℃, put electric heater of tank into running. Stop electric heating when temperature on oil tank is higher than 40℃. c) Put heating belt of oil return pipe into operation when temperature of oil return is lower than 45℃; stop it while it is higher than 49℃. d) Maintain oil temperature behind cooler in scope of 30~40℃, alarm when higher than 60℃. e) Lube oil supplied pressure should be in set valve of 0.15MPa, and alarm when it is lower than 0.09MPa, trip mill when it is ≤ 0.07MPa 2s delayed. f)

Alarm and change lubricate oil filter when its pressure difference is higher than 2.0MPa.

2.5.7 Handling accident of pulverized coal system 2.5.7.1 Stop coal pulverized system when any of following condition occurred. a) Boiler MFT, and trip protection doesn’t work. b) Coal system explodes, and it is dangerous to human. c) Mill is on fire and dangerous to equipment. d) Mill vibrates intensively. e) When there are defects on electric equipment, it is required to stop pulverized coal system. f) Load is dropped abruptly because of grid or electric failure. G) RB trip but load doesn’t drop down automatically. DOCUMENT NO. : HISAR-ZT-07

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h) Trip condition reached but protection refuses to trip. 2.5.7.2 Lubricate oil pressure is low A reason 1) Lubricate oil system leak. 2) Defects are on oil pump or coupling is disengaged. 3) Lubricate oil filter is blocked. 4) Viscosity of lubricate oil is too high. (Has high viscosity) 5) Lubricate oil temperature is high. B operation 1) If oil system leak and could not be isolated, or defects are on oil p ump, stop oil pump and report to foreman to repair. 2) If pressure difference of oil filter is high, change filters and contacts to repair and clean it. 3) If viscosity of lubricate oil is too high, check all oil brands. 4) If lube oil temperature is high, check whether cooling water and auto stopping of electric heater of tank starting is normal. 2.5.7.3 Outlet temperature of mill is too high or low A reason 1) Spontaneous combustion occurred in mill. 2) There are defects in regulator of hot or cold air 3) There are defects of temperature controller on mill outlet. 4) Coal is too humid. B operation 1) If outlet temperature of mill increases abnormally because of firing, stop this mill immediately, and put out fire by steam or water. 2) If outlet temperature of mill decrease too much because of humid coal, decrease coal quantity and open up hot air adjusting damper, shut down cold air regulating damper or adjust setting valve of outlet temperature. 3) If abnormal temperature on mill outlet is caused by defects of regulator or controller, repair them. 2.5.7.4 Coal is blocked in mill A reason 1) Control air quantity of mill incorrectly, air quantity is too low and coal quantity is too much. 2) Mill outlet damper is not open widely or closed by mistake. 3) Coal barrel or ball is worn heavily or force regulated unreasonably. 4) Coal hoper hasn’t cleaned for a long time and makes air room collect ashy heavily. B operation 1) Clean coal. DOCUMENT NO. : HISAR-ZT-07

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2) Decrease coal feed and increase air flow. 3) Open outlet damper fully or open the dampers which are closed by mistake. 4) After taking above measures, defects still exist, stop coal feeder and mill. 2.5.7.5 Handling of mill trip 1) Check mill hot air isolating damper and regulating damper are closed. 2) Check mill cold air isolating damper and regulating damper are closed. 3) Check mill sealing air damper is closed. 4) Check mill outlet damper is closed. 5) Find out reasons for trip, and restart mill after resolve problems. 6) In 30minutes after mill stopping, if it is ready for start, open cold air isolating damper, open cold air regulating damper a little, open outlet damper, blow mill. And monitor rotation speed of other coal feeders, main steam temperature and pressure changing. After blowing for some time, start mill, 10minutes later, restart coal feeder. 7)30minutes after stopping mill, it is still not ready for starting mill, repair mill and clear away the left coal. 2.5.7.6 Trip of coal feeder A Phenomenon 1) Alarm and trip of coal feeder. 2) Total coal feed decrease. 3) Steam temperature and pressure decrease. 4) Coal feeder rotation speed decrease to min. and coal feed decrease to 0. B reason 1) Mill trip or stop emergently. 2) MFT. 3) Electric is failure. 4) Coal chute on mill outlet is blocked. C Handle 1)Shift air flow and outlet air temperature regulating device to be manual, check hot air regulating damper is closed, open up cold primary air regulating damper, and maintain stable temperature on mill outlet. 2) Increase other coal feeders’ rotation speed, try the best to maintain total coal quantity and unit load be stable. 3) Find out reasons for trip, and repair it. 4) After coal feeder is repaired, open hot air isolating damper and regulating damper to warm coal, prepare to restart coal feeder. 5) If coal feeder could not resume in short time, stop respective mill. 2.5.13.7 Firing in mill DOCUMENT NO. : HISAR-ZT-07

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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. 1 2 3 4 5 6 7 8 9

Item model design pressure design temperature suction pressure Suction temperature flow difference of head pressure hydraulic test pressure pump efficiency

Unit

10

absorbing power

KW

11

manufactory

DOCUMENT NO. : HISAR-ZT-07

MPa ℃ MPa ℃ m3/h M MPa %

Data single suck—double discharge 21 359.1 18.9 359 2180 31.1 31.5 82.5 cold conditions 223.5 ， hot condition 122.7 British Haywood·Taylor Company Page

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motor parameters wet stator - rat's cage - induction kW 210 r / min 1450 0.70 heat load 0.86，clod load 0.885 heat load 0.71，cold load 0.73

model output power rotate speed power factor efficiency overall efficiency winding insulators

XLP

8 manufactory British Haywood·Taylor Company 2.6.1.2 Feedwater cooler parameters are shown in the following form. No 1 2 3

Item design pressure design temperature test pressure

Unit Mpa ℃ Mpa

4 running pressure Mpa 5 running flow L / min ℃ 6 inlet temperature ℃ 7 outlet temperature 8 feedwater flow L / min ℃ 9 temperature Remarks: The feeding water must be desalt

High-pressure side 21.0 359.1 31.5

Low-pressure side 1.0 175 1.5

20.96 1.0 12 410 175 40 54 43.6 2.0 ) ≯2.27 ≯40 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 Item

Number 1

motor chamber temperature

2

cooler outlet water temperature pressure difference 1/2 between inlet and outlet cooler outlet water temp

3 4

HH 60℃

H

L

55 ℃

9℃

57 ℃

9℃ 151kPa

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. DOCUMENT NO. : HISAR-ZT-07

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b) Motor inner temperature is＞65 ℃. c) Pressure difference between inlet and outlet is ≤60KPa. d) Steam drum water level is＜－390mm. 2.6.4 Prepare for operation of CCP 2.6.4.1Finish overhauling, finish work ticket procedures or have preliminary operation ticket. 2.6.4.2 Boiler steam and water system work is over. 2.6.4.3 Turn off the cold water, finish maintenance work of water-filled system and water drain system. 2.6.4.4 Closed cold water pipeline of the cooler has finished watering and washing and prepared to use. 2.6.4.5 Motor cooler of the pump has closed cold water. 2.6.4.6 Prepare water-filled water, HP water filling (flow to the main water supply pipeline before HP superheater), and LP water filling (flow to condensate water pipe). 2.6.5 CCP water filling and air exhaust 2.6.5.1 The internal oxide and welding slag and other impurities of all the cooling, filling and cleaning water pipes and pump cooler at HP side must be cleaned before connected with CCP. Rubbish and impurities are strictly prevented entering the pump motor. In order to eliminate any possible pores, operate carefully for filling water into pump so as to exclude the air into the pump. When water filling upward from the bottom of the motor, operate slowly at the speed about 2 liters per minute, and conform to the following steps: a) Check and adjust the correct position of valves by check card. b) Open the inlet and outlet bypass valve and water-discharging bypass valve of CCP. c) Turn off the duplex isolating valve and open the connecting water pipe of condensate water to LP filling valve and LP 1,2 water valve, discharge impurities of the water pipe through the water pipe valve (if necessary firstly clean and discharge impurities of the filters through the filter blow down valves), fill water and exhaust steam after chemical test is checked to be qualified. d) Adjust opening of water regulating valve, measure water flow to make it slightly less than the regulated water flow (2.27 liters per minute), typically 2 liters. e) Open the duplex isolation valve, turn off the sewage valve of water filling pipe. f) Slowly inject condensate water into CCP through the duplex isolation valve. g) The work of water filling for CCP is over when continuous flow of no-air water exhausts from the inlet and outlet bypass trap of boiler water pump. h) Inject water into the boiler only when CCP is filled with water. 2.6.5.2 Precautions of water filling. a) Water temperature is no more than 54 ℃, no less than 4 ℃. b) Changes of filling water pressure. DOCUMENT NO. : HISAR-ZT-07

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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. DOCUMENT NO. : HISAR-ZT-07

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c) Check the current is normal. d) Keep record of the temperature rising of the motor until it is stable. e) No leaks of the electric coolers, filters, pump body, valves, gland bush, flange, and etc. f) Check the closed cold water flow is not low, the water flow indicator is normal, and the cold water temperature in electric cooler are normal. g) Check the motor in field temperature, pump shell temperature, and the inlet temperature difference and the outlet pressure difference between the pump and the pump shell are normal. h) Treat the unusual circumstances in pre-operation timely. 2.6.8 The running of CCP 2.6.8.1 In normal circumstances, CCP should keep three pumps running. 2.6.8.2 When CCP is running, the pump’s vibration, current, motor temperature, pump shell / import temperature, pump shell temperature, import / export pressure differential and closed chilled water system’s water pressure, water temperature normal regularly should be checked. 2.6.9 Stop of CCP 2.6.9.1 Meet stopping pump requirements of disable load, and one CCP run-time load must be less than 60% MCR. 2.6.9.2 The pump’s inlet temperature must be less than 150 ℃ to stop the final CCP. 2.6.9.3 After boiler water is stopped, maintain the closed cold water system in operation, and monitor the various parameters proper, temperature decreasing speed of pump shell more than 1 ℃ / min c. 2.6.9.4 After the pump stopped, maintain opening of outlet valve, import bypass valve, heat balance door at the open position, and outlet micro bypass valve of pump for preparation. 2.6.10 Releasing water of CCP 2.6.10.1 Eject water of CCP after the water wall is ejected water in the order of the inlet pipe. Eject water in the order of CCP inlet pipe, pump body, and finally the motor. 2.6.10.2 It is not allowed to release water of pumps and inlet and outlet pipes through the motor body, neither to release water of the boiler through the pumps. 2.6.10.3 Keep running of the closed cold water system and monitoring motor chamber temperature during water releasing. 2.6.10.4 Releasing water operations of the CCP. a) The boiler has been cooled, the water in boiler body has been released, the temperature of motor and pump shell is lower than 65 ℃. b) Check and open the total water-releasing valve. c) Open the water valve, inlet and outlet bypass valve and inlet and outlet bypass water-releasing valve, and water-release the inlet and outlet pipes and pump body. d) Open the double-septum cut-off valve and release the water to motor after the water in pump body is released over. DOCUMENT NO. : HISAR-ZT-07

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e) Turn off the water valve after water is released. 2.6.11 Isolation, maintenance and repair of CCP 2.6.11.1 Isolation, maintenance and repair of boiler water circulating pump must be carried after ejecting boiler water. 2.6.11.2 Water pumps have been ejected water. 2.6.11.3 Isolate the water-discharging system; turn off the duplex isolation valve, outlet bypass valve and the total water valve. 2.6.11.4 Isolate the water-filled cooler of the pumps; turn off the closed cold water inlet valve. 2.6.11.5 Turn off the closed cold water inlet and outlet valves of the motor cooler of the pumps. 2.6.11.6 Turn off the outlet valves of the CCP. 2.7 Flame inspection of cooling air fan system 2.7.1Interlock protection of flame inspection 2.7.1.1 Main pipe pressure of cooling air is ≥7.25KPa. 2.7.1.2 Pressure difference of cooling air and furnace is ≤1.8KPa, alarm and interlock to start spare cooling air fan. 2.7.1.3 Pressure difference of flame inspection cooling air and furnace≤1.0KPa, boiler MFT 1800s delayed. 2.7.1.4 Alarm when pressure difference of front and rear of flame inspection cooling air fan filter is ≥0.15KPa. 2.7.2 Start flame inspection 2.7.2.2 Start flame inspection a) Check fire inspection system normal, power is on. b) Start cooling air fans remotely, 1A/1B. c) Main pipe pressure of flame inspection cooling air is normal ≥7.25KPa d) Put lock switch of spare cooling fan into running e) Put flame inspecting probe into running. 2.7.3 Stop flame inspection system 2.7.3.1 Check furnace wall temperature lower than 90℃, or fume temperature lower than 70℃ 2.7.3.2 Flame inspecting probe exit. 2.7.3.3 Interlock of cooling air fan exit. 2.7.3.4 Stop cooling fan remotely 2.8 Operation of ESP 2.8.1Test and inspection before commissioning Before ESP is put into use, for the newly-installed or overhauled ESP, test and inspection should be conducted according to related standards and regulations. The inspection mainly includes: (1) Go through all the procedures of the work notice and remove the safety facilities DOCUMENT NO. : HISAR-ZT-07

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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 DOCUMENT NO. : HISAR-ZT-07

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high-voltage power in. Operation procedure of ESP:

Operation starts Switch on the power supply distributed panel Switch on the heating power of the insulator

Close the door of the inlet and maintenance hole

Switch on the dust particle discharging and handling device Switch on the rapping device of the discharging electrode

Switch on the dust collecting electrode rapping device

Switch off the earthing device

Actuate the air blower

Judge whether the treatment of flue gas is normal Switch on ESP Automatic

manual( commission) Automatic or manual

Transmit DC HV to ESP. And then it can work automatically.

Transmit DC voltage to ESP set voltage 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 DOCUMENT NO. : HISAR-ZT-07

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to work until the dust in the field is cleaned. The dust in the hopper should be cleared instead of being emptied completely. When ESP is stopped working because of long-term or middle-term overhaul, treat it as temporary machine halting. The rapping device works at least for 4 hours and then the heating system stops working. Empty the dust in the hopper. In the field, the earth rod is added and the site is kept clean. Make records of the machine halting. Refer to drawing 2 for the machine halting procedure Stop operation

The air blower stops working Close the flue damper The rectifier stops working The earthing device is earthed Stop the discharging electrode rapping Halt the collecting electrode rapping Dust discharging device stops Switch off the insulator heating power (After the machine halting is over 24 hours) Close the hopper heating equipment End 2.8.4 Typical failure and its analysis The life of ESP relates to its design and work conditions, the depreciation period generally is over 20 years. The failure type and failure frequency vary because of different work conditions, but the main component failure and its cause are as follows： 2.8.4.1 Failure of the discharging electrode (1) Broken discharging wire. Broken discharging wires have multiple causes. For instance, aging causes discharging electrode to have no enough strength, electric corrosion, deficiency in the erection and construction work and too much rapping force are also the culprit. Because there are wrong with the flue gas and dust, the supporting component of the discharging electrode is corroded and then its usage life is shortened. High specific resistance leads to inverse corona. When the rapping is conducted repeatedly and the discharging electrode DOCUMENT NO. : HISAR-ZT-07

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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 DOCUMENT NO. : HISAR-ZT-07

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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 DOCUMENT NO. : HISAR-ZT-07

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Item

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Unit

Data IR－3D

1

Model

2

Distance

mm

267

3

Running speed

m/min

0.31

4

Unit set working time

min

～3

5

Unit set soot –blowing time

min

0.43

6

Nozzles diameter

mm

Φ25.4

7

Effective soot –blowing radius

m

～2

8

Soot –blowing medium pressure

MPa

1.5

9

Soot –blowing medium temperature

℃

350

Kg/min

~60

10 Steam consumption 2.9.1.2 Flue duct soot blower parameters NO

Item

1

Type

2

Distance

mm

7160

3

Running speed

M/min

2.5～3.5

4

Unit set working time

min

4.1～5.7

5

Unit set soot –blowing time

min

4.1～5.7

6

Nozzles’ diameter

mm

Φ28.6

7

Effective soot –blowing radius

m

～2

8

Soot –blowing medium pressure

MPa

1.5

9

Soot –blowing medium temperature

℃

350

10

Steam consumption

Kg/min

36~95

Unit

Data IK－525

Φ25.4

Φ22.22

2.9.1.3 PH soot blower parameters(TYPE:IK-AH500) NO

Item

Unit

Data

1

Distance

mm

970

2

Running speed

m/min

0.08

3

Unit set working time

min

23

4

Unit set soot –blowing time

min

23

5

Nozzles’ diameter

mm

Φ12.0)Φ16.0

6

Effective soot –blowing radius

m

2.0

7

Soot –blowing medium pressure

MPa

1.5

8

Soot –blowing medium temperature

℃

degree of superheat≮150

9

Steam consumption

Kg/min

~70

DOCUMENT NO. : HISAR-ZT-07

Page

79 of

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Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.9.2 Conditions and inspection of soot blowing 2.9.2.1 Conditions of soot blowing. a) The boiler works normally，burning condition is stable. b) The furnace soot blowers and the flue soot blowers are working, boiler load should be ≥ 60% MCR, and the first, the secondary steam temperature is stable. The furnace pressure is normal, the operation condition of IDF and FDF is stable, and IDF can still be adjusted. c) Proper sootblower decompression stations and air preheater sootblower decompression stop operate well. 2.9.2.2 Inspect soot blowers before operation a) Inspect that the system meets with the operation conditions, the valves are in their position, and sootblower are complete and available. b) Check that the reducing gear, supporting bearings, gear lubrication are normal. c) Check the body, valves and start-close structure and distance structure of the blowers is complete and well, the driven machine transmission gear and the rack engages normally. d) Check the stem and inner tube filler of sootblower is normal. e) Inspect sootblower are in the position of not operating, the situ control switch is in "ON" position. f) Check the integrity of the electrical wiring and in-situ control box of sootblower. 2.9.3 Operation of sootblower 2.9.3.1 When put into operation, select short blowing and long blowing together, in accordance with the situation of steam temperature. 2.9.3.2 Attention put into sootblower operation a) When sootblower put into operation, special attention should be put into the pressure and steam temperature changes of the furnace. b) When there is a failure in the operation of sootblower, immediately check the sootblower to stop to prevent damage of heating surface. Before sootblower quitting, ensure that there is steam flow, in order to prevent damage to sootblower. c) Soot blowing order: no matter in what manner to soot blowing, first should soot blowing air preheater, and then furnace and flue heating surface, finally soot blowing the air preheater again. d) Furnace sootblowing should be carried out from top to bottom, and firstly blow the front and behind wall on each layer, then blow the wall on both sides. e) Sootblow the flue heating surface according to the flue gas flow. f) Sootblow more in the furnace region easy to fouling of. g) Do not open the inspection hole, people inlet to observe or do manual work in sootblowing process. h) Inspect comprehensively that all sootblower has completely stopped when over. DOCUMENT NO. : HISAR-ZT-07

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80 of

228

Operation Manual for 600MW Unit

2x600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

2.9.4 Sootblower operation period 2.9.4.1When

boiler

operates

normally,

all

heating

surface

should

be

sootblowed

comprehensively every morning, air preheater be sootblowed every working class. 2.9.4.2 Sootblow more when the boiler burns coals with high ash content. 2.9.4.3 The air preheater should be sootblowed continuously when the boiler starts to ignite and shutdown load