Bop Operation Manual Qn1 Sec g 04 Tp 005(195) Dang Doc

QUANG NINH THERMAL POWER JOINT STOCK COMPANY 2×300 MW

BOP OPERATION MANUAL SEC

QUANG NINH THERMAL POWER JOINT STOCK COMPANY

2 × 300 MW – Anthracite Coal Fired Power Station

BOP Operation

Manual

Date 2008-09-16 No. : QN1-SEC-G-04-TP-005 Rev.: A



Index

1 Scope ................................................................................................................................................................... 4

2 Specific quoting documents ............................................................................................................................... 4

3 Fuel Oil Unloading and Storage & Supply System Operation Manual ......................................................... 4

3.1 Equipments and general description of fuel oil system and fire fighting system .......................................... 4

3.2 Basic properties and technical specification of fuel oil system..................................................................... 4

3.3 Interlock and protection of system ................................................................................................................ 6

3.4 Startup and shutdown of system ................................................................................................................... 6

3.5 Inspections and notices before startup of fuel oil system.............................................................................. 9

3.6 Operation regulating of fuel oil system (oil supply and unloading)............................................................ 10

3.7 Operation regulating of effluent oil system..................................................................................................11

3.8 Operation Check and maintenance of fuel oil system ................................................................................. 13

3.9 Safety operation cautions of fuel oil system ............................................................................................... 13

3.10 Common fault, judgment and disposal of fuel oil system and equipments ............................................... 15

4 Water Treatment Plant Operation Manual.................................................................................................... 21

4.1 General Description .................................................................................................................................... 21

4.2 Technical Specification ............................................................................................................................... 21

4.3 Operation .................................................................................................................................................... 22

4.4 Common faults, judgment and treatment at the water purification station ................................................. 27

5 Demineralization system Operation Manual ................................................................................................. 28

5.1 General description ..................................................................................................................................... 28

5.2 Technical specification of equipment.......................................................................................................... 29

5.3 Control standard and period of water quality of feed-water treatment system ........................................... 30

5.4 Operation of demineralized equipments ..................................................................................................... 31

5.5 Common faults, judgment and disposal ...................................................................................................... 43

6 Water Steam Supervision System Operation Manual................................................................................... 46

6.1 Technical specification................................................................................................................................ 46

6.2 Chemical supervision during unit operation ............................................................................................... 51

6.3 Chemical protection of standby unit ........................................................................................................... 55

6.4 Operation of the boiler chemical dosing system of the boiler..................................................................... 57

6.5 Reason and treatment of water steam quality deterioration ........................................................................ 59

7 Waste Water Treatment Plant Operation Manual ........................................................................................ 64

7.1 General description of waste water station and system............................................................................... 64

7.2 Technical specification................................................................................................................................ 64

7.3 Operation of waste water treatment equipments ......................................................................................... 66

7.4 Common faults, judgment and Treatment of wastewater station and wastewater system........................... 69

Date 2008-09-16 No. : QN1-SEC-G-04-TP-005 Page 1

Rev.: A



8 Hydrogen Generation Plant Operation Manual............................................................................................ 70

8.1 General descriptions of hydrogen plant and hydrogen system.................................................................... 70

8.2 Technical norms of equipments .................................................................................................................. 70

8.3 Equipments operation ................................................................................................................................. 72

8.4 Common faults, judgment and Treatment of hydrogen station and hydrogen generation system............... 76

8.5 Special safety cautions of hydrogen generation station and hydrogen generation system .......................... 79

9. Circulating Water System & Auxiary Cooling Water System Operation Manual .................................... 80

9.1 Equipment Technical Specification............................................................................................................. 80

9.2 Circulating Water System ........................................................................................................................... 81

9.3 Auxilary Cooling Water System.................................................................................................................. 87

10 ESP System & Deslagging and Ash Handing System Operation Manual ................................................. 90

10.1 Scope .................................................................................................................................................... 90

10.2 Specific quoting documents ................................................................................................................. 91

10.3 Principal specification of system.......................................................................................................... 91

10.4 Startup, operation and maintenance and stop of ESP system ............................................................... 94

10.5 Startup, operation, maintenance and stop of negative-pressure ash removal system ......................... 100

10.6 Startup, operation, maintenance and stop of the hydraulic deslagging system................................... 105

11 FGD and Limestone Supply System Operation Manual............................................................................110

11.1 SCOPE ................................................................................................................................................110

11.2 NORMALIZED DOCUMENT QUOTATION ...................................................................................111

11.3 FGD SYSTEM QUIPMENT SPECIFICATION .................................................................................111

11.4 START-UP OF DESULFURIZATION SYSTEM .............................................................................. 129

11.5 MONITORING AND REGULATION IN FGD SYSTEM OPERATION ......................................... 145

11.6 SHUT DOWN OF THE FGD SYSTEM ............................................................................................ 160

11.7 FGD SYSTEM FAULT AND ACCIDENT HANDLING .................................................................. 164

11.8 OPERATION OF LIMESTONE SUPPLY SYSTEM ........................................................................ 171

11.9 11.9 LIMESTONE HANDLING SYSTEM DESCRIPTION ............................................................ 174

12 Air Compressor System Operation Manual............................................................................................... 176

12.1 Direction for use of control panel....................................................................................................... 176

12.2 Instrument-use air compressor operation ........................................................................................... 176

12.3 Air compressor operation maintain .................................................................................................... 176

12.4 Air compressor shutdown protection.................................................................................................. 177

12.5 Air compressor dryer operation maintain ........................................................................................... 177

13 Fire-fighting System Operation Manual .................................................................................................... 177

13.1 Overview................................................................................................................................................. 177

13.2 Startup mode of fire-fighting pump ........................................................................................................ 177

13.3 Operation mode of fire-fighting pump .................................................................................................... 178

13.4 Chain conditions of fire-fighting pump................................................................................................... 178


Rev.: A



13.5 Diesel fire-fighting pump system............................................................................................................ 178

13.6 Descriptions of fault and alarm of diesel engine fire-fighting pump ...................................................... 180

13.7 Descriptions of function buttons ............................................................................................................. 180

13.8 Inspection items in the operation of diesel pump group ......................................................................... 181

13.9 Regular maintenance of diesel pump group ............................................................................................ 181

14 Appendix ....................................................................................................................................................... 182

14.1 Twenty-five Key Requirements to Prevent Serious Accident and Failure in Electric Power Operation

(Chemical Part) Issued by China Grid ............................................................................................................ 182

14.1.1 Prevention from large area corrosion............................................................................................ 182

14.1.2 Prevention from tube explosion of pressure vessel .................................................................... 182

13.1.3 Prevention from motor damage ..................................................................................................... 182

14.2 General Principle of Electrical Part and Pump........................................................................................ 182

14.2.1 Inspection items before power on the motor are as follows: ..................................................... 182

14.2.2 Inspection items during operation of the motor are as follows: ................................................. 182

14.2.3 Inspection items during operation of cables are as follows: ...................................................... 183

13.2.4 General operation requirements of the motor.............................................................................. 184

14.2.5 Measurement Manual of insulation resistance of the motor are as follows: ........................... 184

13.2.6 Operation principle of power failure and supply of the motor: ................................................... 184

14.2.7 Permissible startup times of the motor with squirrel cage type rotor shall be in accordance with

following Manual strictly. ............................................................................................................................. 185

13.2.8 Definition of the motor status: ........................................................................................................ 185

14.2.9 Common faults, judgment and treatment of electrical equipments .......................................... 185

14.2.10 Operation of the water pump........................................................................................................ 187

14.3 General Principle of Chemical Technology Supervision ........................................................................ 189

14.3.1 Guidelines of chemical technology supervision........................................................................... 189

14.3.2 Chemical supervision during startup phase of unit ..................................................................... 190

14.3.3 Normal operation management of the unit ................................................................................... 190

14.3.4 Abnormal quality management of water vapor ............................................................................ 192

14.3.5 Supervision during repair phase of the unit.................................................................................. 193


Rev.: A



1 Scope

This teaching material is applicable for technical education of staff engaging in chemical

operation of Quang Ninh 2X300MW Thermal Power Plant in Vietnam, including the operation

principle, start-up, shut-down, operation and maintenance, control and adjustment, accident

disposal of dematerialized water system, water-stem sampling and dosing system, hydrogen

generation system, FGD System and waste water treatment system, as well as the principle,

method and procedures for chemical supervision of water-steam-hydrogen of this thermal power

plant. Staff of Quang Ninh Thermoelectric Co., Ltd. at all levels engaging in chemical operation,

power generation operation, equipment maintenance and production technology management

must be familiar with all the standard and the relevant parts and strictly implement them.

2 Specific quoting documents

DL/T 543-1994 Quality Inspection Standard for Water Treatment Equipment Used in

Power Plant DL/T 561-1995 Guide for Chemical Supervision of Water and Steam in Thermal Power

Plant DL/T 794-2001 Guide for Chemical Cleaning of the boiler in Thermal Power Plant DL/T 5068-1996 Technical Code for Chemical Design of Thermal Power Plant SD 223-1987 Guideline for Lay-up of Thermal Power Equipment in Fossil Fuel Plant DL434-1991 Manual for Implementation of Legal Metering Unit in Chemical Water

Discipline of Power Plant GB12145-1989 Quality Criterion for Water and Steam of Steam Power Equipment and

Thermal Power Unit 3 Fuel Oil Unloading and Storage & Supply System Operation Manual

3.1 Equipments and general description of fuel oil system and fire fighting system

The project is equipped with 2 × 5000 t oil tank, 2 oil unload pumps, 8 oil supply pumps, and 3

scavenge oil pumps, 1 deoiler, 4 fuel oil heaters, 1 drain flash tank, and 1 fuel oil cooler. Fuel oil

system is furnished with oil supply piping and oil return pipe to boiler burner, according to single

header circulating system for oil supply and return to boiler.

The fire fighting systems is equipped with foam tank, various mobile fire fighting apparatuses

and fire water system.

3.2 Basic properties and technical specification of fuel oil system

Model

HSNH1300-54

Quantity

2

Arrange

ment

mode

Indoor,

horizontal

type

Medium Heavy oil, oil

temperature

50

Flow rate

95 m3/h

Lift

80 mH2O

Screw

type oil

unload

pump

Efficienc

y

70%

NPSHr limit value is 6 m,

guaranteed value

is 5.5 m

Speed

1450 r/min


Rev.: A

SEC


2×300 MW BOP OPERATION MANUAL

Model

YB225M-4(防

爆)

Shaft

power

32.2 KW

Rated

power

45 KW

Motor

Speed 1450 r/min Voltage 400 V AC

Model

32QW12-15

Quantity

2

Arrange

ment

mode

Outdoor

submersibl

e pump

Motor

model

YB90S-4(expl

osion-proof

motor )

Flow rate

10m3/h

Lift

10 mH2O

Efficienc

y 40％

NPSHr

5m

Speed

1450 r/min

Submers

ible

pump for

wastewa

ter with

oil

Rated

power

0.9 KW

Shaft

power

1.1 KW

Voltage

400 V AC

Front

screen of

heavy oil

unload

pump

Type

30 mesh

Model

LY-100

Quantity

1LY-100

Heavy oil

Oil

temperature

25~50

Flow rate

95 m3/h (每)

Piping

design

pressure

0.6 MPa

Screen

paramet

ers

Inlet/outl

et pipe

diameter

DN150

Inlet/outlet

operating

pressure

difference

0.1MPa

Inlet/outl

et alarm

pressure

differenc

e

0.5MPa

Type

Horizontal

type U-tube

Model

ZJRQ-28

Arrange

ment

mode

Horizontal

type

Quantity

1 Inlet oil

temperatur

e

25 Outlet oil

temperat

ure

50

Fuel oil

heater

Fuel oil

flow

95 m3/h(each) Operating

oil

pressure

0.8 MPa Design

oil

pressure

1.5 MPa


Rev.: A

SEC



Heated

steam

operatin

g

temperat

ure

250

Heated

steam

design

temperatur

e

300

Heated

steam

Operatin

g

pressure

0.6 MPa

Heated

steam

design

pressure

1.5 MPa

Max.

heater

pressure

drop

< 5 MLC (On shell

side)

Heater

area

28 m2

Model SMH660R40E6-7W23 Flow rate 26.5 m³/h Oil

supply

pump

Motor model

YB180M-4

Lift

100m

3.3 Interlock and protection of system

Interlock control is carried out by 8 oil supply pumps for fuel oil system together with boiler

combustion system.

3.4 Startup and shutdown of system

3.4.1 Startup operation sequence of heavy oil system

Oil store system can be started if oil temperature of large oil tanks is heated to 75 .

3.4.1.1 Purging and preheating for equipment, and system

(1) Contact foreman, shift supervisor to cooperate, and the foreman is responsible for total

command and contact work.

(2) Purge and preheat operation for oil return system

a) Open primary, secondary oil return valve on #1(#2) oil, close main oil feed valve before

the boiler.

b) Open main heat supply valve in heavy oil system, and open heated steam valve of boiler.

Connect turbine, and turn on tracing steam supply for boiler heavy oil. Slightly open boiler

drain valve, wait until remaining water has been drained up before closing.

c) Inform oil store to open front steam, oil interconnection valve, and open steam purge

valve on oil return header, so as to carry out purge and preheat for oil return system.

d) If the gas is emitted at the top of #1 (#2) oil tank, report it to the foreman. Except oil return

valve on #1, #2 oil tank is open, close all valves in items a, c.

(3) Purge and preheat operation for oil feed system

a) Open oil return valve of pump for #1 (#2) oil tank. Open interconnection valve form oil

supply mains to oil return mains of the pump. Open inlet and outlet valves for

corresponding heaters. Report this to foreman.

b) Close front oil return valve, and open oil feed valve of boiler, then open steam, oil

interconnection valve of boiler, finally open steam purge valve on oil feed mains. Then

inform oil store to start purging and preheating for oil feed system.

c) If the gas is emitted at the top of #1 (#2) oil tank, report it to the foreman. Close

interconnection valve form oil supply mains to oil return mains of the pump and all valves


Rev.: A



open in item b. Open oil drain valve of heater.

(4) Purge and preheat operation for large oil tank to pump inlet system

a) Open oil drain valve in pump inlet mains, and open purge valve in outlet mains of oil tank,

in order to carry out purging and preheating.

b) Wait until oil drain valve in pump inlet mains is hot, close all valves open in item a.

(5) Purge and preheat operation for all pump body, filter, and pump oil return system

a) Open inlet valve of first, second-stage oil supply pump, and open oil drain valve at

corresponding filter inlet, then open steam purge valve for first, second-stage oil supply

pump, in order to carry out purging and preheating for all pumps and filters.

b) Wait until oil drain valves for all filters is very hot, open partial circulating valves for first,

second-stage oil supply pump, and open oil return valves for first, second-stage oil

supply pump, and close inlet valves for first, second-stage oil supply pump, then close

outlet valves and oil drain valves for corresponding filters, in order to carry out purging

and preheating for oil return system.

c) Wait until oil return valve is very hot, close all opened valves. By now, purge and preheat

operations before startup of all system, equipment are completed, and report it to the

foreman.

3.4.1.2 Startup operation

(1) open the following valves: oil supply valve on #1 (#2) oil tank, inlet valves on first,

second-stage oil supply pump to be started and outlet, inlet valves for corresponding filters; oil

return valve on #1 (#2) oil tank.

(2) Make an overall, carefully pre-startup inspection for first, second-stage oil supply pumps to be

started.

(3) Close start switches for second, first-stage oil supply pumps to be started respectively, and

start second, first-stage oil supply pumps respectively.

(4) When outlet pressure for first, second-stage oil supply pumps reaches 3.5MPA, slowly open

partial circulating valve up to fully open. At this time, ensurethat outlet pressure is stable, and

maintain partial circulation for 30 minutes under normal condition.

(5) If partial circulating operation is normal and stable within 30 minutes, report it to the foreman

and open the following valves: outlet, inlet valves for corresponding heaters, steam valves and

drain valves for corresponding heaters, and main oil feed valve of boiler. Close oil drain valve

of #1 (#2) heater.

(6) Slightly open outlet bypass valve for first, second-stage oil supply pumps, and close partial

circulating valve a little bit, to pressurize the oil feed pipeline.

(7) When front heavy oil pressure reaches 3.0-3.3 MPA, contact attendant in the oil store to

observe the current change, and slightly open front oil return valve successively. At this time,

ensure that pump current does not exceed the specified value by closing partial circulating

valve of the pump, fully opening outlet valve of oil supply pump, and closing outlet bypass

valve, high speed oil return valve of boiler and interconnection valve from oil supply mains to

oil return mains of the pump etc., then maintain stable operation for 30 minutes.

(8) Adjust heated steam valve on #1 (#2) oil tank. Control the oil outlet temperature in the oil store


Rev.: A



between 80 and 90 degree, and control the oil supply temperature between 100 and 120

degree.

(9) According to the current of oil supply pump, open inlet valves of all standby pumps, and

slightly open outlet bypass valves of all standby pumps successively, in order to prepare for

warm-up of cylinder.

(10) Adjust positions of interlock switches for all pumps. Two primary, secondary pumps operate,

and two primary, secondary pumps serve as standby. Report it to foreman.

By now, startup operations for oil store are completed.

3.4.2 Operation sequence for full shutdown of heavy oil system

3.4.2.1 After boiler shutdown, immediately start to operate as soon as receiving a stop command

form the foreman.

3.4.2.2 Parallel off interlocking of standby pump, and stop operation of oil supply pump, and then

report it to foreman.

3.4.2.3 Purge operation for oil return system

a) Stop oil supply pump and start to operate as soon as receiving a notice form the oil store.

b) Close main oil feed valve before the boiler, and open front steam, oil interconnection valve

and oil return valve, then open purge valve in oil return header. Inform the oil store.

c) If the gas is emitted at the top of #1 (#2) oil tank for 5 minutes, report it to foreman.

d) After receiving a notice form the attendant, the foreman shall close all valves opened in item

b.

3.4.2.4 Purge operation for system & equipment before oil supply pump

a) Shut down oil supply pump and report it to the foreman, then start to operate.

b) Close the following valves: oil supply valve on #1 (#2) oil tank, outlet valves for first,

second-stage oil supply pumps and bypass valve, as well as partial circulating valves for first,

second-stage oil supply pumps.

c) Open the following valves: oil drain valve in inlet mains for first, second-stage oil supply

pumps, inlet valves and oil drain valves for first, second-stage oil supply pumps, oil drain valve

of filter for first, second-stage oil supply pump, and steam purge valve in first, second-stage oil

supply and outlet mains, as well as steam purge valve for first, second-stage oil supply pump.

Start to purge.

d) If oil drain valves is very hot after purging for 10 minutes, close all valves opened in item c.

3.4.2.5 Purge operation for oil feed system, pump outlet and pump’s oil return system & equipment

a) Start to operate as soon as operation of item 3 is finished.

b) Open the following valves: main oil feed valve before the boiler, front steam, oil

interconnection valve, steam purge valve in oil feed mains. Inform the oil store to open the

interconnection valve from oil supply mains to oil return mains of the pump, and then start to

purge.

c) If the gas is emitted at the top of #1 (#2) oil tank, open the following valves

Outlet valves and bypass valves for first, second-stage oil supply pumps, partial circulating

valve for first, second-stage oil supply pump and steam purge valve, and main oil return valve of

the pump, as well as oil drain valve of heater. Start to purge. If main oil return valve of the pump


Rev.: A



and oil drain valve of heater is very hot after 15 minutes, report it to the foreman, and close valves

opened in items b, and c.

3. 4.2.6 Release parallel operation of #1 (#2) oil tank and heated steam valve for corresponding

heater, and fully open drain valve, and close valves of all system, then close main steam feed

valve for oil store steam. Report it to the foreman.

3.4.2.7 Make a detailed record for operation, and timely report equipment defects occurred during

operation to the foreman, and register the defects.

3.4.2.8 Totally check positions of all system, equipment and valves, in order to prevent items

missing.

3.5 Inspections and notices before startup of fuel oil system

3.5.1 Inspection before oil unloading

3.5.1.1 Check oil levels in two oil tanks and remaining oil amount, and make a detailed record.

3.5.1.2 Purging the whole oil unloading system

1) Open oil drain valve in oil unloading mains, and open oil drain valve in the oil unloading pipe

in front of oil unload pump, then open interconnection valve between oil unloading mains and

steam mains, in order to purge for oil unloading mains.

2) Upon completion of purging, close steam, oil interconnection valve, and close two oil drain

valve opened.

3) Open outlet valve of the pump, and close inlet valve of the pump, and open oil valve on #1 (or

#2) oil tank, then open steam purge valve for oil unload pump, so as to purge oil unloading

system.

4) Wait until steam is emitted at the tank top, close steam purge valve.

3.5.1.3 Check valve positions in the system:

1) If the oil is discharged by a steam operated pump, open outlet, inlet valves, and close all

purge valves, and feed oil to all lubrication parts, then drain remaining water in the cylinder.

2) If the oil is discharged by an electrically driven pump, open outlet, inlet valves, and close all

purge valves, and open cooling water and adjust properly, then check that manually-operated

turning is normal.

3.5.1.4 Check oil unloading rubber pipe connection for fastness and oil leakage, and prepare a

small oil bucket for leaked oil.

3.5.2 Prestartup inspection of heavy oil system:

3.5.2.1 Major and minor repairs for all oil store system and equipment are completed, and the work

sheets are handled and finished.

3.5.2.2 Check to see if the gear pump rotates flexibly before operation(gently turn by hand).

3.5.2.3 Check to see if the power pack is normal and rotational direction of the motor is correct.

3.5.2.4 Whether the pipe sizes at oil inlet and outlet meet the requirements, and whether oil

suction height and the lift exceed specified requirements or not.

3.5.2.5 Check to see if all fasteners are secure (including inlet and outlet pipe connections).

3.5.2.6 When inserting the oil tank before startup, the oil inlet pipe cannot be too high, in order to

prevent air from interfusing; the oil pipe cannot be inserted to tank bottom, in order to prevent oil

from being suck up due to closed nozzle.


Rev.: A



3.5.2.7 All valves in the system are complete, and their marks are correct and located in close

positions.

3.5.2.8 All equipments are complete, and entire, and operating power source for oil supply pump is

switched on; all instruments are complete, and entire, and their power source is switched on, and

indicated correctly. All operating handles, and light signals are complete, entire and convenient.

3.5.2.9 Contact the foreman to start the boiler, and slowly open main steam supply valve in oil

store up to fully open.

3.5.2.10 Slightly open steam heating valve and drain valve on oil tank. Wait until remaining water

in the steam system has been drained up, fully open steam heating valve and drain valve, to heat

the large oil tank.

3.5.3 Maintenance and safety of the machine

3.5.3.1 Grounding device shall be provided to prevent getting wound due to creepage.

3.5.3.2 Frequently check fasteners for looseness, and if sound of gear pump is normal.

3.5.3.3 Oil inlet shall be equipped with a strainer, in order to prevent scrap iron and laree impurities

from sucking into the pump, abrading gears or seizing the gear pump.

3.5.3.4 Oil seals are wearing parts. If oil leakage occurs in the drive shaft, the oil seal shall be

replaced.

3.5.3.5 Ball bearing is used by the oil pump. If it is worn, noise of the gear pump is serious, and its

output will be reduced, so the bearing shall be replaced.

3.5.3.6 After maintenance of the gears, the axial clearance, concentricity of the pump shall be

controlled strictly during reassembly. The tolerance cannot be exceeded, otherwise it cannot

operate normally.

3.5.3.7 It is strictly prohibited to operate the gear pump at a place where ambient temperature is

extremely high (over allowable motor temperature)or at the open air.

3.6 Operation regulating of fuel oil system (oil supply and unloading)

3.6.1 Operation sequence of oil unloading system

3.6.1.1 Check heating temperature of oil tank truck for propriety, specific requirements are as

follows:

Oil type heating temperature

#100 heavy oil 60-70 degree

#200 heavy oil 70-80 degree

3.6.1.2 Open steam inlet valve on steam operated oil unload pump, to allow the steam operated

pump to run slowly.

3.6.1.3 Open oil unloading valves at upper and lower parts of oil tanker. If oil leakage is found in oil

unloading joint, then the joint shall be tightened by a copper spanner. If a little of leaked oil persists,

a small oil bucket can be used to hold it. If oil leaked amount is larger, then close oil unloading

valves at upper and lower parts of the oil tanker. Contact maintenance personnel to replace rubber

gasket on oil unloading joint. Restart to unload oil after replacing.

3.6.1.4 Open the oil unloading valve from oil unloading rubber pipe to the main piping, and then

start to unload oil.

3.6.1.5 If oil pumping of steam operated pump is normal, slowly open the steam inlet valve wider,


Rev.: A



to accelerate unloading speed. Based on the feature of dry absorption capability of steam

operated pump, begin with steam operated pump to unload oil, and wait until steam operated

pump is operated normally, then start motorized oil unload pump to unload oil quickly. After oil

unloading is completed, stop motorized oil unload pump, pump out residual oil at bottom of oil tank

truck by the steam operated pump.

3.6.1.6 Wait until residual oil at bottom of the oil tank truck has been removed, then stop steam

operated oil unload pump, and close heated steam valve in the oil tank truck, then remove the

heating coupling.

3.6.1.7 Close inlet valves of all pumps, and open oil drain valves in front of all pumps and oil drain

valve in oil unloading pipeline, and then open interconnection valve form the steam mains to oil

unloading mains, in order to carry out purging. Open steam purge valve and oil drain valve at

outlets of all pumps, to carry out purging.

3.6.1.8 After oil unloading rubber pipe has been purged, close upper and lower unloading valve on

the oil tank truck, and close oil unloading valve from oil unloading rubber pipe to the mains.

Contact maintenance personnel to remove the oil unloading coupling.

3.6.1.9 after the steam is emitted at the top of the oil store and oil unloading mains has been

purged, close steam and oil interconnection valve, and close all purge valves and oil drain valves,

then the purging is completed, finally close oil unloading valve in the oil store.

3.7 Operation regulating of effluent oil system

3.7.1 Specification

3.7.2 Pre-operation inspection of effluent oil system

1) Check to see if connecting pipelines in the system are correct, and if all instruments are intact,

and if power source of electric control box is normal.

2) Close primary drain outlet, and secondary drain outlet on the device.

3) During initial use, open water injection valve above oil collecting chamber of oily sewage

vacuum separator and water injection valve above oil collecting chamber of effluent oil

absorber, and all vent valves. Inject industry water to the vacuum separator and effluent oil

absorber respectively, until they are full. Then close all water injection valves, drain valves,

vent valves.

4) Check oil content of oily sewage in oily sewage pool. If floating oil thickness reaches 5 mm,

start floating oil absorber, otherwise start the vacuum separator.

3.7.3 Operation of effluent oil system

3.7.3.1 Switch on power source of control box, place changeover switch in “Local”, “Automatic”

positions. Press Start button, and press start switch on the vacuum separator or floating oil

absorber (according to floating oil thickness), then the system enters into automatic operating

state.

3.7.3.2 When the level of water pool reaches a high position< start position>, the vacuum

separator or floating oil absorber will automatically start. As soon as the separated oil returns to oil

collecting tank, the purified water from the vacuum separator is discharged to an underground

drain, and the separated water from the floating oil absorber returns to the oily sewage pool.

3.7.3.3 If oil level in oil collecting tank reaches a high position, the oil transfer pump will automatic


Rev.: A



start, and the recovered oil is transferred to an oil tank of the system. If the level reaches stop

position, the oil transfer pump stops.

3.7.34 The drain pipes is connected with a online monitor in parallel(for its operation mode and

maintenance, see the Instruction). The set value of oil concentration in drained water for online

detection is 5 ppm/l. If effluent oil concentration is higher than the value, an automatic alarm is

given, and motorized drainage valve is closed. Drainage to underground drain is forbidden. Water

return valve is open, the effluent is returned to the oily sewage pool for another treatment.

3.7.3.5 The whole system operates automatically, and oily sewage is automatically separated. If

the level in oily sewage pool reaches to a low position<stop position>, the system shut down.

3.7.3.6 If remote control or local manual control is required, place the changeover switch to the

corresponding position, and then remote automatic control or local manual control can be affected

by the system.

3.7.3.7 If differential pressure controller or safety valve operates, the system will raise an alarm.

Shut down and clean up or replace macromolecule filter element.

3.7.3.8 Check if rotational direction of the pump is correct, and check all meters and instruments

for intactness.

3.7.3.9 Close primary drain outlet, and secondary drain outlet on the device.

3.7.3.10 Open the valve at drainage outlet and vent valve at the top of macromolecular adsorption

chamber.

3.7.3.11 Vacuum chamber, oil collecting chamber and inlet pipeline in the machine are filled with

clean tap water.

3.7.3.12 Turn oil drain switch to Automatic position.

3.7.3.13 Press start butt on the electric control box of the machine, motorized screw pump starts to

pump water.

3.7.3.14 If the ambient temperature is low or oil viscosity is large, open the heater.

3.7.3.15 After the oil-water separator is operated normally, observe operating conditions of all

motors at any moment. In case of abnormality, shut down and check.

3.7.3.16 inlet piping in the machine shall be free from air leakage; otherwise suction ability for the

machine would be affected, and even resulting in maloperation of the machine. If a motor-driven

plunger pump has always been kept operating state, while the screw pump does not work, then

shut down and repair the parts leaked, and fill the device with clean water, then restart the

machine.

3.7.3.17 If the gauge glass in oil collecting chamber of the machine is filled with oil, while the

plunger pump for oil drain does not operate automatically, but it can be started when oil drain

pump is turned to Manual position; it is likely to be the unction of oil level electrode. Shut own and

remove the level electrode. Clean up the surface before restarting the machine.

3.7.3.18 If spring loaded safety valve is open(i.e. value of pressure gauge ≥ 0.25 MPa), shut down

and replace filter element in macromolecular adsorption chamber.

3.7.3.19 If the device is out of service for a long time, the water in the device shall be drained and

cut off the power source of the equipment, and motional parts of the pump shall be filled with some

lubrication oil.


Rev.: A



3.8 Operation Check and maintenance of fuel oil system

3.8.1 Maintenance and check during normal operation of oil supply pump

3.8.1.1 Temperature of oil supply pump for operating and all bearing of the motor, vibration, axial

hunting does not exceed specified value.

3.8.1.2 Lubrication oil for all bearings is sufficient, and oil quality is good. Oil type shall meet the

requirements. For bearings with an oil cup, tighten two turns and fill oil in each shift.

3.8.1.3 Cooling water for all bearings is expedite, unblocked, and water flow rate is adequate.

3.8.1.4 Current, pressure for the operating pumps are stable, and oil supply temperature is normal.

3.8.1.5 All gauges are complete, their indications are correct.

3.8.1.6 Valves for all systems are complete and entire. Marks are correct. Switch positions are

correct. There are no signs of oil leakage, steam leakage.

3.8.1.7 Warm-up temperature of standby pump is normal, and positions of all linkage switches

are correct.

3.8.1.8 Isolation for equipments and systems to be repaired is correct, and safety measures are

complete.

3.8.1.9 Operation and standby for all oil tanks are normal. Temperature in oil store meets the

requirements.

3.8.1.10 cooling water return for all operating, standby pumps is unblocked. All equipments and

the ground shall be clean.

3.8.1.11 If steam operated pump runs stably during oil unloading, there are no signs of abnormal

sound and water hammer in the cylinder; steam connections operate normally, all connection

parts are secure and complete, and periodically discharge the accumulated water in the cylinder.

3.8.1.12 All filters are put into operation, and operated normally, without plugging phenomena.

3.8.1.13 The heater is operated normally, free from oil leakage, steam leakage phenomena.

3.8.1.14 Oil level in effluent oil basin keeps at a low position, free from abnormal change.

3.8.1.15 Lightings in the site, in particular, the lightings for all oil tanks are OK.

3.8.1.16 Various fire fighting apparatuses in the oil store shall keep intact, and be placed at

designated place in order.

3.8.1.17 The used waste cotton yarn and garbage shall be placed in a designated box, and

periodic cleaning shall be made for them. It is forbidden to stack waste cotton yarn garbage in the

garbage yard at discretion.

3.8.1.18 No fire is allowed in the oil store. If electric arc welding job is to be carried out, special

work sheet must be prepared, and take corresponding safety measures.

3.8.1.19 Weeds, and garbages in the oil store shall be removed periodically.

3.8.1.20Usually, the oil store shall be tidy, clean, and sanitary.

3.9 Safety operation cautions of fuel oil system

3.9.1 Notices when operating of oil supply pump

3.9.1.1 Before operation, contact the foreman, and shift supervisor to come to an agreement.

3.9.1.2 Once switching is completed, timely report operating conditions to the foreman.

3.9.1.3 If stopping of the operating pump is defective, timely report it to the foreman, and contact

maintenance personnel to remove it or note down the defects.


Rev.: A



3.9.1.4 Shift record shall be made, and current operation and standby mode shall be clearly told.

3.9.2 Notices when startup of heavy oil system

3.9.2.1 Before operation, an overall, earnest, careful inspection operation shall be performed to all

equipments, so as to know everything fairly well.

3.9.2.2 Earnestly review operation ticket. Earnestly operate step by step. Valves not yet opened

must be opened, and valves not yet closed must be closed, in order to prevent back flow of oil and

steam, and running, emitting of heavy oil due to maloperation.

3.9.2.3 After operation is completed, an overall, earnest inspection shall be performed to all oil,

steam systems, equipments, in order to prevent running, emitting of oil, steam due to missing,

maloperation, hidden trouble of the equipment.

3.9.2.4 This job is leaded by operation director or operation technician in the workshop, and

operation foreman is responsible for uniform command. All operating personnel shall strictly

execute the command and perform necessary contact and report works.

3.9.3 Notices when full shutdown of heavy oil system

3.9.3.1 This operation is leaded by an operation director or operation technician, and operation

foreman is responsible for uniform command and contact works. The whole operation is required

to be completed within 60 – 70 minutes.

3.9.3.2 Make sure to earnestly review the operation tickets before operation, and acquaint with

operation sequences, steps and actual positions of all valves, in order to avoid delaying time due

to sheer ignorance.

3.9.3.3 After every operation is carried out, review shall be made to prevent back flow, running,

and emitting of oil and steam due to maloperation.

3.9.3.4 It is required to coordinate the contact between senior staff and junior staff, and strictly,

earnestly execute the command, and obey uniform command. All operating personnel must

contact each other and make necessary report works.

3.9.4 Operation, maintenance and notices for effluent oil system

3.9.4.1 Conditions of all instruments, meters, and indicator lights shall be observed carefully during

operation. Whether level height indicated is identical with the actual height, and whether the

indicator lights are matched with actual operating equipments. In case of any abnormality, shut

down and check.

3.9.4.2 Carefully observe if the levels of oil collecting chamber in oily sewage vacuum separator

and oil collecting chamber in floating oil absorber are stable. If the level drops, it means that

leakage is occurred in suction pipeline in the system, shut down and clean.

3.9.4.3 If water pump and oil drain pump are switched frequently, it means that the electrode bar in

the oil collecting chamber is failed. Shut down, and remove the electrode bar and clean up its

surface, then put it into service.

3.9.4.4 There must be no foreign matter, impurities in the oily sewage poor. If so, shut down and

clean them up. Meanwhile, oil amount at inlet of vacuum separation purifier for oily sewage shall

be less than 500—100 mg/l. Otherwise, oil absorption saturation of macromolecular filter element

would be accelerated, and service lifetime of the filter element would be shorted, and even

resulting in overstandard of drainage.


Rev.: A



3.9.4.5 When online concentration monitor gives a signal which means that oil concentration is too

high, shut down and check. If digital indication is unstable, shut down and clean the detection

elements.

3.9.4.6 If differential pressure controller or pressure or safety valve operates, shut down and clean

up or replace macromolecular filter element. Open right cover plate on the macromolecular

adsorption chamber. Screw off the screws to fasten the filter element. Grasp the filter element with

hand, and draw it out by rotating two turns toward one direction. After the filter element is removed,

cut off 2 – 3 layers with a knife blade, and strip off the outer layer of filter element being cut off.

After washing in the clean water and drying, reinstall the filter element to macromolecular

adsorption chamber. After reinstalling in reverse order of disassembly, it can be put into service. If

the filter element removed cannot be used after cleaning, replacing a new filter element is

necessary.

3.9.4.7 If the device is out of service for a long time, it is required to drain the water in the device,

and cut off power source of the equipment. Motional parts of the pump shall be filled with some

lubrication oil.

3.10 Common fault, judgment and disposal of fuel oil system and equipments

3.10.1 Liquid cannot be drained out or displacement is low

a) Possible cause

1) Pump body is not filled with oil.

2) Oil suction height exceeds vacuum height.

3) Air leaked in oil suction pipeline.

4) Rotational direction is wrong.

5) Oil pipe blocked or other faults.

6) Rotational speed of oil pump is low.

7) Safety valve is open.

8) Cone tightness of safety valve is poor.

b) Remedy:

1) Fill the place where the vacuum pressure gauge is connected with oil.

2) Raise oil suction surface.

3) Check all connections.

4) Reconnect the motor.

5) Check and eliminate the fault.

6) Check and rectify with a tachometer.

7) Adjust the spring pressure of safety valve.

8) Regrind with fine paste.

3.10.2 Liquid leaked in oil pump

a) a) Possible cause

1) Packing gland not compacted.

2) Sealing ring has been used for a long time and worn.

3) Misalignment of sealing ring and not corrected.

4) Oil leaked in some washers .


Rev.: A



b) Remedy:

5) Tighten nuts.

6) Replace.

7) Remove and smoothly tighten nuts.

8) Replace.

3.10.3 Power required by the motor is too big

a) Possible cause

1) Viscosity of sucked liquid is too big.

2) Discharge pressure is too high.

3) Resistance of discharge pipeline is too big.

4) Running of rotary parts is obstructed, resulting in intense heat due to friction.

b) Remedy:

1) Preheat or reduce discharge pressure.

2) Reduce discharge pressure.

3) Check and eliminate the fault.

4) Remove, check and rectify.

3.10.4 Oil supply pump tripped

a) Possible cause

1) Power supply system failed.

2) Mechanical part of pump body damaged.

3) Pump shaft locked.

4) Overload.

b) Remedy:

If linkage pump does not put into service, immediately start standby pump to guarantee the oil

pressure. Inform local patrol operator to check the circumstance, and contact maintenance

personnel to repair.

3.10.5 Vaporization of oil supply pump

a) Possible cause

1) Oil level in oil tank is too low.

2) Flush valve not closed.

3) Fine filter plugged.

4) Inlet temperature is high.

b) b) Remedy

1) Immediately transit operation.

2) Stop failed pump, put into standby pump, check all valves; contact maintenance

personnel to repair if necessary.

3.10.6 Oil pump evacuated

a) Possible cause


2) Air entered into the pump.

b) Remedy


Rev.: A



1) Immediately transit operation.

2) Contact maintenance personnel to repair air leakage point.

3.10.7 Oil supply pressure raised

a) Possible cause

1) Oil return valve is closed a little bit or valve head fallen off.

2) Front linkage valve operated.

3) Oil consumption decreased suddenly.

b) Remedy

1) Check oil return valve, contact maintenance personnel to repair if necessary.

2) Contact shift supervisor to find out the cause.

3.10.8 Low oil supply pressure

a) Possible cause

1) Opening of oil return valve is too big.

2) Oil consumption of boiler increased.

3) Oil supply pipeline leaked.

4) Air admitted to suction inlet.

5) Pump speed is low.

6) Suction pipeline plugged.

7) Impeller channel plugged.

8) Impeller damaged or seal ring worn.

b) Remedy

1) Adjust oil return valve.

2) Immediately link to start standby pump.

3) Contact maintenance personnel to repair.

3.10.9 Bearing leaked

a) Possible cause

1) Gasket of shaft sleeve damaged.

2) Gasket not flat or too hard.

b) Remedy: contact maintenance personnel to repair.

3.10.10 Oil tank caught fire

a) Possible cause

1) Outside open fire.

2) Improper hot work measures.

3) Spark caused due to static electricity.

b) Remedy: immediately dial fire telephone; start foam tank, and extinguish the fire with fire

fighting apparatus; release parallel operation of an oil tank if it catches fire.

3.10.11 Pump cannot pump oil

a) Possible cause

1) Rotational direction of the motor is wrong.

2) Enclosed impeller channel or suction pipeline blocked.

3) Centerline of the impeller not immersed by fuel oil.


Rev.: A



b) Remedy

1) Change rotational direction.

2) Remove blocked part.

3) Adjust immersed height.

3.10.12 Flow rate not enough

a) Possible cause

1) Impeller corroded and worn seriously.

2) Seal ring worn, corrode seriously.

3) Rotational speed not enough.

4) Clearance between open impeller and casing cover is too big.

5) Suction inlet or discharge outlet plugged.

b) Remedy

1) Replace impeller.

2) Replace seal ring.

3) Increase rotational speed.


5) Eliminate blocked part.

3.10.13 Lift not enough

a) Possible cause

1) Oil delivered containing air.

2) Impeller corroded, worn seriously.

3) Clearance between open impeller and casing cover is too big.

b) Remedy

1) Decrease liquid temperature, eliminate gas.


3) Readjust clearance.

3.10.14 Excessive power

a) Possible cause

1) Process exceeds service range.

2) Specific gravity of the medium is too big.

3) Mechanical friction occurred.

b) Remedy

1) Operate the pump within service range.

2) Replace large power motor.

3) Find out the cause, and replace worn parts.

3.10.15 Bearing damage and overheat

a) Possible cause

1) Bearing damaged.

2) Bearing clearance too big.

3) Lubrication oil quality unqualified or short of oil.

4) Misalignment between pump and motor.


Rev.: A



b) Remedy

1) Switch oil supply pump, and inform maintenance personnel to repair.

3.10.16 Noise and vibration

a) Possible cause

1) Misalignment between pump shaft and motor shaft.

2) Liquid delivered containing gas.

3) Rotor unbalanced.

4) Seal ring worn excessively.

5) Coupling bolt loosened.

b) Remedy

1) Adjust concentricity.

2) Decrease liquid temperature, and eliminate gas.

3) Replace parts.

4) Replace seal ring.

5) Tighten various bolts.

3.10.17 Large start load of oil pump

a) Possible cause

1) Due to large thrust clearance of oil pump, thrust function of thrust disk and balance disc is

lost, leading to friction between movable and stationary parts, and excessive start load,

and even that oil pump cannot be started.

b) Remedy

1) Stop pump and repair

3.10.18 Faults of mechanical part

a) Possible cause


2) Air entered into oil inlet pipeline.

3) Packing worn seriously.

4) Oil filter plugged.

b) Remedy

1) After linkage pump is put into service automatically, close operation switch to transit

operation, then stop oil filter and corresponding pump, and start standby pump.

3.10.19 Motor overload

a) Possible cause

1) Misalignment.

2) Specific gravity became larger.

3) Friction occurred in rotating parts.

4) Device resistance become lower, operation point leans to large flow rate.

b) Remedy

1) Align opposite wheels.

2) Change operating process.

3) Repair frictionized portion.


Rev.: A



4) Check pressures in suction and discharge pipelines and original changes.

3.10.20 Auxiliary power interrupted

a) Possible cause

1) Power supply system for auxiliary power failed.

b) Remedy

1) Contact shift supervisor to restore power source, and pull the oil pump switch to stop

position, then release interlocking switch.

3.10.21 Faults of electrical part

a) Possible cause

1) Motor is smoking or catches fire.

2) There is abnormal sound or burnt smell in the motor.

3) Spark occurred in a switch.

4) Motor current exceeds rating.

5) Intensive vibration occurred in a motor.

6) Motor tripped.

b) Remedy

1) Rapidly cut off power source for the motor, and start standby motor.

3.10.22 Fuel oil screen plugged

a) Possible cause

1) There is impurity in the oil.

b) Remedy

2) Switch oil filter, and clean.

3.10.23 Abnormal sound in delivery pump

a) Possible cause

1) Idle running of pump.

2) Screws worn seriously.

3) Pump bearing damaged.

4) There is mechanical impurity in the pump.

b) Remedy

1) Shut down and check inlet pipeline of pump for blocking, and air leakage.

2) Shut down and inform maintenance personnel to repair.



3.10.24 V-belt slipped

a) Possible cause

1) Belt tensions not enough.

2) Pump load is too big.

3) There is oil stain on the pulleys.

b) Remedy

1) Shut own and inform maintenance personnel to repair.

2) Check outlet pipeline for unblocking.


Rev.: A



3) Shut down and remove.

3.10.25 High oil content of blowdown water

a) Possible cause

1) Failure of separator’s adsorption material.

2) The shell not full-flow.

3) Serious oil pollution in each stage.

b) Remedy

1) Regenerate or replace adsorption material.

2) Exhaust gas up to full-flow of the shell.

3) Back wash or clean and perform blowdown.

4 Water Treatment Plant Operation Manual

4.1 General Description

The water purification station system is designed on basis of 4×300MW unit capacity, and the

equipments will be erected in stages. The water amount treated within the capacity of 4×300MW

Power Unit is about 350 m3/h and the equivalent in this 2 × 300MW project will be approx. 200

m3/h. The mechanical acceleration clarifier will be arranged in accordance with capacity of

4×300MW unit, Two sets of mechanical acceleration clarifier and two sets of filter tank with 200%

capacity will be established for this 2×300MW project, and matched with dosing systems of

coagulant, coagulant and sodium hypochlorite.

4.2 Technical Specification

Equipment name Major technical parameter Unit Qty Remark Raw water booster

pump

Q=200m3/h, H=15m

N=15kW, V=400V

Set

2

One is in operation

and the other is for

standby General service

pump

Q=180m3/h, H=65m

N=75kW, V=400V

Set 2

One is in operation


standby Mechanical

acceleration

clarification tank

Q=200m3/h, inlet silt content

≤5kg/m3

Effluent turbidity：≤20PPM

Set 2

One is in operation


standby Clear water lift

pump

Q=200m3/h, H=35m

N=37kW, V=400V

Set 2

One is in operation


standby Filter chamber

Q=200m3/h, inlet turbidity ：≤20PPM

Outlet turbidity：≤3PPM

Set 2

One is in operation


standby Lift pump of filtered

water

Q=190m3/h, H=35m

N=37kW, V=400V

Set 2

One is in operation


standby Electric fire-fighting

pump Q=600m3/h, H=110m

N=315kW, V=6.60kV Set

1 One is in operation



Rev.: A

SEC



standby Fire-fighting pump

driven by diesel fuel

Q=600m3/h, H=110m

N=315kW

Set 1

One is in operation


standby Fire-fighting

pressure stabilizer

Q=21m3/h, H=110m

Set 1

One is in operation


standby Industrial water

pump

Q=110m3/h, H=60m

N=55kW, V=400V

Set 2

One is in operation


standby Living water pump

Q=130m3/h, H=45m

N=37kW, V=400V

Set 2

One is in operation


standby Living frequency

conversion feed

water device

Total feed water volume

Q=0~160m3/h, H=70m

Set 1

Two are in operation

and one is for standby,

each pump has

Q=80m3/h, H=70m,

N=30kW and V=400V. Active carbon filter

backwashing pump

Q=300m3/h, H=30m

N=45kW, V=400V

Set 2

One is in operation


standby Coagulant metering

pump

Q=0-85l/h, H=70m

N=0.25kW, V=400V

Set 2

One is in operation


standby Coagulant aid

metering pump

Q=0-400l/h, H=50m

N=0.37kW, V=400V

Set 2

One is in operation


standby Agitation tank Set 2 Living water

chlorination

equipment

Effective chlorination amount ：9.5g/h

Set 1

Cleaning station

chlorination

equipment

Effective chlorination amount ：700g/h

Set 1

Filter chamber

backwashing pump

Q=350m3/h, H=35m

N=55kW, V=400V

Set 2

One is in operation


standby 4.3 Operation

4.3.1 Control of Operation Parameters

Water

sample

Item

Unit

Control

standard Time

interval

Remark


Rev.: A

SEC



Alkalinity mmol/l — 8h

Turbidity mg/l — 8h

Raw water

Electroconductivity μs/cm — 8h Settling ratio 5min% 10-20% 4h Water out of

classification

tank

Turbidity

mg/l

≤10

4h

Turbidity mg/l ≤5 4h

Residual chlorine mg/l ≤0.1 4

Water out of

gravity filter

chamber Pressure

difference

MPa

≤0.05

4

4.3.2 Startup and shutdown of mechanical agitating clarifier

4.3.2.1 Preparatory work for mechanical agitation clarification tank prior to startup

1) The dosage in the coagulant and coagulant aid solution tank is adequate and the liquid level

is 1/2 high above the solution pool.

2) There should be no debris inside the clarification tank and the manholes are closed.

3) Sampling tubes and washing pipes should be smooth.

4) The agitator should be filled with lubricant, and its oil level is normal and is in good standby.

5) The bottom discharge valve, middle discharge valve, water exit valve, sampling valve and

rinsing water valve of the clarification tank should be closed.

4.3.2.2 Startup of Mechanical agitation clarification tank

1) Start the raw water booster pump, open the exit valve after the pressure is stable, operate the

coagulant and coagulant aid chemical dosing system, and regulate the effluent flow and

dosage according to the needs, the preliminary water discharge is 100-200T/H, and the

quantity of the coagulant and coagulant aid is 1 to 1.5 times the normal amount.

2) Start the mud scraper of the clarification tank, which is operating when lubricant can not be

interrupted.

3) When the impeller of the agitator is immersed into water, start the agitator of the clarification

tank, adjust the rotation speed to 4.8-14.5 r/min and the hoist speed to 120-1200 r/min, and

check whether the agitator is in normal operation; when a circulation is created, fine mud can

be input if sludge is loose with small particles in the first reaction room.

4) When the clarification tank begins to output water, the effluent water should be drained into

trench if it is unqualified; when the effluent water from the clarification tank is qualified

(Turbidity is less than 10mg/L), water can only flow into the clarification tank, and meanwhile

water flow rate slowly increases, there is in general 30 tons of flow in every 10 minutes and

the coagulant is appropriately adjusted to the normal (200-250T/H).

5) When the effluent water quality of the clarification tank is poor, the reasons should be

determined rapidly and the timely treatment should be completed.

6) The sewage on the bottom of the clarification tank prior to startup should be disposed once,

and then the tank is started according to the steps above.

4.3.2.3 Stoppage of mechanical agitation clarification tank


Rev.: A



1) Close the water exit valve of the raw water booster pump, disable the raw water booster pump,

stop inputting water into the clarification tank, stop the coagulant and coagulant aid chemical

dosing system and stop the agitator and mud scraper finally.

2) When the clarification tank stops for a short term (less than 72H), the agitator can continue

running to drain mud appropriately, and the sludge formation maintains not to sediment to

prevent blades from being damaged.

3) When the clarification tank stops for a long term (more than 72H) or is overhauled, the sludge

in the clarification tank should be dumped before the agitator stops running.

4.3.3 Startup and stoppage of Gravity filter chamber

4.3.3.1 Inspection r prior to startup of the gravity filter chambe

1) The inside of the chemical pool should be clean and have no debris.

2) There should be no debris or manhole leakage inside the filter chamber.

3) Water purification blower should be in the standby.

4.3.3.2 Startup of Gravity filter chamber

1) When the effluent turbidity of the clarification tank is less than 10 mg/L, water is allowed to

enter the gravity filter chamber.

2) Open the water inlet valve of the gravity filter chamber and the positive discharge valve of the

gravity filter chamber, and wash the valve positively and open the positive discharge valve

until the effluent turbidity of the gravity filter chamber is less than 5 mg/L, and input water into

the chemical pool through opening the water inlet valve of the chemical pool.

3) Monitor the effluent turbidity of the gravity filter chamber is not more than 5 mg/L and the

residual chlorine in the chemical water is not more than 0.1 mg/L.

4.3.3.4 Stoppage of the gravity filter chamber

1) Stop inputting water into the gravity filter chamber from the clarification tank and close the

water inlet valve of the gravity filter chamber.

2) If the gravity filter chamber stops for overhaul, open the pollution discharge valve at the

bottom of the gravity filter chamber and drain the internal water.

4.3.3.5 Air scrub of Gravity filter chamber

1) Air scrub and backwashing of gravity filter chamber: close the water inlet valve and exhaust

valve of the gravity filter chamber, open the reverse discharge valve and connecting butterfly

valve of the gravity filter chamber and backwash the filter material.

2) Air scrub and waterdrainage of gravity filter chamber: close the reverse discharge valve and

connecting butterfly valve, open the drainage valve, and drain to 100mm above the filter layer

by gravity.

3) Air scrub and air inflow of gravity filter chamber: close the drainage valve, open the front

drainage valve of air inflow and air exit valve and emptying valve of water purification blower

in order to enable smooth exhaust in the air scrub, and air scrub the filter layer.

4) Air scrub, air inflow and backwashing of gravity filter chamber: open the connecting butterfly

valve and close the reverse discharge valve, water from the clean water area at the upper part

of the bulkhead flows into the water separation chamber and filter area via a connecting pipe,


Rev.: A

http://dict.cnki.net/dict_result.aspx?searchword=%e6%8e%92%e6%b1%a1&tjType=sentence&style



and is drained into the gutter from the backwashing pipe via a backwashing drainage valve

(that is, drainage backwashing + Air scrub).

5) Air scrub and backwashing of gravity filter chamber: close the compressed air valve and

blower exit valve and conduct backwashing.

6) Drainage before air scrub and operation of the gravity filter chamber: drain some water that

are unqualified in the preliminary filteration. Close the backwashing drainage valve and the

connecting butterfly valve, open the water inlet valve and drainage valve prior to operation,

drain the preliminarily filtered water, and then close the drainage valve prior to operation.

Open the connecting butterfly valve, and the filter chamber goes into the normal operation.

4.3.4 Operation of chemical dosing system

4.3.4.1 Overview of chemical dosing system

The distance between the chemical dosing room at the cleaning station and the chemical

dosing point is about 30 meters and the water pressure on the chemical dosing point is about 0.15

MPa. A set of coagulant chemical dosing system, a set of coagulant aid chemical dosing system, a

set of sodium hypochlorite chemical dosing system of clarification tank and a set of living water

sodium hypochlorite chemical dosing system are set up.

1) Coagulant dosing: the dosage of PAC is 10 to 20 mg/l and the preparation concentration is

5% to 10%;

2) Coagulant aid dosing: the dosage of solid polyacrylamide (PAM) is 1 to 2 mg/l and the

preparation concentration is 1%, and the dosage concentration is 0.1 to 0.2%;

3) Germicide dosing: sodium hypochlorite (generated from 4% saturated saline solution by

electrolysis). The inlet dosage of the clarification tank si 1.0 to 2.0 mg/L; the dosage of living

water is no more than 1.0 mg/L, and the largest dosage is about 5 g/l and the water pressure

on the dosage point is 0.10MPa.

4.3.4.2 Startup and shutdown of chemical dosing system

4.3.4.2.1 Startup of chemical dosing system

1) The liquid level of coagulant and coagulant aid solution is higher than the 1m.

2) The liquid level of sodium hypochlorite system metering tank is higher than 40 cm, dosage in

the granulated salt storage room is adequate and living water is normal.

3) Check that the metering pump and its motor meet the inspection standard in the General

Clauses.

4) Open the first and second manual dosage oulet valve of coagulant and coagulant aid solution

tank and the living water inlet valve of sodium hypochlorite metering system.

5) Open the inlet and exit valve of the metering pump, start the coagulant and coagulant aid

metering pump and sodium hypochlorite chemical dosing system, and check whether the inlet

pressure is normal.

4.3.4.2.2 Shutdown of chemical dosing system

1) Press “Stop” button at CRT or local metering pump, and close the inlet and exit valve of the

metering pump and the first and second exit valve of the solution pool.

2) Press the raw water pump at CRT or “Stop” button of the domestic water pump and stop the

raw water pump or domestic water pump and then close the water inlet and exit valve.


Rev.: A



4.3.5 Inspection and adjustment during operation

4.3.5.1 Operation, maintenance and attentions of Chemical clarification tank

1) Under the supervision projects and time interval provided, the effluent quality of the

clarification tank should be measured and the results are recorded in the operation

statements.

2) According to the effluent quality the dosage supervision and adjustment should be done.

3) The sludge settling ratio of the second reaction chamber is controlled at 10 to 20% (5 min).

4) Under the sludge settling ratio of the second reaction chamber, the sewage disposal time

interval (one-time sewage disposal every 8H for two minutes) is determined, sludge running

and missing phenomena are not allowed, sewage disposal at the bottom is done once every

day shift and the discharge capacity is determined according to the effluent quality of the

clarification tank and the height of sludge.

5) Stabilize the operating conditions of the clarification tank, and the change scope of the flow is

generally not more than 10% of the original flow each 10 minutes.

6) The oil level of the agitator is strictly controlled and the oil dosage should not exceed the

maximum oil level line and should not be less than the minimum oil level line when it is in

operation.

7) The following matters should be paid attention to in the operation of the agitator:

a) Current should have no unusual fluctuations.

b) The agitator should operate in balance, without abnormal vibration and noise.

c) The oil temperature of the reducer should generally not exceed 30.

d) There should not be obvious leakage at each seal part.

8) When adjusting the startup height of the agitator impeller, it is strictly controlled in the scope of

the upper and lower stop line of the scale and nuts must be locked in the process of

adjustment.

4.3.5.2 Operation, maintenance and attentions of gravity filter chamber

1) Air scrub is carried out when the filter chamber runs for 20 hours.

2) Air scrub is carried out when the effluent quality of the filter chamber deteriorates markedly.

3) Air scrub is carried out when the effluent flow of the filter chamber changes little.

4) Air scrub is carried out when the effluent quality of the filter chamber exceeds the standard.

4.3.5.3 Operation, maintenance and attentions of chemical dosing system

1) The liquid level of the coagulant and coagulant aid solution pool is more than 20cm, and a

prescription if filled if it is less than 20 cm.

2) Check whether the dosage in the granulated salt storage room of sodium hypochlorite

chemical dosing system is adequate, and the liquid level of the measuring tank is above

20cm.

3) Check whether the sodium hypochlorite generator is working normally.

4) The outlet pressure of the metering pump is more than the water pressure of the dosing point,

the pressure gauge pointer swings, and there is no leakage phenomenon at the connection

between the pipeline and flange.

5) Check the metering pump and motor body according to the General Clauses.


Rev.: A



6) If the metering pump fails, the system is switched and another metering pump is put into

operation.

4.4 Common faults, judgment and treatment at the water purification station

4.4.1 Reasons for deteriorated effluent quality of the clarification tank and treatment

S/N Reason Treatment 1 Inadequate or excessive dosage. Stop the filter chamber, drain the effluent of the

clarification tank to the trench, and adjust the

dosage immediately 2 Slagblanket rises as the sludge is not

timely discharged Stop the filter chamber, drain the effluent of the

clarification tank to the trench and dispose

sewage immediately. 3 The flow of the clarification tank is too

big; the lifting load speed of the

clarification tank is over 50 t/h.

Stop the filter chamber, drain the effluent of the

clarification tank to the trench and reduce the

flow. 4 The original water temperature

increases too fast, by 1 to 2 hourly. Stop the filter chamber, drain the effluent of the

clarification tank to the trench and adjust the

system to stabilize temperature and flow. 5 There is mud on the bottom of the

clarification tank due to its long-term

operation.

Drain and wash the clarification tank

6 Inlet water contains air. Clean the pump mesh timely, to prevent pump

flange from leaking. 7 Not clean the clarification tank regularly Clean the clarification tank regularly 4.4.2 All pretreatment rotation equipment trips

Possible reasons: the power supply of MCC cabinet fails and the chemical water fails.

Treatment methods:

1) Report to the leader on duty and professionals and make records.

2) Take inspection and treatment by contacting the centralized control through the leader on

duty.

3) Close the operation switch of the outrage equipment.

4) Put the original operating system into operation again after the power supply is restored.

4.4.3 Sludge in the clarification tank circulates badly and drifts, and sludge formation is in chaos

S/N Reason Treatment 1 The rotation speed of the agitator is

improper, resulting in abnormal

circulation.

Temporarily reduce the rotation speed and wait

for 1 to 2 hours, and recover the rotation speed

after the water is clarified; the rotation speed

may be too high if the clarified water

deteriorates again, but often because of low

rotation speed, the stirring effect changes bad. 2 Due to high turbidity of the raw water,

the impeller runs at low-speed and the

Adjust the rotation speed and eliminate

accumulated silt (sewage) at the lower part of


Rev.: A

SEC



sludge accumulates at the recycling part the enrichment room and outside cover. 4.4.4 Water yield of the clarification tank in operation declines seriously and the water level can not

be maintained

S/N Reason Treatment 1 The sewage valve is not closed or

seriously leaks after it is opened. Close the sewage valve or make maintenance

2 Raw water booster pump runs

abnormally Check whether the current of the raw water

booster pump is normal.

4.4.5 Water quality of the clarification tank blanches

S/N Reason Treatment 1 Excessive dosage Adjust the dosage. 2 Excessive spoil disposal capacity Control the spoil disposal capacity 4.4.6 Alum floats on the clarification tank

S/N Reason Treatment 1 Too big initial flow Reduce the flow 2 Sudden increase in load in operation Adjust the load balance 3 Excessive dosage Control the dosage 4 Too fast rotation speed of the agitator Adjust the rotation speed of the agitator 5 Suddenly declining temperature Reduce the output 6 Inadequate spoil disposal Control the normal spoil disposal 7 Spoil disposal washing valve not closed Close the spoil disposal washing valve 4.4.7 Unqualified effluent turbidity of the filter chamber

S/N Reason Treatment 1 Big turbidity of inlet water Adjust and treat water quality of the clarification

tank 2 Too big load Reduce the load 3 Too long operation time Backwash and strengthen the air scrub 4 Backwash by halves Backwash thoroughly 5 Bias of filter material and water hat

damaged Maintenance

5 Demineralization system Operation Manual

5.1 General description

The normal output of the feed-water treatment system equipment of the boiler is 240 t/h and

the largest output is 290 t/h. The feed-water treatment system of the boiler is set to two columns of

unit first-class desalination (2 sets of 60 t/h activated carbon filter → 1 set of 120 t/h reverse flow

cation exchanger → 1 set of 120 t/h for decarbonizer → 10 m3 middle water tank →reverse flow

anion exchanger) → 2 sets of 120 t/h mixed bed.


Rev.: A

SEC


BOP OPERATION MANUAL

5.2 Technical specification of equipment

Equipment

output

Filling

S/N

Equipment

name

Qty

Nominal

diameter Normal

Max.

Model

Height

Grain

diameter

mm 1

Activated

carbon filter

4

DN2800

60

73

2.0m

0.8~1.6

2

Strong acid

cation

exchanger

2

DN2500

120

145

001X7

1.6m

0.315-1.25

3

Decarbonizer

and blower

2

DN1600

120

Multi-plane

ball

H=1600mm

4

Middle water

tank

2

V=10 m3

5

strong acid

anion

exchanger

2

DN2500

120

145

D202II

2.5m

0.315-1.25

6

Mixed bed

2

DN2000

120

150

MB001X7

MB201X7

Cation

=500mm

Anion

=1000mm

0.7-1.25

0.7-1.25

7

Hydrochloric

acid storage

tank

2

V=25 m3

8

Alkali storage

tank

2

V=25 m3

9

Hydrochloric

acid metering

box（cation）

1

V=1.6m3

10

Hydrochloric

acid metering

box（Mixed）

1

V=1.0m3

11

Alkali metering box（anion）

1

V=1.6m3

12

Alkali metering box（Mixed）

1

V=1.0m3

13

Acid mist absorber （with

filling）

2

DN500

14 Hydrochloric 1 Cation 2.6t/h(0.4mpa)


Rev.: A

SEC



Equipment

output

Filling

S/N

Equipment

name

Qty

Nominal

diameter Normal

Max.

Model

Height

Grain

diameter

mm acid metering

box（cation） bed

15

Hydrochloric

acid metering

box（Mixed）

1

Mixed

bed

1.0t/h(0.4mpa)

16

Alkali metering pump（cation）

1

Anion

bed

2.0t/h(0.4mpa)

17

Alkali metering pump（mixed）

1

Mixed 1.0t/h(0.4mpa)

18 Resin trapper 2 Mixed 19 Safety shower 2

20

Compressed

air tank

2

V=8.0m3

5.3 Control standard and period of water quality of feed-water treatment system

S/N

Name of

water

sample

Analysis item

Symbol

Unit

Control

standard

Supervision

time

Remark

Residual chlorine Cl- mg/L ≌ 0 4h

Oxygen

consumption

CODMn

mg/L

≤1.5

System

assessment

1

Outlet water

of active

carbon filter

Turbidity

mg/L

≤0.2

2h

Backwash

when

exceeding

the

standard sodion

Na+ μg/L

≤100

2h

2

Outlet

water of

cation

exchanger

Acidity

SD

mmol/L

Stable

4h

Increase

the number

of tests

when

putting into

operation

and being

close to

failure

3 Outlet Electroconductivity DD μs/cm ≤5 2h Ditto


Rev.: A

SEC



water of

anion

exchanger

silicon dioxide

SiO2

μg/L

≤100

2h

Electroconductivity DD μs/cm ≤0.2 2h 4

Outlet water

of mixed ion

exchanger

silicon dioxide

SiO2

μg/L

≤20

2h

Ditto

5

Deionization

water tank

Electroconductivity

DD

μs/cm

≤0.2

2h

Ditto

5.4 Operation of demineralized equipments

5.4.1 Startup and shutdown

5.4.1.1 Startup of desalination system

5.4.1.1.1 Preparation before operation of demineralized equipments

1) The water level of the clean pool is one second above and the raw water pump is in good

standby status.

2) The manual inlet valve and outlet valve of the activated carbon filter, cation bed, anion bed

and mixed bed are opened, the emptying valve at the bottom of the resin trapper is closed,

the exit valve is opened, and all the pneumatic valves are closed and display the same as the

CRT; The one-time valves of flow gauge, sodium gauge and conductance meter are closed,

with intact appearance and zero indication; the on-site control cabinet power supply and gas

source are connected, the green valve indicator light is on and the air pressure is 0.4 to 0.8

MPa.

3) The manual inlet valve of the decarbonization valve is opened, the power supply of the

decarbonization fan is connected and is in good standby status, the liaison valve of the middle

water tank is opened, the emptying valve at the bottom is closed, the entrance valve of the

middle water pump is opened, and the outlet valve is closed, meeting the general inspection

standards.

4) The manual inlet valve and outlet valve of the desalination tank are opened and the emptying

valve at the bottom is closed.

5) The desalination pump meets the general inspection standards, and the manual inlet and

outlet valve are opened.

5.4.1.1.2 Commissioning operations of desalination equipments

1) Start the raw water pump, open its outlet valve and supply water to the activated carbon filter.

2) Commissioning of the activated carbon filter: open the water inlet valve and exhaust valve of

the activated carbon filter, fill water into the activated carbon filter, and open the conventional

well-flushing effluent valve and close the exhaust valve after water flows out of the exhaust

pipe; when turbidity is less than 0.2 mg/L, the conventional well-flushing is qualified, open the

effluent valve and close the conventional well-flushing effluent valve.

3) Commissioning of the cation bed: open the water inlet valve and air valve of the same series

cation bed, fill water into the cation bed, and open the conventional well-flushing effluent valve

and close the air valve for conventional well-flushing after water flows out of the air valve of

the cation bed; when the Na+ is less than 100 ug / L, the conventional well-flushing is qualified,


Rev.: A



start the decarbonization fan, open the effluent valve, close the positive discharge valve and

fill water into the middle water tank; when the liquid level in the middle water tank reaches two

thirds above, start the middle water pump, open its outlet valve and send water to the cation

bed.

4) Commissioning of the anion bed: open the water inlet valve and air valve of the same series

anion bed, open the positive discharge valve and close the air valve after water flows out of

the air valve; when DD is less than 5us/cm and SiO2 is less than 100ug/L, the conventional

well-flushing is qualified, open the effluent valve and close the positive discharge valve and fill

water into the mixed bed.

5) Commissioning of the mixed bed: open the water inlet valve and the air valve of the mixed

bed and fill water into the mixed bed; after water flows out of the air valve, open the positive

discharge valve and close the air valve for conventional well-flushing; when DD is less than

0.2us/cm and SiO2 is less than 20ug/L, the conventional well-flushing is qualified; open the

effluent valve and close the positive discharge valve, and send water into the desalination

water tank.

5.4.1.2 Stoppage of the desalination system

1) Stop the raw water pump and close its inlet and outlet valve.

2) Close the pneumatic water inlet valve and the effluent pneumatic valve of the activated

carbon filter.

3) Close the pneumatic water inlet valve and the effluent pneumatic valve of the cation bed, and

stop the decarbonization fan.

4) Stop the middle water pump and close its inlet and outlet valve.

5) Close the pneumatic water inlet valve and the effluent pneumatic valve of the anion bed.

6) Close the pneumatic water inlet valve and the effluent pneumatic valve of the mixed bed as

well as the water inlet valve of the desalination tank.

7) Open the exhaust valves of all equipments, and close all exhaust valves after pressure relief.

8) According to the water level of the chemical pool, decide whether to close the water inlet valve

of the clean water pool.

5.4.2 Inspection and adjustment of the desalination system in operation

1) There is water leakage at the connection between the pipeline and flange, the position of the

valve switch is correct, the effluent residual chlorine and turbidity of the activated carbon filter

is qualified, and the outlet Na+ of the cation bed is less than 100 ug/L, the outlet DD of the

anion bed is less than 5us/cm, the outlet DD of the mixed bed is less than 0.2us/cm and SiO2

is less than 20ug/L.

2) The decarbonization fan has no abnormal sound, with normal vibration and temperature; the

desalination water pump and the middle pump meet the inspection standards of general rules.

3) When the equipment is close to failure, increase the number of tests, prevent the unqualified

water from being sent out.

4) Check whether there is resin inside the resin trapper, stop the mixed bed in time if resin is

found, and record the defects and contact the relevant personnel for maintenance treatment.


Rev.: A



5) Stop the failed equipment timely and regenerate; if two sets of equipments are put into

operation at the same time, adjust the operating conditions of the equipments reasonably,

avoiding two sets of equipments from failing at the same time.

6) When the cation bed Na is more than 100 ug/L, the cation bed fails; when the effluent

electroconductivity of the anion bed is more than 5us/cm or SiO2 is more than 100ug/L, the

anion bed fails and regeneration should be conducted. Check that the pressure difference of

the switch in operation is less than 0.15Mpa, or else decommissioning, regeneration.

7) Analyze the alkalinity of raw water every 2h, the effluent turbidity of the activated carbon filter

and the effluent acidity of the cation bed; when sea water back flows, strengthen the analysis,

measure once every 1h and analyze chlorine every 4h once.

8) Check that the water level of each water tank is above one second height of liquid level.

9) Check that all on-line meters display normally and one-time meter has no discontinuous flow

or leakage.

a) When the mixed bed is put into operation, input the electroconductivity meter: open the

water sample inlet valve of the electroconductivity meter to maintain flow 200 ml/min

around; observe that the water flow should be continuous, stable and have no

disconnected flow and air from the liquid discharge pipe, and input the power supply of

the corresponding electroconductivity meter.

b) When stopping the mixed bed of anion bed, stop the electroconductivity meter: stop the

power supply of the corresponding electroconductivity meter and close the water sample

inlet valve of the electroconductivity meter.

c) When putting the anion bed into operation, put the sodium meter into operation: open the

manual entrance valve of the sodium meter, pull out the black adjustment knob to

regulate the flow rate to be 40 ml/min, and then reset the adjustment knob. Open the

power switch at the bottom of the sodium meter.

d) When putting the cation bed into operation, put the sodium meter into operation:

disconnect the power switch at the bottom of the sodium meter, push in the switch valve

of the flow tank so that the flow tank is full of water and generates siphon phenomenon.

Close the manual sampling entrance valve of the sodium meter.

5.4.3 Backwashing activated carbon filter of activated carbon filter

5.4.3.1 Preparations for backwashing the active carbon filter

1) The clean water tank maintains a high water level, the activated carbon backwashing pump is

provided with startup conditions and the entrance valve is opened.

2) Check whether the backwashing entrance valve of the operating or standby active carbon bed

is closed tightly.

3) Roots blower is in good standby status.

5.4.3.2 Backwashing operation must be carried out if the active carbon filter in operation meets the

following conditions

1) It is put into operaton for the first time or starts after long-term suspension.

2) The inlet and outlet pressure difference is up to 0.1MPa.

3) The effluent quality exceeds the standard.


Rev.: A



4) The activated carbon filter operates continuously for 80 hours.

If stopping for over 24 hours, backwashing should be carried out before stopping.

5.4.3.3 Backwashing steps of active carbon filter

1) Stopping: close the water outlet and inlet valve of the filter, open the exhaust valve and close

it after pressure relief for 30s.

2) Drainage: open the exhaust valve and positive discharge valve of the filter, and close the

positive discharge valve when the water level drops to the sight glass center.

3) Air scrub: open the air inlet valve of the filter, start the Roots blower, adjust the air flow to 10

to15 m3/min and scrub for 5 to 10 min.

4) Backwashing: stop the Roots blower, close the air inlet valve and exhaust valve of the filter,

start the backwashing pump, open the exit valve of the pump, open the backwashing influent

valve and backwashing drainage valve of the filter slowly; when the filter is filled with water,

increase flow gradually and control water intensity at 13 to 16l/m2s, until the drained water is

clarified and transparent, stop the backwashing pump and close the backwashing drainage

valve and water inlet valve.

5) Positive washing: open the water inlet valve and the exhaust valve of the filter; after water

flows out of the air valve (about 60s), open the positive washing drainage valve, and the flow

rate is 5 m/h (flow is 40 m3/h), take the positive washing until the water is clarified and

transparent, and then close the water inlet valve and positive discharge valve of the filter and

turn into operation or standby.


Rev.: A

SEC QUANG NINH THERMAL POWER JOINT STOCK COMPANY

2×300 MW TURBINE & AUXILIARIES OPERATION MANUAL

Table for Operation steps of the activated carbon filter

Control parameter Operation methods

Influe

nt

valve

Efflue

nt

valve

Backwas

hing

influent

valve

Backwas

hing

drainage

valve

Exha

ust

valve

Positiv

e

washi

ng

draina

ge

valve

Air

inle

t

valv

e

Root

s

blow

er

backwash

ing pump

Flo

w 3

m /

h

Rever

se

water

streng

th

l/m2.s

Air

scrub

streng

th

l/m2.s

Tim

e

min

Flo

w

rate

m.h -1

Pre-commissi

oning

5

Commissio

ning Operation <10 Drainage 5-8

Air scrub

Scrubbing

10-15 5-1

0

Back washing 13-16 5 Back

washing Positive

washing 5-1

0

<10

Note： means that the valve starts or the pump operates

Date 2008-09-16 No. : QN1-SEC-G-04-TP-005

Page 35

Rev.: A

SEC


TURBINE & AUXILIARIES OPERATION MANUAL

5.4.4 Regeneration of demineralized equipments

5.4.4.1 Regeneration of one stage desalination equipment

5.4.4.1.1 Preparations for regeneration

1) There is sufficient desalination water in the desalination water tank, and check that all the

water pumps are in good standby status.

2) Adjust the flow and pressure of the operating desalination equipment to ensure making water,

and check that all the related valves of desalination equipment in operation and acid-base

system are closed.

3) The compressed air storage tank is intact and the pressure is around 0.6MPa.

4) Acid and alkali metering box for the anion and cation mixed bed is provided with acid-base

fluid for regenerating a bed body, the high level acid and alkaline storage tank have enough

acid and alkali, and the acid and alkali metering pump and regeneration system are in good

standby status.

5) The acid and alkali concentration are in good standby status.

6) The waste liquid tank is in a low liquid level.

7) Check that all valves of the regeneration system are flexibly used.

8) Close the inlet and outlet valve of the on-line chemical monitoring instruments of the

regeneration equipment, cut off the power supply, and the rest meters are in good operation.

5.4.4.1.2 Regeneration operation of one stage demineralization equipment

1) Small backwashing

Start the self-use desalination water pump, open the small anion (cation) backwashing

influent valve and backwashing drainage valve, backwash for about 10 minutes and control the

backwashing flow, so that resin expands at most and it is suitable that the backwashing height of

resin is up to the peephole middle. After the effluent is clarified, stop small backwashing.

2) Waterdrainage

Stop the self-use desalination water pump, close the small backwashing influent valve and

the backwashing drainage valve, settle the pressure resin layer of resin for five minutes, and then

open the air valve and middle discharge valve to drain water until there is no water in the pressure

resin layer. Close the air valve, and check whether resin falls off when draining.

3) Fill acid (base)

Open the manual regenerated liquid inlet valve and pneumatic valve of the cation (anion) bed,

start the self-use desalination water pump and acid (base) metering pump, open the jet influent

valve of the cation (anion) bed to pre-spray, adjust the cation (anion) bed flow and control it at

15m3/h around; after the flow is stable, open the acid (base) outlet valve of the metering tank,

adjust the acid concentration to be 2% to 2.5% and the alkali concentration to be 1.5% to 2%, fill

2.0m3 acid into the cation bed and fill 2.4 m3 base into the anion bed.

4) Replace

After filling acid (base), stop the acid (base) metering pump, close the exit valve of the acid

(base) metering tank, remain the original flow to replace for about one hour until the acidity of the

middle waste discharge from the cation bed is less than 10 mmol/l and DD of the middle waste

discharge from the anion bed is less than 100 to150us/cm, stop the regeneration water pump and

Date 2008-09-16 No. : QN1-SEC-G-04-TP-005

Page 36

Rev.: A


SEC BOP OPERATION MANUAL

stop replacing, stop the self-use desalination water pump, and close the manual valve at the mixer

outlet and the acid (base) inlet valve of the bed body

5) Small positive washing

Open the manual influent valve, influent pneumatic valve and air valve of the cation bed and

put the activated carbon filter into operation; after water flows out of the air valve of the bed body,

open the middle discharge valve, close the air valve, wash the cation (anion) bed positively slightly,

and control the flow at 100/h for eight minutes.

6) Positive washing

Open the positive discharge valve of the cation (anion) bed, close the effluent pneumatic

valve of the cation (anion) bed, wash the cation (anion) resin positively, control the flow at 120 t/h,

open the one-time sampling valve of instrument, and take positive washing until Na+ in the cation

bed effluent is no less than 100 ug/L; the anion bed effluent DD ≤ 5 us / cm and SiO2 ≤ 100 ug/L,

and the qualified positive washing water is put into opeaiton or for standby.

7) Large backwashing the cation (anion) bed

a) Start the self-use desalination water pump, open its exit valve, open the backwashing

influent valve and backwashing drainage valve of the cation (anion) bed, and adjust the

backwashing flow from small to large as large as possible when no resin falls off.

b) After the drained water is clarified, reduce the flow gradually so that resin can naturally

settle.

c) After backwashing, stop the self-use water pump, close all the valves above, and open

the emptying valve and middle discharge valve of the cation (anion) bed.

d) Drain the cation (anion) bed to the middle discharge and conduct regeneration according

to the regeneration operation steps of the cation (anion) bed.

Note: large backwashing the cation (anion) bed after it is newly put into operation,

maintenance or long-cycle operation, and then the amount of the regenerated anti-acid (base) is 2

times the normal amount.


Rev.: A



Table for regeneration operation sequence of the cation (anion) ion switch:

Cation bed valve Pump fan Flow

rt/h

Influent

valve

Backwashing

valve

Large

backwashing

influent

valve

Small

backwashing

influent

valve

Postitive

discharge

valve

Middle

discharge

valve

Effluent

valve

Mixer

outlet

valve

Acid inlet

valve of

regenerated

liquid

Metering

tank

outlet

valve

Exhaust

valve

Raw

water

pump

Self-use

desalination

water pump

Acid

metering

pump

g

age

tive

g


Date 2008-09-16 No. : QN1-SEC-G-04-TP-005

Page 38

Rev.: A

SEC



5.4.4.2 Regeneration operation of two-stage desalination equipment (mixed bed)

5.4.4.2.1. Preparations for regeneration

1) The operation desk and on-site electromagnetic valve box have been supplied with power

and gas, and the atmospheric pressure is 0.4 MPa above.

2) The acid-base system is in good standby status, and the acid-alkali metering box is provided

with enough acid-base solution.

3) The self-use desalination pump, alkali metering pump and middle water pump are in the good

standby status.

4) All the acid-base entrance valves of the mixed bed system should be closed, and the inlet and

outlet manual and pneumatic valves of the renewable mixed bed are closed.

5) The flow of the equipment in operation is properly adjusted to ensure the water level of the

renewable water and desalination water tank.

6) Various meters are provided with commissioning and operation conditions.

7) The sampling primary valve of the mixed bed outlet electroconductivity and silicon meter

should be closed.

5.4.4.2.2. Regeneration operation

1) Waterdrainage

Close the manual influent valve and influent pneumatic valve, and stop the mixed bed. Open

the positive washing drainage valve and exhaust valve, drain until the second peephole of resin

layer can be seen, close the positive washing drainage valve, and prevent siphon when draining.

2) Air scrub

Open the backwashing effluent valve and air inlet valve, adjust the air pressure at 0.10Mpa to

0.15Mpa, scrub for five minutes and then close the air inlet valve.

3) Backwashing delamination

Open the backwashing influent valve and backwashing drainage valve of the mixed bed, start

the self-use desalination pump, open its outlet valve, backwash the mixed bed, and control the

flow at 50t/h for 15 min. When the anion and cation resin are obviously separated, close the

backwashing influent valve and backwashing drainage valve.

Note: resin should settle stably after delamination. If the water backwashing delamination is

poor, soak it into the alkali, and delaminate again.

4) Waterdrainage

Open the positive washing drainage valve and exhaust valve for drainage, and close them

after draining to around 200 mm above resin.

5) Fill the acid and alkali

Open the regenerated acid liquid manual inlet valve and pneumatic valve of the mixed bed,

the regenerated alkali liquid manual inlet valve, pneumatic valve, middle drainage valve, the

influent pneumatic valve and effluent manual valve of the acid (base) mixer, start the self-use

desalination water pump, open the exit valve of the pump slowly and adjust the flow of

regenerated acid liquid to be 8m3/h and the flow of regenerated alkali liquid to be 9m3/h (the

temperature about 40 ); Open the exit valve of the acid (base) metering box, start the acid (base)

metering pump, open the exit valve of the acid (base) metering pump, and adjust the acid

Date 2008-09-16 No. : QN1-SEC-G-04-TP-005

Page 39

Rev.: A


SEC BOP OPERATION MANUAL

concentration to be 3%; open the manual outlet valve and pneumatic valve of the alkali metering

box, adjust the alkali concentration to be 3%, and fill 0.8m3 acid and 0.8 m3 alkali into the mixed bed respectively.

6) Replacement

After filling the regulated acid (alkali), close the acid outlet valve of the acid metering tank of

the mixed bed, stop the acid metering pump and the alkali outlet valve of the alkali metering box,

stop the alkali metering pump and maintain the flow to replace for 60 min; when replacing to the

drainage neutral, the middle drainage DD is less than 20μs/cm and the replacement ends.

7) Positive washing after replacement

After replacement, stop the self-use demineralization water pump, close the middle drainage

valve of the mixed bed, the manual regenerated acid liquid inlet valve and pneumatic valve of the

mixed bed, the manual regenerated alkali liquid inlet valve and pneumatic valve of the mixed bed,

the influent pneumatic valve and the manual effluent valve of the acid (base) mixer; put the

one-stage desalination equipment into operation, open the influent valve and positive discharge

valve of the mixed bed, and wash the resin of the mixed bed positively. When the

electroconductivity of the positive washing drainage is less than 10μs/cm, the positive washing

ends.

8) Waterdrainage

After replacement, the positive washing is qualified; close the influent valve of the mixed bed,

open the exhaust valve and the positive washing drainage valve of the mixed bed, and drain water

up to 200mm the resin surface, close the positive washing drainage valve, and prevent siphon

when draining.

9) Mix resin

Open the backwashing effluent valve and exhaust valve, manual air inlet valve and pneumatic

air inlet valve of the mixed bed to mix resin for about five minutes, and after the air pressure is 0.1

MPa and it is mixed evenly, close the manual inlet valve and pneumatic valve, wash the drainage

valve fully positively quickly, open the influent valve to drop resin rapidly, and prevent the layered

resin in settlement, for about 30s.

10) Positive washing

After resin drops, adjust the positive washing drainage valve to wash the mixed bed slowly,

and after the exhaust valve drains, close the exhaust valve and wash the mixed bed positively until

the mixed bed effluent DD is less than 0.2us/cm and SiO2 is less than 20ug/L; if the water quality

of the drainage water does not meet the requirements, re-wash the mixed resin positively.


Rev.: A



5.4.4.2.3. Table for operating procedures of desalination mixed bed equipment

Alkali

Acid

Back t

drainage

valve

Backwashing

influent valve

Positive

drainage

valve

Effluent

valve

Influent

valve

of

alkali

mixer

Alkali

inlet

valve

outlet

valve of

the

alkali

metering

box

Influent

valve

of acid

mixer

Acid

inlet

valve

outlet

valve of

the acid

metering

tank

Air

inlet

valve

Exhaust

valve

Middle

discharge

valve

Acid

metering

pump

Alkali

metering

pump

Self-use

Ti demineralization

mwater pump

15

5


Date 2008-09-16 No. : QN1-SEC-G-04-TP-005

Page 41

Rev.: A

SEC



5.4.5 Operations of water supply acid-base system

5.4.5.1. Preparations for dumping acid and alkali

1) Make clear delivery receipts and ask the relevant information clearly after tankers come, to

prevent mixed dumping acid-base.

2) Inform the lab technicians of the laboratory class to take samples for testing.

3) Wear acid-proof suits, rubber boots, protective masks, gloves and gas masks.

4) Record liquid level of high pH level tanker.

5) Prepare water and anti-acid-base burn liquid at the dumping acid-base site, and safety

shower pedal is not blocked and there is sufficient water pressure on the pipe.

6) The acid-base pipeline is not leaked, valve switch is flexible, liquid level indicator is precise,

and the acid mist absorber is normal.

5.4.5.2 Operations of dumping acid (base)

1) When an acid (base) tanker comes to the site, the acid (base) transport hose on the tanker is

butt jointed with the dumping acid (base) pump entrance.

2) The dumping acid (base) delivery pump is powered on and the local indicator light is on.

3) Open slowly the acid outlet valve of the acid (base) tanker.

4) Start the dumping acid (base) delivery pump, and input acid into the high level acid (base)

tank.

5) After dumping acid (base), stop the dumping acid (base) delivery pump, close the pump exit

valve, the acid outlet valve of the acid (base) tanker and the acid inlet valve of the high level

acid (base) tanker, and meanwhile remove the hose connected and clean the ground.

6) Record the acid (base) concentration, quantity, liquid level of high level acid tank and acid

tanker number in the handover sheet.

5.4.5.3 Attentions to dumping acid (base)

1) When connecting the hose, the fixed bolts connected with the flange must be tightened to

prevent leakage when dumping acid (base).

2) When removing the hose, take careful and confirm that no residual pressure exists in the

hose, to prevent residual acid (base) liquid from splashing.

3) When dumping acid (base), wear ant-acid (base) suits, rubber boots, protective masks,

gloves and other protective equipment surely and open the air inlet valve of low level storage

tank slowly.

4) When being splashed by acid (base) liquid, wash with plenty of water or in safety water

shower immediately, and conduct treatment in accordance with the medical protective

provisions of the “Rules of work of electric job security".

5.4.5.4 Operations of filling acid (base) into the metering tank

1) The high level acid (base) tank has enough acid (base) solution.

2) The acid (base) metering tank exit valve and emptying valve have been closed.

3) Acid mist absorber is normal.

4) Pay attention to observing the liquid level of the metering tank at the exit valve of high level

acid (base) tank and acid (base) metering tank inlet acid (base) valve, to prevent overflow.

Date 2008-09-16 No. : QN1-SEC-G-04-TP-005

Page 42

Rev.: A



5) Stop filling acid (base) into the acid (base) metering tank, close the exit valve of the high level

acid (base) tank and the inlet acid (base) of the acid (base) metering tank, and pay attention

to closing to prevent overflow.

Note: when filling acid (base) into the metering tank, the site must be supervised.

5.4.6 Discharge waste liquid from the water treatment waste liquid tank

5.4.6.1 Preparations

1) Waste liquid pump and Roots blower are in good standby status.

2) Self-control air source pressure is 0.4 to 0.8 Mpa.

3) Valves and pipelines are not leaked.

5.4.6.2 Discharge waste liquid from the water treatment waste liquid tank

1) When the wastewater tank is at a high level, start the Roots blower, open the air inlet valve of

the waste liquid tank, stir the air in the waste liquid tank, stop the Roots blower after 5 minutes,

and close the air inlet valve of the wastewater tank.

2) Start the waste liquid pump, open its exit valve and transmit wastewater to the wastewater

treatment station.

3) When the waste liquid tank is at a low level, stop the wastewater pump and close its exit

valve.

5.5 Common faults, judgment and disposal

5.5.1 Analysis of abnormal reasons and treatment principle of water quality of the desalination

water tank

Analysis of abnormal reasons: first: check rapidly whether the online DD or silicon meter fail

or it is caused by the not timely monitoring of the operator, confirm that the meter is accurate, and

then check whether the medicine for test is overdue or fails or a wrong medicine is used, after all

are confirmed to be accurate; 2: sample and test the water quality of the desalination water tank

and the condensation water tank of the unit, drain the unqualified water, and put the standby

desalination water equipment into operation; third: analyze whether the operating equipment has

the following circumstances when being contaminated: 1. the effluent of the anion bed is seriously

deteriorated, impacting the effluent of the mixed bed, thus the water quality is deteriorated; 2. the

mixed bed not regenerated well is put into operation for fails, as is timely not monitored to stop it; 3.

the effluent of the mixed bed flows back or the backwashing valve is not sealed or the air valve is

not sealed, resulting in resin delamination so that the effluent of the mixed bed is deteriorated; 4.

the acid inlet valve or the alkali inlet valve or the backwashing water inlet valve of the operating

equipment is not sealed, the equipment is regenerated to cause the operating equipment being

contaminated; 5. resin contaminated and aged causes the effluent being deteriorated; 6. the

effluent resin trapper of the mixed bed is damaged, causing resin to enter into the thermal system

to be decomposited. Against these possible causes, analyze and eliminate them and find reasons

for treatment.

Treatment principle: first, if the desalination water tank is contaminated, stop filling water into

the condensation water tank of the unit immediately, thus causing the contaminated desalination

system of the desalination water tank to operate and regenerate possibly, and meanwhile close

the effluent valve of a group of desalination water tanks in operation; at the same time, view


Rev.: A



immediately whether there is a change in the indicator of the water vapor system of the unit, and

stop filling water into the unit immediately if the water supply and boiler water indicators change,

drain all water out of the condensation water tank of the unit, and then fill water into the

condensation water tank of the unit with the standby desalination water tank, fill a lot of water in

the unit until the indicator is normal, and meanwhile resume the operation of the standby water

desalination equipment as soon as possible; if PH of the boiler water is low, add sodium hydroxide

and neutralize it; if the quality of the boiler water is poor and the water changed can not be

qualified, when it is up to “Class 3” processing value, report to the leadership about application for

stopping the boiler and draining the boiler water. If the water supply and boiler water indicator has

not changed, suspend to fill water into the unit, confirm the water quality of the desalination water

tank and condensation water tank of the unit, drain the unqualified water, and restore fill water into

the unit after the water quality is ok. Second, take corresponding measures for six possible

reasons: 1. isolate the contaminated anion bed and regenerate it so that it can be normal; 2.

isolate the contaminated mixed bed and regenerate it so that it can be normal; 3. eliminate the

reasons for the mixed bed delamination, re-mix resin and positively wash or re-regenerate; 4.

check the leakage valve, and stop the renewable water into the operating equipment, 5. replace

the contaminated and aged resin, and do not put the equipment into operation before replacement;

6. maintain the effluent resin trapper of the mixed bed, and do not leak resin into thermal system.

5.5.2 Effluent water from the cation bed has hardness

S/N Reason Treatment 1 The depth of the cation bed fails or

regeneration is bad Stop and maintain

2 Load is over allowable value Recover the normal flow 5.5.3 Electroconductivity of one stage demineralization water is big

S/N Reason Treatment 1 The cation bed fails and effluent water

quality is poor Stop the series and put standby series into

operation 2 The efficiency of the decarbonation fan

is low. Contact the maintenance personnel

3 The anion bed fails Stop regenerationand put backup bed into

operation 4 The periodic output amount of fabricated

water from the cation and anion bed is

too low and the influent water quality

changes.

Check water quality

5 The periodic output amount of fabricated


too low and the influent device is

damaged, and current bias occurs

Contact the maintenance personnel



Strengthen backwashing, and conduct

maintenance and treat


Rev.: A

SEC



too low and the backwashing water

volume is insufficient and resin surface

is not level



too low and the amount of acid base is

insufficient or concentration is too low

during regeneration.

Increase the amount of acid base and improve

concentration during regeneration.



too low and resin is reduced

Supplement resin



too low and the resin is polluted

Clean resin and recover

5.5.4 The cation and anion resin backwashing delamination of the mixed bed is not obvious

S/N Reason Treatment 1 Backwashing delamination is

misoperated Conduct backwashing delamination operation

according to the provision of Manual 2 Proportion of cation and anion resin

does not meet the provision Conduct backwashing delamination operation

according to the provision of Manual 3 Resin is not fully ineffective Leach with NaOH solution or immerse resin,

and then re-delaminate. 4 Resin is polluted Clean resin or recover 5 Cation and anion resin cluster or have

bubble Increase backwashing flow and leach with

NaOH 5.5.5 Active carbon falls off when the active carbon bed is backwashed

S/N Reason Treatment 1 Too big backwashing flow Adjust the opening of the backwashing water

entrance valve, and control backwashing flow

strictly 2 Control the backwashing water flow

unstably Open the backwashing entrance valve slowly

3 The drainage valve damaged Stop and maintain 5.5.6 Resin in the mixed bed in operation falls off

S/N Reason Treatment 1 The effluent water hat of the mixed bed

is unqualified or damaged Replace the effluent water hat

2 The water hat installed does not meet

the requirements Contact the maintenance personnel,

investigate the cause and re-install 5.5.7 Quartz sand or resin in the cation or anion bed in conventional well-flushing or operation is

taken out

Date 2008-09-16 No. : QN1-SEC-G-04-TP-005 Page 45 Rev.: A

SEC



S/N Reason Treatment 1 Confused layers at the bottom of switch Stop and maintain 2 Unqualified granularity of quartz sand

cushion causes uneven water

distribution

Change quartz sand cushion with qualified

granularity

5.5.8 Decarburizator has low efficiency

S/N Reason Treatment 1 Fan turns reversely Contact the electrical personnel for

maintenance 2 Inadequate wind pressure and force Contact the maintenance personnel or change

the fan 3 Too much flow Reduce inlet flow 4 Inadquate or too much filling Supplement or reduce filling 5 Water inlet device is damaged or is

provided with uneven water Contact the maintenance personnel to treat

6 Water Steam Supervision System Operation Manual

6.1 Technical specification

6.1.1 Water-vapor sampling system equipment

Parameter of

sampling point

Instrument disposition

Name of sampling

point Pressure

MPa Temper ature

CC

SC

pH

O2

SiO2

N2

H4

M

Condensate pump

outlet

2.8

42

Deaerator outlet pipe

0.8

170

Deaerator inlet pipe

0.8

170

Economizer inlet

20

291

Economizer outlet

20

291

Boiler water（left）

20

360

Boiler water（right）

20

360

Saturated steam

（left）

20

360

Saturated steam

（right）

20

360

Superheated steam

17.5

541

Closed clod water 0．4

50


Rev.: A

SEC



Parameter of

sampling point

Instrument disposition

Name of sampling

point Pressure

MPa Temper ature

CC

SC

pH

O2

SiO2

N2

H4

M

Reheater steam

5

541

Boiler sewage

disposal tank

0.423

153

Low-pressure heater

drainage

0.423

133.5

High-pressure heater

drainage

1.755

181.8

Boiler feedwater

0.2

50

Condenser hotwell 1

Condenser hotwell

21

Note： is the sampling points and instruments set, and is manual sampling points set

is to set a block of meter and all sampling points operate alternately.

Water-vaport on-line instrument:

S/N

Name

Specification and model

Unit

Qty

Manufacturer

1

Conductance meter

DDG-5188

Set

7×2

Shanghai Lihe

2

Hydrogen conductance

meter

DDG-5188

Set 5×2

Shanghai Lihe

3

Acidity meter

PHG-5288 Set

6×2

Shanghai Lihe

4

Oxygen meter

9182

Set 3×2

POLYMETRON

COMPANY 5

Silicon meter

(four-channel)

9210

Set 1×2

POLYMETRON

COMPANY 6

Hydrazine meter

9186

Set

1×2

POLYMETRON

COMPANY

6.1.2 Chemical dosing system equipment

S/N

Name

Model and specification

Unit

Qty

Remark

1

Ammonia solution

tank V=1.0m3，φ1000

Set

2

Material:1Cr18Ni9Ti

with motor agitating


Rev.: A

SEC



device N=1.1kW

2

Feed-water

ammonification

metering pump

Q=58l/h

Set 3

Frequency conversion,

hydraulic pressure

diaphragm 3

Condensated water

ammonification

metering pump

Q=22l/h

Set 3


hydraulic pressure

diaphragm 4

Hydrazine solution

tank

V=1.0m3，φ1000 Set

2

Material:1Cr18Ni9Ti


device N=1.1kW 5

Feed-water

hydrazination

metering pump

Q=58l/h

Set 3


hydraulic pressure

diaphragm 6

Closed cooling water

hydrazination

metering pump

Q=22l/h

Set 2

Hydraulic pressure

diaphragm

7

Phosphate solution

tank

V=1.0m3，φ1000 Set

2

Material:1Cr18Ni9Ti


device N=1.1kW 6.1.3 Vapor-quality control standard

1) Condensated water quality standard

Control standard

Item

Unit Startup

Normal

Expected

value

Time interval

(H)

Remark

Hardness μmol/L ≈0 ≈0 ≈0 24

Positive KWH μs/cm ≤1.0 ≤0.3 ≤0.15 2 Dissolved

oxygen

μg/L

≤50

≤30

≤30

2

Read the online meter

once per 2h and manual

meter once per 24h Sodium μg/L ≤20 ≤10 ≤5 Assessment Ditto silicon dioxide μg/L ≤30 ≤20 ≤5 Ditto Iron μg/L ≤50 ≤20 ≤10

Copper μg/L ≤20 ≤5 ≤3 2) Feed-water quality standard

Control standard

Item

Unit Startup

Normal

Expected

value

Time interval

(H)

Remark

Total hardness μmol/L ≈0 ≈0 ≈0 24


Rev.: A

SEC



silicon dioxide

μg/L

≤30

≤20

≤10

2



meter once per 24h dissolved

oxygen

μg/L

≤30

≤7

≤7

2



meter once per 24h

Chemical

deoxidant

μg/L

-

10-50

10-30

2

PH

9.0-9.6

9.0-9.6

9.0-9.6

2

First-class

ammonification 9.0-9.6 Positive KWH μs/cm ≤0.65 ≤0.3 ≤0.15 2 Iron

μg/L

≤50

≤20

≤10

Startup or

assessment

Copper

μg/L

-

≤5

≤3

Startup or

assessment

3) Boiler water quality standard

Control standard

Item

Unit Startup

Normal

Expected

value

Time

interval

(H)

Remark

silicon dioxide

μg/L

Silicon

cleaning

requireme

nt

≤250

≤100

2


once per 2h and manua

meter once per 24h

PH（25）

9－10

9-10

9.3-9.5

2



meter once per 24h phosphateradica

l

mg/L

0.5-3.0

0.5-3.0

0.5-1.5

2



meter once per 24h Conductivity

μs/cm

-

≤60

≤20

-



meter once per 24h 4) Steam quality standard

Control standard

Item

Unit Startup

Normal

Expected

value

Time

interval

(H)

Remark

Cation

conductance

μs/cm

≈0

≈0

≈0

2


Rev.: A

SEC



Sodium

μg/L

≤20

≤10

≤5

2


once per 2h and

manual meter once per

24h

silicon dioxide

μg/L

≤30

≤20

≤10

2


once per 2h and

manual meter once per

24h

Iron

μg/L

≤50

≤20

≤10

Startup

and

assessme

nt

Copper

μg/L

≤15

≤5

≤3

Startup

and

assessme

nt

5) Cooling water quality standard of generator stator

Item

Unit

Control standard

Expected

value

Time

interval

(H)

Remark

PH

≥6.8

7.0-8.0

2

Read the online

meter once per 2h

and manual meter

once per 24h Hardness μmol/L ≈0 ≈0 24

Electroconductivity

μs/cm

＜1.5

＜1.0

2

Read the online

meter once per 2h

and manual meter

once per 24h Copper μg/L ≤40 ≤30 Assessment 6) Closed circulating cooling water

Item

Unit

Control

standard

Expected

value Time interval

(H)

Remark

PH

8-9

8-9

2

Read the online

meter once per 2h

and manual meter

once per 24h

Electroconductivity

μs/cm

≤30

≤20

2

Read the online

meter once per 2h

and manual meter

once per 24h

Date 2008-09-16

No. : QN1-SEC-G-04-TP-005

Page 50

Rev.: A



6.2 Chemical supervision during unit operation

6.2.1 Chemical supervision at initial startup stage

6.2.1.1 Preparations for startup

1) Prepare analytical instruments and chemical medicines before the start of the units, clean the

instruments and prepare sufficient medicines.

2) Prepare adequate and qualified demineralized water.

3) Check that the steam-water sampling device, dosing equipment and chemical instrument

should be intact and in good standby status, and the closed cooling water system is in normal

use.

4) The dosing pump should be provided with above two thirds lubricant and all dosing pumps are

in good standby status.

5) Check whether the sampling cooling water should be sufficient, and open all the cooling water

inlet valves of samplers and observe whether the cooling water pressure is normal; defects

found will be timely processed.

6) Check that the liquid level of the phosphate metering tank, ammonia metering tank and

hydrazine metering tank should be higher than two thirds, or else it should be dosed.

7) Open the exit valve of the liquid medicine metering tank and the entrance valve of the

phosphate pump, ammonia metering pump and ammonia metering pump.

8) Contact the centralized control operator to open the primary continuous sewage disposal,

sampling and dosing valve.

9) Contact the maintenance thermal-control personnel to prepare for putting the chemical

instruments into operation prior to startup.

6.2.1.2 Chemical monitoring when starting

1) When the unit start, the leader on duty shall timely notify the chemical principal, who arranges

the opening of the cooling water entrance valve of the water-steam sampler of the unit and

observes that the cooling water pressure is normal, and contacts promptly to maintain and

treat the defects found.

2) When the unit begins to start, contact the centralized control operator to open the primary

sampling, dosing and continuous sewage disposal valve; after it has been verified that all the

primary valves are opened, adjust the cooling water volume of each sampler, adjust the

sampling water flow to wash the samplers; after the samplers are clean, adjust the manual

sampling water flow at 500 ml/min, and maintain stable flow and adjust the sampling water

temperature at 25 to 30.

3) Wash the condenser with water: when water flows into the condenser, after starting the

condensate pump, the leader on duty notices the chemical principal to begin washing the

condenser. The chemical principal starts the condensated water ammonification pump to

ammonify condensated water, and adjusts the condensated water pH at 8.8 to 9.3. Wash it

until the condensated water hardness is close to 0 μmol/L, iron content is no more than 50

μg/L and SiO2 content is no more than 30 μg/L, and thus the condenser washed is qualified,

as is reported to the leader on duty. The leader on duty can not conduct the next step until

receiving the chemical water quality report.


Rev.: A



4) Wash the deaerator with water: when starting to fill water into the deaerator, the leader on

duty notices the chemical principal to begin washing the deaerator, and coordinates at the

same time to put the deaerator heater into operation in order to ensure the deoxidization

effect. Chemical operator starts the feedwater ammonification pump and hydrazine pump to

add ammonification and pump into the feedwater, maintaining feedwater pH of 8.8 to 9.3 and

deaerator content of 10 to 50 μg/L. Monitor water samples of the rear sampling point of the

deaerator, and if the hardness is close to 0 μmol/L, iron content is no more than 50 μg/L, SiO2

content is no more than 30 μg/L and dissolved oxygen is no more than 30 μg/L, the deaerator

washed is qualified, as is reported to the leader on duty. The leader on duty can not conduct

the next step until receiving the chemical water quality report.

5) Wash the boiler with water in cold status: when the boiler is filled with water, the leader on

duty notices the chemical principal to fill water into the boiler, and the chemical principal starts

the phosphate dosing pump to dose into the steam drum and opens the continuous and

intermittent blowdown of the boiler. The chemical principal blows down samples of the

water-steam sampling devices and inputs the manual sampling system, and analyzes the

boiler water pH, phosphate content, iron content and SiO2 content. Control the boiler water

pH at 9.0 to10.0 and phosphate radical at 0.5 to 3.0mg/L; when the iron content is no more

than 50 μg/L and SiO2 content is no more than 30 μg/kg, the leader on duty is reported about

the qualified boiler washed in cold status. The leader on duty can not conduct the next step

until receiving the chemical water quality report.

6) Wash the boiler with water in hot status: after the boiler is ignited, the leader on duty notices

the chemical principal that the boiler has been ignited, and the continuous and intermittent

blowdown of the boiler maintain fully open, so that the boiler water is clarified as soon as

possible. Test chemically the boiler water pH, phosphate radical, iron content and SiO2

content, and control the boiler water pH at 9.0 to 10.0, phosphate radical at 0.5 to 3.0mg/L,

iron no more than 300 μg/L and SiO2 content no more than 300 μg/kg; test the iron content,

SiO2 content, copper content and sodium content in steam; when SiO2 content in steam is

more than 30μg/kg, iron content is more than 50 μg/L, copper content is more than 15 μg/L

and sodium content is more than 20 μg/L, the leader on duty is reported about the qualified

steam and rolling can be done. The leader on duty can not conduct the next step until

receiving the chemical water quality report.

7) Recycling requirements of condensated water after the steam turbine is rolled: the leader on

duty notices the chemical principal that the steam turbine has been rolled, and requests at this

time that the condensated water in the steam turbine can not be recovered and must be

discharged from the condenser; after the condensated water of the steam turbine is clear and

transparent visually outside, test the condensated water hardness, iron content and copper

content by sampling; when the condensated water hardness of the steam turbine is close to

0μmol/L, iron content is no more than 50 μg/L, copper content is no more than 15μg/L and

SiO2 content is no more than 20μg/L, the leader on duty is reported that the condensated

water can be recycled .


Rev.: A



8) Wash silicon in the boiler by heating and lifting pressure: begin washing silicon when the main

steam pressure of the boiler rises to 7.5MPa. While washing silicon, monitor the boiler water

pH, phosphate content, iron content and SiO2 content at the same time, and control the boiler

water pH at 9.0 to 10.0, phosphate radical at 0.5-3.0mg/L, iron no more than 300 μg/L and

SiO2 following the requirements of washing silicon; when the SiO2 content in the boiler water

is up to the next pressure level allowable SiO2 content, pressure can continue to rise, and

silicon is washed according to the circular manner of “lifting pressure - lifting load –

decreasing pressure (to the point higher than the starting value of the previous lifting pressure)

– lowering the boiler water concentration (increasing the boiler blowdown and improving water

purity) - lifting pressure” until reaching the rated pressure. SiO2 content of the boiler water and

SiO2 content and pressure of steam are correspondingly shown in the table as follows:

Steam drum pressure

（MPa） 7.5-

10.0 10.0-

12.5 12.5-

15.0 15.0-

16.0 16.0-

17.0 17.0-

18.4 SiO2 content of the boiler water (μg/L）

3000

1500

500

400

300

250

SiO2 content of steam

(μg/L）

30

30

30

30

30

30-20

In the process of lifting pressure of the boiler, the SiO2 content of the boiler water and steam is

continuously analyzed. After SiO2 content of the boiler water and steam is qualified, the leader

on duty is timely reported, in order to adjust the operating conditions of the boiler to conduct

the next parameter pressure.

9) After the end of washing silicon, analyze chemically comprehensively the steam, boiler water,

feedwater and condensated water quality, and adjust dosage or sewage disposal in

accordance with water quality; the water quality indexes of the water-vapor system are up to

the normal value standards within eight hours when the units are parallel in; contact the

leader on duty to make timely adjustment if failing in meeting the standards.

10) Contact the thermal-control personnel to put related chemical instruments into operation (but

the pH scale must be input after the constant temperature system works) and do a good job in

detailed records when starting them.

6.2.2 Chemical supervision during normal operation stage of generating units

1) Patrol inspect and read the online instrument once every two hours, conduct a manual

laboratory test every day, investigate the reasons timely if the water vapor quality is

unqualified, check and confirm the experiment, increase in the number of analysis if the

experiment is correct, and strengthen water supply, correct the boiler water, contact the

centralized control personnel, adjust the operating conditions, and report to the chief and

leader on duty. Treat the problems related and make records in accordance with the vapor

quality deterioration third-class treatment principle and methods.

2) According to water-vapor quality, notice the centralized control personnel to adjust the

continuous blowdown of the boiler and ward the blowdown work regularly.

3) According to analysis conditions of water quality, adjust timely the amount of ammonia,

deoxidant and phosphate, guarantee that their content is qualified and at the same time


Rev.: A



maintain the minimum level of chemical dosage. Chemical dosage should be uniform and

continuous as far as possible.

4) When the dissolved oxygen in the deaerator water and condensed water exceeds the

standard, strengthen supervision and make operating records, control the deaerator content,

and at the same time contact the centralized control personnel to adjust and treat.

5) Check the dosing equipment in operation every two hours once, treat the problems found

timely, or contact the maintenance personnel to eliminate them.

6) Adjust the temperature and flwo of samples in the allowed range and contact promptly the

maintenance personnel to treat the flaws.

7) Wash the sampling water of the high-temperature water-vapor sampling bracket to dispose

sewage at 10:00 every Monday once.

8) During the operation of the units, monitor the leakage of the condenser closely. When the

hardness or conductivity of the condensated water exceeds the standards, increase the

number of analysis, control the boiler water pH and phosphate radical within the qualified

scope, strengthen the sewage disposal, report to the chief and leader on duty and make

records.

9) The continuous blowdown of the boiler should be adjusted based on the control standard of

the boiler water and blowdown rate, avoiding too big blowdown rate from affecting economy

and too small blowdown rate from affecting the steam quality. The regular blowdown of the

boiler under normal circumstances is conducted once every morning shift daily; when the

boiler water concentration is over 50% of the normal value, the boiler water is turbid and the

quality of feedwater is bad, the number of blowdown should be increased.

10) Check the quantity of testing medicines and prepare the dosage for weekend on day shift

every Friday.

6.2.3 Chemical monitoring of the boiler during stoppage stage

1) After the generating unit stops, the chemical person on duty should stop the corresponding

water-vapor chemical monitoring instruments, close the corresponding water-vapor sampling

valve and sampling cooler, cooling water inlet and outlet valve. Pay attention to purging the

remaining water in various sampling pipes, to prevent the sampling system from being

corroded and blocked. When the thermal equipments stop or are backupped, maintain them

according to the relevant provisions of stoppage (backup) maintenance.

2) After the generating unit operates normally in a short term, protect the boiler from corrosion by

maintaining feedwater pressure, and purge the remaining vapor inside the pipeline connected

the steam turbine body for anti-corrosion of the steam turbine after stopping so that the

cylinder keeps dry.

3) When the generating unit is partly repaired or stops for not more than 30 days, protect it by

using the method that hot boiler discharges water and waste heat is used for drying.

4) When the generating unit is overhauled or stops for more than 30 days, protect it by stopping

using octadecyl amine.


Rev.: A

http://dict.cnki.net/dict_result.aspx?searchword=%e5%8d%81%e5%85%ab%e8%83%ba&tjType=sentence&style&t=octadecyl%2Bamine



6.3 Chemical protection of standby unit

In order to prevent the thermal equipment from being corroded during stoppage (standby)

period and ensure the secure and economic operation of the unit, according to “Manual for

chemical supervision” and “Rules of anti-corrosion for thermal stoppage (standby) equipment in

thermal power plants”, it is necessary to take effectiveanti-corrosion protection measures for the

thermal equipment during the stoppage to prevent the boiler, heater, steam turbine and other

equipment from being corroded and damaged, and the protection measures are specially

prepared as follows combined with the actual situation of the company:

6.3.1 Anti-corrosion protection methods

6.3.1.1 Ammonia – deoxidant comined passivation + water discharged from hot boiler and waste

heat for drying

1) Scope of use

The method applies to the circumstance under which the unit stops for less than a week.

2) Technical points

Using feedwater and condensated water chemical dosing system to inject ammonia and

deoxidant to the system two hours before the boiler stops, improve PH value and deoxidant

concentration and form protective membrane under the high temperature, and then the boiler

discharges hot water and is dried by waste heat.

3) Operating methods

Using feedwater and condensated water chemical dosing system to inject ammonia and

deoxidant (acetone oxime in the first and second stage and hydrazine in the third) to the system

two hours before the boiler stops; PH is up to 9.5 to 10.0 at the entrance to the economizer, the

deoxidant concentration is 30 to 50 mg/L and the deaerator concentration of the boiler water is

200 to 400 mg/L. In the process of stopping the boiler, maintain two hours when the steam drum

pressure declines to 4.0 MPa and then continue to release pressure; when the steam drum

pressure declines to 0.5 to 0.7 MPa (135MW generating unit) and 0.6 to 0 .9 MPa (300MW

generating unit), discharge the boiler water rapidly. In the course of discharging water, open fully

the air valve, exhaust valve and water drain valve, and ventilate and discharge moisture in the

boiler naturally. After the end of discharging water, close the air valve, exhaust valve and water

drain valve and seal up the boiler.

4) Attentions

While the boiler release pressure and drains water, control strictly that the temperature of the

upper and lower wall of the steam drum does not exceed the allowable value.

6.3.1.2. Adding octadecylamine and water discharged from hot boiler and waste heat for drying

1) Scope of use

The method applies to the circumstance under which the unit stops for more than a week.

2) Technical points

When the unit stops, add octadecylamine into the thermal system, and it is volatile at a high

temperature to form steam after it enters into the boiler, thus full of the boiler, steam turbine and

the whole thermal system. A layer of hydrophobic octadecylamine protective film forms on the

metal surface of all parts of the thermal system, to separate the metal from the air, thereby


Rev.: A



preventing the metal from being corroded by water, oxygen and carbon dioxide in the atmosphere

during the stoppage of the equipment, protecting the equipment.

3) Operating methods

a) Using special rapid dosing device of octadecylamine emulsion and connect its outlet hose

to the outlet pipe of the hydrazine pump.

b) Dosing: 10% pure octadecylamine emulsion 200 kg/time, (135MW generating unit),

400kg/time (300 MW generating unit).

c) When the main steam temperature drops to 500 below and it is estimated that it is about

1.5 to 2 hours before the main steam valve is closed after the unit stops (usually, it is

estimated under the power level in the coal powder warehouse), and the leader on duty

notices the chemical principal to begin to dose (at this time feedwater flow is suppressed

as much as possible. Superheated steam temperature can be adjusted at 400 to 500 and can not be higher than 500 , and the water level of the steam drum is controlled at

low water level).

d) Chemical dosing is under control completed generally for about 30 minutes. After dosing,

wash the dosing box and pump with water, open the dosing pump for 10 minutes, and

wash the dosing pipeline.

e) Report to the leader on duty after dosing, and the generating unit should systematically

circulate for 1 to 1.5 hours before downtime after completion of dosing.

f) Stop the boiler and hot boiler discharges water: when the steam drum pressure drops to

0.5 to 0.7MPa (135MW generating unit) and 0.6 to 0 .9 MPa (300MW generating unit) in

the process of stopping the boiler, discharge the boiler water quickly. In the course of

discharging water, open fully the air valve, exhaust valve and water drain valve, ventilate

and discharge the moisture from the boiler naturally. After discharging water, close the air

valve, exhaust valve and water drain valve and seal up the boiler.

4) Attentions

a) While the boiler releases pressure and drains water, control strictly that the temperature of

the upper and lower wall of the steam drum does not exceed the allowable value.

b) Since dosing, begin to record PH and conductivity meter of feedwater, boiler water,

superheated steam and condensated water, and make a record every five minutes

(usually, the conductivity increases slightly but PH does not change)l if conductivity and

PH are significantly abnormal, conduct manual re-testing immediately by sampling.

c) Record the boiler operation parameters (load, feedwater flow, main steam temperature

and water level of steam drum) during dosing every five minutes.

d) After beginning to dose, pay attention to water samples at the sampling points. When there

is white turbidity in water samples, dosing is normal, or else the dosing liquid has not

completely entered into the system and the chemical dosing system (including the

feedwater system) should be timely inspected.

e) There is no foreign body in the liquid when dosing, and massive octadecylamine should be

stirred up and scattered to prevent the pump from being blocked.


Rev.: A



6.4 Operation of the boiler chemical dosing system of the boiler

6.4.1 Phosphatizing the boiler water

6.4.1.1 Preparations for phosphatizing

1) Check that the relevant valves of all equipments of the phosphatizing system are switched off.

2) Check that the system is in good standby status.

6.4.1.2. Preparation of phosphate solution

1) Around 1% Na3PO4 • 12 H2O and Na2HPO4 • 12 H2O or NaOH are respectively prepared in

the phosphate solution tank, and a mixed solution is generally not prepared.

2) Weigh appropriate solid Linsuansanna, Na2HPO4 or sodium hydroxide once, pour into the

phosphate solution tank and co-ordination phosphate solution tank, open the inlet valve of the

deionization water, and close the inlet valve after the water level is up to a certain height, start

and stir the motor so that liquid in the solution tank is fully dissolved and mixed evenly before

stopping the stirring motor.

3) If phosphate is easily not dissolved, open the heating device so that the solution temperature is up to 50 to 60, and then open the stirring motor to stir until the solution is dissolved

completely.

6.4.1.3. Phosphate dosing steps

1) Contact the centralized control personnel to open the primary boiler water dosing valve.

2) Open the exit valve of the metering tank.

3) Open the inlet and outlet valve of the metering pump.

6.4.1.4. Manually start and stop the dosing pump

1) Switch the design metering pump to the “on-site” shift, start the dosing pump, and adjust the

dosage of the dosing pump according to needs.

2) Check that the motor, gearbox and all rotating parts have no abnormal noise and pressure

gauge is slightly higher than the steam drum pressure, and the dosing pump can not leave

after the pressure is normal.

3) Stoppage of the dosing pump: stop the dosing pump and close the exit valve of the dosing

pump.

6.4.1.5. Automatic dosing operation

1) Switch the phosphate dosing pump and coordination phosphate dosing pump control knobs

to “Programmed-control” shift and switch the frequency converter to “Input”.

2) In ”Soft hand” state of the CRT, start the dosing pump and adjust the pump frequency

manually on the CRT.

3) In the “Automatic" state of the CRT, phosphate dosing pump and coordination phosphate

dosing pump enter into the automatic dosing state according to the phosphate radical

concentration of the boiler water and automatically start and stop, and coordinate dosing.

4) Stoppage of the pump: in the “Soft hand" state of the CRT, press the dosing stop switch to

end the stopping the pump.

6.4.1.6. Automatic phosphate dosing exists

When the automatic dosing fails, it can be switched to the manual dosing; switch the pump in

the system to the “Soft hand" state of the CRT, and switch the control knob on the start and stop


Rev.: A



button of the CRT or the on-site switch box to “on-site” to start and stop the dosing pump on the

site.

6.4.2 Feedwater and condensated water ammonification treatment

6.4.2.1. Preparations for ammonification

1) Check that the relevant valves of all ammonification system equipments are switched off.


6.4.2.2. Preparation of ammonia solution

1) Open the water inlet valve of ammonia solution metering tank, and close the water inlet valve

when the water level reaches a certain level.

2) Open the ammonia inlet valve of the ammonia metering tank, ammonia filling inlet valve and

ammonia bottle outlet valve to fill ammonia, pay attention to the pressure display (for example,

the ammonia bottle outlet valve should be immediately closed to change the ammonia bottle

filled with ammonia liquid if no pressure), close the ammonia bottle outlet valve, ammonia

filling inlet valve and ammonia inlet valve of the ammonia metering tank after filing sufficient

amount of ammonia.


1) Contact the centralized control personnel to open the primary ammonification valve.

2) Open the exit valve of the ammonia metering tank and the entrance and exit valve of the

ammonia pump, switch the dosing metering pump to the “on-site” shift, start the dosing pump,

and adjust the dosing pump stroke in accordance with needs to adjust dosage.

3) Check that the motor, gearbox and all rotating parts have no abnormal sound, and the dosing

pump can leave after the pressure is normal.

4) Stoppage of the dosing pump: stop the dosing pump and close the exit valve of it.


1) Switch the ammonia pump control knob to the “Programmed-control" shift and switch the

frequency converter to “Input”.



3) In the “Automatic" state of the CRT, phosphate dosing pump enters into the automatic dosing

state according to the feedwater pump, closed cooling water and condensed water pH value.



6.4.2.5. Automatic phosphate dosing exists




site.

6.4.3 Water and closed cold water hydrazination

6.4.3.1. Preparations for hydrazination

1) Check that the relevant valves of all ammonification system equipments are switched off.



Rev.: A



6.4.3.2. Preparation of the ammonia solution

1) Check whether the connecting pipe is connected with the hydrazine metering pump liquid

pump well, and insert the pump inlet pipe into the hydrazine storage barrel.

2) Open the entrance valve of the hydrazine metering tank, start the hydrazine self-suction pump,

and inject appropriate hydrazine to the hydrazine metering tank.

3) Stop the hydrazine metering pump liquid pump, and close the entrance valve of the hydrazine

metering tank.

4) Open the water inlet valve of the hydrazine solution metering tank, and close the water inlet

valve when the water level reaches two thirds liquid level.

5) Start the agitator to stir until the solution is evenly mixed before stopping preparation.


1) Contact the centralized control personnel to open the primary hydrazination valve.

2) Open the exit valve of the hydrazine metering tank and the entrance and exit valve of the

hydrazine pump, switch the dosing metering pump to the “on-site” shift, start the dosing pump,

and adjust the dosing pump stroke in accordance with needs to adjust dosage.

3) Check that the motor, gearbox and all rotating parts have no abnormal sound, and the dosing

pump can leave after the pressure is normal.

4) Stoppage of the dosing pump: stop the dosing pump and close the exit valve of it.


1) Switch the hydrazine dosing pump control knob to the “Programmed-control" shift and switch

the frequency converter to “Input”.



3) In the “Automatic" state of the CRT, hydrazine dosing pump enters into the automatic dosing

state according to the feedwater flow to change frequence automatically.



6.4.3.5. Automatic hydrazine dosing exits




site.

6.5 Reason and treatment of water steam quality deterioration

6.5.1 Water-vapor cracking treatment principle

1) When the water-vapor quality is deteriorated, strengthen the analysis, first of all check

whether our own analysis and determination are right and the sampling containers are clean,

identify whether the water-vapor samples are correct and representative, and then analyze

whether the drugs used go bad and whether calculation methods are accurate and correct.

2) After determining that the analysis is accurate, report to the chief and the leader on duty

timely to propose the chemical supervision and treatment advices.


Rev.: A



3) For the deterioration in the water-vapor quality, the persons on duty make records on the

extent, reasons, and treatment processes and results of water-vapor deterioration. If there are

accidents resulted from chemical reasons, chemical professional staff should be organized to

conduct accident analysis and timely treatment, to restore water-vapor standard value as

soon as possible.

6.5.2 Tertiary treatment principle

The key chemical indexes of the boiler feedwater, boiler water and condensated water are

processed according to the tertiary treatment values, and the meaning of tertiary treatment values

are as follows:

First treatment value - 2 times the normal value, with the possibility of accumulated impurities

and corrosion, it should be restored to the normal value within 72 hours.

Secondary treatment value - 2 times first treatment value, the accumulated impurities and

corrosion will surely occur and it should be restored to the normal value within 24 hours.

Tertiary treatment value - more than the secondary treatment value, experience has shown

that corrosion will be rapidly carried out and the boiler should stop in four hours.

In every level of the non-normal treatment methods, if it can yet not return to the normal within

the required time, a higher level of treatment method should be taken. In the steam drum boiler,

one of the methods for restoration of the normal value is relieve pressure in operation.

When the water-vapor quality is abnormal, the contents in the table below shall be

implemented:

Treatment value Water sample

Item

Normal value

First class Second class Third class

Sodium μg/L ≤10 10～20 20～35 ＞35 Condensated

water Electroconductivity

μs/cm

≤0.3 0.3～0.4 0.4～0.5 ＞0.5

Copper 8.8～9.3 <8.8 or >9.3

pH(25) No

copper 9.0～9.6

<9.0 or >9.6

＜8.0

～

Electroconductivity

μs/cm

≤0.3 0.3～0.4 0.4～0.65 ＞0.65

Feedwater

Dissolved oxygen

μg/L

≤ 7 ＞7 ＞20 ～

Boiler water PH (25) 9～10 ＜9.0 ＜8.5 ＜8.0

If feedwater PH is less than 7.0 or condensated water sodium is more than 400 ug/l, the machine

should be immediately shut down Note: when there is abnormal water quality, CL-, Na+, conductivity and alkalinity in the boiler

water should also be determined in order to identify the reasons and take corresponding

measures.

6.5.3 Feedwater turbidity

S/N Reason Treatment


Rev.: A

SEC



1 The condensated water, drainage and

supply water of feed water are turbid Identify the polluted water source, cut off the

pollution source and treat the water source. 6.5.4 Unqualified dissolved oxygen in feedwater

S/N Reason Treatment 1 The deaerator operates abnormally Adjust the operation of the deaerator 2 The internal device of the deaerator fails Contact the maintenance personnel to treat the

failure. 3 Too much replenished water in the

deaerator Reduce the instantaneous replenished water

and balance replenishment 4 The sampler is not sealed Contact the maintenance personnel to treat

timely 6.5.5 Unqualified silicon content and sodium content（or conductivity）in feedwater

S/N Reason Treatment 1 The silicon content and sodium content

in the condensated water, drainage and

supply water of feed water are

unqualified

Identify the unqualified water source, cut off

the pollution source and treat the water source.

2 When the continuous blowdown

expansion tank is put into operation,

steam with water of the deaerator goes

into it.

Adjust the operation of the continuous

blowdown expansion tank

6.5.6 Unqualified iron and copper content in feedwater

S/N Reason Treatment 1 In the early stage when the generating

unit starts, the water-vapor system has

high copper and iron content.

Change water and increase the sewage

disposal capacity

2 The iron and copper content in drainage

are high. Identify the drainage with high iron and copper

content and remove them. 3 pH controlled too lowly Improve the feedwater pH. 4 Feedwater system is corrided Strengthen ammoniation treatment and do a

good job in antisepticise. 6.5.7 Unqualified feedwater pH

S/N Reason Treatment 1 Too high or low ammonification volume Detect the ammonia solution concentration and

make appropriate adjustment of

ammonification volume. 2 The ammonification system fails Check and contact the maintenance personnel

to eliminate the failure. 3 The pH of condensated water and

feedwater comprising supply water is

Identify the water source with abnormal pH,

and treat the water source.


Rev.: A

SEC



normal

6.5.8 Unqualified condensated water hardness or conductivity

S/N Reason Treatment 1 The condenser leaks Check and block leakage 2 The replenished water in the condenser

is unqualified Change qualified water

3 Unqualified reclaimed drainage water Cut off pollution source and treat the water

source 6.5.9 Unqualified dissolved oxygen in condensated water

S/N Reason Treatment 1 Vacuum part of the condenser leaks. Investigate and block leakage 2 The undercooling degree of the

condenser is too bid. Adjust the under cooling degree of the

condenser 3 Air goes into the condensated water

pump in operation. Activate the standby pump and maintain the

defective pump. 4 Excessive condensated water

replenishing capacity Strengthen the readjustment and balance

water replenishing to prevent water

replenishing capacity from fluctuating. 6.5.10 Silicon and sodium content of steam exceed the standard

S/N Reason Treatment 1 Silicon and sodium content of the boiler

water exceed the standard Increase the discharge capacity of the boiler

2 The operating conditions of the boiler

are instable, steam drum water level is

high and the load changes greatly.

Report to the leader on duty and adjust the

operating conditions of the boiler.

3 The steam-water separator has flaws or

low efficiency. Eliminate defects and improve the separative

efficiency 4 Too big dosing concentration or too fast

dosing. Strengthen sewage disposal and adjust the

chemical dosing situation. 5 Desuperheater water quality is bad. Improve the desuperheater water quality 6.5.11 Boiler water is turbid visually outside

S/N Reason Treatment 1 Turbid feedwater or too big hardness Identify polluted water source, cut off it and

treat water source, to carry the boiler sewage

disposal until clarification 2 The sewage of the boiler is not disposed

for long time or the discharge capacity is

not enough.

Implement the boiler sewage disposal

3 The new period or the initial stage of the

maintenance boiler put into operation. Increase the discharge capacity of the boiler

until water quality is qualified. 6.5.12 Silicon content and sodium content (or conductivity) of the heater water are unqualified


Rev.: A

4

4

SEC



S/N Reason Treatment 1 Feedwater quality is poor Identify polluted water source, cut off it and

treat water source, and adjust the operation of

the continuous sewage disposal expansion

tank of the boiler. 2 Boiler sewage is not normal. Increase the discharge capacity of the boiler or

eliminate the defects of the sewage disposal

device. 6.5.13 The boiler water PO 3-

is higher than the standard

S/N Reason Treatment 1 Too big phosphate solution

concentration Dilute phosphate concentration

2 The outlet liaison valve of the dosing

pump is not closed tightly so that

phosphate is added into another boiler.

Check whether outlet liaison valve of the pump

is opened or closed correctly.

3 The operating conditions of the boiler

change drastically and the concentration

rate of the heater water is high.

Adjust the operating conditions of the boiler

and strengthen the sewage.

4 Hidden phosphate is dissolved. Strengthen supervision and increase the

sewage. 6.5.14 The boiler water PO 3-

is lower than the standard

S/N Reason Treatment 1 Low phosphate solution concentration Increase phosphate concentration 2 Solution tank has no liquid medicine or

the dosage pump does not work Investigate the cause, and eliminate defects

3 The outlet liaison valve of the pump is

loose or opened wrongly. Check whether the outlet liaison valve of the

pump is closed tightly or is opened correctly. 4 The condenser seriously leaks, the

condensated water is badly treated,

causing large feedwater hardness.

Investigate and block the leakage of the

condenser and increase the dosage.

5 Too much discharge capacity Reduce discharge capacity 6 The operating conditions of the boiler

change drastically and phosphate

temporarily disappears.

Adjust the operating conditions of the boiler to

prevent phosphate from disappearing

temporarily. 6.5.15 The boiler water pH is lower than the standard

S/N Reason Treatment 1 Inadequate phosphate dosage Increase phosphate dosage 2 Acid water enters into the boiler Investigate the cause, and eliminate the source

of acid water and add NaOH into acid water to

adjust pH.


Rev.: A

4

SEC



3 Sewage volume is too much. Adjust the discharge capacity 4 Organic matter mixed in feedwater Investigate the cause and eliminate organic

matter 5 Lower ammonia content of feedwater Add ammonia content of feedwater to the

applicable scope 6.5.16 The boiler water pH declines sharply and PO 3-

is basically normal

S/N Reason Treatment 1 Acid water enters into the boiler Identify the source of acidic water quickly,

eliminate acid water to enter into the boiler, and

strengthen the regular discharge and open the

continuous blowdown volume. Add NaOH and

Na3PO4 mixture to the boiler so that the boiler

water pH returns to the normal as soon as

possible. 2 The condenser leaks Contact relevant departments to investigate the

leakage of the condenser. 6.5.17 Unqualified conductivity, copper and pH in cooling water of generator

S/N Reason Treatment 1 The generator cooling water system is

corrided seriously. Taking antisepsis measures.

2 The cooling system maintained is

cleaned incompletely Exchange the qualified cooling water and input

small mixed bed. 7 Waste Water Treatment Plant Operation Manual

7.1 General description of waste water station and system

7.1.1 Waste Water Disposal System Flow

Waste Water→ Waste Water Pool →Ph Adjusting Box→ Coagulation Pool →Clarification

Pool→ Clear Water Tank→ Activated Carbon Filter→ Neutralization Pool → Outlet Water Pool→

Ash Handling System→ Sludge Pool→ Concentrate Pool →Ash Slurry Pool

Chemical feed devise and compress air system is also included.

7.1.2 Requirement of effluent quality of wastewater treatment system

No. Parameter Unit Limited value 1 Temperature 40 2 pH - 5.5~9 3 BOD5 mg/l 50 4 COD mg/l 100 5 SS mg/l 100 6 Mineral Oil mg/l 1 7.2 Technical specification

S/N Name Parameter Unit Qty Remark


Rev.: A

SEC



1

Generating unit drain

tank

V=200m3 Set

1

2

Drain pump of

generating unit drain

tank

Q=150t/h，P=0.4MPa Set

2

3 Roots blower Q=8.68 m3/min，P=0.06MPa Set 2 4 Roots blower Q=30m3/min，P=0.06MPa Set 2

5

Irregular wastewater

tank V=1500m3，25×18×4 Set

1

6

Irregular wastewater

tank discharge pump Q=100t/h，P=0.2MPa Set

2 N=15kW

7 Wastewater tank V=1500m3，25×18×4 Set 1 8 Wastewater pump Q=100t/h，P=0.3MPa Set 2 N=22kW 9 pH adjustment pump V=50m3，5×3×4 Set 1 10 Flocculation tank V=50m3，5×3×4 Set 1

11

Clarification tank

Q=100t/h ， 9800mm

diameter Set

1

12 Sludge sump V=20m3，4×3×4 Set 1 13 Sludge discharge pump Q=10t/h，P=0.3MPa Set 2 14 Clarification pool V=150m3，6×8×4 Set 1

15

Clarification water

delivery pump Q=100t/h，P=0.3MPa Set

2 N=22kW

16

Activated carbon filter

2000mm filling and 3200mm

diameter Set

2

17 Neutralizing tank V=100m3，5×5×4 Set 1 18 Outlet pool V=200m3，5×10×4 Set 1 19 Bckwashing pump Q=200t/h，P=0.3MPa Set 2 N=55kW 20 Output pump Q=100t/h，P=0.3MPa Set 2 N=22kW 21 Unloading alkali pump Q=10t/h，P=0.2MPa Set 1 N=4kW

22

Sodium hydroxide

storage tank

V=10m3 PCS

1

23 Alkali metering pump Q=100L/h，P=0.5MPa Set 2 24 Unloading acid pump Q=100t/h，P=0.3MPa Set 1 N=4kW 25 Acid storage tank V=10m3 PCS 1 26 Acid metering pump Q=20L/h，P=0.5MPa Set 2 27 Oxidant metering tank V=3m3 PCS 1

28 Oxidant metering pump Q=300L/h，P=0.5MPa Set 2 29 FeCL3 dissolution tank V=20m3 PCS 1 30 FeCL3 delivery pump Q=10t/h，P=0.2MPa Set 1 N=4kW 31 FeCL3 metering tank V=1m3 PCS 2


Rev.: A

SEC



32 FeCL3 metering pump Q=20L/h，P=0.5MPa Set 2 33

Wastewater delivery

pump Q=100t/h，P=0.2MPa Set

2 N=15kW

7.3 Operation of waste water treatment equipments

7.3.1 Operation of chemical dosing system

7.3.1.1 General

Waste water station chemical feed system include a set of oxidant dosing system, a set of

coagulant aid dosing system, a set of hydrochloric acid dosing system and a set of sodium

hydroxide dosing system.

1) Oxidant dosing: bleaching powder, significant chlorine 10%, adjusts waste liquid pool COD

less than 80 mg/L.

To locate dosing point at unfrequent waste water pool and waste water pool in order to

sterilize.

2) Coagulant aid dosing: Iron(Ⅲ ) chloride（FeCl3），clarification pool inlet dosage 27 to 63mg/l,

turbid degree of outlet water less than 20 mg/L.

To locate dosing point at inlet water pipe of Clarification Pool in order to coagulation and

clarification disposal, and remove the suspend substance and colloid.

3) Hydrochloric acid dosing: 30% technical hydrochloric acid, dosage 0 to 0.20kg/m3,

4) Sodium hydroxide dosing: 30% to 40% sodium hydroxide, dosage 0 to 0.60 kg/m3，pH value

control 6～9.

7.3.1.2 Source of wastewater

1) Pickling waste liquid of the boiler

2) Drainage from backwashing the filter and regenerated wastewater of ion exchanger

3) Wastewater from washing the air preheater

4) Industrial wastewater

7.3.2 Wastewater treatment method and procedure

7.3.2.1. Operation of the water pump

1) Inspection before startup

a) Clean the water pump body and its surrounding, where there is no sundries to obstruct

operation of the water pump.

b) Guarantee sufficient liquid level in the pool.

c) Open the inlet valve of the pressure gauge of the water pump and check if the indicator of

the pressure gauge is normal or not.

d) Check if there is full of liquid in the water pump or not or it is required to open exhaust

valve of the water pump and inject liquid into the water pump.

2) Startup of the water pump

a) Close the outlet valve of the water pump.

b) Power on the water pump for startup.

c) Check if operation of pump is normal or not and open outlet valve of the water pump to

check if flow of the water pump and indicator of the pressure gauge are within regulated

scope.


Rev.: A



d) Variation of pressure and flow of the water pump shall meet manual when flow changes.

3) Shutdown of the water pump

a) Close outlet valve of the water pump and stop the water pump.

b) Close the water inlet and outlet valve and isolate the power supply and then hang an

alarm board according to the manual when stopping the pump for repair.

7.3.2.2 Startup and shutdown of Roots blower


a) Check if there are sundries which may obstruct operation of the water pump around the

blower.

b) Check if the pressure gauge and amperemeter are normal or not.

c) Check if the pipeline valves of Roots blower are opened or not.

2) Startup of Roots blower

a) Open the air outlet and exhaust valves of Roots blower.

b) Power on the blower for startup and operate for about 0.5 minute. Open air inlet valve of

wastewater storage pool which needs air inlet and close exhaust valve of blower.

c) Check if operation of blower is normal or not after operation.

d) Check if indicators of the pressure gauge and amperemeter are within regulated scope or

not.

e) It is only required to start up another blower after opening air inlet valve of wastewater

storage pool which needs air inlet if one blower is already in operation.

3) Shutdown of Roots blower

a) Open exhaust valve of blower and close corresponding air inlet valve of wastewater

storage pool.

b) Stop Roots blower and close air outlet and exhaust valves of blower.

7.3.2.3 Startup and shutdown of the dosing metering pump (acid, alkali, flocculating agent and

oxidation pump)


a) Clean the water pump and surrounding environment to remove sundries which may

obstruct operation of the water pump.

b) Guarantee sufficient liquid level in the metering tank.

c) Open inlet valve of the pressure gauge of the water pump to check if indicator of the

pressure gauge is normal or not.

2) Startup of the dosing pump

a) Open inlet and outlet valves of the water pump.

b) Power on the water pump for startup.

c) Check if operation of the water pump is normal and indicator of the pressure gauge of the

water pump is within regulated scope or not.

3) Shutdown of the dosing pump

a) Power off the dosing pump.

b) Close water inlet and outlet valves and isolate the power supply and then hang an alarm

board according to the manual when stopping the water pump for repair.


Rev.: A



7.3.2.4 Operation of the wastewater treatment system


a) Check if the wastewater treatment system is powered on or not.

b) Check if pumps and blowers are in good standby status or not.

c) Guarantee sufficient liquid medicine, acid and alkali in every dosing box.

d) Check if the irregular wastewater Treatment basin, wastewater Treatment basin, PH

adjustment box, flocculation tank, clarification tank, concentrated tank, neutralizing tank

and water outlet pool are in good standby status or not.

e) Check if ampere meter, pressure gauge, flow meter and every chemical measurement

instrument are in good standby status or not.

f) Check if the activated carbon filter is in good standby status or not.

2) Irregular wastewater treatment operation of the drainage tank of the unit

a) Open air inlet valve of irregular wastewater Treatment basin and start up drainage pump

of drainage tank of the unit.

b) Open the water inlet valve of the wastewater Treatment basin and close the irregular

wastewater Treatment basin when irregular wastewater Treatment basin has a high

liquid level.

c) Start up one Roots blower for aeration for about 20 hours and open the dosing valve then

start up the dosing pump of the deoxidizer to adjust the dosage so that COD of

wastewater can be less than 80ppm when one of irregular wastewater Treatment basins

has a high liquid level.

d) Open the water outlet valve of the wastewater Treatment basin and start up the

wastewater pump so that wastewater can pass through PH adjustment tank, flocculation

tank, activated carbon filter, neutralizing tank and water outlet pool and so on in

sequence. PH adjustment tank and final neutralizing tank shall monitor values according

to on-line PH meter and acid and alkaline system can charge and adjust automatically.

e) Start up water outlet pump to store the water in water storage box of the ash removal

system after the water quality meets the drainage standard.

f) Sludge in the clarification pool is drained to the concentrated tank, and start up drainage

pump of the concentrated tank to drain sludge to the sludge pool of the ash removal

system at the same time.

3) Constant wastewater treatment operation of drainage tank of the unit and water supply

treatment system of the boiler

a) Open the water inlet valve of the wastewater Treatment basin when there is wastewater

in the drainage tank of the unit and water supply treatment system of the boiler.

b) Open water outlet valve of wastewater Treatment pool and start up wastewater pump

when liquid level of the waste liquid tank is high. Wastewater will pass through PH

adjustment tank, flocculation tank, clarification tank, activated carbon filter, neutralizing

tank and water outlet pool and so on in sequence. The acid and alkaline system can be

automatically adjusted by dosing in the PH adjustment tank and final neutralizing tank

according to the monitoring values of on-line PH meter


Rev.: A



c) Start up the water outlet pump to drain to the ash system water storage tank after the

water quality meets the drainage standard.

d) Sludge in the clarification tank is drained into the concentrated tank, and start up

drainage pump of the concentrated tank to drain sludge to the sludge pool of the ash

removal system at the same time.

4) Operation and supervision of the wastewater treatment equipment

a) Sample and analyze turbidity, COD, BOD5 and PH before drainage of treated

wastewater and wastewater can not be drained until every indicator is qualified.

b) Strengthen inspection of every rotary mechanical equipment during operation of the

wastewater equipment.

c) Inspect and supervise PH valve of the drainage constantly during operation of

equipments.

d) Ensure that the liquid level of acid and alkaline metering tank and solution tank and

others is more than one third, and prepare it in a timely manner if it is insufficient.

e) Check if cooling water of every pump is smooth or not.

f) Idler running of every mechanical mixer is strictly prohibited when there is no liquid.

g) Backwash when inlet and outlet pressure difference of the activated carbon filter is more

than 0.1MPa according to the manual in the water generation manual.

7.4 Common faults, judgment and Treatment of wastewater station and wastewater system

1) Unqualified pH of water outlet of wastewater station

a) Reason: On-line PH meter fails. Treatment: Contact a thermal control person for repair. b)

Reason: Acid can not be added due to abnormal acid dosing pump. Treatment: Contact

the relevant person for repair.

c) Reason: Alkali can not be added due to abnormal alkali dosing pump. Treatment:

Contact the relevant person for repair.

d) Reason: Excessive or insufficient acid or alkali dosage. Treatment: Adjust acid or alkali

dosage.

2) Unqualified turbidity or chromaticity of water outlet of wastewater station

a) Reason: Large drainage quantity and poor quality of wastewater of desulphurization

specialty. Treatment: Dilute and circulate until water is qualified.

b) Reason: Abnormal sludge scraped from flocculation tank and clarification tank.

Treatment: Contact an electrical repairer.

c) Reason: Sludge in flocculation tank and clarification tank can not be discharged.

Treatment: Wash pipelines with industrial water and contact the relevant person for

repair.

d) Reason: The dosing pump of flocculation tank is dosed abnormally. Treatment: Adjust

dosage of coagulating agent.

e) Reason: The dosing pump of coagulant aid is dosed abnormally. Treatment: Adjust

dosage of coagulant.


Rev.: A



Serial No.

Item

Unit

Data

Remark

8.2.1

Hydrogen generator

1) Hydrogen treatment quantity

3

8.4

2)

Working pressure

MPa

0.7

3)

Purity of outlet hydrogen ％

99. 8

4)

Purity of outlet oxygen ％

99.5

5) Humidity of outlet hydrogen

3 mg/m ≤0.049gH2O/N.Cu.m3

6) Temperature of outlet hydrogen

35

7) Requirements of cooling water

Cooling water quantity m3／h

2.64

PH value

≈7

Soluble solids

ppm

1

8 Hydrogen Generation Plant Operation Manual

8.1 General descriptions of hydrogen plant and hydrogen system

8.1.1 General descriptions of hydrogen generation system

The system includes auxiliary hydrogen generation and supply equipments of 4X300MW

Project of Vietnam Quang Ning Power Plant. It consists of three sets of HM water electrolysis and

hydrogen generation equipments of 8.4m3/h, three sets of medium-pressure and high-pressure

compressor systems, three sets of medium-pressure drying systems, one set of closed cooling

water device, medium-pressure cache equipment, high-pressure storage equipment, hydrogen

distribution device and auxiliary water tank, vacuumization device, nitrogen system and control

system used for blowing and cleaning.

8.1.2 Operational principle

Water will be decomposed to hydrogen and oxgyen when DC passes through potassium

hydroxide solution and its chemical reaction is as follows:

Cathode:

Anode:

Power-on:

2H2O +2e → H2↑+ 2OH-

2OH-－2e → H2O + 1/2O2↑

2H2O = 2H2↑+ O2↑

In general, electrolyte used in the HM system is KOH solution whose weight ratio is 25% and

the corresponding specific gravity is 1.236（20）.

8.2 Technical norms of equipments

Nm ／h


Rev.: A

Sony

Highlight

(!) Dung dịch Kali Hidroxit

SEC



Serial No.

Item

Unit

Data

Remark

Rigidity （ Calculated by CaCO3）

ppm

1

8.2.2

Busbar

1)

Working pressure

MPa

0.7

2)

Quantity

Set

1

3)

Producer

Beijing CEC

8.2.3

Pure water tank

1)

Volume m3

0.219

2)

Outer diameter

mm

2700*1800*2270

3)

Quantity

Box

1

4)

Producer China Power New Energy Group

8.2.4

Hydrogen compressor

1) Hydrogen generation quantity

3 0.8～20

2)

Inlet pressure

MPa

1.0

3)

Outlet pressure

MPa 5．0 -15.0

4)

Working temperature

-36—50

5)

Working voltage

V(DC)

380

6)

Outline dimension

mm

550×300×700

7)

Quantity

Compressor

6

8)

Producer

Beijing Tiangao Company

8.2.5

Storage tank

1)

Type

Vertical

2)

Design pressure

MPa

15.5

3)

Working pressure

MPa

14.0

4)

Design temperature

50

5)

Working temperature

-36~50

6)

Volume m3

0.51

Nm ／h


Rev.: A

SEC



Serial No.

Item

Unit

Data

Remark

7)

Diameter

mm

457

8)

Wall thickness

mm

22

9)

Total height

mm

3810

10)

Material

16MnR

11)

Quantity

Tank

27

12)

Producer Kaiyuan Chemical Machine Co., Ltd

8.2.6 Desalinated water & cooling device

1)

Model

CLZ-100

2) Closed cooling water flow：

T/h

10

3) Industrial cooling water flow：

T/h

25

4) Closed cooling water pressure：

MPa

0.2-0.6

5) Volume of reflux water tank：

3

1.4

6) Power：

kW

8

7)

Quantity

Set

1

m

8.3 Equipments operation

8.3.1 Startup and shutdown of hydrogen plant and hydrogen system

8.3.1.1 Startup and shutdown of hydrogen generation equipment

8.3.1.1.1 Preparation before startup of the hydrogen generator

1) Carry out hydrostatic test of 1.5MPa and airtight test of 1.0MPa for 30 minutes respectively

before startup of the inspected hydrogen generation equipment system and electrolytic tank,

and check if there is no leakage or not with soap solution; tests are qualified if there are no

bubbles and pressure drop of the pressure gauge.

2) Measure insulation degree of every part with 500V Meg-ohmmeter before startup of the

repaired the electrolytic tank and treat instantly if there is any unconformity until it is qualified.

3) Clean electrolytic tank, pure water tank, pressure adjuster, washer and separator with

condensation water and analyze water quality.

4) Check if valves and switches in all systems are flexible and pressure gauge is normal or not.

5) Prepare for sufficient nitrogen cylinders, carbon dioxide cylinders and potassium hydroxide

and potassium dichromate and so on for replacement.

6) Clean the maintenance equipments and the electrolytic tank to guarantee there is no seeper

on the ground.

7) Inject electrolyte and take inspection.


Rev.: A



8) Open water inlet valve of water supply pump to inject water.

8.3.1.1.2 Startup of the hydrogen generator

1) It is required to adopt equipment power and water supply during operation of the system.

2) Close the main loop breaker connected to the power supply to receive power energy, and the

programmable controller must be in operation mode.

3) Turn on control switch of the power contactor to power on two control loops of the generator

and power supply.

4) Press touch switch of “Alarm to reset” on the parking screen and then “Generator is ready” is

displayed; the system will begin to run after pressing touch switch of “startup/reset”.

5) Blow and clean the pipe valve system at the side of the generator oxygen by blowing and

cleaning with nitrogen for 30 seconds after operation of the system; the pipe valve system has

also been pre-pressed to the required pre-pressure with the development of blowing and

cleaning. When the hydrogen pressure begins to rise, the oxygen pressure will rise

correspondingly and maintain a pressure difference of 3Psi to 10Ps on the “blowing and

cleaning screen of the generator; when the hydrogen pressure reaches 20Psig (namely,

1.4kg/cm2), the pre-pressure period of 15 minutes begins and the countdown of 900 seconds

is shown on the “pre-pressure” screen.

8.3.1.1.3 Shutdown of the hydrogen generator

1) From operation to standby: Internal pressure of the system will begin to rise due to no air

supply, and air will not be generated when pressure reaches 115Psig (namely, 8.1kg/cm2). 6#

lamp on controller module of 2# slot will be off. The system will remain pressure and be in

standby status and be ready for air supply according to nees. Touch screen will display

“Generator is in standby status” of hydrogen and oxygen pressure, and air will be generated

again when internal pressure of the system drops to the rated system pressure.

2) Shutdown: Hydrogen generator will stop automatically by contacting “Generator has stopped.”;

press the pressure release switch to release pressure automatically if releasing pressure

3) Automatic shutdown and protection of the unit:

Shutdown conditions Alarm input Setting point

High temperature of KOH

High liquid level of KOH LS2

Low liquid level of KOH LS1 90 seconds

Low flow of KOH FS1 10l/min

High hydrogen pressure PT1 120Psig

Low hydrogen pressure PT1 120Psig

High oxygen pressure PT12 115Psig

Low oxygen pressure PT12 39Psig

Low differential pressure PT1-PT2 3Psig

Low pre-pressure PT1 5Psig

High temperature pressure in oxygen TC3-TC4 200 Power alarm

Low water supply resistance FQM 200Ω-cm


Rev.: A



External alarm

Power failure PLC

High ambient temperature

TC4

50Low ambient temperature TC4 5 Drying circulation trouble PT3, PT4 Drying & blow-cleaning trouble PT3, PT4

8.3.1.2 Startup and shutdown of the diaphragm compressor

8.3.1.2.1 Prepare before boot-strap

1) Clean equipments;

2) Check if all valves are closed tightly or not;

3) Check if the pointer of the pressure gauge returns to “zero position” or not;

4) Check if lubricating oil in crankcase is qualified or not. Check if oil level is between the upper

and lower scribed lines of the oil leveler or not.

8.3.1.2.2 Startup

1) Open the valve of the exhaust pipe, and turn to open bypass vent pipe if there is air pressure

in the externally connected pipeline;

2) Rotate the fly wheel for several circles;

3) Start up the diaphragm compressor so that rotary speed of the crankcase can reach the rated

rotary speed, when the oil pressure in the oil cylinder will rise gradually to 3.6 MPa to 3.8

MPa;

4) Open the valve of the air inlet pipe slightly and then close the air release valve of the exhaust

pipeline quickly;

5) Operate under low load for ten minutes and then operate under full load.

8.3.1.2.2 Shutdown

1) Close valves of the air inlet or exhaust pipeline in sequence;

2) Stop the diaphragm compressor;

3) Open the air release valve of the exhaust pipes to release air pressure in every cylinder;

4) Open meter valve below oil-pressure gauge and release oil pressure in every cylinder;

5) Close all valves tightly.

Note: Diaphragm compressor can not be started or stopped frequently. In general, the interval

between shutdown and boot-strap shall be not less than 2 hours (and it can be shortened properly

if the ambient temperature is less than 10).

8.3.2 Adjustment in operation of hydrogen plant and hydrogen system

8.3.2.1. Adjustment in operation of the hydrogen generator

1) Indicator of ampere meter shall be 50A to 280A according to user demand during operation

period; the corresponding voltage shall be determined according to the specification of the

electrolytic tank and several operation factors. Voltage of the electrolytic tank shall be within

the scope of following table.

Voltage of the electrolytic tank at 250A

Specification of the electrolytic tank Voltage scope

HM 50 54-65


Rev.: A

SEC



HM 100 108-125 HM 125 135-160 HM 150 162-190 HM 200 215-250

2) KOH temperature without heat exchanger (TC1) shall be within permissible KOH temperature

control scope during operation of the system. The temperature regulator shall control the

initially prepared program according to proportion so that KOH temperature can be 64.

Temperature regulator (BV1) will be opened or closed according to demand. The valve

position and temperature of electrolyte can be monitored on screen of “temperature control

valve position” which is selected from “system information” of the display.

3) Water supply system is replenished with water intermittently and supply water flows to a

storage tank periodically during the ordinary operation, as shown 3# input lamp of 1# slot and

1# and 3# output lamps of 2# slot which are all on. Water supply shall be shown by injection

image of touch display for 30 seconds. Water supply frequency depends on consumption rate

and it changes with air outlet and electrolytic rate. Water quality monitor shall indicate the

permissible green lamp for the minimum electric resistivity of 200Ω-cm.

4) Temperature rise of hydrogen in oxygen during operation of the generator and under almost full load shall be less than 20. It will increase greatly when the system is in standby mode.

Sensor of hydrogen in oxygen needs a constant oxygen flow of 100CC/min.

5) The pressure gauge of at least one drier shall be under pressure during ordinary operation.

Drier program can be monitored by pressing touch switch of “drier program” on the screen

which displays “Generator is in operation”. 4# output lamp of 6 # slot module shall be on

before switchover of drying except pre-pressure period for 30 minutes to indicate that

blow-cleaning valve of the drier is on. 2# or 3# lamp shall be on according to the program

timing to indicate that the heater of the drier is in operation.

6) Data and working days shall be assigned to the generator so that documents can verify the

daily operation data. The recorded data can provide useful information to daily maintenance

and general diagnosis of operation problems, and such information shall be recorded within

24 hours.

8.3.2.2 Adjustment in operation of the diaphragm compressor

Take the subsection and boost lifting pressure and turn to trial operation under rated

exhaust pressure gradually after normal operation without load. It is required to lift the suction

pressure in sections and then lift the exhaust pressure gradually. (Please refer to Table 2 for

details.)

Table 2

Serial No. Suction pressure, MPa Exhaust pressure, MPa Operation period, min 1 0 1.0 10 2 0.4 2.5 10 3 0.7 3.2 80 8.3.2.2.1. Operation and adjustment:

1) Inspection of oil supply pump Oil supply pump will operate normally by touching oil exit pipe manually or it is required to find


Rev.: A



out reasons in Table 5. 2) Removal of gas in pressure measurement pipes in the oil cylinder

Unscrew the tightening bolt on the meter valve slightly, and screw down tightening the bolt if there are no bubbles in fluids to flow out of the oil pipe. 3) Adjustment of oil-pressure gauge of the oil cylinder

Pointer of the oil-pressure gauge of the oil cylinder shall swing slightly and the swinging scope is suggested to be between two minimum scales. Handle of the meter valve can be screwed or unscrewed for adjustment due to excessive or insufficient amplitude of the swing. 4) Lifting pressure

Boost suction or exhaust pressure in sections according to requirements in the table. Oil pressure will rise correspondingly after the exhaust pressure rises, and it shall be always

higher than the exhaust pressure by 10% to 20%. Note: Oil pressure will not decline due to effect of the check valve below, and the oil-pressure

gauge will not drop when the exhaust pressure drops, and at the time the actual valve can be gained by operation according to the above (3). 5) Thermal stable status

Operate continuously for 60 minutes when the suction or exhaust pressure can reach the rated pressure so that the machine can be in the thermal stable status to facilitate inspection and find out problems. 8.3.2.2.2. Water quality requirements of the cooling water of the diaphragm compressor are as

follows:

1) The suspended matter content of organic and mechanical sundries shall be less than

100mg/L and the oil content can be less than 5mg/L； 2) Cooling water is almost neutral. That is, PH indicator of hydrogen ion is suggested to be

between 6.5 and 9.5;

3) It has thermal stability and the temporary rigidity is less than 10°. (Note: rigidity 1° is equivalent to 10mg CaO or 7.19mg MgO in every liter of water.)

It is required to filter and purify if the water quality can not meet the above requirements. Urban drinking water is permitted to use as the cooling water. Inspect and clean the oil filter when the oil pressure is less than 0.15MPa, and then inspect

the gear pump if there is still no effect. 8.3.2.2.3. Items to be inspected itinerantly during operation as follows:

1) Check if the operation of the suction valve, exhaust valve, oil supply pump, pressure

regulation valve and gear pump and others is normal or not;

2) Check if there is leakage from the oil or air pipeline or not;

3) Check if the connecting rod bearing, copper bush, bearing and plunger and others are

overheated or not;

4) Oil temperature of the crankcase shall not exceed 70;

5) Exhaust temperature can not exceed 140,

It is required to stop for inspection instantly if there is any abnormal equipment.

8.4 Common faults, judgment and Treatment of hydrogen station and hydrogen generation

system

8.4.1 Treatment under emergent conditions

8.4.1.1 Cut off the silicon rectifier power quickly for treatment if there is any emergent condition.

1) Short-circuit, fire-fighting and fulmination of the electrolytic tank

2) The pressure of the hydrogen generation system rises rapidly and is invalid after adjustment


Rev.: A



3) Severe leakage of gas or alkali of hydrogen generation system

4) Severe scorched flavor and short-circuit of the silicon rectifier

5) Circulation shutdown of the electrolyte

8.4.1.2 Fire and explosion in the hydrogenation station

It is required to cut off DC and AC power supply of the silicon rectifier instantly and solve

problems if there is any emergent condition. Record the Treatment result on the operation log after

the event happens; and report it to the chemical worker and leader on duty.

8.4.2 Treatment of common troubles during operation

8.4.2.1 Unqualified purity of hydrogen and oxygen

Reason Treatment Diaphragm ruptured Severe electro corrosion which may cause

corrosion and perforation of pole plate

Overhaul the electrolytic tank if it exceeds the

overhaul term.

Large water level difference of pressure

adjuster of hydrogen and oxygen Adjust hydrogen or oxygen discharge vale to

guarantee normal water level. Too dirty electrolyte or too low concentration

of electrolyte in electrolytic tank Re-fabrication of electrolyte

Deposits in electrolytic tank Shutdown and backwashing of electrolytic tank 8.4.2.2 The maximum current of the electrolytic tank only rises to 220A.

Reason Treatment One-phase quick fuser is fused. Notify the electrical maintenance personnel to

replace quick fuser. One phase of silicon rectifier fails. Electrical maintenance personnel shall find out

trouble points and solve problems and record in

guard records. 8.4.2.3 Severe leakage of alkali and gas from the electrolytic tank

Reason Treatment Frequent startup, expansion or uneven

shrinkage Strengthen operation and supervision and

prevent alkaline liquid from splitting and hurting

people The electrolytic tank has operated for a long

time to damage leakproofness Reduce startup times and decrease load slowly

Corrosion on the surface of pole plate or

diaphragm frame Damaged insulation cushion Ruptured coil spring

Replace insulation cushion, pole plate,

diaphragm frame and coil spring and so on

during overhaul and shutdown

8.4.2.4 Sudden shutdown of electrolytic tank

Reason Treatment Power failure caused by vibration of connecting

points of mercury relay of silicon rectifier blower

Inspect silicon rectifier then start up it for

operation if there are no other troubles. Sudden power failure of the plant Contact integrated control guard for power

Date 2008-09-16


Page 77

Rev.: A

SEC



supply. Trouble of silicon rectifier and protection motion Notify the electrical maintenance personnel to

solve problems. 8.4.2.5 Large temperature difference of positive and negative poles and hydrogen-oxygen outlet of

electrolytic tank

Reason Treatment Jammed filter and unsmooth circulation of acid

and alkali Clean or close inlet and outlet valves of filter

and open bypass valve for operation Jammed air outlet pipe or alkaline liquid hole of

electrolytic tank Stopping the tank for backwashing

Uneven opening of cooling water of

hydrogen-oxygen separator Check if concentration of alkaline liquid is

normal or not. Too high or low concentration of electrolyte Adjust water inlet quantity of cooling water of

hydrogen-oxygen separator. 8.4.2.6 Water tank which is full of water

Reason Treatment Misuse of water inlet valve of water tank Check if outlet valve of hydrogen pressure

regulator is closed or not and remove water in

the U-type pipe. Internal leakage of water inlet valve of the water

supply tank Close main valve of condensing water and

open water inlet valve and blowdown valve of

water tank to release partial condensing water

in the water tank. Hydrogen system pressure is more than

pressure in water tank Inspect water inlet valve if there is leakage in

the valve. 8.4.2.7. System pressure is more than pressure of hydrogen storage tank by 0.003MPa of gauge

pressure

Reason Treatment Jammed valve or pipe before hydrogen storage

tank Dredge jammed pipe valves

Frozen outdoor valve or pipe to hydrogen

storage tank Unfreeze outdoor pipe valves by steam

Jammed float connecting rod of pressure

regulator Fluctuate water level of pressure regulator for

several times Large reserve pressure of the check valve Correct and evaluate pressure difference of the

check valve again 8.4.2.8. Unbalanced water levels of hydrogen and oxygen sides before startup of electrolytic tank

Reason Treatment Leakage of hydrogen or oxygen system Find out leakage positions carefully and solve

problems.


Rev.: A

SEC



Automatic water supply valve of water tank is

not closed tightly with internal leakage. Open automatic water supply valve again to

check if it is closed tightly or not. Take

measures to start up the electrolytic tank

normally and adjust balanced water levels of

two sides. 8.4.2.9. Variable pressure of hydrogen system during operation and noise in the hydrogen cooler

Reason Treatment Check if drainage quantity of blowdown valve

on the bottom of the hydrogen cooler exceeds

the normal scope. Check if there are bubbles in industrial water

from peephole of cooling water of cooler or not. Check if there is no noise in the cooler or not by

ears.

Stop the electrolytic tank instantly if there are

any phenomena, and release the system

pressure to 0.02MPa and replace H2 system by

N2.

The hydrogen cooler is sinked in industrial

water for severe corrosion and perforation. Detach and overhaul the hydrogen cooler and

replace the serpent-type pipe. 8.5 Special safety cautions of hydrogen generation station and hydrogen generation

system

1) Repair and maintain relevant devices and instruments of hydrogen generation station

periodically to guarantee normal operation so as to ensure that purity and humidity of

hydrogen can meet requirements.

2) Fireworks of equipments with hydrogen in and out of hydrogen supply station are strictly

prohibited. It is strictly prohibited to place inflammables and explosives. It is required to hang

an alarm board with “No smoking” and enclosure around the hydrogen storage tank (namely,

within 10m) and prepare for necessary firefighting equipments in the hydrogen supply station.

3) Irrelevant people are strictly prohibited to enter into the hydrogen supply station.

4) Fire operation or jobs with spark is strictly prohibited in the hydrogen supply station. Staff can

not wear shoes with nails. Measure hydrogen content in advance if it is required to weld or

carry out fire operation to validate that hydrogen content in the air within work area is less

than 1% and the staff can not work until examination and approval of the chief engineer.

Unfreeze pipe valves or other equipments in the hydrogen supply station by steam or hot

water and it is strictly prohibited to fire. Check if there is hydrogen leakage of every connecting

pipe or not by instruments or soap water and it is strictly prohibited to inspect by fire.

5) Partition repair part and connecting part and install a tight block plate then replace the

hydrogen by air before repair of hydrogen storage equipments (including pipe system) and

hydrogen-cooled system of generator.

6) Open valves on equipments evenly and slowly when discharging hydrogen with pressure or

dumping hydrogen to release gas slowly and it is strictly prohibited to release gas rapidly to

avoid spontaneous combustion caused by friction.

7) Erect gas bottles on the support vertically and avoid heat and direct solar radiation. Coat

white on the surface of storage tank and inspect safety valve on the hydrogen storage tank


Rev.: A



periodically to guarantee excellent motion.

8) It is required to cut off electrical equipments and power instantly to release system pressure

and extinguish fire by carbon dioxide when hydrogen supply station. Extinguish fire by carbon

dioxide and caulk leakage by asbestos cloth to guarantee no hydrogen emission or preclude

gas source by other methods if fire is caused by hydrogen leakage.

9) It is strictly prohibited to use tools which may cause spark and it is suggested to use tools

which are made of copper during repair and operation of hydrogen system.

10) Hydrogen supply station shall adopt explosion-proof electrical devices.

11) Mixed hydrogen and oxygen has explosion danger and upper limit is 96% of hydrogen and

4% of oxygen and lower limit is 5% of hydrogen and 95% of oxygen.

12) It is not allowed to repair equipments in the hydrogen supply station during operation and it is

required to stop equipments then repair according to relevant manual if they must be repaired.

13) Operators are not suggested to wear work clothes which are made of synthetic fiber and wool.

14) Freshmen shall be familiar with system operation of hydrogen supply station and they can not

work individually until passing examinations.

15) Door of hydrogen supply station shall be closed constantly and operators shall submit kindling

and register before entering into the hydrogen supply station.

9. Circulating Water System & Auxiary Cooling Water System Operation Manual

9.1 Equipment Technical Specification

NUMBER

NUMBER

NAME

MODEL AND

SPECIFICATION

UNIT

1# 2#

MANUFACTURE

REMARK

CLOSED CYCLE

COOLING

WATER PUMP

MODEL NUMBER:

20SAP-10

Q=2000m3/h

H=45mH2O

SET 2 2 CHANGSHA

WATER PUMP

CO.,LTD

1

MOTOR MODEL NUMBER:

YKK4504-6

400kW 6600V

980rpm

SET 2 2 SUPPLIED

WITH

PUMP

2 CLOSED CYCLE

COOLING

WATER COOLER

MODEL NUMBER:

SJ-1530-1

HEAT EXCHANGE

AREA: 1580m2

SET 2 2 SHANGHAI

POWER

EQUIPMENT

CO.,LTD

3 CLOSED CYCLE

COOLING

WATER

EXPANSION

TANK

VOLUME: 30m3 SET 1 1 JINAN

PRESSURE

VESSEL

CO.,LTD


Rev.: A

SEC



NUMBER

NUMBER

NAME

MODEL AND

SPECIFICATION

UNIT

1# 2#

MANUFACTURE

REMARK

OPEN CYCLE

WATER PUMP MODEL NUMBER:

28SAP-25

Q=3600m3/h

H=12mH2O

SET 2 2 CHANGSHA

WATER PUMP

CO.,LTD

4

MOTOR MODEL NUMBER:

Y2-355L2-10

160kW 400V

590rpm

SET 2 2 SUPPLIED

WITH

PUMP

CIRCULATING

WATER PIT

BLOWDOWN

PUMP

MODEL NUMBER:

50CYL25-8

25 m3/h 8mH2O

SET 2 2 ZHENGJIANG

CHANGKAI

MECHANICAL

EQUIPMENT

CO.,LTD

5

MOTOR MODEL NUMBER:

Y2100L2-4

3kW 400V

1450rpm

SET 2 2 SUPPLIED

WITH

PUMP

9.2 Circulating Water System

9.2.1 Inspection and Adjustment before Startup

a) Examination and repair is complete, working order form is filled; safety measures have

removed and site has cleaned completely;

b) C&I group shall be informed to apply operating power source and gauge power for

circulating water pump control panel; to check the gauges operate normally.

c) Motor insulation of circulating water pump and hydraulic control butterfly valve oil pump

are qualified; interlock protection test is qualified.

d) Open the water filling valve of cooling water manifold.

e) Open water inlet valve of condenser cooling water.

f) Open water outlet valve of condenser cooling water

g) Close outlet/inlet drain valve of condenser circulating water..

h) Open vent valve of inlet water chamber and then it shall be closed after continuous water

discharging.

i) Cooling water shall be opened to circulating water pump A&B and electromotor cooling

water inlet valve, and then to adjust the opening of valves (rubber bearing shall be filled

with water for 20mins washing in the first startup).

j) To adjust lube cooling water pressure of circulating water pump A&B until achieving

normal condition.


Rev.: A

k) Lube oil level and quality of Motor bearing of circulating water pump A&B is normal with oil temperature not less than 15; oil level of hydraulic control butterfly valve shall be at

1/2～1/3,

l) Interlock switching of circulating water pump set at “CUTTOFF” position, and then power

supply will be provided to circulating water pump. Circulating water pump protection shall

be put into service.

9.2.2 Startup of Circulating Water Pump

a) Operate rotary filter screen continuously, pressure difference before/after filter screen

shall be <100mm.

b) Circulating pump is provided with startup condition.

c) Press “SEQUENCE STARTUP” button of circulating water pump.

d) Hydraulic control butterfly valve at the outlet is opening gradually, and then circulating

water pump starts up when the valve opens to 15º.

e) Hydraulic control butterfly valve at the outlet opens keep opening and will be fully open in

25s.

f) Current, circulating water manifold pressure and pump and electromotor bearing of

circulating water pump are normal;

g) When the pressure difference before/after rotary filter screen is <100mm, then filter

screen can be shutdown if no sundries being filtered off.

9.2.3 Circulating Water Pump Shutdown

a) Press “SEQUENCE STARTUP” button of circulating water pump

b) Hydraulic control butterfly valve at the outlet is closing gradually, and then circulating

water pump shutdown when the valve closes to 15º.

c) Hydraulic control butterfly valve at the outlet opens keep closing without circulating water

pump inversion.

d) Idle circulating water pump will be on standby or maintained according to the actual

situation.

9.2.4 Circulating Water Pump Shifting

a) Standby circulating water is provided with startup condition.

b) Startup standby circulating water pump according to startup sequence of circulating water

pump; attention shall be paid to the pressure changing of circulating manifold.

c) Standby pump starts normally;

d) Operating pump shall be stopped according to the shutdown sequence of circulating

water pump; attention shall be paid to the pressure changing of circulating manifold;

pump shall not operate inversely after shutdown.

e) Idle circulating water pump will be on standby or maintained according to the actual

situation.

9.2.5 Operating Maintenance of Circulating Water Pump

a) Pump current and water outlet pressure is normal during operating.

b) Lube oil level of from bearing on the circulating water pump Motor is at 1/2-2/3; oil quality

and cooling water flux is normal;


Rev.: A

c) Water level difference before/after filter screen of cleaning machine shall be less than

400mm.

d) Bearing temperature of running circulating water pump electromotor shall not be higher

than 70(alarm warning at 70, protection will act at 80); thrust bush temperature

shall not be higher than 75(alarm warning at 95); winding temperature of Motor

stator winding shall not be higher than 80(alarm warning at 110 and protection will

act at 120)

e) Upper and lower shaft vibration of running circulating water pump Motor shall not be

larger than 0.06mm.

f) Adjustment shall be carried out when the cooling water pressure decreases to 0.1MPa.

9.2.6 Startup and Shutdown of Rotary Filter Screen

a) All gauges completed and power is available normally;

b) Lube oil quality of lube components is qualified; lube level is normal;

c) Tightness degree of chain is appropriate, main axis is level;

d) Alarm device is available;

e) Rotary filter screen shall be accepted by manual inching test and no-load test before

operation.

f) Auto startup of rotary filter screen

1) Flushing water pump will startup automatically when the water level difference

before/after the filter screen achieved 100mm(adjustable); to open motorized valve of

flushing water, the rotary filter screen will startup automatically after 10s(adjustable)

2) Rotary filter screen will be shut down after 15mins (adjustable) continuous flushing

and the water level difference before/after the rotary filter screen lower than 50mm;

and then close to close motorized valve of flushing water, finally to shutdown flushing

water pump.

3) If the water level difference is still more then 50mm within the specified 15 mins

flushing time, the flushing will be go on until the water level difference before/after the

rotary filter screen lower than 50mm.Meanwhile, alarm signal will be sent to the

shifting room(or control room).

4) If the water source is clean which results in the water level difference before/after filter

screen cannot achieves 100mm, rotary filter screen and flushing water pump will be

operated 15min(adjustable) automatically each 8 hours; 1-1.5 rounds will be applied

to each operation flushing.

5) Alarm signal will be sent to control room immediately when the water level

before/after filter screen achieves or more than 400mm.

g) Rotary Filter Screen Startup in Manual Way:

1) When the rotary filter screen fails to operate, manual running will be applied; manual

running shall be carried out twice during each shift according to the start up sequence

of: flush pump – electric valve – filter screen, shutdown will base on the sequence of

filter screen – electric valve – flush pump;


Rev.: A



2) Manual way will apply when the rotary filter screen meet the startup condition with

large filter screen differential pressure;

3) Flushing water pump starts up by opening the outlet manual valve and the electric

valve of corresponding rotary filter screen water source; pump outlet pressure is

0.3~0.5 MPa;

4) Switching sets at manual position, then startup rotary filter screen to check if the

rotation parts is operating normally; attention shall be paid to the operating sound and

vibration as well as heating of each parts; relevant flushing water will be provided and

drained to sewer tunnel outlet;

5) Rotary filter screen operates stably without blockage and serious twist;

6) Sewage in the cleaning groove shall be removed by flushing water.

h) Rotary Filter Screen Shutdown:

1) Rotary filter screen can be shutdown when the pressure difference is small;

2) Cutoff the power for Motor, power gauge shown “zero”;

3) Rotary filter screen stops operating without abnormity;

4) Shutdown flush pump.

i) Operating Maintenance of Rotary Filter Screen

1) Sewage cleaning shall be carried out in time according to the original water; sewage

cleaning shall be strengthen continuously; for the cleaning water source, filter screen

shall be runned 1-1.5 round in each 8 hours;

2) Nozzel shall be checked and cleaned termly to improve cleaning quality;

3) Safety device shall be inspected frequently to ensre safety operation;

4) According to the alarm signal for chain loosening, chain shall be calibrated in time;

5) Inspection and repair shall be carried out if the chain or screen plate being blocked

during operating;

9.2.7 Condenser Rubber Ball Cleaning System

a) Ensure circulating water system and outlet siphon are normal, and outlet/inlet water valve

of condenser is open;

b) Ensure the differential pressure before/after ball collector is normal, then operator

records the vacuum, TTD/DCA and temperature increasing of condenser;

c) Check the rotor plate of rubber ball cleaning pump to ensure normal bearing oil level and

quality.

d) Overall inspection of condenser;

e) Rubber collector A&B set at ball collecting position;

f) Add 700 balls with φ29 into ball chamber A&B respectively;

g) Open water inlet/outlet valve of rubber ball pump, water outlet valve and vent valve of ball

chamber;

h) Apply rubber ball cleaning procedure and startup rubber ball pump; vent valve of ball

chamber will be closed automatically after water drain off;


Rev.: A



i) Water outlet valve of ball chamber shall be opened adequately and screen plate of ball

chamber shall be opened; rubber balls shall be checked to ensure they are into main

system completely;

j) Screen plate of ball chamber sets at “balls collecting” position after 24 hours operation;

balls collecting time will be 30 mins;

k) Close outlet valve of rubber ball pump, and then shutdown the pump and the water outlet

valve of ball chamber;

l) Water drain and vent valve of ball chamber will be opened for water drain and pressure

releasing; hand hole will be opened to count the rubber after complete water draining;

ball return rate shall be more than 95%;

m) Ball collector on water outlet pipe of circulating water shall set at “FLUSHING” position

after cleaning according to the real situation.

9.2.7.1 Condenser Isolation Cleaning and Leakage Checking (Half)

a) Ball cleaning device of the part to be shutdown shall finish ball collecting, balls stop

running, then ball cleaning procedure will be exited; meanwhile power for rubber ball

pump will be cut of;

b) Shifting engineer is informed to loading down below 75% according to the unit vacuum

situation;

c) Water inlet/outlet of condenser circulating water operated side shall be opened properly;

d) Close isolation valve from shutdown side to vacuum pump inlet;

e) Close condenser exhaust vacuum isolation valve of shutdown side;

f) Close inlet/outlet valve of condenser shutdown side and to open drain valves on

inlet/outlet pipe;

g) Vent valve of condenser shutdown side shall be opened adequately to destroy its outlet

siphoning;

h) Drain valve of condenser shutdown side water chamber shall be opened for water drain

and pressure releasing;

i) Cutoff the power for the following devices:

1) condenser pump inlet/outlet electric valves

2) Rubber ball pump.

3) Electric inlet/outlet valve of rubber ball pump.

j) After water pressure decreased to zero, manhole of shutdown side shall be opened

slowly for cleaning and leakage checking; condenser vacuum shall be checking during

isolation procedure, If vacuum drops, operation shall be stopped immediately to recover

the vacuum;

9.2.8 Condenser Recovery after Isolation Cleaning.

a) Condenser overhaul is complete; personnel leave site complete, tools and waste are

removed completely; holes and valves are closed, and then power shall be provided to

the following devices:

1) Inlet/outlet electric valves of condensers.

2) Rubber ball pump.


Rev.: A



3) Rubber ball pump inlet/outlet electric valve.

b) Close all drain valves of condensate circulating water.

c) Circulating water outlet valve opens 10%

d) Open condenser water inlet valve gradually;

e) Vent valve on circulating water inlet/outlet pipes shall be closed after water is drain off;

f) Open electric valve of circulating water outlet gradually;

g) Water outlet valve on two sides of condenser circulating water shall be adjusted to

ensure average water temperature;

h) Condenser vacuum valve of shutdown side shall be opened slowly to adequate opening

after water side of condenser circulating water working normally;

i) Open water inlet valve of water chamber vacuum pump; to open the isolation valve form

reported water chamber to inlet of water chamber vacuum pump according to the actual

need;

j) Unit load will be recovered according to the condenser vacuum if necessary, or to carry

out cleaning of the other side;

k) Condenser rubber cleaning device procedure can be applied according to the actual

need.

9.2.9 9.2.9 chlorine feeding system of circulating water

9.2.9.1 Adjusting the Dosing Flow

9.2.9.1.1 Increasing the dosing flow

a) Open the flap

b) Turn hand wheel slowly to the left

c) Close the flap

9.2.9.1.2 Decreasing the dosing flow

a) Open the flap

b) Turn hand wheel slowly to the right

c) Close the flap

9.2.9.2 Switching between Automatic and Manual Adjusting of the Dosing Flow

9.2.9.2.1 Switching from manual to automatic adjusting of the dosing flow

a) Open the flap

b) Turn hand wheel totally to the right

c) Press hand wheel upwards until upper limit is reached

d) Close the flap

9.2.9.2.2 Switching from automatic to manual adjusting of the dosing flow

a) Open the flap

b) Pull hand wheel down

c) Close the flap

9.2.9.3 Switching on

9.2.9.3.1 Close rate valve

9.2.9.3.2 Close shut-off valve at the injection unit

9.2.9.3.3 Open motive water valves


Rev.: A



9.2.9.3.4Switch on booster pump

9.2.9.3.5 Open valve of the gas container

9.2.9.3.6 Slowly open the rate valve until the desired gas flow is displayed by the measuring tube

9.2.9.4 Switching off

9.2.9.4.1 Emergency Stop

a) Put on safety equipment!

b) Immediately close all container valves

c) Let the plant run until all parts are evacuated from the dosing medium

d) Swith off the plant as described in the following

9.2.9.4.2 Short-term Stop(up to 6 hours)

a) Close rate valve

b) Switch off booster pump

c) Close motive water valves

d) Close shut-off valve at the injection unit

9.2.9.4.3 Long-term Stop While the plant is still running:

a) Close all container valves

b) Let the plant run until the measuring tube shows no more gas flow

c) Close rate valve

d) Switch off booster pump

e) Close motive water valves

f) Close shut-off valve at the injection unit

9.3 Auxilary Cooling Water System

9.3.1 Open Cooling Water System

9.3.1.1 Startup of Open Circulating Cooling Water Pump

a) Inspection and repair for opened cooling water system have completed; working order

form is finished; safety measures is removed; Construction site is cleaning; C&I

instrument are complete, instruction valves are open. Oil level of bearing shall be at

1/2-2/3 with normal quality.

b) Confirm that the circulating water system operates normally.

c) Clean the filter screen of opened circulating cooling watr , and then to close the drain

valve.

d) Open water inlet valve of opened circulating cooling water pump.

e) The vent valve of open circulating cooling water pump shall be opened, and then it shall

be closed after air exhausting completely.

f) Open water outlet valve of opened circulating cooling water pump.

g) Open the inlet/outlet valve of closed water heat exchanger which to be started (two sets

operating and one set standby in total 3 heater exchangers A, B and C); to open water

side vent valve of closed water heat exchanger, and then it shall be closed after water

drain off continuously.

h) Power will be supplied to opened circulating cooling water pump after insulation of Motor

is qualified; Motor power shall be provided to the test position for the first startup after


Rev.: A



overhaul, and switch static open/close test is accepted; Motor operates normally without

coupling.

i) Close outlet valve of opened pump and the cooling water control switch; if water pump

and Motor operate in good condition, outlet valve of open circulating water will be

opened.

j) Bypass electric valve shall be opened before opened circulating cooling water pump

shutdown.

9.3.1.2 Shutdown of opened circulating cooling water pump

a) Bypass operates in good condition

b) Close outlet valve of open circulating cooling water pump slowly, and then open

circulating cooling water pump shall be shutdown if the closed heat exchanger operates

normally.

c) If opened circulating cooling water pump need to be shutdown or bypass need to be

closed, the system shall be checked to ensure that no system users operate.

9.3.1.3 Operation Maintenance of Open Circulating Cooling Water Pump

a) Current and outlet water pressure of operating pump are normal.

b) Motor, bearing temperature and gland water return shall be normal;

c) Operating pump and Motor bearing vibration shall be normal;

d) No alarm warning for pressure difference of opened circulating water filter screen; filter

screen shall be cleaned termly according to the working requirement;

e) When opened circulating water pump tripped or pressure decreased to 0.18MPa, bypass

operation shall be adjusted to ensure normal working condition for closed circulating

water heat exchanger. In the normal operation, a group of device will be standby while

the other group puts into service.

9.3.2 Closed Cooling Water System

9.3.2.1 Startup of Closed Circulating Cooling Water Pump

a) Inspection and repair have completed; working order form is finished; safety measures is

removed; Construction site is cleaning; C&I marks is complete, instruction valves are

open; the inlet/outlet valve of Motor cooler shall be closed if no pressure in the Motor.

b) to open the isolation valve form condensate transferpump to closed expansion water tank,

to close inlet valve of closed water pump; drain valve shall be opened to wash the

expansion water tank, and then water level of expansion water tank shall be filled to the

overflow pipe after water is qualified, and then to closed the tank. Condensate is

accepted to apply in the above procedure, but condensate shall not used as make-up

water during normal operation to avoid water quality affected by different water.

c) Vent valve after closed circulating water outlet valve shall be closed after water is

draining off continuously.

d) Open the water inlet valve of closed cooling water pump A&B

e) to open the van valve of closed circulating water pump A &B, and then close after air

exhausting completely; pressure difference before/after closed pump inlet filter is normal;

f) Open water outlet valve of closed cooling water pump A&B.


Rev.: A



g) Sampling valve before water outlet valve of closed cooling water pump A&B shall be

closed.

h) Open closed inlet/outlet valve, pressure governor valve and front/back electric butterfly

valve of two heat exchangers; close drain valve and vent valve.

i) At least a group of cooler is put into service.

j) Power will be supplied to opened circulating cooling water pump after insulation of Motor

is qualified; Motor power shall be provided to the test position for the first startup after

overhaul, and switch static open/close test and interlock loop test is accepted; Motor

operates normally without coupling.

k) Controlling switch of closed circulating water pump shall be closed to check if the water

pump and Motor operate normally.

l) Standby pump interlock shall be set at “INPUT” position.

9.3.2.2 Shutdown of Closed Cooling Water Pump

a) Shifting engineer, shifting personnel of Chemical, FGD and boiler group shall be informed

before closed circulating pump shutdown.

b) Interlock of standby closed circulating cooling water pump shall be cutoff.

c) Closed circulating cooling water pump shutdown without inversion operation, or the water

outlet valve of inversed operate water pump shall be closed immediately; startup is

forbidden when water pump is inversion operating to avoid equipment damage.

d) If both the closed circulating cooling water pumps need to be shutdown, the system shall

be checked to ensure that no any user; if cooling water is required by chemical and FGD,

it shall be provided from adjacent units.

9.3.2.3 Closed Heat Exchanger Shifting (e.g.: Operation changed from A to B)

a) Closed water pressure, water level of water tank shall be recorded and shifting engineer

shall be informed before closed heat exchanger shifting;

b) Close bottom water drain valve of closed heat exchanger B;

c) Open water inlet valve of closed heat exchanger B slightly for water filling.

d) Vent valve of closed heat exchanger B opens slightly, and it shall be closed when water

comes out.

e) Water inlet valve of closed heat exchanger B opens slowly to observe water level

changing of closed water tank.

f) Open cooling water inlet valve of closed heat exchanger B.

g) Cooling water side vent valve of closed heat exchanger B is closed.

h) Cooling water side drain valve of closed heat exchanger B is closed.

i) Open cooling water outlet valve of closed heat exchanger B.

j) Water outlet valve of closed heat exchanger B shall be opened slowly and attention shall

be paid to the closed water pressure changing.

k) Cooling water outlet vale of closed heat exchanger B shall be adjusted to maintain the temperature of closed water less than 38.

l) Water inlet valve of closed heat exchanger A shall be closed slowly and attention shall be

paid to the changing of closed water pressure.


Rev.: A



m) Close water outlet valve of closed heat exchanger A.

n) Close cooling water inlet valve of closed heat exchanger A. o)

Close cooling water outlet valve of closed heat exchanger A.

p) Open the cooling water drain valve on two ends of closed heat exchanger A.

q) Shifting engineer inform chemical group to test the hardness of closed water.

r) To record the shifting time of closed heat exchanger.

9.3.2.4 Operation Maintenance of Closed Circulating Cooling Water Pump

a) Water level of expansion water tank is normal; water level adjustment system of

expansion water tank shall put into service.

b) Outlet pressure of operating pump shall not be less than 0.5MPa.

c) Operating pump current and outlet water pressure are normal.

d) Motor and bearing temperature of operating pump is normal;

e) Motor and bearing vibration of operating pump is normal;

f) When closed circulating cooling water pump trips or manifold pressure of closed

circulating cooling water decreased to 0.3MPa, standby closed circulating cooling water

pump will startup automatically and alarm warning;

g) When water level of water tank achieves 1800mm, High water level switch will act to

alarm at control room; when water level of water tank decreased to 1500mm, low water

level switch will act to alarm, meanwhile, water makeup governor valve of expansion

water tank will be fully open; when water level of water tank decreased to 500, LL water

level switch will act to alarm in the control room.

h) After closed cooling water pump trips, and standby cooling water pump fails to act in 3

secs. Shutdown protection pump will startup automatically; water source of shutdown

protection pump is induced from condensate storage tank; attention shall be pay to the

water level, if shutdown protection pump fails to startup or trips automatically after startup,

manual cooling water inlet valve from expansion water tank and boiler-water circulating

pump. Meanwhile, attention shall be paid to other temperature changing.

10 ESP System & Deslagging and Ash Handing System Operation Manual

10.1Scope

The standard provides for the principles, methods and steps of startup, stop, operation and

maintenance, control and adjustment, maintenance, trouble removal and others of gas

electrostatic precipitator (ESP), deslagging and ash removal system in Vietnam Quang Ninh

Thermal Power Co., Ltd. 2 × 300MW generating units. Personnel at all levels engaging in ESP and

ash system operation, equipment maintenance and production technology management of

Vietnam Quang Ninh Thermal Power Co., Ltd. 2 × 300MW generating units must be familiar with

all or relevant parts of the standard and strictly implement them.


Rev.: A



10.2 Specific quoting documents

The provisions contained in the following standards and adopted by the manual are the

provisions of the manual. When the manual is promulgated, all the shown standards are valid. All

the standards will be revised, and all parties using the manual should explore the possibility of

using the following standards with the latest versions and their latest versions apply to the manual.

S/N Symbol of standard Name of Standard 01

No. 277 electricity safety

（1994） Rules of work of electric job security（thermal-mechanical

part） 02

DL408-91

Rules of work of electric job security (Power plant and substation electrical part）

03

Technical agreements and equipment data of Quang Ninh

Power Plant 10.3Principal specification of system

10.3.1 Overview

Vietnam Quang Ninh Thermal Power Co., Ltd. 2 × 300MW generating units are provided with

double-arched W flame single hearth and one-time middle reheating, forced circulation and

sub-critical steam drum furnace. Solid deslagging method is used and ash residue at the furnace

bottom is discharged to a residue slurry tank via slag crusher and hydraulic ejector. ESP uses

double-room four-electric-field electrostatic precipitator and negative pressure ash removal system.

The fly ash collected from the air heater, economizer and ESP is delivered to large ash silos (the

volume of each of two ash silos is 2500 m3), and dry ash is further mixed through ash

and water and sent to the residue slurry tank, and then is transported to the ash yard by mortar

pump (meanwhile dry ash retains the way of comprehensive utilization).

Each generating unit consists of two negative pressure delivery subsystems. Four separate

subsystems (1A, 1B, 2A and 2B) can at the same time automatically (or manually) run and sent

out the ash in their respective ESP ash buckets, economizer ash bucket and air preheater bucket

through the negative pressure fan. The production systems of three negative pressure fans of

each generating unit run the necessary vacuum, of which two run and the other one is for standby.

The two ash silos can at the same time receive ash from four transportation subsystems. Four

subsystems include their respective independent and specialized pipeline and respective ash silos,

and each generating unit contains two pipelines.

ESP ash bucket is provided with a gasification system, which transports continuous and

stable compressed air provided by the ash bucket gasification fan and heated to the ESP ash

bucket, enabling ash in the ash bucket to remain dry and flow, so that ash in the ash bucket can

smoothly flow to the pipeline while the fly ash system is running.

The dust collection equipment is installed on the top of the ash silo and includes 2 sets of bag

filter dust collectors, each of which is equipped with two gas lock valves. The bag filter dust

collector includes an automatic injection bag filter attached with relevant instruments. The bag

filter can filter fly ash and prevent dust from entering into the negative pressure fan.

The ash collected in the bag collectors in the role of their own gravity goes into the ash silos

through four air lock valves (each ash collector is equipped with two air lock valves). The air lock


Rev.: A



valve is used to ensure the fly ash falls smoothly into the ash silos but the system in operation will

not be interrupted. Ash is temporarily stored in the ash silos until fly ash is discharged and finally

handled through the unloading devices.

A ventilation filter is arranged on top of each fly ash silo. Air is replaced out when the system

runs and the ash silos discharge ash is filtered and then discharged into the atmosphere by the

ventilation filter.

Each fly ash silo is equipped with an air chute. The air chute can evenly distribute the

gasification air in the silo and cause ash to flow toward the discharge mouth. Gasification air is

from three sets of ash silo gasification fans and is heated by air circulation heater installed on the

gasification pipeline to make the gasification air keep dry. The ash silo gasification device is

designed to the continuous operation mode.

10.3.2 Technical specification of major equipment

10.3.2.1 Electrostatic precipitator

1 Model 2

Quantity

Set ／ furnace

2

3 Distance between

the same poles mm

450/400

4 Number of channel PCS 2×21/2×24 5 Number of electric

field PCS

4

6 Height of electric

field m

15

7 Type of anode

plate

480C

8 Length of electric

field m 4.55（Single electric field）

9

Type of cathode

wires

BS Barbed Wires of the first and second electric field;

high chrome high nickel stainless steel spiral line of the

third and fourth electric field 10 Cathode vibration

type

Lateral transmission vibration

12 Anion vibration

type

Lateral transmission vibration D of the top transmission

13 Groove type polar

plate system Set／set

14 Electric field wind

speed m/s

15 Number of ash

buckets pcs/electric

field


Rev.: A

SEC



16 Number of power

supply regions pcs/electric

field

17 Design pressure Pa 18 Body resistance Pa 19 efficiency of dust

collection ％

20 Manufacturer Shanghai Metallurgical Mining Machinery Plant 1 Model/specification GGAJ02—1.2A/72kV 2 Quantity set／set 3 3 AC input voltage V 380 4 AC input current A 271 5 AC input power kVA 6 DC output voltage kV 72 7 DC output current A 1.2 8 DC output power kW 9

Rectifier system Single-phase full-wave bridge type, negative

high-pressure output 10 Cooling pattern 11 Manufacturer Fujian Longking Environmental Protection Co.Ltd.

1

Girder electric

heater

2

Ceramics axis

electric heater

3

Ash bucket electric

heater

4

Ash bucket level

gage

10.3.2.2 Negative pressure fan

S/N

Item name

Unit

Design data

1 Model BK9020 2 Maximum

working

pressure

kpa

－49

3 Flow m3/min 69 4 Quantity Set 3 5 Motor model QA280M4A 6 Motor power kW 90 7 Rated current A 8 Rated voltage V 400


Rev.: A

SEC



9 Manufacturer China Diamond Power Machine (Hubei) Co. Inc. 10.3.2.3 Combination bag type ash collector

S/N

Item name

Unit

Design data

1 Model DMD250 2 Filter area m2 90 3 Efficiency of

dust collection ％

99.95

9 Manufacturer China Diamond Power Machine (Hubei) Co. Inc. 10.4Startup, operation and maintenance and stop of ESP system

10.4.1 Interlocking and Protection

10.4.1.1 If the security interlocking key of the ESP is disconnected, the silicon rectifier transformer

of the corresponding electric field can not be put into operation; when the ESP runs, if the

interlocking key is disconnected, the silicon rectifier transformer of the corresponding electric

field will trip.

10.4.1.2 If the lock switch of the switch cabinet valve of the silicon rectifier transformer is

disconnected, the silicon rectifier transformer of the corresponding electric field can not be

put into operation; when the ESP runs, if the lock switch is disconnected, the silicon rectifier

transformer of the corresponding electric field will trip.

10.4.1.3 Silicon rectifier transformer is provided with gas protection: light gas alarm and heavy gas

tripping.

10.4.1.4 Silicon rectifier transformer is provided with the oil temperature protection, and it will alarm if the oil temperature is more than 80 (ambient temperature +30 to 40 ) and it will

trip if the oil temperature is more than 85 (as is commissioned and set on the site). Alarm

oil temperature signal is in parallel connected with light gas signal and tripping oil

temperature signal is in parallel connected with heavy gas signal.

10.4.1.5 Silicon rectifier transformer is provided with input over-current, load open circuit, load

short circuit, SCR short circuit, SCR open circuit and partial excition protection.

10.4.2 Preparation and inspection of pre-operation

10.4.2.1 ESP body and relevant electrical parts are all repaired, all components fully inspected

are qualified, the inside is clean without person, debris and others, manholes are closed

and locked tightly, mechanical and electrical work sheets are ended, and the idle load

pressure build-up test is qualified.

10.4.2.2 All the equipment parts are complete, equipment signs are clear and correct, all

manholes are sealed well, heating devices of girders, insulators and ohters are intact, and

each part provides complete thermal insulation.

10.4.2.3 All the temporary grounding wires inside the electric field are disassembled and the ESP

body is grounded well.

10.4.2.4 The grounding resistance of the ESP body should be no more than 1Ω, and the shells of

all electric field, low-voltage distribution devices, control cabinets and motors as well as

high-voltage isolation switch grounding ends and others must be reliably grounded.


Rev.: A



10.4.2.5 The motor connections of all the rotating equipment are correct firm with complete

appearance, and the direction is right after commissioning; the local switch is at the

“cabinet” posiiton and the power switch in the control cabinet is closed.

10.4.2.6 The oil of all the rotating equipment (including reducers) is qualified, the oil level is

normal, there is no oil leakage, the protection covers are intact, the arming pins are firmly

connected, and the transmission mechanisms do not fall off..

10.4.2.7 The rectifier transformers have no oil infiltration or leakage, the oil is qualified, the oil

level is normal, the silica gel inside the respirator is blue, high and low-voltage cables are

not damaged, high-voltage cable joints have no flashover traces, and the grounding wires of

transformer shells are complete and firmly.

10.4.2.8 The isolation switch of the rectifier transformer is at the closing position of “electric field”

and contacts well, cabinet valves are well locked, insulation porcelain pieces are clean

without crack and discharge traces, and damping resistors do not fall off and fracture; ash

bucket ;evel switches, insulators, porcelain axis electric heaters and their temperature

measurement devices are installed firmly and connections are intact.

10.4.2.9 The switches of high-voltage control cabinets and low-voltage control cabinets as well as

meters are complete and integral, all brakes are operated flexibly, indicaiton locations are

correct, connections do not fall off, and the power supply of low-voltage busbar at the PC

section is turned on.

10.4.2.10 The security interlocking cabinet keys inside the low-voltage cabinets are complete and

are placed to “Turn-on”, the low-voltage power switch and the power control switch of the

control cabinet are closed, the “control the power switch” button on each control cabinet

panel is pressed, and then the low-voltage power and power control indicator lights on the

panel are on. (Operate intelligent monitoring instruments of control cabinets in No. 3 to 6

generating units: close the power supply of all electric field intelligent monitoring

instruments, and the intelligent monitoring instruments after completion of their

self-inspection should show “CCCC”; check whehter all parameters of the intelligent

monitoring instruments are set up correctly, and “sparks setting” operation mode under

normal circumstances should be used in the high-voltage electic field.)

10.4.2.11 The insulation resistance of high-voltage coil, rectifier component and high-voltage

ceramic casing in the high-voltage electic field. tested with 2500V megohm meter is no less

than 1000MΩ, the insulation resistance of the electric field is no less than 500MΩ; the

insulation resistance of the vibration motor, electric heater and their cables (380V and

below electrical equipment) tested with 500V megohm meter is no less than 0.5MΩ, and

the insulation resistance of the low-voltage coils and low-voltage ceramic casing of the

silicon rectifier transformer is no less than 300MΩ.

10.4.2.12 The dust removal transformer and dust removal PC section operate normally.

10.4.2.13 The fly ash system is in the standby status, ash bucket electric heater, ash bucket

gasification fan and ash bucket level meter all can work properly.

10.4.2.14 ESP stairs and platform are solid and clean, with adequate lighting and complete fire

prevention facilities.


Rev.: A



10.4.2.15 The upper PC of the system operation control is normally put into operation.

10.4.2.16 All the remote monitoring equipment (meters) are intact, the measured values are

correct and the alarm system is intact.

10.4.3 Commissioning and operation of the ESP

10.4.3.1 The ESP operates in priority in the PC and can also be operated on the control cabinet

on the site, and the switch of the on-site control cabinet is placed at the “on-site” position in

the implementation process of the on-site operations of the on-site control cabinet.

10.4.3.2 Close the switches of the power supply and the control power supply inside the

high-voltage control cabinet and low-voltage control cabinet, and the power switches of

electric heater and vibration motor inside the low-voltage cabinet, and th indicator lights

show correctly without warning and it is confirmed that all the set parameters are right.

10.4.3.3 Before the boiler is ignited, ceramics axis, insulator (porcelain sleeve), girder, ash bucket

and others are input for heating in 12 to 24 hours (18 to 24 hours optional in the rainy

season mostly and 12 to 18 hours optional in the dry season), and the electrostatic

precipitator body and the ash bucket are preheated.

10.4.3.4 Before the boiler is ignited, input all the electric field ash bucket gasification fans in 2 to 4

hours, and put the vibration motor into operation in 1 to 0.5 hours.

10.4.3.5 After the boiler with coal dust input operates stably (usually, there are two sets of milling

systems of the boiler in operation, there are not more than four oil guns for fuel, and the inlet

gas temperature of the ESP under normal circumstances should be more than 110 and

the minimum should be not less than 95), the leader on duty notices the ESP to be put

into operation. When operating the on-site control cabinet, press the “Reset” button, and

then press the Startup button to commission and operate the high-voltage electric field (the

electric field is input in order according to the inverse direction of flue gas flow direction, and

300MW generating unit ESP is first input into Ⅳ electric field and then into Ⅲ , Ⅱ , Ⅰ electric field). If there is still oil gun in operation in the boiler burning, boost in the “Manual”

mode, and adjust the secondary voltage to 40kV in operation; after the withdrawal of all oil

guns for the boiler burning, the secondary voltage is adjusted to the normal best state and

the operation switch is set to “Automatic” position. After each field is put into operation, a

period of time to observe and stability (5 to 10 minutes) should be provided, to verify

whether their work is normal, and the problems found should be timely examined, analyzed

and treated.

10.4.3.6 Adjust the operating mode and setting values of high-voltage parameters according to

the secondary voltage and current value, the operating conditions of the boiler and load of

the generating unit .

10.4.4 Stop the ESP

10.4.4.1 While the boiler stops, after the oil gun is put into operation, when the exhaust gas

temperature drops to below 100 , the operation of high voltage electric field can be

gradually cease.

10.4.4.2 After stopping the ESP upon the command of the leader on duty, start to stop the

high-voltage electric field, and operate in priority the upper PC and also operate the on-site

control cabinet.


Rev.: A



10.4.4.3 When stopping the high-voltage electric field in the inverse direction of flue gas flow

likewise, that is, start with the last electric field in series to stop it. In the process of stopping,

adjust first the secondary voltage and current to the minimum, and then stop it.

10.4.4.4 When stopping on the on-site control cabinet, adjust first the secondary voltage and

current to the minimum, press “Reset” button on the control panel and then press the

“Shutdown” button.

10.4.4.5 Shut off the main circuit switch of the high-voltage control cabinet.

10.4.4.6 Under normal circumstances, after the high-voltage field stops, maintain the vibration

device to continue to operate for four to eight hours and then stop it.

10.4.4.7 If the boiler stops in two days and the ESP is not repaired, the girder, cermics axis and

other heating devices will not stop. If they need to be disabled due to maintenance or other

inspections, testing and so on, stop them according to the normal stop operation and take

the power outage and other related security measures.

10.4.4.8 If the boiler has stopped for more than two days, the heating device should be suspended

and the power switches and the control power switches and others of all branches of the

low-voltage cabinet are disconnected.

10.4.5 Inspection in operation and contents of maintenance

10.4.5.1 The vibration device is installed firmly and its anchor bolts are not loose; the motor is in

normal operation, turns correctly and has no abnormal sound; the motor surface temperature

can not exceed the ambient temperature 45, its vibration is no more than 0.08mm, and the

fan is in normal operation; the maximum motor bearing temperature is not allowed to be

more than the ambient temperature 45 ; the reducer lubricates well, with adequate

lubricant, and no oil permeability exists on all vent caps and oil discharge mouthes.

10.4.5.2 The arming pins of the transmission mechanism are intact, shift forks are not fractured,

and the vibration sound inside the ESP is normal.

10.4.5.3 Each manhole of ESP body, insulator room valve and vibration axis penetration body

should be closed and seamless, and the ash bucket outputs ash normally.

10.4.5.4 Check that the on-site control cabinet of the vibration motor is normal and under

emergency circumstances, stop the vibration motor through the on-site cabinet control

switch.

10.4.5.5 After the anode vibration motor stops, the corresponding electric field continues to run for

a peirod time that should not exceed 24h.

10.4.5.6 After the cathode vibration motor stops, when the secondary current is less than 100mA,

it should be suspended, and the corresponding electric field continues to run for a peirod

time that should not exceed seven days.

10.4.5.7 The oil level of the high-voltage silicon rectifier transformer is one second to two thirds,

and oil is transparent without debris and oil leakage; the transformer has no abnormal sound

and smell, no abnormal increase in oil temperature occurs, silica gel inside the respirator is

blue, the isolation brake is in the electric field, the red indicator light is on, and the ceramic

casing has no climbing electricity and discharge phenomenon.


Rev.: A



10.4.5.8 The primary and secondary voltage and current of the high-voltage cabinet should be

lower than the rated values, otherwise they should be adjusted or the reasons are identified

and eliminated.

10.4.5.9 The operating indicator light of the high-voltage cabinet control panel is on, with no fault

alarm, and the cooling fan of the high-voltage cabinet SCR operates normally.

10.4.5.10 The vibration motor of the low-voltage cabinet and electric heater have no fault alarm,

and the displayed temperature value of the electric heater is in the set scope.

4.5.11 There is no abnormal sound, smell and smoke phenomena in the cabinet, each meter and

indicator right show normally, the switch position is correct, and the cabinet valve is locked.

10.4.6 Operation of ESP and Attentions to Maintenance

10.4.6.1 ESP uses high-voltage DC power supply, so the relevant provisions of “Safety” should be

strictly enforced in the process of operation and maintenance, with particular attention to

personal safety and equipment.

10.4.6.2 The rectifier transformer is not put into operation in the boiler-fuel stage and can be

appropriately input in the co-combustion of coal oil stage when the fuel is very little.

10.4.6.3 Before commissioning and operating the high-voltage electric field, the temperature of the

ceramics axis, insulator and others heated should be more than the smoke dew point

(normally 70 to 80) temperature of 20 to 30 and the inlet smoke temperature of the ESP

exceeds 95 (less than 160 ).

10.4.6.4 It is prohibited in operation that the manholes of the ESP body, ceremics axis and

insulator room are opened and the isolation switches must be locked; it is prohibited in the

operating process of the rectifier transformer to operate the high voltage isolation switch or

directly cut off the power supply.

10.4.6.5 If the operations inside the ESP are necessary, the operations must be conducted after the boiler stops and cools down, the outlet temperature of the ESP drops to below 40, the

ESP body is reliably grounded by inspection, and the power off and other security measures

are prepared and it is confirmed that the content of the internal toxic gas meets labor

protection requirements. If it is urgent to operate the ESP inside, after the boiler stops for

eight hours, open the manhole of ESP body and start a guide ventilatorto speed up the

cooling.

10.4.7 Common faults and trouble shooting of ESP

10.4.7.1 The primary and secondary voltmeter and ammeter of ESP have no significant display

values

-- Reasons

The power supply of the power circuit of the rectifier transformer is disconnected;

The automatic adjustor is powered off.

-- Treatment

Check the power circuit;

Check the control power supply of the automatic adjustor.

10.4.7.2 The primary voltage of the ESP is very low, its current is large, its secondary voltage is

close to zero and the secondary current is very large


Rev.: A



-- Reasons

The high-voltage isolation switch is placed on the “Ground”;

High-voltage cable is broken down or terminal joint insulator is damaged to cause short

circuit;

The electric field ash bucket is seriously accumulated with dust to cause short-circuit between

the anode and the cathode;

The broken cathode line causes short circuit;

The rotational ceramics axis of the cathode vibration device is damaged or the ceramics axis

box is seriously accumulated with dust, causing short circuit to earth;

The damping resistor at the top of electric field falls off to the ground;

There is a metal foreign body between two poles to cause short circuit;

The high-voltage insulator is damaged or quartz casing is condensed or has ash, causing the

short circuit.

-- Treatment

The high-voltage isolation switch is placed on the “Electric field” position;

Treat or replace cables and terminal joints;

Reduce the fouling inside the ash bucket as soon as possible;

Stop the boiler and treat the broken line;

Replace the rotation axis or remove the fouling;

Restore or replace the damping resistor;

Stop the boiler and treat the foreign body;

Replace the damaged insulation porcelain pieces, remove the fouling and improve the

heating temperature.

10.4.7.3 The secondary voltage of the ESP is normal and its secondary current is small

-- Reasons

Corona is closed;

The vibration effect is bad, resulting in weighty corona line or anode plate with too thick

fouling.

-- Treatment

Understand the boiler load, and observe whether it is relieved in low load;

Input the continuous vibration or adjust the vibration cycle.

10.4.7.4 The switch inside the ESP control cabinet trips or trips again after it is closed

-- Reasons

There is a foreign body in the electric field, causing double-pole short circuit;

The cathode line is broken or components fall off, causing double-pole short circuit;

The ash bucket is full of ash, causing the cathode short-circuit to earth;

The heating device of the insulator room at the top of the cathode fails or thermal insulation is

bad, causing the insulator surface to be condensated and flashover resulted from

insulation;

The fouling surface on the insulator at the top of the cathode discharges and is broken down.

-- Treatment


Rev.: A



Stop the boiler and treat the debris;

Stop the boiler and treat the broken line or components;

Reduce the fouling inside the ash bucket;

Restore thermal insulation or heating devices;

Swab the insulator.

10.4.7.5 Light and heavy gas alarm happen in the gas relay of ESP rectifier transformer

-- Reasons

Rectifier transformer fails inside

-- Treatment

Check whether the abnormal temperature of the outage rectifier transformer rises, check and

confirm the nature of the gas inside the gas relay, and inform the maintenance staff to

check and test insulating oil.

10.5Startup, operation, maintenance and stop of negative-pressure ash removal system

10.5.1 Interlocking and permision conditions

Before the system vacuum breaker valve is closed, the system must form a single and

smooth negative pressure air flow channel.

While the system is running, only an ash bucket material transport valve (H-type valve) is

allowed to be opened.

Before the ash removal procedures of the system ash transport pipeline start, all H-type

valves must be closed.

Before the negative pressure fan is allowed to commence, there must be a single and smooth

transport channel to form.

Before H-type valve is allowed to be opened in automatic ash transport mode during the

operation, the value of negative pressure the system must meet the minimum allowable

transmission value of PSML.

Before the upper valve of the gas lock valve is allowed to be opened, the lower valve of the

gas lock valve must be fully closed.

Before the lower valve of the gas lock valve is allowed to be opened, the upper valve of the

gas lock valve must be fully closed.

If the ash warehouse provides the alarm condition of “the material level of the ash warehouse

is high”, the system associated with the ash warehouse could not be activated. However,

when the relevant ash warehouse provides the alarm condition of “the material level of

the ash warehouse is high” after the system has begun to operate, the system continues

to run (only alarm).

Before the electric gasification air heater of the ash bucket (the ash warehouse) is put into

operation, the gasification fan of the corresponding ash bucket (the ash) must have been

put into operation normally.

Before the electric gasification air heater of the ash bucket (the ash warehouse) commences,

it must be ensured that the outlet pipeline valve has been opened and a smooth air flow

channel has formed.

10.5.2 Inspection and preparation before commissioning and operation


Rev.: A



The maintenance of all equipment of the negative pressure pneumatic ash removal system is

all over, and the work sheet ends and passes the acceptance.

Check whether there is no debris inside the ash bucket.

Check that the appearance of the on-site control box is intact and the switches and buttons in

the disc are complete and are operated flexibly.

Contact a heat engineer to connect the PLC program-controlled power supply of the ash

removal system, and the indicator light shows correctly, without alarm.

Check that the pneumatic and manual valves for all instruments are at the full position, and

adjust the gas pressure for the instruments to be 0.4 to 0.6 Mpa.

Click, open and close all pneumatic valves on the CRT one by one, and observe that the

actual location is consistent with the position of the CRT and the on-site control panel on

the site and the pneumatic implementing mechanism switch is flexible and in place and is

not jammed.

Check that the appearance of the bag-type dust collector is intact, the outlet mesh grid is

intact, the general compressed air valve is open, the pressure is about 0.6Mpa, without

air leakage phenomenon, the power switch inside the on-site control cabinet is closed,

the indicator light shows right and all the switches are flexible.

The manhole of the ash warehouse is closed, the appearance of the vacuum pressure

release valve is intact, the connections of the level meter and material level switch do not

fall off, the indication is correct, and the CRT has no wrong alarm.

The inlet and outlet manual valve of the gas storage cylinder in the ash warehouse are both

opened, and the pressure is 0.4 to 0.6 Mpa. The pneumatic and manual valve of the

pneumatic valve at the top of the ash warehouse for the electromagnetic valve control

cabinet is opened, the switch location is right and the control power supply is closed.

Open the manual dry ash valves of each ash bucket to the full open status.

Open the manual isolation valve of each branch pipeline of the gasification fan of the ash

bucket to the full open status.

Deliver the power supply of the gasification fan, ash warehouse and gasification fan heater of

the ash bucket, and gasification fan heater of the ash warehouse.

Check and set the temperature (120) of the gasification fan electric heater of the ash bucket

(the ash warehouse) correctly, and set the control mode of the heater to the position of

“Remote control”.

10.5.3 Startup of the gasification system of the ash bucket and air warehouse

10.5.3.1 Check and confirm that the isolation valve of each branch of the ash bucket (the ash

warehouse) gasification fan has been opened.

10.5.3.2 Open the outlet pneumatic valve of the gasification fan of the ash bucket (the ash

warehouse) until the “Full open” feedback signal is sent out.

10.5.3.3 Start the gasification fan of the ash bucket (the ash warehouse).

10.5.3.4 Delay three minutes and then start the gasification fan electric heater of the ash bucket

(the ash warehouse).

10.5.4 Commissioning and operation of the negative pressure ash removal system


Rev.: A



10.5.4.1 Start the ventilation filter of the ash warehouse.

10.5.4.2 Complete the following options based on the operating control station CRT of the ash

removal system:

• Select the ash bucket of each ESP, air preheater and economizer until “COLLECT” status is

through the BYPASS - COLLECT selection button)

• Select the ash removal subsystem A and B to AUTO status (relative MANUAL)

• According to the standby status of the negative pressure dedusting fan, select two fans on

work.

10.5.4.3 Press “START” button of the system

10.5.4.4 Observe that the system should run in accordance with the following procedures:

10.5.4.4.1 The filter dust collector of the ash warehouse A begins to circulate, and its impulse

control timer is excited (powered on) so that the bag-type filter starts to work. The upper

and lower valve of the corresponding air lock valve combined with the balance valve begin

to open and close circulatorily. At the same time the fluidization electromagnetic valve of

the filter dust collector is excited (powered on) and is open. When the lower valve of the air

lock valve is open, its fluidization electromagnetic valve is excited and is open, and the

fluidization electromagnetic valve is de-excited (powered off) and is closed when the lower

valve is closed.

10.5.4.4.2 The opening/closure of the following system isolation valve can form a separate ash

transport channel and vacuum channel through the filter dust collector A:

The vacuum fan isolation valve is adjusted to the correct channel.

The first branch pipe isolation valve of the ESP ash bucket is opened.

•Check the procedure logic and make sure that the ash warehouse is not in the high material

level, and a separate smooth transport channel has been established (through the limit

switch of the valve).

The vacuum breaker valve is excited (powered on) and is closed.

10.5.4.4.3 Startup of vacuum fan A.

10.5.4.4.4 When all the ash bucket relief valves (H-type valves) are closed after the fan

commences, the vacuum degree of the system will rise. When the vacuum degree reaches

the set point PSML, PLC will send signals so that the most remote ash bucket relief valves

(H-type valves) in the first column of the ESP ash bucket are opened.

If it can not reach the set point of PSML in the scheduled time, it will send a warning signal

“low vacuum” (FLY ASH SYSTEM VACUUM LOW). The phenomenon is likely resulted

from the vacuum leakage of the pipeline system or an H-type valve not closed.

When the H-type valve is opened after receiving the signal, the timer begins to work. In the

scheduled time, the vacuum degree of the system must decline to the set point PSL

below, otherwise it will trigger the “high vacuum” alarm (FLY ASH SYSTEM VACUUM

HIGH). (Usually, the time set by the timer is determined based on the time for dumping

the entire ash bucket). Before the end of the timer delay, if the vacuum degree of the

system declines to the PSL below, the timer returns to zero (reset).


Rev.: A



When the ash in the ash bucket is discharged into the flying ash pipeline, the vacuum degree

of the system will increase to the set point PSH, and at the time, the E-type valve that is

currently open receives the signal and is closed to prevent the pipeline from over load.

When the H-type valve is closed, as no more ash is discharged into the pipeline, the

vacuum degree of the system will gradually drop to PSMH, and at this time, the H-type

valve receives the signal and is re-opened.

As ash in the ash bucket is gradually discharged, the vacuum degree of the system will

gradually decline. When the vacuum degree of the system declines to the set point of

PSL, the ash bucket is basically emptied, and thus the H-type valve of the ash bucket

receives the signal and is closed. The closure of the H-type valve leads to the vacuum

degree of the system to rise again, when the vacuum degree reaches the set point of

PSML, PLC sends signals to open the H-type valve of the selected next ash bucket in the

ash collection order.

10.5.4.4.5 Repeat the operation order in the above steps from C to E for every ash bucket in the

column.

10.5.4.4.6 When the vacuum degree of the system declines to PSL in the operation process of the

chosen last ash bucket in the column, or the fourth ash bucket, its H-type valve is closed.

10.5.4.4.7 The branch pipe isolation valve of the ash bucket in the second row receives signals

and is opened, and meanwhile branch pipe isolation valve of the ash bucket in the row that

has completed ash output receives signals and is closed.

10.5.4.4.8 The order of ash output and the operation process of the ash bucket in the second row

are completely the same as the ash bucket of the row completed.

10.5.5 Inspection of the negative pressure ash removal system in operation

10.5.5.1 The gasification fan and vacuum fan of the ash bucket (the ash wareshoue) are in normal

operation, without abnormal sound, the vibration is less than 0.08mm, the bearing

temperature is less than 80 , and belts slack appropriately, without fault; oil of the

lubricating parts is good, transparent and colorless, the oil level is one third to two thirds,

without oil leakage.

10.5.5.2 The combination faces of all air pipelines and pipeline flanges have no air or ash leakage.

10.5.5.3 Ammeter three-phase of the electric heater control cabinet is uniform, the voltage is

around 380V, the indicator light is right and can automatically start and stop according to the

set temperature, there is no burnt flavour inside the cabinet, and the SCR cooling fan is in

normal operation.

10.5.5.4 The ash transport pipeline has no vacuum leakage and each ash bucket discharges ash

normally;

10.5.5.5 The compressed air pressure of the system is normal, withotu air leakage phenomenon,

all the pressure gauges show correctly, the pneumatic valve operates flexibly and is not

jammed, and the on-site switch position is the same as the indicated on the CRT and on-site

disc;

10.5.5.6 Check the ash discharge pressure curve of each ash bucket timely, analyze the ash

discharge status, and confirm the alarm in the larm column after it is analyzed.


Rev.: A



10.5.5.7 The electromagnetic valve of the bag-type dust collector works properly, the effect of

pulse vibration is good, and the air exhaust does not output ash.

10.5.5.8 The on-site state of all remote control equipment and valves are consistent with the CRT.

10.5.6 The negative pressure ash removal system stops normally:

10.5.6.1 The pulse injection timer of the filter dust collector still remains the working condition, and

the upper and lower valve of the corresponding air lock valve continue to circulate for a

scheduled period of time to ensure that the filter bag is clean and the filter dust collector is

completely emptied.

10.5.6.2 After a delay for cleaning the transmission pipeline, the running vacuum fan receives

signals and stops. Before the fan stops (about 2 seconds), the corresponding vacuum

breaker valve is powered off and is opened.

10.5.6.3 The branch pipe isolation valve of the ash bucket and the isolation valve of the fan are

closed.

10.5.6.4 The operating process of ash removal ends.

10.5.7 Common faults and trouble shooting of negative pressure ash removal system

When there is an alarm signal, press (ACK) button first of all; after eliminating the alarm

situations, press (RESET) to remove the alarm display. (For the critical alarm signal of the

system, the system must be reset before it is allowed to restart.)

10.5.7.1 Low vacuum of fly ash system

Reason: A “low vacuum” alarm signal lasts more than 30 seconds. The possible reason is that

the material transport valve of the ash bucket can not be closed or the pipeline is

damaged.

System response: the system stops at the current ash bucket because the vacuum degree of

the system fails to rise to PSML, it can not be transferred to the next ash bucket.

Treatment: check whether H-type valve of the current ash bucket moves normally, and find

the leakage point and eliminate it

10.5.7.2 High vacuum of fly ash system

Reason: the vacuum value continues to maintain the set point of PSMH for more than 15

minutes. The possible reason is that the ash bucket is blocked or the material transport

valve of the ash bucket can not be opened.

System response: the system stops at the current ash bucket because the vacuum degree of

the system fails to decline to PSL, the current H-type valve maintains open.

Treatment: switch the status of the ash bucket to the BYPASS status, and check whether the

manual lower ash valve of the ash bucket is opened, and treat the blocked ash of the ash

bucket.

10.5.7.3 High temperature outlet of negative pressure fan A (B)

Reason: the outlet temperature of the negative pressure fan is high, and the possible reasons

include the bad lubrication or the fan has mechanical failure.

System response: the transportation system is shut down

Treatment: the system is put into operation again after switching the standby fan

10.5.7.4 High pressure difference of filter dust collector A (B or C)


Rev.: A



Reason: the differential pressure switch senses the high differential pressure inside and

outside the cloth bag, and three times of this situation within 10 minutes appear

continuously. Possible reason is that the cloth bag is blocked or the cloth bag cleaning

equipment fails.

System response: when the cloth bag dust collector alarms for the first time due to the high

differential pressure of the cloth bag, the current H-type valve should be closed and the

system vacuum breaker valve is powered off and is opened. The “on demand” ash

removal control procedures of the filter dust collector continue to operate, and the air lock

valve below the dust collector runs circulatorily for a scheduled period of time (about two

minutes). The vacuum breaker valve is powered on and is closed, and the current H-type

valve is re-opened so that the system resumes operating. If the dust collector cloth bag

has high differential pressure for three times continuously within 10 minutes, an alarm

signal appears, and the system starts to stop normally. (After cleaning the pipeline,

before the system stops, the pulse injection control procedures of the filter dust collector

and the circulation procedures of the air lock valve continue to run for 5 to 10 minutes).

Treatment: check the pulse electromagnetic valve of the cloth bag dust collector and check

the pressure of the gas source for the cloth bag dust collector.

10.5.7.5 The cloth bag A (B) of the filter dust collector is broken

Reason: the determined significant changes in dust grain flow are detected by the dust

monitor installed on the front air inlet mother tube at the entrance of the negative

pressure fan and this situation continues for a scheduled period of time. The reason is

usually that the cloth bag of the filter dust collector is damaged or the cloth bag falls off.

System response: the system alarms.

Treatment: stop the system to check the cloth bag dust collector and calibrate the dust

detector.

10.6Startup, operation, maintenance and stop of the hydraulic deslagging system

10.6.1 Interlocking and protection

10.6.1.1 After the slag crusher is overload, it stops and sends out fault alarm signal.

10.6.1.2 A, B slag bucket of each boiler are at the same time not allowed to discharge slag, and

two boilers discharge slag alternately.

10.6.1.3 When the liquid level of the front buffer tank of the slurry pump of No.1, 2 generating unit

(the front tansfer warehouse of the slurry pump for No. 3 to 6 generating unit) is “too low”

value, the operation pump stops; when it is “low” value, the slurry pump is locked and is

allowed not to start. If the high-pressure pump at this time is in operation, the water

replenishing valve is opened; when it is the normal value, the water replenishing valve is

closed, and when it is high value, the slurry pump should be start or continue to run; when

the liquid level of the front buffer of the slurry pump is “low” value and the high-pressure

water pump does not run, the water replenishing valve is not closed. (No. 3 to 6 generating

unit is yet not provided wih logical chain, so the “low” value is 1.5m in the actual operation

and the “too low” value is provided by 0.5m)

10.6.1.4 When the liquid level of the front buffer tank of the slurry pump of No.1, 2 generating unit


Rev.: A



is “too low” value, the washing valve of the slurry pump is opened, the inlet valve is closed,

and the slurry pump stops and the washing valve is closed after washing for some time.

10.6.1.5 When the high, medium and low-pressure water pump begin to be put into operation, the

electric bypass valve is opened first automatically, the bypass valve is closed after the pump

operates stably, and when the pressure of the mother tube is high in the course of running,

the bypass valve is opened to relieve pressure.

10.6.1.6 The overflow pump and sewage discharge pump start under the “high water level” signal

sent by the liquid level meter, and they stop when it is “low water level " signal.

10.6.1.7 When the water storage tank sends “low water level” signal, the water replenishing

electric valve is opened to supply water to the water storage tank, until the water level is

normal before the water replenishing electric valve is closed.

10.6.2 Preparation and inspection prior to commissioning and operation

10.6.2.1 Confirm that the maintenance of all the equipment of the system is all over and the work

sheets are ended and pass the acceptance.

10.6.2.2 The manholes of the slag bucket are closed tight, overflow pipes are smooth, there is no

slag deposition in the overflow water tank, each manual valve of water seal slot and sight

glass washing valve are opened, the slag discharge gate and each aerodynamic nozzle

vavle are closed, sight glass is intact, and all the pipelines are connected tightly.

10.6.2.3 The water storage tank for controlling the slag discharge valve of the slag bucket is filled

with water by 15 to 25cm, and its water inlet valve, overflow water valve,and the water

discharge valve at the bottom and the control emptying valve at the top are all closed,

without water and air leakage.

10.6.2.4 The appearance of the slag crusher is intact, the anchor bolts are connected tightly, the

shaft seal water is normal, the oil level of the reducer is one second to two thirds, and oil

quality is good, without oil permeability and leakage, the transmission chain is appropriate

elastic with good lubrication, the shield is solidly installed, the hydraulic injector is smooth,

and the inlet and outlet flange are connected tightly.

10.6.2.5 The liquid level of the water storage tank is normal and the liquid level indicator shows

correctly.

10.6.2.6 The anchor bolts of high and medium pressure water pumps are connected tightly, the

inlet manual valve and bypass manual valve are open, the shaft seal water and bearing

cooling water are appropriately adjusted, the oil level is one second to two thirds, and the oil

quality is good, without oil permeability and leakage, and the coupling shield is installed

firmly.

10.6.2.7 The anchor bolts of low-pressure water pumps are connected tightly, the inlet manual

valve and bypass manual valve are open, the bearing lubricant is good, the belt is intact and

is appropriately elastic, and the shield is installed firmly.

10.6.2.8 Start a slag bucket cooling water pump to supply the corresponding the water seal groove

at the bottom of the boiler with water before 1h when the boiler is ignited.

10.6.2.9 The anchor bolts of the overflow pumps are connected tightly, the bearing lubricant is

good, the belt is intact and is elastic appropriately, the shield is installed firmly, and the shaft


Rev.: A



seal water is appropriately adjusted.

10.6.2.10 There are no big blocks of slag deposition, debris and others inside the slag bucket

buffer pool (transfer warehouse), and the liquid level shows correctly.

10.6.2.11 The anchor bolts of the slurry pump are connected tightly, the inlet manual valve and

outlet manual valve are open, the shaft seal water and bearing cooling water are

appropriately adjusted, the oil level is one second to two thirds, and the oil quality is good,

without oil permeability and leakage, and the coupling shield is installed firmly.

10.6.2.12 Contact a heat engineer to connect the PLC power supply, open the pneumatic and

manual valve of the slag bucket for the electromagnetic on-site cabinet instrument, close the

control power supply, and the indicator light shows correctly and the switch is placed at the

“Remote” position.

10.6.2.13 Close the power supply inside the on-site control cabinet of the slag crusher, and the

indicator light shows correctly and the switch is placed at the “Remote” position.

10.6.2.14The air pressure of the instrument is 0.4 to 0.6 Mpa, all the pressure transmitting

instruments and pressure switches are input, the pressure gauge is intact, the pneumatic

valve and electric valve switches are flexible and the feedback signals are correct.

10.6.2.15 The ash water recycling system is in good standby status.

10.6.3 Startup and stop of slag bucket cooling water pump

10.6.3.1 Operation steps of starting the slag bucket cooling water pump

10.6.3.1.1 According to the operating conditions of the generating units, open the general electric

valve of the low-pressure water replenishment and the manual valve of each branch line

(appropriate opening).

10.6.3.1.2 Open the electric bypass valve of the low-pressure water pump.

10.6.3.1.3 Press “Start” button of the low-pressure water pump, observe that the outlet pressure

gauge of the low pressure water pump is normal, and open the electric valve of the

low-pressure water pump.

10.6.3.1.4 After the low-pressure water pump works normally, close the electric bypass valve of

the low-pressure water pump, and adjust the electric outlet valve according to the water

replenishing status of the boiler water seal.

10.6.3.2 Operation steps of switching slag bucket cooling water pump (switching the high and

medium pressure water pump by reference to the operation steps)

10.6.3.2.1 Report to the leader on duty before switching.

10.6.3.2.2 Start the standby pump.

10.6.3.2.3 Open the exit valve of the standby pump and close the exit valve of the operating pump,

and at this time pay attention to the changes in the outlet mother tube pressure and the

overflow water.

10.6.3.2.4 Stop the original operating pump after the startup pump is operating normally.

10.6.3.3 Operation steps of stopping the slag bucket cooling water pump

10.6.3.3.1 Stop the slag bucket cooling water pump when the leader on duty orders to stop the

slag bucket cooling water pump.

10.6.3.3.2 Press “Stop” button of the low-pressure water pump to stop it.


Rev.: A



10.6.3.3.3 Close the inlet and outlet valve, and shaft seal water and bearing cooling water.after the

low-pressure water pump stops

10.6.4 Startup and stop of overflow pump

10.6.4.1 Operation steps of starting the overflow pump

10.6.4.1.1 Check whether the overflow pump and its motor have the startup conditions, connect

the power supply and confirm the power current and the control power supply are normal.

10.6.4.1.2 Confirm that the slag bucket cooling water pump is running normally, the overflow of the

water seal slag discharge groove is normal and the water level of the overflow water tank

is normal.

10.6.4.1.3 When the water level of the overflow water tank is high, start the overflow pump on the

CRT, open the electric outlet valve of the overflow pump in the interlocking or manual

mode, and confirm on the site that the overflow pump starts normally. (When the water

level “high” signal of the overflow water tank is sent, the overflow pump should be

interlocked and start automatically)

10.6.4.1.4 After the overflow pump is running, pay attention to the changes in the outlet pressure

of the overflow pump and the water level of the overflow water tank.

10.6.4.2 Operation steps of stopping the overflow pump

10.6.4.2.1 When confirming that the water level of the overflow water tank is low, the overflow

pump can be suspended. (When the overflow water tank sends a “low water level” signal,

the overflow pump should chain and automatically stop, and the electric inlet valve will

shut down automatically).

10.6.4.2.2 Press “stop” button of the overflow pump on the CRT to stop operating the overflow

pump, and close its electric outlet valve.

10.6.4.2.3 If the overflow pump stops for a long time and there is no water in the overflow water

tank, close the manual water valve of shaft seal of the overflow pump.

10.6.5 Startup and stop of deslagging water pump

10.6.5.1 Operation steps of starting the deslagging water pumps

10.6.5.1.1 Check whether the liquid level of the water storage tank is normal;

10.6.5.1.2 Check that the deslagging water pump and its motor are provided with startup

conditions, connect the power supply, and confirm that the power supply and the control

power supply are normal.

10.6.5.1.3 Open the electric bypass valve of high-pressure water pump.

10.6.5.1.4 Press “Start” button of the deslagging water pump on the CRT, observe the outlet

pressure gauge of the deslagging water pump shows normally, and open the electric outlet

valve of the deslagging water pump, when the changes in the outlet pressure of the

deslagging water pump and the water level of the water storage tank should be paid

attention to.

10.6.5.1.5 Close the electric bypass valve of the deslagging water pump after opening the inlet

and outlet valve of the slag discharge hydraulic ejector.

10.6.5.2 Operation steps of stopping the deslagging water pump

10.6.5.2.1 Confirm that the slag discharge out of the slag bucket ends.


Rev.: A



10.6.5.2.2 Press “Stop” button of the deslagging water pump on the CRT

10.6.5.2.3 Close the electric outlet valve of the deslagging water pump

10.6.5.2.4 Confirm that the deslagging water pump stops running.

10.6.5.2.5 Close the shaft seal water valve and bearing cooling water valve of the deslagging

water pump.

10.6.6 Operations of slag bucket slag discharge

10.6.6.1 Place the switches of the electromagnetic valve control cabinet and slag crusher on-site

control cabinet to “Remote” position.

10.6.6.2 Open the outlet pneumatic valve of the hydraulic ejector.

10.6.6.3 Open the inlet pneumatic valve of the hydraulic ejector.

10.6.6.4 Start the deslagging water pump.

10.6.6.5 Start the front-wall slant nozzle of the slag bucket.

10.6.6.6 Start the slag crusher and open the back dilution valve of the slag gate and the slag

discharge gate.

10.6.6.7 When slag in the slag bucket is emptied basically (time to be determined after

commissioning) , close the front-wall slant flush valve of the slag bucket, open the outer slant

flush valve, rinse it for 2 to 3 minutes and then close it, open the lower oblique flush valve

inside the slag bucket for 2 to 3 minutes and then close it, open the upper oblique flush valve

inside the slag bucket for 2 to 3 minutes and then close it, open the front-wall slant flush

valve of the slag bucket for 2 to 3 minutes and then close it, and open the emergency flush

valve of slag bucket gate for 1 to 2 minutes and then close it.

10.6.6.8 Close the slag discharge gate. Open the upper oblique flush valve inside the slag bucket

to inject water to the slag bucket for 20 minutes and then close it.

10.6.6.9 Stop the slag crusher.

10.6.6.10 Open the outlet pneumatic valve of the hydraulic injector of another slag bucket.

10.6.6.11 Open the inlet pneumatic valve of the hydraulic injector of another slag bucket.

10.6.6.12 Repeat Item 6.6.5 to 6.6.9 and discharge slag out of another slag bucket

10.6.6.13 Stop the deslagging water pump after the end of discharging slag out of the slag bucket

10.6.6.14 Close the inlet valve of the hydraulic injector.

10.6.6.15 Close the outlet valve of the hydraulic injector.

10.6.7 Startup and stop of slurry pump

6.7.1 Operation steps of starting the slurry pump

10.6.7.1.1 Check that the liquid level of the slurry buffer tank or transfer warehouse is normal, and

wash the slurry pumps of No. 1 and No.2 generating unit and close the electric valve.

10.6.7.1.2 Confirm that the slurry pump and its motor are provided with startup conditions, connect

the power supply, and confirm the power supply and the control power supply are normal.

10.6.7.1.3 Start the inlet valve of the slurry pump, press “Startup” button of the slurry pump and

observe that the outlet pressure gauge of the slurry pump shows normally (more than

0.4Mpa), and open the exit valve of the slurry pump (but a slurry pump should be avoided

from transporting to two slag pipes at the same time, and two slurry pumps are

prohibited to transport to a slag pipe at the same time), when the changes in the outlet


Rev.: A



pressure of the slurry pump and the water level of the slurry buffer tank should be paid

attention to.

10.6.7.1.4 The inspection on concentration of slag water, size of slag grain, pressure of slag pipe

and others of the slurry pump during operation should be strengthened to prevent the

slurry pump from being jammed, overflowing or the slag pipe from being blocked as well

as unusual situations from occurring.

6.7.2 Operation steps of stopping the slurry pump

10.6.7.2.1 When it is confirmed that sediment in the slag bucket at the bottom of the furnace or in

the slurry buffer tank has been transported cleanly, the desulfurization and ash warehouse

stop discharging gypsum (mortar) and the liquid level of the slurry buffer tank or transfer

warehouse reduces to the low value, open the backwashing valve at the entrance to the

slurry pump, close the inlet valve of the slurry pump and rinse the slag pipe for 15 minutes.

10.6.7.2.2 Press “Stop” button of the slurry pump to stop operating the slurry pump.

10.6.7.2.3 Close the outlet valve of the slurry pump.

10.6.8 Inspection of commission and operation and contents of maintenance

10.6.8.1 All the slag buckets, pipelines and valves have no water leakage, the fire holes are not

ruptured, and the positions of the valves are correct.

10.6.8.2 There is no abnormal sound from the slag crusher in operation, shaft seal is supplied with water normally, vibration is less than 0.08mm, bearing temperature is no more than 80,

and the chain transmission is normal.

10.6.8.3 Water storage tank provides normal liquid level and has no water or gas leakage

phenomenon.

10.6.8.4 The outlet pressure of the hydraulic ejector in the process of discharging slag increases

abnormally, the water output of the slag pipe becomes small, the slag discharge gate of the

slag bucket should be timely closed and the slag pipe is washed.

10.6.8.5 The liquid level of the water storage tank and slurry buffer tank is normal, the float valve

sends signal right in time, and water supply is input in a timely manner.

10.6.8.6 The sound of the water pump is normal in operation, and the pump body does no leak and the shaft seal drips normal. Bearing temperature does not exceed 80, vibration is less

than 0.08mm, water of the shaft seal is properly adjusted, the belt does not skid or is not

broken, and the outlet pressure is normal.

10.6.8.7 The indicator lights of all on-site control cabinets are right, the air pressure for instruments

is 0.4 to 0.6Mpa, the pipeline does not leak, and all the pressure gauges and pressure

transmitting instruments are input normally.

11 FGD and Limestone Supply System Operation Manual

11.1 SCOPE

This standard prescribes the principle, method and procedure for the start up, shut down,

operation & maintenance, control & regulation, dead status upkeep, accident handling and so on

of the 2x300MW power generation unit flue gas desulfurization (FGD) system in Vietnam


Rev.: A



Guangning Power Corporation, Ltd. The 2x300MW power generation unit FGD system operation,

equipment maintenance and production technical management staff at all levels engaged in

Vietnam Guangning Power Corporation, Ltd. must acquaint themselves with entire or related parts

and carry through strictly.

11.2 NORMALIZED DOCUMENT QUOTATION

The terms in the documents listed below become the terms of this standard through quotation.

For every dated quotated documents, all subsequent revision sheets or versions shall not be

applicable. However, it is encouraged that all parties who come into agreement on this standard

can investigate the workablity of the latest versions of these documents. For every undated

qutoted documents, the latest version shall be applicable under this standard.

S. No. Standard Code Name Standard Title 01

DL277-94

Working Regulation of Power Safety (Thermal Mechnical

Part) 02

DL408-91

Working Regulation of Power Safety (Power Station and

Substation Electrical Part) 03

Shanghai Shichuan Island Guangning Desulfurization

System Operation And Maintenance Manual 11.3FGD SYSTEM QUIPMENT SPECIFICATION

11.3.1 General

Vietnam Guangning first phase 2x300MW coal firing generation units consist of 2 sets of

subcritical drum boiler with controlled circulation, single drum, one regenerative stage, “W” flame

combustion (middle storage, hot air powder feeding, third air not entering the furnace), balanced

ventilation, solid deslag, open arrangement and complete steel suppension structure. The raw flue

gas shall be dedusted by ESP. The FGD is set at the furnace rear area after the ID fan. The

limestone-gypsum wet full flue gas desulfurization method shall be used under BMCR operation

conditions by FGD project. The design efficiency is 93% and the guarantee desulfurization

efficiency is not less than 90%. Desulfurization process shall use limestone-gypsum wet

desulfurization method. The spray empty absorber towers are adopted. One absorber tower is set

for each boiler.

The wet milling proposal is used in limestone preparation system which is design into two sets.

One set of the milling machine shall meet the 100% limestone consumption requirement by 2

boilers under BMCR operation conditions.

The Gas-Gas-Heater (GGH) is used.

The monitoring and control of FGD are set in Ash Control Building. One DCS system is

adopted for control of 2 boilers’ FGD and common systems.

The desulfurization sewage treatment system is not given in this project temporarily. The

desulfurization sewage is discharged into the plant ash slurry reservoir directly.

11.3.2 Project Design Conditions

11.3.2.1 Boiler Survey

11.3.2.1.1 Major design parameters for boiler

Equipment Parameter Unit Value


Rev.: A

SEC



Type SUBCRITICAL NATURAL CIRCULATION, “W” FLAME, DRUM BOILER

MCR t/h 996.33 Quantity set 2

Boiler

Actual coal consumption t/h 130~145 Quantity (per boiler) set 2 Type DOUBLE ROOM FOUR

FIELDS ESP

Deduster

efficiency % >99.1 Type Static blade adjustable axial

draft type Quantity (per boiler) set 2 Air quantity (T.B) m3/s 258.7

ID fan

Air pressure (T.B) Pa height m 200 Inner diameter at outlet m 4600

chimney Internal anticorrosive material

11.3.2.1.2 Parameters for flue gas and its ducting

Item Unit Value Flue gas speed (design flow) m/s ﹤ID fan outlet flue duct dimension (steel structure) m×m R=4500 ID fan outlet flue duct central line elevation m 2.9 11.3.2.1.3 Flue gas parameters at FGD system inlet

Boiler BMCR Operation Conditions Flue Gas Analysis (Design coal, Standard conditions, Actual O2)

Item Unit Dry basis Wet basis Remark CO2 Vol% 13.26 12.57 α=1.477 O2 Vol% 6.85 6.49 N2 Vol% 79.84 75.67

SO2 Vol% 0.06 0.053 H2O Vol% 4.98 5.2176

Boiler BMCR Operation Conditions Flue Gas Parameters Design coal remark

Nm3/s Dry basis, α=1.447

Nm3/s Wet basis, α=1.447

Nm3/h Standard conditions, Dry basis, α=1.4

ID fan outlet flue gas quantity(BMCR)

Nm3/h Standard conditions, Wet basis, α=1.4

ID fan outlet flue gas temperature

ID fan outlet flue gas pressure

Pa BMCR Operation Conditions

ID fan outlet flue gas quantity and temperature under different loads Item Unit RO 75%RO 65%RO 30%RO

ID fan outlet dry flue gas quantity

Nm3/h


Rev.: A

SEC



ID fan outlet wet flue gas quantity

Nm3/h

ID fan outlet flue gas temperature

Boiler BMCR Operation Conditions Flue Gas Pollutant Analysis(Standard conditions, Dry basis, 6%O2)

Item Unit Design coal Min Max SO2 mg/Nm3 934 573 1504 SO3 mg/Nm3

Cl(HCl) mg/Nm3 F(HF) mg/Nm3

Soot (ID fan outlet) mg/Nm3 400 400 400 11.3.2.2 Fuel

No. Components Symbol Unit Range Data Design Data I Heating values

High heating value HHV kcal/kg 4680 - 5300 4980 Low heating value LHV kcal/kg 4490 - 5157 4790 Proximate analysis 1 Total moisture (as received) War % 5.55 - 12.0 9.00 2 Surface moisture Ws % 4.81 - 9.88 7.63 3 Inherent moisture Win % 0.78 - 2.35 1.48 4 Air-dried moisture Wad % 0.80 - 2.41 1.39 5 Fixed carbon (as received) Cf

ar % 49.54 - 63.15 53.68 6 Volatile matter (as received) Var % 5.82 - 8.61 6.83 7 Ash content (dry) Ad % 28.0 - 37.36 33.5 8 Ash content (as received) Aar % 25.48 - 34.0 30.49

To tal 100.00 Ultimate analysis

1 Carbon (as received) Car % 46.83 - 63.75 54.62 2 Hydrogen (as received) Har % 2.56 - 2.97 2.62 3 Oxygen (as received) Oar % 1.66 - 2.68 2.09 4 Nitrogen (as received) Nar % 0.73 - 0.86 0.77 5 Sulphur (as received) Sar

or % 0.27 - 0.66 0.41 6 Ash (as received) Aar % 25.48 – 34.0 30.49 7 Moisture (as received) War % 5.55 - 12.0 9.00

Total 100.00 Physical criteria 1 Hardgrove Grindability Index - 45 - 70 47 2 Dust coal particle size

(0-15mm) 100

+10 mm size % 6.16 - 17.5 10.53 5-10 mm size % 9.89 - 18.3 14.22


Rev.: A

Item Value Colour: No Smell: No

CO2 (Concentration): 2.64 mg/l

Date 2008-09-16


Page 114

Rev.: A

SEC



No. Components Symbol Unit Range Data Design Data 2.5-5 mm size % 15.60 - 21.71 18.62 1.25-2.5 mm size % 8.73 - 13.76 10.97 0.63-1.25 mm size % 12.36 - 18.13 14.89 0.315-0.63 mm size % 6.80 - 14.45 10.02 - 0.315 mm size % 11.47 - 31.47 20.77 3 Density - 0.92 - 1.10 1.00 4 Angel of repose degree 33 - 39 37 No. Components Symbol Unit Range Data Design Data

Ash content 1 SiO2 % 57.60 - 64.10 62.83 2 Al2O3 % 23.3 - 28.64 24.76 3 Fe2O3 % 4.26 - 6.16 5.41 4 V2O5 % 0.018 - 0.028 0.026 5 TiO2 % 0.50 - 0.91 0.68 6 CaO % 0.30 - 0.77 0.44 7 MgO % 0.67 - 1.42 1.11 8 K2O % 3.35 - 4.70 3.64 9 Na2O % 0.15 - 0.55 0.48 10 P2O5 % 0.19 - 0.30 0.24 11 SO3 % 0.251 - 0.481 0.341 12 MnO % 0.006 - 0.050 0.043 13 Others % 0.00 0.00

Total 100.00 1 Ash density g/cm3 0.224 - 0.370 0.291 2 Ash resistivity (for reference

only) R Ωcm 301x102 -

603x102 525x102

Ash Fusibility

1 Initial deformation temperature T1 0C 1210 - 1280 1250 2 Hemispherical softening

temperature T2 0C 1430 - 1600 1570

3 Fluid temperature T3 0C 1530 - 1600 1600 11.3.2.3 Water Conditions

The process water comes from plant industrial water with temperature less than 35 and

pressure of 0.2～0.5MPa(g). The cooling water sources from the process water and circles within

the process system. It is not returned. The quantity is included in the process water. The industrial

water analysis is as follows:

SEC



Item Value Total hardness: 0.10 me/l

Total Cation: 0.17 mol/l Total Anion: 0.175 mol/l

SiO2: 1.80 mg/l Total sludge: 50 mg/l

Mean Corrosiveness: Weak 11.3.2.4 Limestone Conditions

Parameter Unit Value CaCO3 content wt % 92 – 95

Analysis:

MgO Fe2

O3

SiO2

Al2 O3

wt %

wt %

wt %

wt %

0.19 - 2

0.1 - 1.2

0.16 - 0.6

0.14 - 2.0 Bond work index KWh/Mt 10 (estimated)

Solid limestone (dense) Kg/m3 2400 - 2600 Solid limestone size mm 0 - 20 or more

11.3.2.5 FGD Design Guarantee Value

11.3.2.5.1 Once the FGD is in commercial operation, the FGD utilization ratio shall be not

less than 98% of the boiler ESP operating time, the definition is as the below

formula:

A − B

Utilization ratio = A

×100%

Here: A- hours with FGD device in-operation conditions

B- forced shut down hours with FGD’s causes

11.3.2.5.2 Desulfurization efficiency, SO2 emission density

Under the conditions of no excessive limestone, process water and power consumptionns,

firing the coal provided by client (sulfur 0.27%-0.66%) and handling complete flue gas under

BMCR operation comditions, the guarantee desulfurization effciency is over 90% so that the FGD

outlet SO2 density shall not exceed max permissible density 150mg/Nm3 (Dry basis, 6%O2).

11.3.2.5.3 FGD gypsum slurry quality

Item Unit Value

- purity mass-%dry 90

- pH / 5.5~7.5

- density mg/m3 1

- smell / Nil

- average particle diameter / 40μ

- MgO(water soluble) mass-%dry 0.021

- Na2O(water soluble) mass-%dry 0.035


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Item Unit Value

- K2O mass-%dry 0.07

- Cl(water soluble) mass-%dry 0.01

- CaSO3·1/2H2O(as SO2) mass-%dry 0.35

- (Oxidable organics)

- soot mass-%dry 1.32

-Al2O3 mass-%dry 0.26

-Fe2O3 mass-%dry 0.10

-SiO2 mass-%dry 0.70

-CaCO3 mass-%dry 2.9

-K2O mass-%dry 0.07

11.3.2.5.4 Flue gas emission

When the coal sulfur content comes up to 200% of the design value, the polutant emission

density shall not exceed:

SO2: 150 mg/Nm3(Dry basis)

HCl: 1 mg/D.Nm3

Soot: <100mg/Nm3(Dry basis)

11.3.2.5.5 Limestone consumption

Ca:S≤1.03

When S content = 0.66%, average limestone consumption≤5.7 t/h.

When S content = 0.41%, average limestone consumption≤3.3t/h.

11.3.2.5.6 Water consumption

Max: 100 t/h (When S content = 0.66%)

Normal: 80 t/h (When S content = 0.41%)

11.3.2.5.7 Steam consumption

Under the boiler rated loading and worst conditions, FGD maximum steam consumption is 5.5

t/h. The superheated steam used by desulfurization island comes from the main power house with

quality of: 1.2Mpa, 300.

11.3.2.5.8 Power consumption

The desulfurization island total power consumption is 5800 Kw.

11.3.2.5.9 Flue gas temperature at chimney inlet and mist content at mist eliminator outlet

The chimney inlet flue gas temperature is not less than 82 (boiler BMCR operation

conditions), the water drop carried by the flue gas shound be less than 100mg/Nm3(dry).

11.3.3 Production Process

11.3.3.1 The FGD system consists of the following subsystems:

Sorbent Preparation and Supply System;

Flue Gas System;

So2 Absorbing System;


Rev.: A



Common System;

Electrical System.

11.3.3.2 FGD System Process Flow

11.3.3.2.1 Absorber

The flue gas exhausted by ID fan flows into the bottom of the absorber under the function of

boost fans, to the top, to mix with the suspension of sorbent. The slurry is delivered to the top of

the absorber via slurry pipe and spray section by the recirculation pump, the slurry is sprayed out

to be specified droplets by atomization nozzle, and dispersed in the circulating reaction pool by the

self weight. The droplets absorb the acidity content in the flue gas, such as SO2, SO3, HF and HCl,

etc. During the process that gas passes through absorber and absorbs the acidity content, it is

vaporized by the water in slurry to saturation condition, and cooled to the adiabatic saturation

temperature.

Upon the spray section in the absorber, two-stage mist eliminator is arranged to separate the

slurry droplets in the gas. The separate droplets drop to the slurry pool by its self weight. It is easy

for the slurry droplets to paste on the flakes of mist eliminator, so it is necessary to wash the flakes

of mist eliminator periodically to ensure the smooth transfer of gas in the mist eliminator. In the

mean time, the washing water makes up most of the lost water being carried away by gas.

Fresh limestone slurry must be fed in the absorber to make up the consumed limestone. At

the same time, the outgrowth (most is gypsum) should also be discharged to control the

concentration of absorption slurry.

The absorber is divided basically to three sections:

Absorption Section

The absorption section is from the surface of circulation slurry to the bottom of mist eliminator.

In this section, some acidity content is absorbed, most is SO2, SO3; SO2 is absorbed to be HSO3-,

further to be oxidized SO42-, then react with limestone to be gypsum.

Circulation Slurry Tank

The circulation slurry tank is section from the absorber bottom to the surface of slurry pool, the

depth of slurry pool is 6.0M under normal condition.

The function of circulation slurry pool:

Oxidize sulfite to be sulfate

Dissolve the fresh limestone slurry

The sulfate reacts with the dissolved limestone to be gypsum

Gypsum crystal formation

The slurry pool is large enough to meet the requirement of the formation of favorable gypsum

crystal (CaSO4υ2H2O).The slurry is discharged to gypsum tank by absorber bleed pump.

3 sets of agitators are arranged in the absorber to avoid the sediment of slurry. The agitators

undertake not only the function of agitation, but also the function of air dispersion.

Flue gas Section

On the upper part of the absorber, the flue gas passes through the two-stage roof type mist

eliminator to minimize the droplets. The start-up of washing program for mist eliminator is

controlled by the slurry level.


Rev.: A



11.3.3.2.2 The oxidization air

Three sets of oxidization fans are adopted for two absorbers, 2 working 1 stand by. The

oxidization fan is Roots fan. Three sets of mixers are set per absorber. The oxidization air is fed

into the absorber slurry reservoir through the front nozzles. And then the mixers shall distribute the

bubbles equally in the reservoir. The oxidization air can be well distributed among the slurry, so

that the SO3 can be oxidized into SO4.

11.3.3.2.3 Flue gas reheat system

During the desulfurization, the flue gas is cooled to adiabatic saturated temperature by

circulating slurry. The flue gas is reheated before entry into the existing chimney to prevent the

condensation in the chimney. The flue gas reheat system major equipments include gas gas

heater (GGH) and its auxiliaries.

Gas gas heater (GGH)

To use the heat of the untreated flue gas from the boiler, one set of rotary GGH is adopted.

The clean flue gas at the absorber outlet is heated by this device. The flue gas uplift floatage in

and at the outlet of the chimney is increased so that it can prevent the chimney corrosion bought

by condensate maximumly. The GGH device has increased the power consumption and

maintenance expense of the FGD, but it is a must.

The philosophy of GGH (like air preheater) is as follows: The heating components

circumvolve slowly through original gas and clean gas. They absorb the heat energy from original

gas when it is on the original gas side, and transfer the heat to the clean gas when they rotate to

the clean gas side. The clean gas is isolated from original gas by seal plate. The two streams pass

through the section bodies on rotor separately. The two gas streams flow in reverse directions.

The GGH has higher and stricter requirements than boiler air preheater in aspects of sealing,

leakage, flue gas contacting surface anti-corrosion, sweeping and etc.

The anti-leakage control system is arranged to bring the leakage of original gas to clean gas

down to the minimum. That is to say some clean gas is extracted and charged to the heating

elements between clean gas and original gas. Because the pressure of seal gas is higher than

original gas, the leakage of original gas to clean gas is prevented maximumly.

Auxiliaries for reheater

The reheater is mate with one set of cleaning device for removing the dust on the heating

surface. The steam and pressure water is used as cleaning medium in the device.

The steam sweeping is in use under normal operation. When the device is operating up to

some time (preliminary fixed as five days, or according to the pressure drop between the GGH

inlet & outlet), the HP water is used. After the system stop operation, the LP water is used.

11.3.3.2.4 Boost fan system

To compensate the pressure lost because of the absorber, GGH and flue duct, the boost fan

is installed at the upriver of the original flue gas side. The boost fan is of static blade axial fan.

11.3.3.2.5 Flue gas duct system

There is main flue gas duct connection between the flue gas duct system and boiler ID fan

outlet. There is bypass flue gas damper set at the section connecting main flue gas duct and

chimney. FGD device is equipped with independent flue duct system, consisting of:


Rev.: A



Original flue gas duct, from the main flue gas duct with original flue gas damper to the

absorber inlet through boost fan.

Clean flue gas duct, from the absorber outlet, GGH, through main flue gas duct with clean flue

gas damper, to the chimney.

Partial original flue gas duct and all clean flue gas duct is lined with anti-corrosion (glass scale)

protection.

The flue gas duct system is equipped with double layer damper. The damper sealing fan

system will provide sealing air to these dampers to fulfill zero leakage.

11.3.3.2.6 Limestone storage, milling and slurry supply system

The limestone (0-20mm) is transported to the site by truck. Two unloading fuel hoppers are

used in this project. Heavy grating is set at each unloading fuel hopper to prevent large size

material from entering the downriver equipment. One set of dedusting system is adopted to

eliminate the dust in the unloading room and around to the minimum.

The limestone is conveyed on the ripple belt conveyor through the bottom of the unloading

hopper by the vibrating feeder and then fed into the two limestone storage silo. The conveying

system is designed to be of close negative pressure which can decrease the fly ash to the

minimum.

One scale weighing fuel feeder is set at the bottom of the limestone silo which sends the

limestone particle. There is air locking device at the milling fuel adding hole.

The limestone preparation system shall be two sets (one working one stand by). Each set is

equipped with one scale weighing feeder, one wet miller with slurry tank, two slurry pumps and

one group of limestone swirling machine. The scale weighing feeder sends the middle silo

limestone particle into the wet miller for milling. Single wet miller is of 75% FDG-BMCR. The

limestone slurry after milling overflows into the wet milling slurry tank. Then it is centrifuged in

limestone swirling machine with fineness of 90% of the particle can pass through screen of 0.045

(325) and quality of smooth overflow into the buffer tank. The unqualified particle returns to the wet

milling for remilling through the bottom of the swirling machine. The limestone slurry preparation

system automatically make limestone and water into 30% density slurry which is sent into

absorber through two stage pumps (buffer pump and slurry supply pump).

11.3.3.2.7 Process water system

The process water system is mainly used for absorber mist eliminator cleaning (absorber

make up), pipe cleaning, GGH HP & LP cleaning. The process water for FGD comes from the

plant industrial water system. 1x150m3 water tank as middle storage tank supplies continuous

make up water to maintain the normal operation of the system. The FGD island industrial water

and process water system shall common pump delivery and network system.

In FGD system, the major process water consumption includes flue gas evaporation, waste

water drainage and etc.

11.3.3.2.8 Industrial water system

The industrial water is mainly for high quality consumer, including milling oil station cooling,

pump mechanical sealing water, rotary equipment bearing cooling water and so on. The water

supply system is the same as in process water system.


Rev.: A



Most part of the industrial water is circulating within the FGD system.

11.3.3.2.9 Instrument air system

There is one set of instrument air tank for two units in the FGD island which is mainly used for

bypass flue gas damper actuator and instrument cleaning in FGD island.

11.3.3.2.10 Auxiliary steam system

The auxiliary steam is of GGH cleaning with steam. The auxiliary steam comes from the plant

hot and cool section.

11.3.3.2.11 Vent, discharge system

The vent system consists of emergency slurry tank, ground channel and pit. When FGD in

normal operation, the overflow slurry or water and water shall be collected in the pit and then sent.

Emergency is used for storage of the slurry during the absorber overhauling and for

emergency storage.

After FGD system into operation, the cleaning of the absorber and connecting network among

all parts of the water drainage system will be done manually. Therefore, there will be few times in

actual application.

All overflow water in the system, except of the life sewage, will be recovered into the system.

The discharge system mainly consists of gypsum discharge pump, absorbing area pit pump,

emergency slurry return pump. When the circulating slurry PH and density in the absorber reaches

the discharge requirements, the gypsum discharge pump will start and discharge part of the slurry

into the reservoir.

11.3.4 Major equipment specifications

11.3.4.1 Boost fan

Item Parameters

Type

Remark

1. Equipment type TB BMCR ECR

- Fan efficiency 86.3% 85.7%

- Axial power 1999kW 1489kW - Fan total weight(exclusive of motor)

75000kg

- Fan speed 480r/min

- Shell material Q235 - Blade material

16MnR

Spraying nickel based carbon wolfram

- Front/rear guide plate material

Q235/Q345

Spraying nickel based carbon wolfram

- Wheel hub material 16MnR

- Axis material 35CrMo

2. Motor type YKK series

- Rated power 2100kW


Rev.: A

SEC



- Rated voltage 6kV

- Rated voltage 480r/min

- Shell protection degree IP54

- Cooling mode Air-air cooling

3. Gearbox type Nil

4. Coupling type Form13 series

11.3.4.2 GGH

Type

Item

Type

Remark

1.GGH proper design

parameters:

⑴ Type Rotary GGH

⑵ Speed(working/cleaning) 1.2/0.6rpm

⑶ Effective anti-leak system

type Double channel sealing structure, low

leaking system

⑷ Pressure drop

Raw flue gas terminal (design value):

462Pa

Clean flue gas terminal (design value):

450Pa

⑸ Heat exchange element

Material Low carbon steel+enamel

Heat exchange surface 23500 m2(both sides)

Total height 780 mm

⑹ Shell

Material Q235-A

Lining material and thickness Scale resin, 1.5～2.0mm

⑺ Rotor

Main shaft material CORTEN

Cubicle frame material CORTEN

⑻ Motor and its driven device

Motor capacity 15KW

Rotary power consumption (shaft

power consumption)

11.6KW

Rated voltage 380V

Motor rated speed 1500rpm

Cooling mode Oil-bath

Gear box mode Gear driven

Gear box model B4VV09 or related model of indicated FLENDER

Date 2008-09-16


Page 121

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Type

Item

Type

Remark

brand

Coupling type Flexible coupling

Coupling model Undetermined

⑼ Sealing pad

Material 316L.TEFLON

⑽ Guiding bearing SKF Bearing type and model

Double row rolling

bearing/23060(CCK/W33 )

Lubrication mode Oil-bath

⑾ Supporting bearing SKF

Bearing type and model Thrust rolling bearing/29488E

Lubrication mode Oil-bath

2.Soot blower and its air

compressing system

⑴ Soot blower

Operating duty Online intermittent operation

Installation quantity 2X2

Installation location Raw flue gas upper and lower

Air consumption 5.5t/hr

LP water consumption 45t/h

LP water pressure 0.3～0.5Mpa

3.Sealing fan

Type and model Centrifugal fan /GMB16

Quantity 2X2

Flow 7500 Nm3/hr

Pressure 5000Pa

Shell/impeller material Carbon Steel/Carbon Steel

Medium Air

Motor type

Motor capacity 18.5kw

Motor insulation degree F(check as per B)

Motor protection degree IP55

4. Purifying fan

Type and model HMB 40


Rev.: A

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Type

Item

Type

Remark

Quantity 1X2

Flow 63000Nm3/hr

Pressure 6500Pa

Shell/impeller material 316L

Medium Clean flue gas

Motor type

Motor capacity 185kw


Motor protection degree IF55

5.HP flush water pump

Type and model Ram pump GP5136

Quantity 1

Flow 160 L/min

Pressure 13Mpa

Shell/impeller material Cast steel/cast steel

Motor type

Motor capacity 50KW


Motor protection degree IP54

Inlet screen type and material Cylinder/stainless steel

11.3.4.3 Slurry circulating pump

Item Unit -Quantity set (3+1)×2

-Type Centrifugal pump -Shell material Anticorrosive alloy or lining rubber

-Impeller material Anticorrosive alloy -Anti abrasion material Anticorrosive alloy or carborundum

-Axis capacity kW 225/255/285/315 -Motor rated power kW 260/300/330/370

-Suction screen Yes/no Yes -Suction side pressure kPa 52

-Head kPa 15/17/19/21 -Volume flow m3/h 4254

-Solid content in medium % 20 -Sealing system type Mechanical sealing

-Sealing medium SiC


Rev.: A

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-Suction side valve material

Spheroidal graphite cast iron+EPDM/stainless

steel 11.3.4.4 Absorber

-Absorber type Spray tower -Flow direction(direct/reverse) Reverse

-Flue gas quantity before absorber (standard conditions, wet basis, Actual O2)

Nm 3/h 1,258,254

-Flue gas quantity after absorber (standard conditions, wet basis, Actual O2)

Nm3/h 1,304,741

-Design pressure Pa 5000 -Stop time for slurry circulation min 2.5 -Time for all slurry discharge h 13.4

-Flue gas speed m/s 3.94 -Time for flue gas in the absorber s 2.9

-Chemical measure ratio CaCO3/removed SO2 mol/mol 1.03 -Slurry reservoir solid content: Min/Max Wt% 15/25

-Slurry Cl content g/l <20 -Slurry pH 4.5~6.0

-Absorbing area diameter in absorber(or length x width)

m 11.6

-Absorbing area height in absorber m 7.5 -Slurry reservoir diameter(or length x width) m 11.6

-Slurry reservoir height m 5.3 -Slurry reservoir level normal/max/min m 4.8/5.3/5.8

-Slurry reservoir capacity m3 560 -Total height of absorber m 28.2

-Material ·Absorber shell/internal lining Carbon steel/1.4529

·Inlet flue gas duct material/thickness/length -/mm/m C276 clad plate/2/6.8 ·Spray layer/nozzle FRP/SiSic ·Mixer shaft/impeller DIN1.4529/DIN1.4529

·Oxidization air duct/nozzle DIN1.4529 -Spray layer number/layer space 4/2.0

-Nozzle number per layer 68 -Nozzle type Screw /air awl

-Mixer or mixing device quantity pic/tower 3 -Mixer or mixing device power kW 22

-Mixer specific power kW/m3 0.11 -Oxidization air nozzle quantity 3

-Absorber insulation ·Thickness mm ·Material

·External layer material ·Flue gas resistance in absorber(including mist

eliminator) Pa 1190

Mist eliminator -Location Inside tower

-Stage number Two -Height 3.65

-material polypropylene -Mist eliminator cleaning nozzle number pic/tower 420

Date 2008-09-16


Page 124

Rev.: A

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-Nozzle pressure Pa 0.2×10^6 -Nozzle material polypropylene

-Nozzle flow l/min 63 -Cleaning mode(constant/intermittent) intermittent -Average cleaning water consumption m3/h·set 1

-Instantaneous max cleaning water consumption m3/h·set 26.46 -Flue gas resistance in mist eliminator Pa 190

11.3.4.5 Oxidization fan

-Quantity set 1×2+1 -Type Roots -Head kPa 88

-Shaft power kW 113 -Motor rated power kW 128 -Inlet flow (per set) Nm3/h 3364

-Flow allowance % 10 -Outlet oxidization air temperature 130

- Fan inlet strainer type Sound absorbing pipe type - Fan inlet & outlet silencer type Sound absorbing pipe type

11.3.4.6 Slurry discharge pump

-Quantity Set (1+1)×2 -Type Centrifugal pump

-Shell material Anticorrosive alloy or lining

rubber -Impeller material Anticorrosive alloy

-Anti-abrasion material Anticorrosive alloy -Shaft power kW 7.7

-Motor rated power kW 11 -Suction side screen Yes/no Yes

-Suction side pressure kPa 50 -Head kPa 40

-Volume flow m3/h 60 -Sealing type Mechanical sealing

-With/without sealing material SiC 11.3.4.7 Limestone silo

-Quantity pic 1 -Effective volume m3 90

-Material Carbon steel -Height m 7

-Diameter m 5 -Anti-abrasion material 16Mn

-Discharge type Screw unloading -Discharge outlet Quantity 1+1

-Limestone silo top deduster Type/Quantity -/set Silo top type/1 11.3.4.8 Metal separator

-Quantity set 2 -Type Electromagnetic

11.3.4.9 Crusher

-Quantity set 2


Rev.: A

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-Type Hammer type -Capacity t/h 10～15

-Inlet particle size mm 80 -Outlet particle size mm ﹤

-Shaft power kW 22 -Motor power kW 30

11.3.4.10 Scale weighing belt conveyor

-Quantity set 2 -Capacity t/h 5~15 -Accuracy % 0.5

-Motor power kW 3.7 11.3.4.11 Wet type ball miller

-Quantity 2 -Type Wet type horizontal ball miller

-Rating per set % 100 -Handling capacity per set t/h 7

-Shell size m×m 2.5x7.5 -Anti-abrasion component Rubber lining

-Shaft power kW -Motor rated power kW 380

-Output size mm/% 0.63/90 11.3.4.12 Gypsum slurry cyclone

Gypsum slurry cyclone -Cyclone Quantity 1×2

-Cyclone Quantity per set -Standby Cyclone Quantity 1×2

-Cyclone material Carbon steel+Rubber lining/ polyurethane

-Feeding material solid content % 30 -Overflow solid content % 20

-Bottom flow solid content % 35 11.3.4.13 Gypsum miller slurry circulation tank

-Quantity set 2 -Effective volume m3 50

-Material Carbon steel -Anti-corrosion material Rubber lining

-Mixer Quantity set 1 -Mixer Material (Impeller/shaft) Carbon steel Rubber lining

-Mixer power kW 5.5 11.3.4.14 Miller slurry circulation pump

-Quantity set 1+3 -Type Centrifugal pump -Head kPa 200

-Capacity m3/h 90 -Medium solid content % 30

-Sealing type Mechanical sealing -shaft power kW 6.5

-Motor rated power kW 7.5 11.3.4.15 Limestone slurry reservoir


Rev.: A

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-Diameter m 6.77 -Height m 6

-Anti-corrosion material Synthetic resin -Mixer Quantity set 1

-Mixer material (Impeller /shaft) Rubber lining -Mixer power kW 22

11.3.4.16 Limestone slurry pump

-Quantity Set 2+2 -Type Centrifugal pump

-Shell /Impeller Material Anticorrosive alloy or lining rubber / Anticorrosive alloy


-Capacity m3/h 30 -Medium solid content % 20

-Sealing type Mechanical sealing -Sealing material SiC

-Shaft power kW 6.5 -Motor rated power kW 7.5

11.3.4.17 Process water tank

-Quantity Set 1 -Effective volume m3 100

-Diameter m 5.8 -Height m 4.5

-Material Carbon steel+Synthetic resin lining

11.3.4.18 Process water pump

-Quantity set 1+1 -Type Centrifugal pump

-Shell material Spheroidal graphite cast iron -Impeller material Spheroidal graphite cast iron

-Shaft power kW 26 -Motor rated power kW 30

-Suction screen Yes/no No -Suction side pressure kPa 30

-Head kPa 400 -Volume flow m3/h 120 -Sealing type Mechanical sealing

-Sealing material SiC 11.3.4.19 Mist eliminator cleaning pump

-Quantity set 1×2 -Type Centrifugal pump

-Shell material Cast iron -Impeller material Cast iron

-Shaft power kW 30 -Motor rated power kW 45

-Suction screen Yes/no Yes


Rev.: A

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-Volume flow m3/h 156 -Sealing type Mechanical sealing

-Sealing material SiC 11.3.4.20 Emergency slurry reservoir


-Diameter m 9 -Height m 9

-Anti-corrosion material Synthetic resin -Mixer Quantity set 1

-Mixer material (Impeller /shaft) Anticorrosive alloy or carbon steel+lining rubber / Anticorrosive alloy

-Mixer power kW 22 11.3.4.21 Emergency slurry return pump

-Quantity set 1 -Type Centrifugal pump

-Shell /Impeller material Anticorrosive alloy or carbon steel+lining rubber / Anticorrosive alloy

-Suction side pressure kPa 520 -Head kPa 200 -Flow m3/h 60

-Medium solid content % 20 -Sealing type Mechanical

-Sealing material SiC/alloy -Shaft power kW 6.5

-Motor rated power kW 7.5 11.3.4.22 Absorber water discharge pit

-Quantity set 1×2 -Effective volume m3 17

-material Concrete -anti-corrosion material Synthetic resin lining

-Mixer Quantity set 1 -Mixer material (Impeller /shaft) Anticorrosive alloy or carbon

steel+lining rubber / Anticorrosive alloy

-Mixer power kW 3.7 11.3.4.23 Absorber water discharge pit pump

-Quantity set 4 -Type Vertical pump -Head kPa 200

-Capacity m3/h 60 -Shaft power kW 4.8

-Motor rated power kW 5.5 11.3.4.24 Limestone slurry preparation area water discharge pit



Rev.: A

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-Material Concrete -anti-corrosion material Synthetic resin lining

-Mixer Quantity set 1 -Mixer material (Impeller/shaft) Anticorrosive alloy or carbon

steel+lining rubber / Anticorrosive alloy

-Mixer power kW 2.2 11.3.4.25 Limestone slurry preparation area water discharge pit pump

-Quantity set 1 -Type Vertical -Head kPa 300

-Capacity m3/h 30 -Shaft power kW 3.0

-Motor rated power kW 3.7 11.3.4.26 Instrument air tank

-Quantity set 1 -Volume m3 3


-Working pressure MPa 1 11.3.4.27 Miscellaneous use air tank

-Quantity set 1 -Volume m3 4


-Working pressure MPa 1 11.4START-UP OF DESULFURIZATION SYSTEM

11.4.1 Acceptance and test after maintenance

11.4.1.1 Acceptance after overhaul

11.4.1.1.1 After overhaul of the desulfurization devices, institute responsible for the overhaul

work should offer overhaul summary, acceptance report, deviation report of the

equipment and detailed explanation to the operation department.

11.4.1.1.2 The operation department should organize its managing and operating personnel

to attend the overhaul acceptance above level 2; to attend every stand-alone and

system pre-commissioning of main and auxiliary equipment, and record various

primary data, confirm the data is right in the range regulated by the specification; to

attend pre-commissioning, test and confirm the DCS control system is in right

logical relation while having normal protection and interlock movement.

11.4.1.1.3 The entire acceptance file before start-up should be kept in generating department

as file materials.

11.4.1.2 Inspection and acceptance after overhaul

11.4.1.2.1 Once the overhaul work finished, overhaul personnel and tools should be

evacuated from the operating field, safeguard measures cancelled, false work

cancelled, no sundries can be saw on the equipment, ambient environment,

passway and the lighting should be satisfying.


Rev.: A



11.4.1.2.2 Foundation bolts and coupling wheel screw of rotating equipment should be

tightened, hood of the coupling wheel should be complete and tightly installed;

qualified lubrication, oil level is above oil gauge’s centerline but between the upper

limit red line and lower limit red line, no leakage in the oil system, clear and

complete oil gauge and oil level mirror, try the oil tank heater and confirm it’s in

normal operating; clear, unblocked and controlled shaft cooling water; complete

inlet/outlet damper(valve) with flexible switches on close position; complete and

tight grounding of the motor; and no things around is to interfere the start-up.

11.4.1.2.3 No deviation for the equipment’s appearance, good insulation, correct and clear

equipment’s name plate, color ring on the pipe, rotating direction and medium’s

flowing direction.

11.4.1.2.4 Inspect the flue duct, absorber, mist eliminator, each water tank and pit, reservoir,

boost fan, GGH, and make sure it is clean inside without foreign matters & medium

along with intact anti-corrosion layer. After inspection, manhole and vent valve is

tightly closed.

11.4.1.2.5 All manual, pneumatic, motorized air doors and valve should be tight, flexible in

switch, complete in travel and of no leakage on dynamic & static sealing area. The

local switch indications of all pneumatic and motorized valves are in line with the

displays of DCS, which are at the off position.

11.4.1.2.6 The tightness of al mechanical driven V shape belt is appropriate.

11.4.1.2.7 Upon the completion of DCS commissioning, the configuration parameters are

correct and all instrument power supply is put in use. All automatic, protection and

alarming device is correctly launched after commissioning. The installation of local

instruments and testing point finishes with firm wiring and correct position. The

measuring and testing of transmitters and transformers are in normal conditions.

All testing data and acceptance procedures are complete.

11.4.1.2.8 The local control cabinet is in normal operation and the indication light testing is in

order.

11.4.1.2.9 The gauges for distribution device are complete, intact and verified. The terminal,

plug and socket are of no abnormal looseness and mobilization.

11.4.1.2.10 All switches and contactors are of clear and correct switch-in & off indication. They

are qualified in switch-in & off testing with switch at testing positions.

11.4.1.3 Testing after overhaul

11.4.1.3.1 Trial operation of mechanical equipment

z The trial operation of mechanical equipment is to confirm that there is no abnormal

condition before the formal operation of the FGD system. The inspection and

measuring of the current, vibration, temperature and sound of the motor and

mechanical equipments as well as the performance of the design values are done in

this trial operation. Any abnormal conditions are to be eliminated before normal

start-up. At the same time of trial operation , the inspection and testing for equipment


Rev.: A



start up, shut down, interlock procedure, sequence, time, alarm and trip preset

values shall be done.

z Before trial operation of all mechanical equipments, the motors should be

independently operated for 1-4 hours with unfastened coupling connecting screw.

After confirmation on correction of its vibration, temperature rise, current and

direction, the coupling connecting screw should be connected. The rotor is in normal

operation under related torque without stuck, unsmooth or abnormal sounds. The

insulation resistance should be confirmed qualified before trail operation and power

supply of the motors.

z The trial operation of conveyor belt and feeder should be conducted with no load.

The trial operation of steel ball crusher should be done in phased manner from no

load to full load gradually as per the requirements in the manual and the retightening

of its steel tiles should be done by the installation workers during the process.

z The trial operation of the rotary machinery should continuously operate for 1-4 hours

in principles. The operation can be extended if the person in charge thinks it is

necessary, but the reasons and results for doing the same should be clearly noted

down.

z During the trial operation period, the engaged equipments should be regularly

inspected, measured and recorded: motor current (on/off load), bearing temperature,

bearing vibration, noise, inlet & outlet pressure, rotary speed, current & its flow curve

generated by damper (air door, valve) open degree variation, equipment interlock,

alarm & protection, and to confirm whether they are in the normal value range.

z The remote control of all air door, damper, pneumatic & motorized valve should be

agile in action and properly switched to on/off positions.

z During the trial operation, the thermal control persons should inspect, check and

modify the travel & torque of motorized actuator; the accordance between the actual

open degree of valve & air door damper and the display on DCS screen; the

correctness of interlock logic; the correctness of protection action.

z During the trial operation, the electrical persons should observe and inspect the

operation conditions of the transformer, switches & motors, record all data; examine

and check the protection setting, electrical interlock & emergency switch.

11.4.1.3.2 Preparation before equipment trial operation

z Examine & test the start up/shut down circuit, interlock circuit and control circuit to

make sure they are in normal conditions; the testing of overload relay and earthing

relay drivers is done;

z Test the insulation resistance of motors & cables and supply the power after

resistors’ qualification;

z Supply power for the thermal instruments & meters and check whether they are in

normal operation;

z The cleaning work of miscellaneous and instrument air pipes is done, and the

internal & external obstacle are completely removed;


Rev.: A



z The water tank and reservoir is internally clean with industrial water fed at indicated

level (above permitted start up level), confirm the accordance between the level

gauge and actual testing value, and no leakage;

z The lubrication oil for all rotary equipments are qualified in testing; the lubrication oil

level for all equipments is normal; all cooling water can go smoothly; the oil

temperature of start up oil tank heater or start up oil cooler is in the prescriptive

range;

z The on/off speed correction of pneumatic valve regulated by speed controller is

done; its operation normality is confirmed by using manual switch;

z For belt driven equipments, the adjustment & correction of the capstan and the

follower is done; the qualified belt has been installed; the belt tightness is suitable;

the tightness should be measured again and adjusted after completion of the

machinery’s trial operation;

z The control relay has been set to standard values.

11.4.1.3.3 Matters to be taken care in trial operation

z When start the rotary equipments, besides the regular protection measures, the

commissioning persons should stand at the shaft direction position of the

equipments to avoid accidental injury.

z In the specific time period, the start up times of HV motors can not exceed the

provision in the regulation. The on load start up times of AC motors should be in line

with the products technical regulation. If there is no clear regulation in products’

technical conditions, the following Manual shall be followed:

z The start up can be done twice in cold state, with interval not less than 5 mins.

z The start up can be done once in hot state; when in accident handling & the start up

time for big motors is less than 2-3s, it can be restarted again.

z Prevent the body and the tools from contact with the rotary parts.

z Before the trial operation, the handling preparative proposals for abnormal interlock

or protection action conditions should be though over carefully to insure the

equipment and personal safety.

z The trial operation should be stopped when after start up obvious abnormal

conditions and high possibility of equipment damage & personal injury occur. During

the machinery trial operation, if there are abnormal sounds or vibration or

temperature rise, the measures such as inspection, retighten foundation bolts,

appropriate addition or change of lubrication oil and so on should be done, under the

premises of personal & equipment safety and the monitoring of the progress should

be kept on. If it is still abnormal, the fault equipment should be stopped. The

equipment can not restart for trial operation until the reasons are found out and the

problem is solved.

z After the completion of the trial operation, all left medium in equipment and pipes

should be discharged as much as possible. If the equipments shall not be in


Rev.: A



operation right after trial operation, the power supply of motors and other electrical

equipments should be cut off and necessary maintenance is to be done.

11.4.1.3.4 Testing items for equipments’ trial operation

z The time period from start-up to back and the current value under no-load and load

changing conditions of the large-scale HP motors and equipments should be

measured and recorded when start-up for the first time. The start-up, operation and

shut down of the motors and equipments should follow the orders of the personnel

who measure the current.

z Inspect and record interlocking action sequence and time of equipments; inspect

and test the alarm and interlock protection setting value; inspect and test emergency

button.

z Check whether the current value is in the regulated range; whether the vibration and

temperature rise of the machinery and motors is in the regulated range; whether the

noise is normal; whether there is peculiar smell, leakage of gas or fluid; whether the

changes of the water level of the water tank and pond is in the regulated range;

whether the operation of the motorized or pneumatic valves are normal; record with

details.

11.4.1.3.5 Normal operation standard of motors and mechanical equipments

z The operation time of motors and mechanical equipments is 1-4 hours, during which:

bearing temperature rise: gliding bearing temperature should not exceed 80;

rolling bearing temperature should not exceed 95.

z No unexpected noise should occur during the operation of the machinery; machinery

vibration should be in the normal range.

Synchronous speed

(r/min) 3000 1500 1000 750 and below

Double amplitude value

（mm） 0.05 0.085 0.10 0.12

z The motor’s operation current should exceed the rated value on the name plate.

z If there is specific regulation of the above parameters from the manufacturers, then

these Manual will be followed.

11.4.1.4 Simulative test of water circulation

11.4.1.4.1 Aim of the water circulation test: using water instead of limestone slurry and

gypsum slurry, simulative operations will be carried out to all equipments of FGD

system, inspecting and confirming the system rigour and stability, as well as the

desulfurization control system, start-up and shut down sequence, related interlock

and protection, so that the potential equipment defects and errors might occur after

formal start up of FGD system can be discovered in advance.

11.4.1.4.2 The scope of water circulation tests: equipments and systems for handling

limestone slurry and gypsum slurry.

11.4.1.4.3 The qualified standard for water circulation test:


Rev.: A



z To conduct preliminary modifications for control system and confirm the correctness

of the logic relationship;

z To confirm the control system, its start-up & shutdown operation sequence, related

working parameters, interlocks and protection in normal conditions;

z The equipments are in normal operation without leakage and the system is water

balanced;

z To confirm the flow characteristic curve of all control valves.

11.4.1.4.4 The preparation of water circulation test

z Sufficient qualified water source;

z DCS system is qualified with application conditions;

z All instruments correction, testing & interlock, protection examinations are

completed;

z The trial operation of all pumps and mixers machinery related to water circulation are

accomplished;

z The dampers of original and clean flue gas are insulated from the control system;

z The water circulation system is qualified with all start-up conditions.

11.4.1.4.5 Matters to be taken care of during water circulation test:

z The water circulation tests should not influence the boiler safety operation. The

bypass damper fixings should be all open. The dampers of original and clean flue

gas should be closed. Its sealing fans should be operating. The FGD system is

insulated from the boiler flue gas system.

z The levels of absorber, limestone slurry tank and filtrate tank should be closed

monitored during water circulation tests. Due to different liquid densities, the level

displayed by DCS might be a little bit higher than the actual level in absorber and

other equipments. The operating personnel should master the actual level of the

absorber in line with various situations.

11.4.1.4.6 The start-up operation of water circulation tests and operations requiring water

circulation tests:

z Injecting the water till normal level for the following equipments:

Equipment name Unit Absorber m Limestone slurry reservoir m Industrial water tank m Gypsum buffer tank m Filtrate tank m

z When there is no system and equipment fault, maintenance, cleaning signals, all

liquid levels are in line with start up requirements, all inlet and outlet doors are at the

pre-start state, individual equipment can meet the start up requirements after

inspection, the following equipments will be started in DCS system:

Industrial water pump;

Absorber mixer;


Rev.: A



Filtrate tank mixer;

Limestone slurry tank mixer;

Absorber pit mixer;

Gypsum slurry buffer tank mixer;

Absorber gypsum discharge pump;

Gypsum eddy station charge pump;

Sewage eddy station charge pump;

Absorber slurry discharge pump;

Absorber slurry circulation pump;

z The control room operators should get the permission from the local inspection and

side station monitoring personnel before start up the above equipments in

sequence.

z After the normal start up completion of each equipment, the related inlet & outlet

doors should be opened and stopped at the required positions through automatic or

manual remote operation. Until inspectors’ confirmation on the successful start up

and normal operation of this equipment, can the start up of the next equipment be

arranged.

z After all equipments normal start up, the operating conditions at every positions

should be regulated so that the flow, water level and pressure correspond to the

system water balance requirements and the machinery is in sound operation.

z After completion of the testing, the testing equipments should be stopped one by

one in the sequence which is reverse of the start up and the related valves should be

closed.

z Each characteristic curve and words obtained in the testing should be recorded and

kept in files.

11.4.1.5 Major equipment emergency button test

11.4.1.5.1 After the overhaul of FGD system, the emergency buttons of each major

equipment in FGD system shall be tested to examine and ensure the operation

withdrawals under emergency conditions.

11.4.1.5.2 Test procedure:

z Pull the switches of the engaged equipments to the testing positions;

z Enforce all related conditions in DCS manual manner to meet the start up

requirements of the testing equipments;

z Close the switches of all individual 6KV equipments on CRT;

z Press the emergency button close to the equipment;

z Observe the equipment switch which should be normally disjunct;

z Resume all related forced conditions in testing to the normal original state.

11.4.1.6 Flue gas test

11.4.1.6.1 Test purpose

z The initial flue gas test is to conduct simulative operation of all equipments in flue

gas system and absorber system, inspecting and confirming the system rigour and


Rev.: A



equipment reliability as per the design requirments, as well as onece more

examination of the desulfurization control system, start-up and shut down sequence,

related interlock and protection, so that the potential equipment defects and errors

might occurr after formal start up of FGD system can be discovdered in advance.

Particularly, a preliminary estimation of each flue gas damper’s reliability, fexibility,

rigour & influence to the boiler & unit and the standardrization & check of each

instrument testing point as well as a comparison with the design values can be done

through the test, making good preparation for the system commissioning and normal

placing in operation in future.

11.4.1.6.2 Test conditions

z FGD system has passed the water circulation test: each tank, reservoir, pipe, valve

and all equipments are qualified without leakage, and environment, passage,

illumination and communication conditions can meet with the requirements;

z Each equipment in FGD system has been proved to be qualified in individual tests;

z Each subsystem in FGD system instruments, control sequence, thermal signals,

interlock protections has been installed well and tested to be qualified;

z Common systems can be normal operating and standby, including water, power,

steam, air and etc;

z The absorber is ready with gypsum slurry; the limestone slurry reservoir is ready

with enough slurry of qualified density;

z The FGD system has been proved to be qualified in “emergency shut down” button

test.

11.4.1.6.3 Test procedure

z Report to the operating manager and obtain the permission;

z Start cleaning pump, compressing air system, GGH system with its sealing fans

successively;

z Start gypsum discharge pump and limestone slurry pump for circulation;

z Start slurry circulation pumps (two sets at least) and oxidization air system;

z Close the evacuation door on the top of the absorber and open the clean flue gas

damper;

z Start the original flue gas damper;

z Start the boost fan;

z Adjust the boost fan guiding blades, and slowly close the bypass damper door

depending on the situations;

z Put mist eliminator cleaning, PH device cleaning and limestone slurry feeding

system in service.

11.4.1.6.4 Test items

z Inspect, measure and correct the site obtained values with the display values on

CRT including flue gas system inlet oxygen content, SO2, flue gas temperature, flue

gas flow, dust content, inlet pressure and etc;


Rev.: A




CRT including flue gas system outlet oxygen content, SO2, flue gas temperature,

pressure differential & temperature between GGH original flue gas side & clean flue

gas side, GGH outlet pressure and etc;


CRT including slurry PH in the absorber, process water consumption, limestone

consumption, power consumption, the influence of open degrees of all damper

doors & boost fan guiding blades to the boiler & desulfurization system and etc;

z Dynamically verify the bypass damper door quick open function when the boost fan

trip.

11.4.1.6.5 Matters to be taken care of in the test

z Conduct accident anticipations and measures to keep the accidents away for the

boost fan, inlet & outlet damper doors of FGD system; the boiler operating personnel

should conduct accident anticipations when the testing bypass damper door is

closed, and the test personnel should take other measures to ensure the quick open

action of the bypass damper door;

z Adjust slowly the boost fan guiding blades to reduce the negative influence on boiler

negative pressure;

z Record the site measured and control displayed parameters on time;

z Reinforce the going-around inspection and monitoring of the system trial operation;

z Each characteristic curve and words obtained in the testing should be recorded and

kept in files.

11.4.2 Inspection and preparation before start up of FGD system

11.4.2.1 Cold standby state start up: when desulfurization device in operation for the first time

after installation, or long time shut down for overhaul or other reasons, all the chemical

tanks are without absorbent and water, all the mechanical equipments are out of

operation, and all the operations start from “OFF” state.

11.4.2.2 Hot standby state start up: when desulfurization device experiences short time shut

down for debugging maintenance or other reasons, flue gas removing system is not in

operation, and the other systems are under start-up operation of standby or operating

state.

11.4.2.3 Inspection before start up of FGD system

11.4.2.3.1 After confirming the accomplishment of the maintenance and operation orders,

safety measures are removed; field sundries be cleared up with unblock passages,

sufficient illumination, safe & stable handrails & stairs, clean channels, floors &

equipments, and complete covers.

11.4.2.3.2 For each rotary equipment, the oil level is normal with good quality oil, clear &

intact oil gauge & oil level mirror and no leakage; the cooling water is unblocked

and the water temperature is normal.


Rev.: A



11.4.2.3.3 All signs and marks for the revisions of the equipment name, serial number, color

ring, medium flow direction, due to the maintenance, changes of the equipments or

system, or other reasons, should be clear, intact and correct.

11.4.2.3.4 Inner space of the flue duct, earth pit, channel, tanks, towers, bunkers and GGH

should be cleaned already; intact anti-corrosion layer; no left over; manholes are

closed after inspection; intact insulation of the flue duct and the pipes.

11.4.2.3.5 Put the DCS system in operation and the power supply for each instrument in

operation; the parameters are correct in each group and state; the measuring

indications and regulating actions are normal; field testing points, instruments,

transmitters and sensors are in good operation state and at the right positions.

11.4.2.3.6 Measure the insulation resistance of the electrical equipment and supply the power

after a qualified test result.

11.4.2.3.7 Mechanical and electrical equipment having normal appearances with foundation

bolts, motor connection and grounding wiring in safe and stable state, complete

shield, normal installation of connector and fasteners.

11.4.2.3.8 Normal air compressing system of FGD system with pressure of 0.5--0.8MPa.

Make sure that all the steam source doors of the start up actuators are at open

position.

11.4.2.3.9 Switches of air doors and valves should be flexible and on the right position.

Inspect each air door and valve of every system according to the requirements

before the start up of the FGD system, and then adjust the doors & valves to the

specified position.

11.4.2.4 The following conditions should be satisfied before the start up of the FGD system:

11.4.2.4.1 Qualified crystal seeds have been injected into the absorber.

11.4.2.4.2 The limestone slurry preparation system is under normal operation and can

produce qualified limestone slurry.

11.4.2.4.3 The unit is under normal operation with ESP, whose outlet flue gas turbialty can

meet the requirements of the FGD system.

11.4.2.4.4 The water level of the process water tank is normal and can guarantee the

constant water supply of the process water.

11.4.2.5 Absorber slurry crystal seeds make up & install conditions and slurry charge method:

11.4.2.5.1 The process water pump can work properly and the process water tank is filled

with water. The commissioning of each protection and interlock in process water

system has completed. To check whether the absorber level gauge is at the

pre-start up position.

11.4.2.5.2 Inspect the inside of absorber, emergency slurry reservoir (tank) and its water

discharge pit is clean without sundries. Each manhole is tightly closed. The

evacuation valve door to the earth pit is closed. Suitable screen (over 6mm can not

pass) is installed at the emergency slurry reservoir earth pit inlet to prevent the

entry of caking gypsum or sundries. Instruments should be prepared

simultaneously including measuring bottle, density meter, gablock and etc. The


Rev.: A



trail operation of emergency slurry tank discharge pit pump and emergency slurry

tank discharge pump have been finished. The commissioning of protection and

interlock has completed.

11.4.2.5.3 The air pressure of the compressing air tank is normal. The commissioning of each

manual and pneumatic door has been completed and doors can work properly.

11.4.2.5.4 The trial operation of slurry circulation pump, gypsum discharge pump and

oxidization fan have completed. The commissioning of the protection and interlock

has finished. All mixers have accomplished the trial operation.

11.4.2.5.5 The clean industrial water is injected into the emergency slurry reservoir from the

absorber up to around 4 meters. The emergency slurry reservoir mixer should be

started.

11.4.2.5.6 Check the valve from the gypsum slurry discharge pump to ash slag front reservoir

is closed, the absorber earth pit pump outlet manual door is closed, the valve to

emergency slurry reservoir is closed and the circulation pipe manual door of the

gypsum slurry discharge pump is open.

11.4.2.5.7 The gypsum crystal seed which is 10% of the gypsum is fed into the emergency

slurry reservoir uniformly to keep the density of slurry at around 10%.

11.4.2.5.8 Start the gypsum slurry discharge pump, open the valve from the gypsum

discharge pump to emergency slurry reservoir and inject water into the emergency

slurry reservoir slowly.

11.4.2.5.9 Check the valve from the emergency slurry pump to the ash slag reservoir is

closed and the shaft sealing water is normally put into service.

11.4.2.5.10 Start the emergency slurry pump, open the outlet door manually and inject the

gypsum crystal seed slurry into the absorber.

11.4.2.5.11 When the absorber level is above 3 meters, the 4 mixers should be started

successively.

11.4.2.5.12 Inject the water continuously and inject the gypsum crystal seeds uniformly at the

rate of 10% gypsum into the emergency slurry reservoir, keeping the slurry density

at around 10%. Maintain the emergency reservoir level higher than the trip position

of mixer and emergency slurry pump until the absorber level reaches 9.63 m, then

stop injecting the gypsum crystal seeds & emergency slurry pump and close its

outlet door.

11.4.2.5.13 Discharge the gypsum crystal seeds in the emergency slurry pump pipe

completely and conduct reverse cleaning when necessary.

11.4.2.6 The FGD system whole set start up

11.4.2.6.1 To shorten the start up time as much as possible, several function groups should

be started in parallel and operated under standby state. The FGD system device

should be put in service as per the following order: (If the system starts after a

short time shut down and the process water pump and mist eliminator cleaning

water pump do not stop during the short shut down, the related steps can be

skipped.)


Rev.: A



Special name KKS Action

Limestone slurry supply system drawing 06019S-J-03-13 (absorber area slurry supply pipe part) Limestone slurry non return valve

*HTK71 AA901

The switch should be

flexible Limestone slurry regulating valve up stream

isolation valve

*HTK71 AA501

Open

Limestone slurry regulating valve down stream

isolation valve

*HTK71 AA502

Open

Limestone slurry regulating valve bypass

orifice plate inlet isolation valve

*HTK71 AA503

Close

Limestone slurry regulating valve bypass

orifice plate outlet isolation valve

*HTK71 AA504

Close

Slurry supply pipe outlet to circulation pipe 2#

inlet isolation valve

*HTK71 AA510

Open (circulation pump in operation）

Slurry supply pipe outlet to circulation pipe 1#

inlet isolation valve

*HTK71 AA511


Limestone slurry to circulation pipe 2# inlet

isolation valve

*HTK71 AA520


Limestone slurry o circulation pipe 1# inlet

isolation valve

*HTK71 AA521


Absorber system drawing 06019S-J-03-02 & 06019S-J-03-03 Absorber level gauge cleaning isolation valve

*HTD10 AA213

*HTD10 AA214

*HTD10 AA214

Close

Close

Close

Absorber level gauge isolation valve

*HTD10 AA303

*HTD10 AA304

*HTD10 AA305

Open

Open

Open

Absorber evacuation valve *HTD10 AA202 Close

Absorber evacuation tank cleaning valve *HTD10 AA203 Close Absorber lower mixer cleaning pipes isolation

valve

*HTD10 AA204

*HTD10 AA205

*HTD10 AA206

Close

Close

Close

z Process water pump;

z Mist eliminator cleaning water pump;

z Absorber slurry circulation pump;

z Flue gas duct;

z Oxidization fan;

z Limestone slurry conveying system.

11.4.2.6.2 The positions of the related manual valves should be checked as per the following

table before put the system in service:


Rev.: A

Special name KKS 号 Position

FGD process water inlet master valve Open

Process water tank water discharge valve Close

SEC



Special name KKS Action Absorber low position mixer cleaning pipe

isolation valve

*HTD10 AA204

*HTD10 AA205

*HTD10 AA206

Close

Close

Close Mist eliminator pressure differential measuring

pipe isolation valve *HTD10 AA301

*HTD10 AA302 Open

Open Mist eliminator pressure differential measuring

pipe cleaning pipe isolation valve *HTD10 AA211

*HTD10 AA212 Close

Close

Gypsum slurry sampling valve *HTL11 AA401 Close

Absorber to gypsum slurry buffer tank *HTL11 AA501 Open

Absorber to emergency tank isolation valve *HTL13 AA501 Close

Gypsum slurry PH value measuring bypass

outlet manual valve

*HTL30 AA501

Open

PH gauge 1 cleaning pipe inlet isolation valve

PH gauge 2 cleaning pipe inlet isolation valve *HTL30 AA511

*HTL30 AA512

Open

Circulation pump inlet pipe pressure gauge

isolation valve

*HTF11 CP301

*HTF12 CP301

*HTF13 CP301

Open

Circulation pump outlet pipe pressure gauge

isolation valve

*HTF11 CP510

*HTF12 CP510

*HTF13 CP510

Open

Oxidization air system 06019S-J-03-10

#1 oxidization fan outlet manual valve *HTG11 AA510 Open

#2 oxidization fan outlet manual valve *HTG12 AA510 Open

#1 oxidization fan outlet non return valve *HTG11 AA901 Flexible open

#2 oxidization fan outlet non return valve *HTG12 AA901 Flexible open

Oxidization air main pipe to absorber manual

valve *HTG50 AA501 Open

Oxidization air main pipe to GGH dry manual

valve *HTG51 AA501 Close

Instrument valves for each pressure,

temperature gauges Open

11.4.2.6.3 Put the process water system in service

z Check and ensure the process water tank is not less than 3.0 m;

z Check the related system valves is at the required positions as per the following

table:


Rev.: A

SEC



Special name KKS 号 Position

#1 process water pump inlet isolation valve Open



#2 emergency process water pump inlet isolation

valve Open

#1 process water pump outlet isolation valve Open



#2 emergency process water pump outlet isolation

valve Open

Master water supply valve to emergency slurry tank

area Open

Emergency slurry return pump cleaning valve Close

Emergency slurry mixer cleaning valve Close

Emergency slurry tank area ground cleaning valve Close

Turn-off valve of water supply to Limestone slurry

tank area Open

Mater valve of other water supply to milling &

preparation workshop Open

Master water valve at dehydration process building

first floor Open

Water supply valve for vacuum pump unit groups Open

Desulfurization sewage treatment system

hydrochloric room water valve Close

Desulfurization sewage treatment dosing unit area

master water valve Close

Cleaning valve at neutralization, coagulation aids

and precipitation tank Close

Mater cleaning valve at gypsum eddy station sewage

eddy pump Open

Master water valve for absorber area slurry pump,

mixers and etc Close

Cleaning turn-off valve to GGH LP water Close

Cleaning turn-off valve to absorber mist eliminator Close

Water supply valve to GGH HP cleaning water pump Open

z Start #1 or #2 process water pump;

z Put the standby pump interlock in service;

11.4.2.6.4 Start up of mist eliminator cleaning water pump:


Rev.: A



z Check and ensure the process water tank is not less than 3.0 m;

z Check the related valves is at the required positions as per the following table:

Special name KKS Position

#1 mist eliminator cleaning water pump inlet isolation valve Open

#2 mist eliminator cleaning water pump inlet isolation valve Open

#1 mist eliminator cleaning water pump outlet isolation valve Open

#2 mist eliminator cleaning water pump outlet isolation valve Open

#1 mist eliminator cleaning water pump inlet isolation valve evacuation

valve Close

#2 mist eliminator cleaning water pump inlet isolation valve evacuation

valve Close

Master door from mist eliminator cleaning water pump to #1 FGD mist

eliminator Open

Master door from mist eliminator cleaning water pump to #1 FGD mist

eliminator Open

z Start #1 or #2 mist eliminator cleaning water pump;

z Put the standby pump interlock in service;

11.4.2.6.5 Put the absorber slurry circulation pump in service:

z Check and ensure the absorber level is not less than 5.0m;

z Check and ensure the start up interval with other 6Kv equipment in the system is

over 60s;

z Invoke the slurry circulation pump start up function group or operate as per the

following sequence:

a) Close the slurry circulation pump evacuation door and ensure the action

completeness;

b) Start the slurry circulation pump inlet motorized door and ensure the action

completeness;

c) Start the slurry circulation pump in 60s delay manner and observe the current which

should return to the normal value in time.

11.4.2.6.6 Put the flue gas system equipment in service:

z The following conditions have to be fulfilled before put the flue gas system in service:

a) The boiler ESP has been put in service normally;

b) The boiler ID fan is operating normally;

c) The boiler combustion is normal without heavy oil aiding;

d) The limestone slurry preparation system can normally supply the limestone slurry

continuously;

e) The absorber system has qualified conditions for put in service and 2 sets or above

slurry circulation pump is in operation.

z Invoke the flue gas system start up function group or operate as per the following

sequence:

z Start the GGH sealing fan;


Rev.: A



z Start the GGH major or standby driven motor and wait for the return of signal for

normal GGH speed;

z Open the low leakage fan inlet damper;

z Close the low leakage fan outlet damper;

z Start the low leakage fan;

z Open the low leakage fan outlet damper;

z Put the GGH rotor low speed signal interlock in service;

z Open the clean flue gas damper;

z Close the motorised absorber evacuation buffer fly valve;

z Open the original flue gas damper;

z Put the boost fan static blade actuator at the manual position and adjust its open

degree to less than 10%;

z Check and ensure the following start up permission conditions are fulfilled:

a) The clean flue gas damper is open;

b) The original flue gas damper is open;

c) GGH is in normal operation with speed not less than 0.75 r/min;

d) 2 sets or above slurry circulation pumps are in operation;

e) The temperature of boost fan bearing is less than 70;

f) The temperature of boost fan main motor bearing 1# and 2# is less than 75;

g) The main motor winding temperature is normal;

z Start 1# or 2# bearing cooling fan;

z Start boost fan main motor;

z Increase the open degree of static blade manually depending on the boost fan inlet

negative pressure situation after return of boost fan main motor current;

z Close the bypass damper gradually and adjust the open degree of static blade

manually to maintain the boost fan inlet pressure around -200Pa;

z Set the boost fan pressure close circuit control setting value (bypass damper

pressure differential is zero or the boost fan inlet pressure is -200Pa) and put the

boost fan static blade automatic control mode in service.

11.4.2.6.7 Put the oxidization fan in service

z Check and confirm all manual valves on air duct from the oxidization fan outlet to

absorber are open;

z Open the oxidization fan bypass unloading valve;

z Open the oxidization fan sound arresting covering fan;

z Start the oxidization fan and observe the current to return in 20-6S normally;

z Close the oxidization fan bypass unloading valve.

11.4.2.6.8 Put the limestone slurry supply system in service

z Check the related valves is at the required positions as per the following table:


Isolation valve before limestone slurry supply pipe density gauge Open

Isolation valve after limestone slurry supply pipe density gauge Open


Rev.: A

SEC




Limestone slurry supply pipe density gauge bypass valve Close

Limestone slurry supply pipe density gauge valve group evacuation

valve Close

Isolation valve before absorber slurry charge regulating door group Open

Isolation valve after absorber slurry charge regulating door group Open

Absorber slurry charge regulating door group bypass valve Close

Absorber slurry charge regulating door group evacuation valve Open

Primary door for all measuring instruments Open

z Close the motorized evacuation valve at the limestone slurry pump inlet;

z Set the open degree of the absorber slurry charging regulation door below 30%

manually;

z Close the motorized cleaning valve on the limestone slurry pump outlet pipe;

z Start the limestone slurry pump;

z Start the limestone slurry pump outlet motorized door;

z Put the standby limestone slurry pump interlock in service;

z Set the absorber slurry PH automatic control setting value at 5.6 and put the

absorber gypsum slurry PH valve close circuit control.

11.5MONITORING AND REGULATION IN FGD SYSTEM OPERATION

11.5.1 Major purpose and task of monitoring and regulation

The major purpose and task of monitoring and regulation is to ensure the continuous steay

operation of the FGD system, the qualified desulfurization efficiency, the long term application life

of the equipments, the safe operation of the equipments under accident conditions, and maintain

the FGD system in favourable working conditions through corrrect monitoring and regulation of the

FGD system and the equipments.

11.5.2 Crucial control parameters and limitations in the FGD system

11.5.2.1 Absorber inlet flue gas density control

As per the design requirement, the soot density at the FGD system inlet should be controlled

below 370mg/Nm3, (i.e. the dust content of the flue gas at the inlet). If the dust content is too high,

the system working conditions shall deteriorate and the SO2 absorbing efficiency shall decrease

with occurrence of abnormal conditions such as the belt conveyor dehydration difficulty,

influencing the quality and utility value of the desulfurization gypsum. Therefore, the dust content

variation should be strictly watched over in operation regulation. When the system dust content

gose above the normal scale seriouly, the unit operating personnel should be contacted in time

and the operation of the FGD system should be stopped without delay.

11.5.2.2 Fan inlet air pressure control

To ensure the safe and steady operation of the boiler, the flue gas presssure is controlled by

regulating the open degree of the boost fan guiding blades and the boost fan inlet pressure

stablization is maintained. In order to obtain the better dynamic features, the boiler loading and ID

fan situatin singals are led in as subsidiary signals. During the process of putting the FGD flue gas


Rev.: A



in service, the open degrees of the flue gas bypass damper door and the boost fan guding blades

should be controlled coordinately, maintaining the pressure stablization at the boost fan inlet.

When the bypass damper door is closed to certain degree, the preesure control close circuit will be

put in service and the bypass damper door will be closed. In the operation process, the boost fan

inlet pressure should be closely watched over. If there is big variation in boost fan inlet pressure,

the open degree of the boost fan moving blades should be manually regulated in good time to

keep the boost fan inlet pressure stable.

11.5.2.3 Absorber slurry PH control

The PH value of the absorber slurry should be controlled within the specific arange. If it is very

low, the slurry will lose the absorbing capability, influencing the SO2 removing rate and by product

desulfurization gypsum quality. Simultaneously, high PH value will bring the consequences of

scaling and jam to the system. The stability of PH is maintained by the online dynamic regulating

the open degree of the limestone slurry regulation door to control the limestone slurry supply

quantity. The best PH value for single circuit absorber is controlled between 4.5 and 5.8.

11.5.2.4 Absorber level control

The absorber level varies due to the changes in factors such as the control of the absorber

limestone slurry supply quantity, the gypsum slurry discharge quantity, the flue gas inlet quantity

and etc. Based on the measured level value, the filtrate pipe regulation valve and the time interval

for mist eliminator cleanings are controlled to keep the level stable. The level of absorer should be

controlled at 13.5±0.5m. If the level is at14.00m or above, the operation is forbidden to avoiding

GGH heat exchange surface pollution by gypsum slurry overflowing through the absorber inlet

glue gas duct.

11.5.2.5 Absorber gypsum slurry density control

The density of the absorber gypsum slurry should be controlled within the specific range. If

the density is too low, it will result in the slurry gypsum crystalization difficulty and belt dehydration

difficulty. If the density is too high, the system abrasion, the slurry circulation pump power

consumption and risks of system scaling will be increased. The FGD absorber density should be

controlled between 1050—1150Kg/m3. The absorber gypsum slurry density is controlled through

regulation of the gypsum slurry quantity discharged to the ash and slag system.

When the density of the absorber gypsum slurry reaches 1100Kg/m3, check and confirm

the ash and slag system is ready with necessary conditions to receive gypsum slurry;

To control the absorber gypsum slurry discharge quantity through regulating the open

degree of the slurry discharge pneumatic door from the absorber to the front slurry

reservoir by absorber gypsum slurry density close circuit control or manual control, and

keep the absorber gypsum slurry density relatively stabilize at 1050—1150Kg/m3.

11.5.2.6 Absorber slurry Chloridion content control

To protect and reduce the corrosion of the equipment and system pipes, ensure the normal

operation of the FGD sewage system and maintain the suitable sewage discharge quantity, the

asborber slurry Chloridion content should be controlled below 10000ppm. When the Cloridion is

relatively high, the slurry discharge quanaity to the ash and slag system should be increased and

the absorber level should be maintain by increasing the absorber process water make up quantity.


Rev.: A



11.5.2.7 To ensure the limestone reaction activity, the CaO ore of good quality and qualified

fineness is generally used.

11.5.2.8 The SO2 content in outlet flue gas should be strictly watched over. When deviation

occurs, comprehensive analysis of the boiler loading, inlet SO2 density, circulation

pump operation conditions and slurry PH should be conducted and suitable counter

measurement should be adopted.

Comparison Table of Parameters and Power Consumption

Influencing SO2 Desulfurization Efficiency

Value SO2 desulfurization

efficiency Power consumption

Absorber circulating

flow ↑ ↑ ↑

PH ↑ ↑ ＝ CaCO3 in absorber ↑ ↑ ＝ Limestone activity ↑ ↑ ＝ Flue gas flow ↑ ↓ ↑ SO2 density at FGD

inlet ↑ ↓ ＝

Cl content in flue gas ↑ ↓ ＝ 11.5.3 Major operation control parameters limitation

11.5.3.1 Flue gas system

Range KKS

Specification

From To

Unit

Operatin

g value

Min/Max

Valu

e

Action

*HTA10

CP001

Boost fan up stream

untreated flue gas

pressure

-40

40

mbar

-5

*HTA10

CP002

Boost fan up stream

untreated flue gas

pressure

-40

40

mbar

-5

*HTA10

CP003

Boost fan up stream

untreated flue gas

pressure

-40

40

mbar

-5

*HTA10

CP901

Boost fan up stream

untreated flue gas logic

pressure (two values out

of 3)

> Max

XXX

X

Bypass

protectio

n start up

*HNA50

AA601

*HTA10

CT001

FGD device up stream

untreated flue gas

temperature

0

350

< 180


Rev.: A

SEC



Range KKS

Specification

From To

Unit

Operatin

g value

Min/Max

Valu

e

Action

*HTA10

CT002


untreated flue gas

temperature

0

350

< 180

*HTA10

CT003


untreated flue gas

temperature

0

350

< 180

*HTA10

CT901


untreated flue gas logic

temperature (two values

out of 3)

0

350

< 180

> Max1

140

>Max 2

180

Bypass

damper

protectio

n start up

*HNA50

AA601

<Min1

120

Bypass

damper

protectio

n start up

*HNA50

AA111

>Min1

120

Sending

out

signals

for

starting

up of

treated

flue gas

damper

*HTA50

AA601 <Min 2 110

*HTA20

CQ001


untreated flue gas SO2

content

0

5000

mg/m3

dry

basis

<3605

>Max1

3605

*HTA20

CQ002 FGD device up stream

untreated flue gas O2

0

21

%

6-8

Date 2008-09-16


Page 148

Rev.: A

SEC



Range KKS

Specification

From To

Unit

Operatin

g value

Min/Max

Valu

e

Action

content

*HTA30

CT001

Absorber (inlet) up

stream untreated flue gas

temperature

0

200

<120

Max1

125

Failure

alarm *HTA50

CP001 FGD device down stream

treated flue gas pressure

-10

40

mbar

+5

*HTA50



-10

40

mbar

+5

*HTA50



-10

40

mbar

+5

*HTA50

CP901

Absorber down stream

treated flue gas logic

temperature (two values

out of 3)

> Max 1

10

> Max2 40

*HTA50

CQ001

FGD device down stream

treated flue gas SO2

content

0

500 mg/m3

dry

basis

<150

*HTA50

CQ002


treated flue gas NOX

content

0

1000

mg/m3

dry

basis

<1000

*HTA50

CQ003


treated flue gas O2

content

0

21

% dry

basis

7

*HTA50

CQ004


treated flue gas ash

content

0

200 mg/m3

dry

basis

<50

> Max1

50

*HTA50

CM001


treated flue gas moisture

content

0

100

%

<12

*HTA50

CT010 Down stream treated flue

gas temperature

0

200

>=80

*HUD10

CS901

GGH rotary body speed

<0.7 rpm

rpm

< Min1

0.2

FGD

device

flue gas

pipe


Rev.: A

SEC



Range KKS

Specification

From To

Unit

Operatin

g value

Min/Max

Valu

e

Action

failure

*HTAOO

EG001

*HUD10

CS902

GGH rotary body speed

<1.2 rpm

rpm

< Min1

0.7

Flue gas

ready to

receive

*HTA00

EG002 11.5.3.2 Boost fan

Range KKS

Specification

From To

Unit

Operatin

g value

Min/Ma

x Valu

e

Action

*HTC10

AA001 Boost fan static blade

actuator

0

100

%

>max1 5 Warning

>max2 10 Alarm <min1 -15 Warning

*HTA10

CP901

(see flue gas

system)

Boost fan inlet pressure

-40

+40

mbar

<min2 -18 Alarm >max1 30 Warning

>max2 35 Alarm <min1 -5 Warning

*HTC10

CP001

Boost fan outlet

pressure

-40

+40

mbar

<min2 -10 Alarm <min1 40 Alarm

*HTC10

CF901

Flue gas flow signa

calculated from the

pressure differential of

*HTC10 CP003

0

150

%

40-120

>max1

120

Alarm

>max1 85 Alarm *HTC10

CT001 Boost fan front bearing

temperature

-25

120

oC

<70

>max2 95 Trip


CT002 Boost fan front bearing

temperature

-25

120

oC

<70

>max2 95 Trip


CT011 Boost fan middle bearing

temperature

-25

120

oC

<70

>max2 95 Trip >max1 85 Alarm *HTC10

CT012 Boost fan middle bearing

temperature

-25

120

oC

<70

>max2 95 Alarm >max1 85 Alarm *HTC10

CT051 Boost fan rear bearing

temperature

-25

120

oC

<70

>max2 95 Alarm >max1 85 Trip *HTC10

CT052 Boost fan rear bearing

temperature

-25

120

oC

<70

>max2 95 Alarm


Rev.: A

SEC



Range KKS

Specification

From To

Unit

Operatin

g value

Min/Ma

x Valu

e

Action

>max1 75 Trip *HTC10

CT031 Boost fan motor front

bearing temperature

-25

120

oC

<70


CT032 Boost fan motor front

bearing temperature

-25

120

oC

<70

>max2 80 Trip >max1 75 Trip *HTC10

CT031 Boost fan motor rear

bearing temperature

-25

120

oC

<70


CT032 Boost fan motor rear

bearing temperature

-25

120

oC

<70

>max2 80 Trip >max1 125 Alarm *HTC10

CT021 Boost fan motor stator

winding temperature

oC

<125 >max2 130 Trip >max1 125 Alarm *HTC10


winding temperature

oC



winding temperature

oC



winding temperature



winding temperature



winding temperature

<125 >max2 130 Alarm >max1 6.3 Trip *HTC10

CY301 Boost fan bearing

vibration value

mm/s

<5 >max2 7.1 Alarm >max1 6.3 Alarm *HTC10

CY302 Boost fan bearing

vibration value

mm/s

<5 >max2 7.1 Trip

*HTC10

CP301

Boost fan surging alarm

Signal

spark

Alarm60S

unrelease

d Trip 11.5.3.3 GGH

KKS

Specification

Range

Unit

Operatin

g value

Less/mo

re than

Value

Action

*HUD10

CS901

GGH rotor speed

*HUD10 CS001～003 (2

out of 3)

0～2

rpm

1～1.5 Normal

operating

speed

GGH speed<0.2rpm

<Min1

0.2 Alarm,

stop rotor

driver GGH speed <0.7rpm <Min1 0.7 Stop HP


Rev.: A

SEC



KKS

Specification

Range

Unit

Operatin

g value Less/mo

re than

Value

Action

water

cleaning

procedure

GGH speed <1.0rpm <Min1 1.0 Alarm

*HUD10

CT001 Guiding bearing

lubricating oil temperature

0～ 200

60 >Max1

Alarm

>Max2

*HUD10

CT002 Supporting bearing

lubricating oil temperature

0

>Max1

>Max2

*HUG01

CP001

Cleaning steam pressure

bar

10

<Min1

6 Stop

steam

cleaning *HUG20

CT001 Cleaning steam drainage

discharge temperature

300

<Min1

250

3HUQ01

CP002

HP cleaning water pump

up stream pressure

bar

<Min1

5

Stop HP

water

cleaning

procedure

3HUQ01

CP005

HP cleaning water pump

outlet pressure

bar

>Max1

100

Stop HP

water

cleaning

procedure

*HUW01

CP001 Positive pressure sealing

fan down stream pressure

mbar

11.5.3.4 Absorber

Range KKS

Specification

From To

Unit

Operatin

g value Min/Ma

x

Value

Action

>MAX2

14300

Absorber

inlet PO,

2 out of 3

*HTD10

CL001

1# absorber level

13500

<MIN4

10000

Upper

mixer PO,

2 out of 3


Rev.: A

SEC



<MIN7

3000

Circulatio

n pump

PO, 2 out

of 3

<MIN9

1800 Mixer PO,

2 out of 3

<MIN1

1

1200

Gypsum

discharge

pump

PO, 2 out

of 3

>MAX2

14300

Absorber

inlet PO,

2 out of 3

<MIN4

10000

Upper

mixer PO,

2 out of 3

<MIN7

3000

Circulatio

n pump

PO, 2 out

of 3

<MIN9

1800 Mixer PO,

2 out of 3

*HTD10

CL002

2# absorber level

13500

<MIN1

1

1200

Gypsum

discharge

pump

PO, 2 out

of 3

>MAX2

14300

Absorber

inlet PO,

2 out of 3

<MIN4

10000

Upper

mixer PO,

2 out of 3

<MIN7

3000

Circulatio

n pump

PO, 2 out

of 3

*HTD10

CL003

3# absorber level

13500

<MIN9

1800

Mixer PO,

2 out of 3


Rev.: A

SEC



<MIN1

1

1200

Gypsum

discharge

pump

PO, 2 out

of 3

>MAX1

14000

Alarm,

mist

eliminator

sequence

group

control

stop

>MIN1

X Stand by

signal

<MIN2

12700

Close

circuit

control

start up

cleaning

<MIN3

10500

Alarm,

upper

mixer PO

>MIN3

10500

Release

connectin

g upper

mixer

>MIN5

3500

Release

connectin

g

circulatio

n pump

<MIN6

3000

Alarm

circulatio

n pump

PO

<MIN8

1900 Alarm

mixer PO

*HTD10

CL901

Absorber logic

level

>MIN8

1900 Release

connectin

g mixer


Rev.: A

SEC



>MIN9

1800

Release

connectin

g gypsum

discharge

pump

<MIN1

0

1700

Alarm

gypsum

discharge

pump PO 11.5.3.5 Limestone slurry supply system

Range

KKS

Specification Fro

m

To

Unit

Operatin

g value

Less/Mor

e than

Valu

e

Action

0HTK60

CL901 Limestone

slurry tank

level

0 500

0 MM 2000-4

500 More

than 480

0 High level alarm

More

than 450

0 Unconditional

start slurry

preparation

terminal

procedure More

than 420

0 Conditional start

slurry preparation

procedure More

than 300

0 Conditional start

slurry preparation

terminal

procedure Less

than 200

0 Start slurry

preparation

procedure Less

than 180

0 Low level alarm

More

than 150

0 Allowing mixer

start up More

than 150

0 Allowing

limestone slurry

pump start up Less

than 100

0 Stop mixer, alarm

limestone slurry

pump stop


Rev.: A

SEC



Less

than 400 Stop limestone

slurry pump 11.5.3.6 Process water system

Range KKS

Specification

From To

Unit

Operating

value

Min/Max

Value

Action

0HTQ10

CL901 Process water

tank level mm Continuous

>Max1

5800 High level

alarm

>Max2

5500 Make up

valve close

(0HTQ10

AA101)

<MIN1

3000 Make up

valve open

(0HTQ10

AA101)

>MIN1

3000 Allowing

process water

pump

activation

<MIN2 2000 Low level

alarm

<MIN3

1000 Stop all

process water

pumps 0HTQ15

AA091 Process water

return pressure

stabilizing valve

MPa 0.65

*HTQ50

AA090 Absorber mist

eliminating

cleaning pressure

relief valve

MPa 0.21

11.5.3.7 Emergency slurry system

Range KKS

Specification

From To

Unit

Operatin

value g

Min/Max

Value

Action

Emergency slurry tank 0HTT10

CL001 Emergency

slurry tank

level

mm 13500 ＞MAX1 13000 High level

alarm

Date 2008-09-16


Page 156

Rev.: A

SEC



Range KKS

Specification

From To

Unit

Operatin

value g

Min/Max

Value

Action

Emergency

slurry tank

level

mm ＞MIN1 3000 Allowing mixer

activation

mm ＜MIN2 2000 Alarm mixer

termination mm ＜MIN3 1800 Stop mixer mm ＜MIN4 1200 Alarm

emergency

discharge

pump

termination mm ＜MIN5 1000 Stop

emergency

discharge

pump Absorber earth pit

*HTT41

CL001 Absorber

earth pit level mm 1300 ＞MAX2 2800 High level

alarm mm ＞MAX1 2300 Allowing earth

pit pump

activation mm ＞MIN1 1400 Allowing mixer

activation mm ＜MIN2 1300 Stop earth pit

pump (level

protection) mm ＜MIN3 1100 Stop mixer mm ＜MIN4 500 Stop earth pit

pump

protection Unloading room earth pit

0HTT51

CL001 Unloading

room earth pit

level

mm 700 ＞MAX2 800 High level

alarm

mm ＞MAX1 600 Activated

earth pit pump

mm ＞MIN1 200 Stop earth pit

pump 11.5.4 Inspection in FGD system operation


Rev.: A

SEC



Equipment name Inspection item and requirements Boost fan and its

auxiliaries For all rotary parts, current, vibration and sound are normal; machinery

and motor bearing temperatures are normal; cooling water flow and

temperature are normal; lubricating (hydraulic) oil pressure,

temperature, quality and level are normal; all connectings, including

guiding blade actuator and air dampers, are firm without deformation,

bending and rip; no leakage points; CRT displays of outlet pressure and

flue gas flow are normal. Sealing fan For all rotary parts, current, vibration and sound are normal; machinery

and motor bearing temperatures are normal; outlet pressure value is

normal; inlet screen is clean. Oxidization fan and all

types of pumps For all rotary parts, current, vibration and sound are normal; machinery

and motor bearing temperatures are normal; cooling water flow and

temperature are normal; lubricating (hydraulic) oil pressure,

temperature, quality and level are normal; driven belt tightness is

suitable, without distortion and abrasion is within the normal standard;

inlet and outlet pressure are normal; non return valve and pipes have

no self-sustained oscillation or syntony appearance; inlet strainer is

clean; all connectings are firm without deformation and bending; all

valves are at the right positions; no leakage points. Mixer For all rotary parts, current, vibration and sound are normal; machinery

and motor bearing temperatures are normal; lubricating oil level is

normal and quality is good; all connecting bolts and nuts are firm; no

leakage points. Hydraulic cyclone Without blockage; open degrees of valves are normal; inlet flow is

normal; no leakage points. Gypsum separator and

vacuum dehydration

belt

For all rotary parts, current, vibration and sound are normal; machinery

and motor bearing temperatures are normal; gypsum conveying

conditions and the gypsum lump thickness are normal; the open

degrees of valves and the solenoid valve action frequency are normal;

the roller and its driven device works normally; the filter cloth is without

blockage, broken holes or rip; cleaning conveying nozzle is without

blockage conditions; water cleaning filter cloth is clean; the vacuum

conditions is suitable; the gypsum splattering conditions are normal;

local instruments indications are right; no leakage points. Rotary heat exchanger

（GGH） For all rotary parts, current, vibration and sound are normal; machinery

and motor bearing temperatures are normal; the cleaning water

pressure is normal; lubricating oil level and quality are normal; sealing

air pressure is normal; no leakage points. Dampers with sealing

device The open degree of dampers are right, drivers for air cylinder are

normal; sealing air pressure and flow is normal; sealing components


Rev.: A

SEC



are without leakage. Absorber Absorber level is within the normal range; current, vibration and sound

of rotary parts, including circulation pump, mixer and so on, are normal;

machinery and motor bearing temperatures are normal; the open

degrees of valves and automatic valves are normal; PH gauge pipe is

without blockage; there is no abnormal vibration and sound in the area;

local instruments indications are right; no leakage points. All water tanks and

slurry tanks All water tank levels are within the normal range; the open degrees of

valves and instrument valves are right; there is no abnormal vibration

and sound in pipes; equipments and its auxiliaries in the system area

are without leakage. Silo The level gauge indications of limestone lump bunker and powder

bunker are right; all instruments indications are within the normal range;

the valve open degrees and pipe vibration are normal; the fluidizing

device works properly; no leakage points. CRT All indication values are within the design range; all interlocks and

protections are normally put in service; no alarm signals; the operators

on duty records on time. 11.5.5 Maintenance During the FGD System Operation

11.5.5.1 GGH Cleaning.

To prevent the scaling inside GGH, the online cleaning must be adopted to GGH when the

pressure difference enlarges in a faster speed or exceeds the designed value. During the normal

operation of GGH (rotary proper of GGH: rotating speed n≈1.5), the steam cleaning should be

carried out every 8 hours and the entire process (1 time) lasts for about 2.3 hours. The process is

manually started by operators.

When pressure difference (∆P) of GGH rises to ~1.5 P under clean conditions, alarms shall

reminder the operators to start-up HP water cleaning.

The intending frequency of HP water cleaning: during the normal operation of GGH, the

system shall be cleaned once a week, or during the GGH system shut down process. The entire

process lasts for about 9 hours. This process can only be manually adopted upon the operator’s

request.

The process is to be automatically accomplished by GGH soot blowing local control cabinet

(including feedback of fault signal), and only remote “start” and “stop” signal will be issued by the

operator.

11.5.5.1.1GGH steam cleaning

Check and confirm the start-up conditions of GGH steam cleaning are fulfilled (not

interlocked).

¾ GGH system is in operation and the rotor speed n≈1.5 (min 1). ¾ Upper and lower soot blowers are at the outer side. ¾ Air valve is closed. ¾ HP nozzle cleaning valve is open.

Invoke GGH steam cleaning start-up function group to start GGH steam cleaning.


Rev.: A



11.5.5.1.2GGH HP water cleaning

Check and confirm the GGH water cleaning conditions are fulfilled (not interlocked).

¾ GGH system is in operation.

¾ HP pump is not in operation.

¾ Chief water valve is closed.

Invoke GGH HP water cleaning group to start GGH HP water cleaning.

HP water cleaning procedure specification:

¾ During the HP water cleaning, GGH rotating speed is changed to low rotating

speed of 0.75n.

¾ Start HP water cleaning procedure, which is controlled by soot blower control

cabinet and the “start” & “stop” signals are sent out by DCS.

Monitoring of HP water cleaning.

¾ The HP water procedure should be stopped when the following signals

occurring:

HP water pressure P>100 bar (3HUQ10 CP310), max 1.

11.5.5.2 PH gauge’s cleaning and correction

11.5.5.2.1Absorbing tower has two PH gauges, clean them alternately in the specific sequence.

When the fault value and large warp alarm occur, it is necessary to start the

cleaning device manually. The PH gauges should not be in operation during the

cleaning.

11.5.5.2.2The results of manual analysis and online measurement should be compared at least

once a week, and the online PH gauge should be adjusted when there is

difference in the comparison.

11.5.5.3 Cleaning of oxidization air pipe

11.5.5.3.1To prevent blockage, every oxidization air pipe is equipped with a cleaning pipe, and

every oxidization air pipe should be cleaned sequently every week.

11.5.5.3.2Each oxidization air pipe should be cleaned as per the following procedure:

Check if the cleaning water pump is in normal operation.

Slowly close separate valve of branch oxidization air pipe, wait until the oxidization air

pipe pressure gauge turns to ZERO.

Open the cleaning water separate valve of the oxidization air pipe, clean it and monitor

the pressure gauge.

Close the cleaning water separate valve of the oxidization air pipe after the cleaning.

Slowly open the cleaning water separate valve of the oxidization air pipe.

11.5.5.4 The complete discharge and cleaning of the centrifugal pump for limestone and

gypsum slurry transportation and the pipes after shut down

11.5.5.5 Periodic test for bypass damper door

11.6SHUT DOWN OF THE FGD SYSTEM

Due to periodic overhaul or tear of the system, the FGD system will shut down after

transacting the shut down procedure. Only after the operator manager’s approval can the FGD

system be shut down. During the shut down process, the relative operations especially the flue


Rev.: A



gas system should be operated in stable order by closely contacting the operators, so as to

guarantee the boiler safe operation and safe shut down of the FGD system. The methods of the

equipments putting in service vary due to the different shut down methods of the FGD system.

11.6.1 Preparation before shut down of the FGD system

11.6.1.1 As each slurry pump is to be cleared and cleaned after shut down of the FGD system,

the water level of absorber should be lower properly to keep the normal low level

operations of the absorber discharge pit and emergency slurry reservoir.

11.6.1.2 Before shut down of FGD system, GGH should be cleaned by online steam or HP

water.

11.6.2 FGD system from operating state to hot standby state

The shut down of FGD system means that the FGD system changes from the operating state

to the hot standby state; or after shut down of the boiler, the FGD system changes from the

operating state to the hot standby state. This operation is accomplished by running flue gas

system stop function group and absorber’s stop function group, or by the remote sequent control

of FGD system centralized controller.

11.6.2.1 Discuss with operator manager and chief operator to request for shut down of this unit’s

FGD system. After receiving the approval of the operator manager, invoke the flue gas

system stop function group and absorber stop function group or manually stop the FGD

system as per the following procedures:

11.6.2.2 Open the bypass damper

z Manually open the bypass damper, add 5% extent for each time. Add with the

same extent till 50% opening of the damper when the booster air fan’s inlet

pressure reaches to a stable state.

z Change the booster air fan’s automatic control to manually controlling state.

z Add 5% extent to the opening of bypass damper while manually reducing boost

fan’s static blade opening. After maintaining the boost fan’s inlet pressure, add

bypass damper’s opening to 100% by adding 5% opening extent.

11.6.2.3 Stop the boost fan

z Make sure that the bypass damper opens to 100%.

z Close the booster’s static blade until the opening is under 10%.

z Stop the operation of boost fan’s main motor.

11.6.2.4 Close the original flue gas damper

11.6.2.5 Close the clean flue gas damper

11.6.2.6 Start 1 set damper airproof fan

z Start damper airproof fan

z Start the electrical door at damper airproof fan’s inlet

11.6.2.7 Open the drainage door at the top of absorber

11.6.2.8 Shut down the GGH low leakage fan

z Close the electrical door at outlet of low leakage fan

z Shut down the low leakage fan

z Close the electrical door at inlet of low leakage fan


Rev.: A



11.6.2.9 Close the limestone slurry feeding door to opening 0.

11.6.2.10 Shut down the absorber’s slurry circulation pump by sequence

z Make sure that the conditions for slurry circulation pump’s shut down are

fulfilled(boost fan is shut down, original flue gas damper and clean flue gas

damper are closed)

z Shut down the slurry circulation pump

z Close the electrical door at slurry circulation pump inlet after a 120s delay.

z Make sure that the water level at absorber’s drainage pit is not high.

z Start the drainage electrical door at the shut down slurry circulation pump’s inlet

z Close the drainage electrical door at the shut down slurry circulation pump’s

inlet after a 300s delay.

11.6.2.11 Shut down the oxidation fan

z Open the bypass discharge valve of oxidation fan

z Shut down the oxidation fan

z Close the bypass discharge valve of oxidation fan

z Shut down the sound proof fan of oxidation fan

z Close the main humid adding door of oxidation air

11.6.2.12 Stop the gypsum slurry’s PH gauge at absorber

z Close the manual sampling door for PH measuring of gypsum slurry at

absorber.

z Open the drainage door at PH measuring slot’s bottom of gypsum slurry and

drain the gypsum slurry inside.

z Open the measuring loop of PH measuring of gypsum slurry and flush the

manual door for 5 minutes.

z Close the drainage door at PH measuring slot’s bottom of gypsum slurry and

drain the gypsum slurry inside

z Close the gypsum slurry’s PH measuring loop and flush the manual door after

treatment liquid is fulfilled in the PH measuring slot’s bottom of gypsum slurry.

11.6.2.13 Shut down GGH

z Cancel the low rotating speed interlock of GGH stand by motor

z Stop the GGH driven device

z Stop GGH sealing fan

11.6.2.14 Shut down the limestone slurry pump

z Shut down the limestone slurry pump

z Open the flush door of limestone slurry feeding pipe and flush the feeding pump

11.6.2.15 Main equipments’ state under hot and stand by state of FGD system

System Description of main auxiliaries State Boost fan Stopped Original flue gas damper door of FGD Closed Clean flue gas damper door of FGD Closed

Absorber system

Bypass flue gas damper door of FGD Open


Rev.: A

SEC



System Description of main auxiliaries State Absorber ventilation door Open Absorber circulation pump Stopped Gypsum drainage pump In operation Absorber mixer In operation Oxidation fan Stopped Absorber PH control Manually Mist remover flush system Stopped Absorber water level control Automatic Damper airproof fan In operation Absorber pit pump According to the pit water level

Absorber pit mixer According to the pit water level Soot blower Stopped Main and supplement drive motor Stopped GGH airproof fan Stopped GGH low leakage fan Stopped Low leakage fan inlet door Adjusted to corresponding

position GGH soot blower airproof fan Stopped Limestone slurry pump In operation Limestone slurry tank mixer In operation Limestone slurry tank feedwater flow

control Automatic

Limestone slurry tank’s water level

control Automatic

Milling district pit pump According to Milling district’s pit

water level

GGH system

Milling district pit mixer According to Milling district’s pit

water level Flush water system In operation Closed cooling water system In operation

Multi use air system In operation

Auxiliary system

Instrument air system In operation Emergency slurry pool mixer According to the emergency

slurry pool’s water level

Emergency slurry

pool Emergency slurry pump Stopped

11.6.3 FGD system changes from hot standby state to cold standby state

When the FGD system requires overhaul and the shut down mood need to be changed into

cold standby state, it demands that each system should shut down, drain the slurry from tanks and

pools into emergency slurry pool for storage and keep the emergency pool mixer on running.


Rev.: A

11.6.4 Matter to be taken care of after shut down of the FGD system

11.6.4.1 All the gypsum, limestone slurry transporting pump and pipe should be drained and

flushed after the shut down operation

11.6.4.2 Mixers of tanks containing slurry should maintain constant operation mood.

11.7 FGD SYSTEM FAULT AND ACCIDENT HANDLING

11.7.1 FGD system fault and general principles for accident treatments

11.7.1.1 When FGD system has faults or emergencies, the operator manager and chief operator

should lead all the operators to deal with the accidents according to Manual. Otherwise it’s

harmful to personnel and equipments’ safety; all the orders should be followed.

11.7.1.2 When FGD system has faults or emergencies, the operators should report to chief

operator, operator manager and relative leaders, and adopt effective and doable methods

to prevent the accidents extend, restrict the accidents’ scope, clear up the causations and

resume the operation of the FGD system. Under emergency conditions, the treatment

comes first and then report to the leaders.

11.7.1.3 The main equipments of FGD system should be stopped and treated when they can not

fulfill the operation conditions and can threaten operators and equipments safety.

11.7.1.4 The operators should immediately and positively adopt solutions by personal experience

and judge for accidents not listed in this specification.

11.7.1.5 After treating accidents, the operators should record the time, accident, treatment

process and solutions on the duty relay recording notebook and submit the raw report to

the safety department of the plant.

11.7.1.6 When the accident occurred during the duty relay time, duty deliver that has not finished

duty relay should go on for work and treat the accidents with duty relay personnel. The

duty can only be relayed when the accident treatment is over or stopped for a rest time.

11.7.1.7 When noticing the FGD system’s flue gas system shut down due to accidents, check if

the bypass damper door is automatically opened or press the quick open button on the

bypass damper, then report to operator manager and contact boiler operators to ensure

the safety operation of boiler.

11.7.1.8 The consideration equipment scope of FGD system’s accident treating does not only

including the main equipments and systems inside the FGD system, but also the effects to

the other service systems; take the possible secondary pollutions into consideration and

avoid them.

11.7.2 Emergency shut down of the FGD system

11.7.2.1 Emergency shut down conditions of FGD system

The FGD system should be immediately shut down when comes to the following conditions. If

the system can not be shut down, the bypass damper should be opened manually and shut down

the FGD system.

z Boost fan trips

z Less than 2 sets of operating slurry circulation pumps in operation

z Flue gas temperature at inlet of boost fan is over 180


Rev.: A

z Operating original flue gas damper or clean flue gas damper are closed due to

faults

z Boiler MFT

z ESP fault trips or less than 2 flue gas channels are flowing to electric field.

z GGH operation motor trips and the stand by drive motor can not be connected

to start, leading to the shut down of GGH.

11.7.3 FGD system shut down due to not emergent faults

The FGD system should be shut down when comes to the following conditions, but the

department leader’s agreement is the precondition.

z 2 sets of absorber mixers out of operation

z Operators should shut down the FGD system when the soot concentration at

the inlet of FGD system.

z The limestone slurry producing equipments and feeding system can not supply

slurry to the absorber, and PH value of slurry insider the tower is under 4.0 and

keep on dropping.

z Density of gypsum exceeds 1200Kg/ m3 and can not be reverted to normal in

short time.

z The accidents occur at producing field and control room threaten personnel’s

and equipments’ safety.

z FGD system’s controlling system can not monitor the faults.

z GGH pressure difference can not be treated by the operators and keeps on

enlarging.

11.7.4 System’s common fault treatment

The following should be carried out when the DCS alarms for faults:

z Make sure of the operation state of FGD system;

z Find out the causes of alarming;

z Adjusting operation should be done to remove the fault.

z Revert and back to operation, resume the FGD system to normal operation.

11.7.4.1 Causations and solutions for the decreasing efficiency of FGD system:

Causations Appearance and analyzing results Solutions Limestone slurry’s

supply can be fulfilled

inside the absorber

Low control level of PH value Improve the PH control level

properly and increase the

limestone slurry’s supply Not exact data for PH

online measuring,

which leads to low

measuring(control

value) of actual PH

level inside the

absorber

Compare the test result with online

measuring value manually to find out the

existing difference

Mark the PH gauge

comparatively and periodically.


Rev.: A

SEC



Blockage inside the

spraying pipes or

nozzles

Slurry circulation pump’s flow(current)

decreases and outlet pressure increases Deal when shut down

Flue gas flow

increases

Online measuring indicates the increasing

of flow and each section’s resistance of

the flue gas system increases at the

same time

Add a spray coat if possible

Density of SO2 inside

flue gas increases

Flue gas online measuring indicates that

the density of SO2 increases and the

boiler’s coal consumption increases

Add a spray coat if possible

Quality of slurry turns

down and the

densities of Cl, dust

and heavy metal are

too high

Enlarge the sewage drainage

flow

Measuring value of

online measuring

gauge is not exact

due to faults, which

leads to wrong

calculation of FGD

efficiency

SO2 value at the inlet of online measuring

absorber is different(less) with SO2 value

contained inside the coal; SO2 value at

the outlet of online measuring absorber is

larger than the actual value.

Calibrate the online gauges

11.7.4.2 Tripping during boost fan’s operation

z Appearance

¾ --Boost fan’s current on the DCS screen turns to “0”, inlet pressure turns to

positive, and motor’s screen turns from red to green.

¾ --Bypass damper opens automatically, inlet and outlet dampers close

automatically, ventilation damper of absorber opens automatically, and boiler’s

induced fan may have short time positive pressure.

¾ --FGD system shut down automatically.

z Treatment process

¾ --Make sure the flue gas bypass damper is already open, or open it by

other means. --Report to operator manager and chief manager of centralized

control about the boost fan’s tripping.

¾ --Check whether the operation of absorber’s circulation pump, oil temperature of

boost fan’s bearing and motor’s bearing and the fan’s vibration are normal. Make

sure if they are the causations for the tripping.

¾ --Check the operation of electrical and thermal protection and compare with the

field equipments’ operation, then contact the maintaining personnel to check the

validity of the protecting operation and reset the protection after handling the

problems, check the insulating resistance of the boost fan’s motor, booster motor


Rev.: A

proper and oil station, make sure of the causation of tripping and deal with it.

¾ --Check the overall equipments of FGD system and turn them into hot standby

state.

¾ --If the causation of the fault can be found and treated in short time, then restart

the FGD system.

11.7.4.3 Blackout of treatment liquid

z Appearance

¾ Treatment liquid sends out alarm signals

¾ Blackout of treatment water at production fields.

z Treatment procedure

¾ Check the operation state of operating pump, and if there is abnormality, start the

stand by pump (start the coupling pumps when the treatment liquid pressure is

under 300 kpa).

¾ Check the water level of the treatment liquid tank and make sure that the makeup

water of treatment liquid is normal;

¾ When the blackout can not be renewed for a short time, then request the long

time shut down of FGD system;

¾ Drain the slurry pipe, try to renew the water source as soon as possible, then

flush the pipe and restart the FGD system.

11.7.4.4 Large GGH pressure difference

z Appearance

¾ Alarming for large GGH pressure difference

Treatment procedure

¾ Increase the times of soot blowing and reduce the time space of soot blowing.

¾ Start HP water pump when the treatments above are of no effect.

¾ Reduce the opening of the boost fan, reduce the system’s air flow and renew the

system after treating to normal state.

11.7.4.5 Complete shut down of slurry circulation pumps

z Appearance

¾ Complete shut down the operating slurry circulation pumps, switch of the DCS

system turns to green, current changes into ZERO and alarm rings.

¾ Shut down of FGD system.


¾ Make sure that the boost fan is tripped, manually stop the boost fan when

necessary and shut down the FGD system;

¾ Check if the absorber level is in the normal scope;

¾ Contact the thermal control personnel and check if there are abnormal conditions

in absorber level control system, the level indicator is right or not, and clean or

correct the level indicator depending on the actual conditions;

¾ Send a notice to the electrical maintenance personnel to check whether the slurry

circulation pump motor, cable and switch cabinet are in normal operation; check


Rev.: A

whether the electrical protection is in action;

¾ After eliminating the defects, restart up.

11.7.4.6 Abnormal in absorber level

z Cause

¾ Absorber level gauge out of order or metering error;

¾ Absorber slurry circulation pipe leakage;

¾ All valves which is connected to the absorber inside leakage;

¾ Absorber leakage;

¾ Absorber level control module failure;

¾ Mist eliminator cleaning water cutoff or nozzle blockage.


¾ Check and adjust the level gauge indication;

¾ Check and repair the leaking pipe;

¾ Check the valves’ inside leakage conditions, and change the related leaking

valves;

¾ Check the discharging doors at the absorber proper and the bottom.

11.7.4.7 Accident trip of the FGD flue gas system

z Appearance

¾ DCS alarm signal sent out;

¾ Boost fan trip;

¾ Bypass damper open, original and clean flue gas damper door close;

z Cause

¾ Boost fan failure trip;

¾ GGH driven motor speed less than 0.5r/min;

¾ Less than 2 sets of absorber circulation pumps in operation;

¾ Clean flue gas damper closed;

¾ The FGD system main power supply failure trip.


¾ Closely adjust and monitor each slurry tank and absorber slurry level,

consistency and density after the FGD system trip;

¾ If the FGD system main power supply trip, then it should be treated as equipment

shut down;

¾ After finding out the failure causes and eliminating the defects, restore the FGD

system operation.

11.7.4.8 FGD system other defects causes and treatment methods

Defect type Defect cause Treatment methods

Limestone slurry

density decrease

1. Limestone powder feeder

blockage

2. Powder bridging in the

powder bunker

3. Valve control out of order

1. Clean up the powder feeder

2. Adopt all clean up measurements, to

increase the powder bunker discharge

quantity

3. Inspect and repair the valves


Rev.: A

SEC



4. Limestone slurry tank over

water feeding 4. Inspect relative pipes and valves

Limestone slurry

flow decrease

1. Valve blockage

2. Relative valve out of order

3. Flow gauge out of order

4. Limestone slurry pump failure

5. Relative valve can not open or

close to the right positions

1. Clean up the pipe

2. Inspect, clean and repair the relative

valves

3. Inspect or change the flow gauge

4. Change to stand by pump

5. Inspect and correct the valves Inexact PH gauge

indication

1.PH gauge slurry supply

quantity is not enough

2.PH gauge slurry supply mixed

with cleaning water

3. Gauge not correct

1. Inspect and correct the valves, and

inspect whether the slurry discharge valves

are at the right positions

2. The cleaning water valve has leakage or

not, examine by cleaning and comparison

with the standard liquid Absorber outlet

SO2 density

increase

1. Absorber circulation slurry

quantity decrease

2. Limestone slurry quantity

decrease

3. Limestone slurry density

decrease


1. Contact the centralized control operating

manager, to know the boiler operation

adjusting conditions and coal combustion

analysis;

2. Inspect the circulation slurry pump

operation conditions and put 1 more

circulation slurry pump in service when

necessary;

3. Inspect and restore the limestone slurry

density;

4. Correct the gauge. Absorber inlet flue

gas temperature

high

1.GGH rotation not in good

conditions

2.GGH blockage

3. FGD system inlet flue gas

temperature high

1. Treat after find out the reasons

2. Check the pressure differential and treat

3. Contact to conduct boiler modification

GGH outlet flue

gas temperature

high

All absorber circulation pumps

shut down

The temperature rises to the specific value.

GGH outlet flue

gas temperature

low

1.GGH blockage

2. FGD system inlet flue gas

temperature low

1. Check the pressure differential and treat

2. Contact to conduct boiler modification

when it is lower than the specific value Mist eliminator

pressure

differential high

1. Elements blockage


1. Inspect the blockage, adjust mist

eliminator cleaning flow and time intervals

2. Correct the pressure gauge Oxidization air flow

abnormal 1. Pipe or oxidization fan inlet

blockage 1. Inspect the oxidization fan inlet filter and

clean the air duct up to the absorber


Rev.: A

SEC



2. Oxidization fan failure or pipe

leakage 2. Inspect the oxidization fan or pipe

Limestone silo

fluidizing fan

output pressure

low

1. Inlet filter blockage

Inspect the inlet filter, clean or change

11.7.4.9 The FGD system shall shut down due to failure interlock when with the following

conditions:

11.7.4.9.1There are less than 2 absorber slurry circulation pumps in operation;

11.7.4.9.2The FGD system inlet temperature is over the maximum value permitted;

11.7.4.9.3The inlet temperature is below the minimum value permitted;

11.7.4.9.4The boost fan is not in operation;

11.7.4.9.5The GGH is not in operation;

11.7.4.9.6Boiler MFT (2 boilers MFT of 2 boilers +1 absorber or boiler MFT of 1 boiler+1

absorber);

11.7.4.9.7The main power supply fails.

11.7.4.10 The FGD system shall shut down due to the non interlock failure when with the

following conditions, and the approval of the department leaders should be obtained

before the shut down:

11.7.4.10.1 The operators should shut down the system when 2 sets out of 4 absorber mixers are

shut down;

11.7.4.10.2 The operators should shut down the system when the FGD system inlet soot density is over 300mg/Nm3.

11.7.4.10.3 The operators should shut down the system when original damper for 2boilers+1absorber or 1boiler+1absorber is closed;

11.7.4.10.4 The operators should shut down the system when the clean flue gas damper is not open thoroughly.

11.7.4.10.5 When the FGD system outlet flue gas temperature is less than 80 and the adjustment is not effective, the operators should shut down the system after obtaining the approval.

11.7.4.10.6 The instrument air system failure and the pressure can not be kept; when it can not meet the FGD system’s requirements, the operators should shut down the system;

11.7.4.10.7 The system should be shut down when the FGD system parameters are seriously deteriorating and can not maintain the normal operation;

11.7.4.10.8 When accidents happen at the site and in the control room, and personal and equipments safety are in danger, the system should be shut down;

11.7.4.10.9 When the control system of the FGD system fails and can not conduct the normal monitoring, the system should be shut down;


Rev.: A



11.7.4.10.10 When the GGH pressure differential is high, and continuously increase after ineffective treatment conducted by the operators, the system should be shut down.

11.8 OPERATION OF LIMESTONE SUPPLY SYSTEM

11.8.1 Start up of the limestone preparation system

11.8.1.1 To choose the start up of the wet miller LP lubricating oil pump on the local control panel,

and set the interlock of wet miller LP lubricating oil pump A & B when the lubricating oil

pressure is more than 0.4MPa.

11.8.1.2 Start the wet miller spray fan.

11.8.1.3 Start the wet miller ejecting oil pump.

11.8.1.4 Start the wet miller gear box oil pump; if the oil pressure is over 0.5bar, start after a time

delay of 120s.

11.8.1.5 Start wet miller LP oil pump (jacking); if the oil pressure (is over 3.0MPa) does not

establish, then wet miller can refuse to start.

11.8.1.6 The wet miller main motor can only start after the wet miller slow driven device trips.

11.8.1.7 Start the limestone miller process water inlet motorized door, and set the wet miller inlet

water recovery regulation door at the automatic mode to mix water as per the limestone

quantity so that the wet miller slurry density can be controlled.

11.8.1.8 Start the scale feeder, when the limestone quantity is around 12t, lower the feeder at the

setting necessary quantity after half an hour. (Considering that: at the initial stage of start

up, the wet miller is on zero load, and large quantities of materials are needed to

counteract the grinding consumption between the steel balls.)

11.8.1.9 Start the wet miller slurry tank mixer.

11.8.1.10 Add materials and water into the wet miller to control the wet miller recirculation

slurry tank (through level mode) at the setting value of 1500mm; (stabilization at this level

is a little bit inclined to the upper limit).

11.8.1.11 Start wet miller slurry recirculation pump, adjust the frequency up to 40-50Hz, and

regulate the limestone slurry eddy station inlet pressure.

11.8.1.11.1 Choose the wet miller recirculation pump A or B, (please pay attention to the

corresponding relationship).

11.8.1.11.2 Invoke the wet miller recirculation pump cleaning sub function group.

11.8.1.11.3 Open the wet miller recirculation inlet door, close the wet miller slurry pump outlet door

and manually close the discharge door.

11.8.1.11.4 Open the process water cleaning door.

11.8.1.11.5 A time delay of 300s.

11.8.1.11.6 Close the wet miller slurry inlet door.

11.8.1.11.7 Open the wet miller slurry outlet door.

11.8.1.11.8 A time delay of 300s.

11.8.1.11.9 Close the wet miller slurry pump outlet door, close the process water cleaning door;

control the outlet pressure (the setting value is around 200kPa) to discharge to the

limestone slurry eddy station (close the outlet door initially and open the overflow

outlet after the fineness is qualified).


Rev.: A



11.8.1.12 Send the samplings for chemical examination.

11.8.1.13 After the start up of the wet miller slurry pump, open the wet miller slurry pump outlet

door, adjusting the frequency up to 50Hz, so that the limestone slurry eddy station inlet

pressure can be regulated over 200kPa or 2 eddy in the limestone slurry eddy station are

in operation.

11.8.1.14 The slurry enters the buffer tank after pass the chemical examination with qualified

results.

11.8.1.15 After confirmation of slurry tank level reaches 5.5m, start all slurry supply pumps to

supply slurry to the each absorber.

11.8.2 Upkeep of the wet miller

11.8.2.1 During the long time shut down, the bowl shall cool and shrink gradually, and the journal

will slip on the bearing bushing. To reduce the friction and the axial tensile force induced by

the bowl shrink, the LP oil pump should automatically supply oil for 3mins in every other

30mins after 24hr shut down so that a certain oil membrane thickness can be maintained

between the journal and the bearing bushing.

11.8.2.2 During the shut down in winter, the cooling water in the water cooler should be

discharged entirely to avoid pipe frozen and split.

11.8.2.3 Generally, the material feeding should be stopped before shut down and stop the wet

miller operation as soon as possible.

11.8.2.4 If the wet miller will shut down for a long time, the steel balls should be spilled out to

prevent the bowl from deformation.

11.8.2.5 The operators should comply with and pay attention to the following matters during

normal operation:

11.8.2.6 The wet miller can not operate for long without feeding so as not to damage the lining

plate and consume the medium (otherwise there should be water in the milling bowl).

11.8.2.7 To feed equally is the one of the most important conditions for the wet miller to achieve

the most working efficiency, so that the operators should ensure the feeding equality of the

materials.

11.8.2.8 To exam the friction conditions of the lining plate and the medium inside the wet miller

bowl, change the lining plates which has been worn and split in time, to screw and

exchange the bolts which are not firm and fractured to prevent bowl from being worn out.

11.8.2.9 Inspect and ensure from time to time each lubricating point (including the main shaft

bearing sealing ring) has enough and clean lubricating oil (fat); to clean the oil station

return oil strainer once every month at least; to examine the lubricating oil quality every

half a year and replace by the new oil when necessary.

11.8.2.10 To inspect the wet miller big & small gears mesh conditions and the junction bolt

tightness, and there is no abnormal vibration and sounds in gear box operation.

11.8.2.11 To regulate the steel ball quantity and stage configuration based on the milling

materials and products granularity requirements; to add steel balls into the wet miller in

time so as to keep the best state of the steel balls in the wet miller; the steel balls added


Rev.: A



should be of the maximum size of the initial adding (but if there is long time without adding

new balls, smaller size balls can be added).

11.8.2.12 The protective cover for wet miller coupling & clutch and other safety protection

device should be intact and caution boards should be hung at the dangerous area.

11.8.2.13 Any proper disassembly or maintenance work is forbidden when the wet miller is in

operation. When it is necessary to enter the bowl, the operation order sheet should be

applied & issued, the safety measurements have been strictly followed and the monitoring

measurements have been handled well.

11.8.2.14 During the inspection and maintenance of the wet miller and its auxiliaries, the LP

illumination equipments should be used. When conduct welding to the parts on the wet

miller, necessary earthing protection should be noticed to avoid current burning gear

surface and bearing bushing surface.

11.8.2.15 The cooling water temperature and flow for the main shaft and each oil station

should be meeting with the requirements that the bushing temperature does not exceed

the permitted temperature and can be adjusted appropriately.

11.8.2.16 Periodic inspection Manual should be worked out during the application procedure,

and the equipments maintenance should be conducted.

11.8.2.17 To upkeep the equipments carefully, clean the ambience, and ensure there is no

water leakage, slurry leakage, oil pollution, screw untightness and sundries next to the

equipments.

11.8.3 Shut down of the limestone preparation system

11.8.3.1 Stop the scale feeder.

11.8.3.2 Adjust the setting values of the 2 recover water doors at the wet miller inlet and slurry

tank to 0m3/h and then close the doors.

11.8.3.3 Adjust the wet miller recirculation slurry tank to the normal and maintain the wet miller

slurry pump operate for some time to dilute the pipe density.

11.8.3.4 To adjust the wet miller slurry tank level to the low position and ensure the wet miller

inside materials decrease obviously.

11.8.3.5 Start P oil pump (jacking oil pump with establishment of oil pressure), stop wet miller and

then stop the jacking oil pump after 3-5min.

11.8.3.6 Stop the wet miller big gear ejecting oil pump and spray fan.

11.8.3.7 Stop the bearing lubricating system. (Keep the lubricating oil system in operation in

winter)

11.8.3.8 Invoke the cleaning function group when shut down the wet miller recirculation pump:

11.8.3.8.1Stop the wet miller recirculation pump.

11.8.3.8.2Close the wet miller recirculation pump outlet door.

11.8.3.8.3Open the wet miller recirculation pump cleaning door.

11.8.3.8.4Close the wet miller recirculation pump cleaning door and close the inlet door.

11.8.3.8.5Confirm the limestone eddy station is clean after cleaning. In 10.5.3.3 the wet miller

slurry discharge dilatation has been conducted, but manual cleaning shall be

conducted again when necessary.


Rev.: A



11.8.3.8.6The limestone slurry reservoir mixer can shut down only when the tank level is at 2.0m,

otherwise it can not be stopped.

11.911.9 LIMESTONE HANDLING SYSTEM DESCRIPTION

Limestone with particle size of 5-20mm will be supplied by the Owner through barges of

100-200T capacity near to the plant limestone unloading station. The limestone consumption

for both phases (4x300 MW) has been assessed as about 120,000 t/year. The scope of work

start from Limestone unloading from the barge, conveying to Limestone storage shed

(common for 4 Units), further conveying to limestone Silo.

The limestone supply system shall include but not be limited to the following: Common

unloading facility (4 Units) at jetty complete with bucketed rotary crane of capacity not less

than 70 T/Hr with bucket of capacity 2 m3. One (1) limestone storage shed having storage

capacity of twelve (12) days (about 6000 tons) consumption with the worst sulfur coal at

BMCR for 4 Units. Bridge type grab crane with the capacity of 60 T/Hr will be provided for the

limestone storage shed. One (1) 100% duty limestone supply conveyor system common for 4

Units. The specification of belt conveyor from unloading station to limestone storage shed and

to the limestone Silo is of width B=500mm, speed v=1.0m/s, capacity 60t/h, All Conveyors will

be one streams,. For the flow diagram of limestone handling system see DWG

F4091S-M0104-02.

11.9.1 Startup of limestone belt conveyor

11.9.1.1 All belt conveyors are started in reverse flow sequence.

11.9.1.2 The changeover switch on local control & operating box is place at Local position,

interlock switch is place at correct Interlock position, startup of belt conveyor is strictly

prohibited without turning on interlock.

11.9.1.3 Ring the alarm bell before startup. After 30 seconds, startup operations are

performed by pressing Start button. If the startup is failure, the reason shall be found out

immediately. Startup again is permitted only after the fault is removed. Interval between two

operations must not be less than 15 minutes.

11.9.1.4 After limestone loading is finished, press Stop buttons on various belt conveyors

in forward limestone flow sequence to stop the belt conveyors.

11.9.1.5 On-load start or stop of belt conveyor is forbidden except for special condition.

11.9.1.6 If the belt conveyor is stopped due to tripping, the reason shall be found out.

Startup again is permitted only after the fault is removed. Press Start button, the

conveyor will operate and operating indicator is illuminated after sound-light alarm

device sounds for 30 seconds.

11.9.2 Shutdown of limestone belt conveyor

11. 9.2.1 Shutdown operations may be performed only if shutdown instruction has been

received after local test is finished.

11.9.2.2 Press Stop button, the belt conveyor will stop, stop indicator is illuminated .

11.9.2.3 After confirming the stop of belt conveyor, place the selector switch on local control

box at Remote Control position.

11.9.2.4 After confirming the test run of belt conveyor is satisfactory, equipments are ready


Rev.: A



for operation.

11.9.3 Notices for operation

11. 9.3.1 During operation of the equipments, any maintenance and defect elimination jobs

must not be carried out.

11.9.3.2 During operation, changes in current indicator of all operational equipment shall be

monitored closely, the limit must not exceeded.

11.9.3.3 During operation of the equipments, care shall be taken to watch operating

conditions of all rotational equipments, and oil level in reduction gearbox shall be

normal. Temperature shall be ≤75,vibration ≤0.01mm,all bearing temperatures

≤85. If the above data is approached or reached, the shift supervisor shall be

reported promptly to take preventive measures.

11.9.3.4 The belt conveyor shall be free from serious misalignment, slippage, tearing etc. All

idler and roller shall be flexible in rotation, free from jamming and abnormal sound.


Rev.: A



12 Air Compressor System Operation Manual

12.1 Direction for use of control panel

1) Θ—startup button —stop button

The three indicator lamp indicates: ο---operating ο---fault ο---power supply

The operating indicator lamp and power indicator lamp are on in normal operation, and

the fault indicator lamp is on when fault happens in operation.

2) Emergency button: the red button below the display panel

a) Press the button when fault appears to emergently stop the air compressor; the fault

lamp is on;

b) The reset screen appears when the emergency button is pulled out; press F3 to

reset.

3) Modify the high/low limit of the pressure

a) Press F1 and the main menu (meau) screen appears;

b) When the main menu appear after pressing F1 button, press the down arrow until

the Modify Params appears; press the horizontal arrow until Parameters appears,

and then press the horizontal arrow again to modify the low limit of the pressure.

c) Press F2 button to carry out modification; use up and down arrow to modify the low

limit, and press F1 to confirm; then press F1 to return. The high limit is preset by the

manufacturer, and is not allowed to be modified.

d) Continuously press the F1 button can return to the main menu (meau) screen, and

F3 button can also be pressed to reset

4) Press F1 button and up, low and horizontal arrow for browsing the main menu, check the

startup times, operation time, oil temperature, differential pressure and other parameters.

12.2 Instrument-use air compressor operation

1) The high limit of pressure of No.1 to four air compressor is set as 0.8MPa, and the low

limits are set as 0.7MPa, 0.69MPa, 0.68MPa and 0.67MPa in sequence.

2) In normal operation and conditions, No.1 air compressor (with the high limit of 0.8MPa

and the low limit of 0.7MPa) and No. 2 air compressor (with the high limit of 0.8Mpa and

the low limit of 0.69MPa) are in operation, and the No.3 and No. 4 air compressor are in

reserve. No. 1 air compressor will automatically stop when the system compress air

pressure is higher than 0.8Mpa; when the system compress air pressure is lower than

0.8Mp, No.1 air compressor is automatically started; when the system compress air

pressure is lowered to 0.69Mpa, No.2 air compressor is started and operates in

synchronization with No.1 air compressor; and the rest may be deduced by analogy.

12.3 Air compressor operation maintain

1) Check the room temperature and the ventilation before starting the air compressor, and

the room temperature should be less than or equal to 46 degrees Celsius.

2) Check whether the oil level is normal or not, and whether the automatic water discharge

valve is open or not.

3) Check oil leakage inside the air compressor and whether the machine has abnormal

noise or not after the air compressor is started.


Rev.: A



4) Frequently open the manual water discharge valve and check discharge water content

and oil content.

5) Periodically clean the filter according to the differential pressure (not more than 0.08Mpa)

in the air compressor.

6) The red emergency shutting down button should not be pressed randomly unless

emergency happens.

7) When the air compressor is shut down, the outlet valve of the air compressor should be

closed, the manual water discharge valve should be opened and the remained water

inside the air compressor should be drained completely.

12.4 Air compressor shutdown protection

1) Main motor overload protection.

2) Emergent shutdown protection.

3) Fan overloads protection.

4) High oil temperature protection (alarms at 100 degrees Celsius and shut down at 110

degrees Celsius).

12.5 Air compressor dryer operation maintain

1) Dryer startup and shutdown operation

a) Switch the startup-shutdown position to the startup position, and when the dryer is

normally started, the local operation indicator lamp is on (green).

b) When trying to stop the dryer, switch the startup-shutdown position to the shutdown

position while the pressure of the two dryer tank is balanced as much as possible,

and then the dryer is shutdown..

2) Dryer maintenance

a) The dryer should be started or shutdown at pressurized conditions.

b) The filter indicated P8P is used for dedust; the filter indicated P8C is used for oil

removal.

c) The dryer filter should be periodically blowdown; the cartridge of the filter should be

replaced when the differential pressure gauge is more than 0.1MPa (the gauge

shows red color)

d) In the operation process of the dryer, the dryer tank has pressure, while the

regeneration tank is pressure free. The two tanks are shifted every five minutes.

13 Fire-fighting System Operation Manual

13.1 Overview

Fire-fighting water system comprises a fire-fighting pump, stabilized pressure pump,

fire-fighting pool, high and low pressure fire-fighting pipe network, invalve and outvalve fire-fighting

hydrants, sprinkler extinguishment facilities and others, and also provides foam fire-fighting water

to the oil depot region. Fire-fighting pump only provides high-pressure fire-fighting water.

13.2 Startup mode of fire-fighting pump

In addition to the self startup according to the chain conditions, the fire-fighting pump can start

and stop by the remote controller of the CRT in the chemical control room (the switch of the

fire-fighting pump of the local control panel is placed on the remote control position) and can also


Rev.: A



start and stop on the site (the switch of the fire-fighting pump of the local control panel is placed on

the local position).

13.3 Operation mode of fire-fighting pump

At present the operation mode of the fire-fighting pump is that the stabilized pressure pump

operates for a long term to maintain the pressure of the high and low pressure fire-fighting pipe

network (the stabilized pressure pump is switched per week regularly), and the fire-fighting pump

will automatically start and stop according to the chain conditions when the pressure of the

fire-fighting pipe network declines.

13.4 Chain conditions of fire-fighting pump

1) The pressure of the fire-fighting system is maintained at 1.06 MPa (adjustable) by the

fire-fighting atmospheric pressure stabilizer.

2) When the pressure of the high-pressure fire-fighting pipe network is less than 0.8Mpa

(adjustable), the electric fire-fighting pump is input.

3) When the electric fire-fighting pump fails, the diesel fire-fighting pump is automatically input.

4) When the pressure of the high-pressure fire-fighting pipe network is more than 1.06Mpa, the

fire-fighting pump stops.

5) When the liquid level of the fire-fighting pool is below 1.5 m, two fire-fighting pumps and two

stabilized pressure pumps stop.

13.5 Diesel fire-fighting pump system

Diesel fire-fighting pump body includes a diesel engine, heat exchanger, expansion water

tank, cooling pipeline, flexible coupler, water pump, diesel tank, storage batteries and control

panel and other equipments. Water pump is connected with the diesel engine through the flexible

coupler directly.

13.5.1 Preparations for operation and use

1) Make preparations for operating and using the supporting equipment of the diesel engine

pumping group, such as: oil, water and electricity are in the proper state.

2) Ensure that all cable connections are correct and various switches of the control screen are in

the correct position before operation.

13.5.2 Startup of diesel fire-fighting pump

1) The diesel fire-fighting pump control panel is powered on

2) After the preparatory work is completed, turn on the “Power” switch on the panel (DC control

power supply, or switch from zero position to manual or automatic position), when the DC

control circuit of the diesel engine is powered on, the “power” indicator light is on, and at the

same time the monitor will display the rotation speed, water temperature, oil temperature and

pressure of the diesel engine.

3) Start the diesel fire-fighting pump manually

a) Place the “Manual\automatical” switch on the panel to the “Manual” position, when the

diesel pump group enters into the manual control state.

b) Preheating: when the weather is cold, the pump is preheated prior to startup, the

preheating switch is connected, the preheating indicator light is on, the cooling water of

the diesel engine begins heating, and there is a temperature switch of the water heater,


Rev.: A



and the water temperature can be controlled to a certain range. The diesel engine

stops heating if the preheating switch is disconnected.

c) “EDC” power supply: press “EDC Power Supply” button before starting the pumping

group, when “EDC power supply” indicator light is on and an electric spraying controller

is powered on. (Note: the follow-up operations will not be conducted only until “EDC

power supply” indicator light is on)

d) Startup: press “No.1 Battery Startup” button of the diesel engine, and the startup

contact of No.1 Battery is pulled in, when the No.1 Battery provides power supply; if the

No.1Battery lacks of electricity, press the “No.2 Battery Startup” button, when the No. 2

Battery starts and the contact is connected, the No.2 Battery provides power supply, a

motor starts to drive the diesel engine to rotate, and then the operation light is on after

the diesel engine starts successfully. The startup button can be released at this time, a

second startup operation is conducted after the interval of 5 to 10 seconds, and the

appropriate inspection should be carried out if three consecutive startups fail.

e) Speedup: press the “Speedup” button after the diesel engine starts, and the diesel

engine will operate at high speed, and the rotation speed of the diesel engine through

the potentiometer of the screen is adjusted to operate in the rated state or the

necessary rotation speed.

f) Idle speed: press the “Idle speed” button to allow the diesel engine to operate at idle

speed.

g) Stop: press the “Stop” button after it operates at idle speed for three minutes, and

the“Stop” light is on, the diesel engine stop and then the button is released.

13.5.3 Automatic control of diesel fire-fighting pump

1) The control panel automatically works if “Manual/automatic” switch is placed on “Automatic”

position.

2) In the automatic mode, the controller gives out “No.1 Battery Startup” order of diesel engine

when there is automatic startup signal, and meanwhile EDC power supply is automatically

connected so that the diesel engine starts, the controller can give out three consecutive “No.1

Battery Startup” orders if it fails to start, the controller gives out “No.2 Battery Startup” order to

activate the diesel engine if it is not successful in the three times, the controller can give out

three consecutive “No.2 Battery Startup” orders if the activiation fails, and the controller gives

out sound and light alarm signal due to failing in activiation if the activiation is unsuccessful.

After the activiation is successful, the controller will control the diesel engine to run at idling

speed for about five seconds, and then give out idle speed order, so that the diesel engine

operates at the rated rotation speed.

3) During operation of the diesel engine, the controller will give out idle speed order if it receives

automatic shutdown signal, to make the diesel engine run at idle speed for about three

minutes, and then the controller will give out shutdown order so that the diesel engine stops

completely.


Rev.: A



13.6 Descriptions of fault and alarm of diesel engine fire-fighting pump

1) In operation, if the cooling water temperature, oil temperature, oil pressure and rotation speed

of the diesel engine are beyond the limits, the control panel will give out sound and light alarm

signal and the alarm signal light will give out flashing bright, and at the same time a flashing

LED on the corresponding digital display corresponding to the overranging parameters is also

on, indicating the parameters are beyond the limits. After pressing “Silencer” button, the

sound alarm signal disappears, the light alarm signal is converted to matt indication and

always maintains until the parameters have resumed to the normal. When the overranging

parameters are up to the stopping values, the controller will give out sound and light alarm

signal while giving out stopping signal so that the diesel engine stops emergently due to

failure. At this time, the sound alarm signal can be eliminated by pressing “Silencer” button; as

the light alarm signal has memory function, it will remain until the failure is eliminated, and it

will disappear after pressing “Reset” button.

2) In standby, the alarm signal of a storage battery with low voltage is given out if the voltage of

the storage battery is low.

3) In operation, the sound and light alarm signal of the liquid level is given out if the liquid level is

low.

4) In standby, the alarm signal of charging failure is given out if the charger has no DC

rechargeable power output.

13.7 Descriptions of function buttons

1) “Reset”: When there is fault alarm and the diesel engine stops working, the diesel engine fails

and need be ruled out; press first “Reset” button after the person on duty troubleshoots when

re-starting the generating unit, so that the control screen undoes the alarm signal and is in the

alarm state. In addition, when the control power supply is just connected or the diesel engine

starts, if there are any unusual characters to appear on the digital display, the control panel is

not working properly, this is usually caused by excessively low voltage of the control power

supply, and the control screen can work properly by pressing the “Reset” button. Note: it is

prohibited to press the “Reset” button during normal operation of the diesel engine.

2) “Self-check”: press the “Self-check” button, when the control screen implements the

self-check program. The control screen will simulate the change in the parameters of all

working conditions in the self-check process, and a sound and light alarm and stopping signal

is given out when reaching the overranging alarm and stopping value, and the sound and light

alarm signal can be eliminated by pressing the “Silencer” button and thus light alarm becomes

smooth light. Accordingly, users can check whether the overranging fixed value is correct and

the protection functions meet the requirements.

3) “Silencer”: the control screen can shown a sound and light alarm signal after there are all

kinds of faults. The sound alarm disappears after pressing the “Silencer” button, and all the

light alarms turn into smooth light and continues to work normally.

4) “Time”: when pressing the “Time” button, the total operation time will be shown on the location

of speed display and the original speed display will restore after several seconds.


Rev.: A



13.8 Inspection items in the operation of diesel pump group

1) Check whether the connecting studs of the diesel engine, water pump and public base are

loose;

2) Check whether the connecting studs and screws of all connecting parts are loose;

3) Check whether the liquid level of the fuel tank is normal and there is leakage in the system;

4) Check whether the liquid level of the oil pan maintains the normal;

5) Check whether the lubrication pre-heating device works normally;

6) Check whether the pressure of the lubrication pre-supply pump in operation is normal;

7) Check whether the water level height of the expansion water tank is normal;

8) Check whether the cooling water preheating device works normally;

9) Check whether there is leakage phenomenon in the cooling water system;

10) Check whether the storage battery starts normally, its voltage is adequate and the charging

device works properly;

13.9 Regular maintenance of diesel pump group

1) Regular maintenance

a) Start the machine once every two weeks and operate it for 15 minutes to check whether

the machine set and all devices maintain still a good state, and conduct a simulation

test of the automated devices to check whether they maintain still a good state.

b) Pay attention to heat preservation of diesel engine and water pump in the cold season

to prevent the equipment from being frozen badly due to low water temperature.. The

room temperature should maintain 5 above.

c) Before the storage battery is used for the first time, it is charged after the battery liquid

is filled.

d) Check the voltage of the diesel engine for starting the battery and the height of storage

battery electrolyte. Maintain the storage battery, storage battery terminals and wiring to

be clean and contact well.

e) Check the siliencer and exhaust pipeline, remove carbon deposition and prevent sparks

from generating.

f) Check whether the water pump packing seal is worn, and replace it timely if necessary.

Check whether the lubricating resin of the water pump is consumed.

g) The fuel storage tank should always be full as much as possible but be definitely not

less than 50% of the fuel tank capacity. When refueling, it should be ensured that

moisture content and impurities are excluded.

2) Switching and maintenance mode

a) When it can not automatically be put into operation and the fire-fighting water is

required for fire, the startup mode should first be switched to the manual mode. The

pump selection switch turns to the pump to be activated and then the startup button is

pressed.

b) Trial run # 1 and # 2 electrical fire-fighting pump every Monday on day shift. Trial run

the diesel fire-fighting pump on the 10th and 25th day monthly.


Rev.: A



14 Appendix

14.1 Twenty-five Key Requirements to Prevent Serious Accident and Failure in Electric

Power Operation (Chemical Part) Issued by China Grid

14.1.1 Prevention from large area corrosion

1) Be in accordance with “Quality Criterion of Water and Steam for Generating Unit and Steam

Power Equipment” (GB12145—1999), “Guide for Chemical Supervision of Water and Steam

in Thermal Power Plants” (DL/T561—1995), “Opinions of Corrosion of The condenser Copper

Alloy Tube of Thermal Power Plant” and “Correction Measures and Requirements to Prevent

Corrosion of the boiler Structure in Power Plant” and other relevant Manual strictly and

strengthen chemical supervision.

2) Unqualified water is strictly prohibited to enter into the boiler and unqualified steam is strictly

prohibited to mix. Acid wash water-cooled wall in a timely manner if deposit can meet pickling

requirements to avoid corrosion or hydrogen brittleness. Stop and protect boiler according to

requirements of “Guide for Lay-up of Thermal Power Equipment in Fossil Fuel Power Plant”

(SD—223—1987) to avoid shutdown and corrosion of furnace tubes.

14.1.2 Prevention from tube explosion of pressure vessel

Color of gas bottles in use is strictly prohibited to change to avoid misuse. Take measures to

not dump gas bottles and place steel cylinders containing liquid chlorine horizontally and

temperature of locations to place liquid chlorine or ammonia shall meet requirements.

13.1.3 Prevention from motor damage

Water quality of water-internal-cooling generator shall be within regulated scope and it is

allowed to add corrosion inhibitor in water during operation of units whose power is equal to or less

than 125MW to slow up copper tubes but PH value must be more than 7.0.

14.2 General Principle of Electrical Part and Pump

14.2.1 Inspection items before power on the motor are as follows:

1) Inspect integrity of electrical loop and equipments with terminated work order and put them

into protection devices.

2) Fix connecting wires of the motor and cable shell firmly.

3) Fix protective cover of cable head of the motor and blower cover firmly.

4) Check if there is oil in the startup device of wire wound the motor with normal oil level or not.

5) Guarantee no water in the cold air chamber if the motor is cooled by air.

6) The motor and mechanical equipments shall be intact without startup obstacle so that they

can meet startup conditions.

7) Guarantee sufficient oil in the bearing oil level and cover then place the oil system into

operation if it belongs to reinforced lubrication. It is also required to open cooling water if

bearing is cooled by water.

8) Supply cooling water if the motor is cooled by air cooler.

14.2.2 Inspection items during operation of the motor are as follows:

1) Fix connecting wires of shell and protective cover of cable head firmly.

2) Check if there is spark for slip ring or commuter of DC the motor and cover protective cover of

commuter and slip ring and handle of slip ring can not exceed dangerous mark.


Rev.: A



3) Guarantee no obstacle in ventilation hole of the motor and normal operation of air cooler

without water leakage.

4) Guarantee no accumulated ash and water on the motor and remove sundries such as ash,

powder and water vapor and so on which may enter into the motor and startup devices in a

timely manner.

5) Monitor and compare temperature of the motor shell and bearing under the same ambient

temperature and find out reasons if there is abnormal temperature rise and take measures to

strengthen ventilation and monitoring and reduce load if necessary. The maximum monitoring

temperature of the motor coil and iron core can not exceed the temperature under any

circumstance according to the Manual of manufacturer and it can not exceed 105 and

temperature rise can not exceed 65 if there are no Manual of manufacturer. The maximum

temperature of sliding bearing can not exceed 80 (and temperature rise can not exceed

40) and that of rolling bearing can not exceed 100(and temperature rise can not exceed

60).

6) In general, the motor shall operate within variation scope of －5％ to ＋10％ of rated

voltage with constant rated output (which is between 5.7kV and 6.6kV and voltage is

between 360V and 420V). Unbalanced value of voltage in phases during operation under

rated output can not exceed 5% and pay attention to heating and vibration and so on of the

motor during unbalanced operation period of voltage.

7) Current of the motor can not exceed ＋5％ of rated value during normal operation and

guards shall strive to reduce it to rated current within 15 minutes if it is exceeded by ＋5％ to

＋10％.

8) Measured amplitude of every bearing during operation of the motor can not exceed following

values:

Rated rotary speed

(r/min)

3000

1500

1000

750 and below

Amplitude

（dual-amplitude）(mm)

0.05

0.085

0.10

0.12

14.2.3 Inspection items during operation of cables are as follows:

1) Guarantee intact cover plate of cable trench and no water, oil or other sundries in the cable

trench.

2) Check if pavement with laid cables is normal or not. Check if stakes are intact without

excavation trace or not.

3) It is not allowed to pile rubbles, slag, building materials, lumpish matters, acid or alkaline

excrement or stack swallow hole and so on along cable lines.

4) Check if cable head is not heated without casing rupture and discharging trace or not.

5) Guarantee intact ventilation, drainage and lighting facilities and so on in cable trench or cable

channel and check if fire prevention facilities are intact or not.

6) Temperature of cable sheath can not exceed permissible normal value and load current can

not exceed permissible value.

7) Pay attention to water level of cable trench in summer or thunder storm season.


Rev.: A



13.2.4 General operation requirements of the motor

1) Guards of mechanical equipments driven by every motor shall master power supply mode of

the motor and operation mode of relay protection and automatic device.

2) Every motor shall have rated nameplate of original manufacturer on the shell and repair

personnel shall supplement nameplates in a timely manner if they are lost.

3) Paint on shell of the motor, ventilation pipes and metallic structure and name and enumerate

equipments according to the unit.

4) The motor and machines shall have arrow marks to indicate rotation direction.

5) Outgoing lines of the motor and cable heads and exposed rotary parts shall have firm barrier

or protective guard.

6) Shell of the motor and startup device shall be grounded according to the Manual of “Technical

Specifications of Grounding” and it is strictly prohibited to work on grounding body of the

motor in operation.

7) Standby the motor shall be started at any time and it is required to prepare for periodic chart of

shifting operation or trial operation of the motor. Every guard shall operate the motor

according to periodic chart of shifting operation or trial operation strictly.

8) The motor with normal switchover and startup conditions shall be started according to

switchover cycle and measure insulation resistance if volume of the motor without startup

conditions is more than 50kW and it is stopped for 10 consecutive days or it is necessary to

measure insulation resistance before startup. (There is no need to measure insulation

resistance with normal heater input of the motor with moisture-proof heater but repair

personnel must measure insulation resistance after repairing the motor or cables.)

9) Put standby the motor into trial operation for every 10 days to prevent it from being affected

with damp if it is installed in wet locations.

14.2.5 Measurement Manual of insulation resistance of the motor are as follows:

1) Insulation of high-voltage the motor shall be measured by magneto-ohmmeter of 2500V and

insulation resistance can not be less than 1 mega ohm for every 1000V and that of

low-voltage the motor whose voltage is equal to or less than 380V shall be measured by

magneto-ohmmeter of 500V and insulation resistance can not be less than 0.5 mega ohm for

every 1000V. (Insulation resistance of DC the motor can not be less than 0.5 mega ohm.)

2) Insulation resistance of the motor must be measured under cold standby status of loop.

3) Insulation resistance must be measured after the motor is affected with damp, smoked by

steam or poured by water.

13.2.6 Operation principle of power failure and supply of the motor:

1) Supply power to the motor by primary loop and operate according to sequence of power knife

switch and switch and operate according to reverse sequence during power failure.

2) Check if control fuse is placed in its accurate position or not during power supply. That is,

check if green lamp is on or not then take control fuse down during power failure.

3) Selection switch shall be in remote control position according to operation mode of switch

panel of the motor.

4) It is strictly prohibited to use gauge and indicator light as the only judgment basis of opened or


Rev.: A



closed switch.

5) Close knife switch and inspect whether blade is in closing or opening position if applicable.

6) Remote operators can not start the motor until contacting local guards if its knife switch is

closed remotely. Local guard shall keep the motor until its rotary speed can increase to rated

rotary speed. Monitor startup process according to ampere meter if applicable and inspect the

motor body according to detailed conditions after startup.

14.2.7 Permissible startup times of the motor with squirrel cage type rotor shall be in accordance

with following Manual strictly.

1) The motor whose volume is equal to or more than 100kW is allowed to start up twice

continuously under cold condition and once under hot condition.

2) The motor whose volume is less than 100kW is allowed to start up for three times

continuously under cold condition and twice under hot condition.

3) Startup times of the motor with accident treatment whose startup time is not more than 3

seconds can be increased by one.

13.2.8 Definition of the motor status:

1) Cold condition means that stalling time of the motor is equal to or more than 30 minutes.

2) Thermal condition means that stalling time or attenuation time of startup current of the motor

is less than 30 minutes.

3) Attentions to startup of motors as follows:

4) Start up the motor one by one and it is usually not allowed to start up two or more the motors

with large volume on one bus at the same time. It is required to contact integration control

personnel to adjust bus voltage before startup of the motor with large volume.

5) It is strictly prohibited to close the knife switch again under normal conditions if switch can not

be closed or before finding out tripping reasons during startup of the motor. It is required to

open power switch of the motor and find out reasons if startup time exceeds general startup

time of the motor and current has not been attenuated to normal value.

6) Open power switch of the motor and find out reasons instantly if the motor has noise without

rotation or it can not reach normal rotary speed after closing knife switch of the motor.

14.2.9 Common faults, judgment and treatment of electrical equipments

14.2.9.1 Stop the motor instantly if there is any circumstance:

1) Instant personal injury caused by accident of the motor if necessary;

2) Strongly vibrated or damaged motor or mechanical parts;

3) Fired or scorched motor;

4) Rapid temperature rise of the motor or bearing which has exceeded limit and rapid declination

of rotary speed;

5) The motor. flooded

14.2.9.2 The motor does not start up

1) Possible reasons

a) Inaccurate position of conversion switch;

b) Inaccurate interlocked position under program control status;

c) No reposition after protection motion of the motor;


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d) Power failure or broken fuse protector;

e) Damaged contact point of AC contactor which can not be suction.

2) Treatment method

a) Turn interlocked switch to the correct position.

b) Ask local personnel to check if the motor is excellent or not.

c) Supply power after resetting for thermo-couple motion.

d) Ask repair personnel to inspect and treat for other electrical protection motions.

e) Replace fuse or supply power again.

f) Find out reasons and remove mechanical faults.

14.2.9.3 Trip during operation of the motor

1) Possible reasons

a) Excessive current and over load;

b) Failure of startup switch;

c) Unclosed outlet valve or excessive opening;

d) Broken phase of three phases of grounding wires;

e) Abrasive or jammed rotary parts;

f) Friction between impeller and pump shell;

g) Bent shaft and damaged bearing;

h) Vane jammed by sundries;

i) Power failure.

2) Treatment method

a) Startup of standby motor;

b) Load adjustment;

c) Repair and treatment.

14.2.9.4 Larger noise during operation of the motor

1) Possible reasons

a) Single-phase operation;

b) Unbalanced three-phase current of the motor;

c) Uneven air gap between stator and rotor of the motor;

d) Collision or sundries between blower and cover;

e) The motor is installed roughly or loose foot screw;

f) Bearing problem.

2) Treatment method: Stop operation instantly and contact repair personnel for treatment.

14.2.9.5 Excessive temperature rise of the motor or burnt winding

1) Possible reasons

a) Overload for a long time;

b) Trouble of heat engine;

c) Broken one-phase fuse;

d) Poor ventilation and heat elimination;

e) Local short-circuit or grounding of stator winding;

f) Other reasons such as inflexible driving mechanism;


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14.2.9.6 Heated bearing of the motor

1) Possible reasons

a) Incorrect installation and excessive vibration;

b) Inconsistent gap between crankshaft, bearing and end cover or improper installation and

excessive axial float.

c) Poor lubrication or incorrect oil quality.


14.2.9.7 Air switch of main power which can not be closed

1) Possible reasons

a) Emergency stop button not reset;

b) Damage trip coil or not voltage;

c) Damaged tripping mechanism not reset.

2) Treatment method: Contact repair personnel for treatment.

14.2.9.8 Large noise after closing knife switch of main power switch

1) Possible reasons

a) Insufficient voltage of trip coil;

b) Unadjusted tripper and excessive gap between suctioned armature iron;

c) Obstacle to armature iron after tightening switch cover.


13.2.9.9 Noise after suctioning contactor

1) Possible reasons

a) Insufficient suction of coil;

b) Poor suction problems such as blocked armature iron or inaccurate alignment;

c) Ruptured short-circuit ring;

d) Excessive axial offset.


14.2.9.10 Electric leakage of shell

1) Possible reasons

a) Low insulation resistance of the motor;

b) Rupture or aging of outgoing lines or connection between connecting plug and shell;

c) Damaged bottom plate of terminal or local connection in the winding;

d) Poor grounding of shell.


14.2.10 Operation of the water pump

14.2.10.1 Inspection before startup of the water pump

1) Finish repair and work order with written records for repair equipments.

2) Supply power to electrical valve of pump inlet and guarantee intact valve and normal

operation without leakage.

3) Guarantee intact water pump without foreign matters which may obstacle operation.

4) Check if manual segregation valve is in correct position or not according to conditions of the


Rev.: A



water pump.

5) Check if bearings can be connected firmly with intact protective cover and firm fixation without

loss foot screw or not.

6) Guarantee intact gauges in pump outlet and manual valve of the pressure gauge is in closed

position and indicators of flow and pressure converters are zero.

7) Guarantee firm supply of water supply pipes of the water pump and intact insulation layer.

8) Bearing oil level of the water pump shall be between 1/2 and 2/3 and oil shall be transparent

without sundries.

9) Guarantee sufficient lighting on the site and excellent ventilation and complete fire prevention

measures.

14.2.10.2 Operation during operation of the water pump

1) Guarantee normal operation sound and excellent integrity during operation of the water pump

without leakage of the water pump.

2) Bearing temperature of the water pump can not exceed ambient temperature which is 35 and the maximum temperature can not exceed 85 and vibration shall be less than 0.08mm.

Flange temperature shall be the same to that of pump body and drainage pipes shall be

smooth after dripping water for 10 to 20 drips for every minute.

3) Guarantee firm tightening piece and intact protective cover and foundation bolt can not be

loose.

4) Operation of remote and local gauges shall be normal and pressure shall be within the scope

of regulated pressure and current is less than rated value. Flow shall be within the regulated

scope and flow, pressure and current shall correspond mutually.

5) Guarantee correct position and indication of every valve ad excellent appearance of valve

without water leakage or misplacement.

6) Guarantee normal operation of pressure and flow converters and correct fixation of

connecting wires without water leakage.

7) Guarantee no inversion for standby pump.

8) Erect support of water supply pipes without distortion or deformation of expansion joints and

guarantee excellent insulation layer without water leakage for system pipes.

14.2.10.3 Common faults, judgment and treatment of the water pump

14.2.10.3.1 Abnormal sound of the water pump

1) Possible reasons

a) Damaged impeller, bearing or loss rotary parts.

b) Foreign matters suctioned into the water pump.

c) Operation under overload.

2) Treatment method

a) Integral load;

b) Stop the water pump and contract repair personnel for treatment.

14.2.10.3.2 Large vibration of the water pump

1) Possible reasons

a) Air in the water pump or insufficient opening of outlet valve;


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b) Loose foot screw;

c) Unbalanced motor and axial line and severely abrasive bearing and rotary parts.

d) Loose or damaged parts of rotary parts;

e) Operation under overload.

2) Treatment method

a) Remove air in the water pump and open the valve of large opening;

b) Operate under reduced load;

c) Contact repair personnel for treatment.

14.2.10.3.3 No water outlet or reduce water supply quantity of the water pump

1) Possible reasons

a) Non-hermetic water absorption pipes with air;

b) Unexhausted air in the water pump;

c) Jammed water passageways;

d) Low rotary speed and reverse direction of the motor;

e) Damaged impeller key;

f) Water source problems (such as low water level and so on);

g) High pressure of main pipe and little water consumption;

h) Unopened inlet valve or shed core.

2) Treatment method

a) Gas-tight pipes;

b) Startup again after exhausting air;

c) Inspection and dredging of passageways;

d) Inspection of power lines;

e) Repair and treatment;

f) Sufficient water source;

g) Some pumps are out of operation;

h) Open the inlet valve or contact repair personnel for repair.

14.2.10.3.4 Overheated bearing or with noise

1) Possible reasons

a) Poor quality or low oil level;

b) Improper gap between bearings;

c) Abrasive bearing;

d) High oil level;

e) Operation under overload.

2) Treatment method

a) Turn down outlet valve and reduce the load;

b) Stop the water pump and replace or add oil;

c) Contact repair personnel for repair.

14.3 General Principle of Chemical Technology Supervision

14.3.1 Guidelines of chemical technology supervision

Chemical supervision is one of important links to guarantee safe, economic and stable


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operation of power supply equipments and its main task is to take detection measures which can

adapt power generation development and scientific management method in a timely manner to

strength quality supervision of water, steam, gasoline, hydrogen and fuel and so on to avoid and

slow up corrosion, scale, salt accumulation and inferior oil quality during operation, shutdown and

standby period of thermodynamic equipments. It is required to find out latent troubles of oil-filled

electrical equipments in a timely manner and strengthen fuel supervision to coordinate with

economic and safe combustion of the boiler to increase efficiency of the unit and find out and solve

hidden troubles caused by chemical problems in a timely manner to avoid occurrence of

accidents.

1) Insist in guideline of “precaution primary and quality first” and realistic and scientific attitude

for chemical supervision and research continuously and take new technology to enhance

supervision level.

2) Be in accordance with relevant Manual of management during system design, installation,

debugging, operation and repair phases for chemical supervision to guarantee health unit.

14.3.2 Chemical supervision during startup phase of unit

1) Operation department shall wash the condenser, water supply system and boiler in sections

by desalinated water of regulated PH value after adding ammonia and chemical deoxidizer

before startup of the unit. Next system can not be washed until every washed section is

qualified and ignition is not allowed until water quality of the boiler is qualified. Carry out

hydrostatic test after repairing boiler and it is required to use chemical desalinated water of a

certain quantity of ammonia and deoxidizer.

2) Wash samplers during startup of the unit and adjust flow according to the Manual so that

sample flow can be between 500 mL/min and 700 mL/min and temperature shall be less than

30.

3) Add deoxidizer for heating and adjust steam exhausting opening during startup of the unit to

guarantee qualified oxygen dissolved in the water supplied to boiler.

4) Strengthen sewage treatment and charging treatment during startup of the unit and

unqualified condensing water and drained water can not be recycled and unqualified steam

can not be washed and rotated. Strengthen sewage treatment treatment after startup of the

boiler if the boiler water is turbid and take measures such as limiting load, reducing pressure

and replacing water and so on if necessary until boiler water is clear.

5) Wash silicon according to requirements strictly when boosting the pressure of the boiler and

pressure of silicon dioxide in boiler water can not be boosted until meeting requirements of

next phase. Reduce pressure for operation if silicon dioxide in boiler water exceeds limit.

6) Startup time shall be calculated according to startup standard from watering of the unit to 8

hours after synchronization and result after 8 hours shall be recorded into the operation data

for statistics of chemical specialty.

14.3.3 Normal operation management of the unit

1) Please refer to the manual for quality supervision items of water vapor and control standard

and times of operation unit and water treatment system and add analysis times and items

according to detailed conditions if there is abnormal operation or during startup of the unit.


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2) Chemical operator shall fill in the daily chemical operation report every day and report it to

supervisor and chemical engineer after manual analysis and confirmation of items which

exceed the standard. Contact chemical examination group for validation if chemical operation

can not define accuracy of chemical examination result and chemical examination group shall

examine water supply and water vapor systems once every week and report it to chemical

operator and engineer if standard is exceeded so that chemical operator can treat and report

it to supervisor for treatment if unit operation needs coordination. Definite the technical

disclosure of requirements which can not be treated by the construction team with next

construction team and make records at the same time. It is required to report it to chemical

engineer, assistant branch manager and manager when it reaching the primary treatment

value and report it to chemical engineer, assistant branch manager, manager and vice

general operation engineer when it reaching the secondary treatment value and report it to

chemical engineer, assistant branch manager, manager, vice general operation engineer and

vice general production manager when it reaching the tertiary treatment value and people of

various levels shall treat according to treatment principle of abnormal water vapor in three

levels.

3) Wash sampler periodically during operation and sample periodically to remove copper and

iron according to the Manual.

4) Strengthen quality supervision of drained water and returned water and it can not enter into

the system directly without treatment. It is required to control water vapor loss in the plant and

it shall meet following requirements.

5) 300MW Unit Not more than 1.5% of rated evaporation rate

6) 135MW Unit Not more than 2.0% of rated evaporation rate

7) Take effective measures scientifically to enhance boiler water quality and reduce blow-down

rate but it can not be less than 0.3% by considering various indicators of energy-saving

supervision and chemical technological supervision comprehensively.

8) Water and vapor quality standard issued by electricity authority refers to controlled limit value

(namely, normal value) to maintain reliable and stable operation for a long time. 50% to 70%

of limit value shall be regarded as the control value of actual operation in accordance with

Manual of electricity authority to guarantee safe and economic operation of the unit on the

basis of enhanced integral level of the equipments.

9) Switch over operation equipments periodically and notify defects of equipments to

maintenance department for treatment in a timely manner to ensure that equipments can

operate normally at any time.

10) Fossil-fired power plant must have necessary on-line chemical instruments to enhance

reliability, timeliness and continuity of quality supervision of water vapor. Supplied water and

boiler water shall have PH, conductivity and phosphate radical tables and supplied water

(namely, water outlet of deoxidizer) and condensing water shall have dissolved oxygen table

and supplied water and condensing water shall have conductivity table (of hydrogen sensing).

Main stream shall have silicon and sodium tables and supplied water shall have conductivity

table (of hydrogen sensing). Prepare for other instruments one after the other according to


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detailed conditions and instruments used in the laboratory shall meet requirements in

“Compilation of Testing Methods, Standards and Manual of Water Vapor of Fossil-fired Power

Plant” and they shall be examined periodically and used within the period of validity.

11) Analyze technology and economy of chemical specialty and save medicines to reduce

material consumption.

14.3.4 Abnormal quality management of water vapor

Report deteriorated water vapor quality to leaders in a timely manner and find out reasons

for treatment and treat according to following tertiary treatment principle if water vapor continues

to deteriorate.

That is, the primary treatment begins from deteriorated water vapor quality (which exceeds

the standard) and abnormal conditions shall be restored within 72 hours. Secondary treatment

shall be restored within 24 hours and tertiary treatment shall be restored within 4 hours. Stop the

boiler for treatment instantly if deteriorated water vapor quality can not be restored normally on

time. It is required to take measures of a higher level for abnormal treatment method if

deteriorated water vapor quality can not be restored normally within regulated time. Normal

values of drum boiler can be restored by pressure drop and it is required to stop boiler

emergently when PH of the boiler water is less than 7.0 and sodium content in the condensing

water is more than 400μg／L.

Tertiary treatment value is as follows:

Treatment value Water sample

Item

Normal value

Primary Secondary Tertiary Sodium: μg/L ≤10 10～20 20～35 ＞35

Condensing water Electric

conductivity: μs/cm

≤0.3 0.3～0.4 0.4～0.5 ＞0.5

With

copper8.8～9.3

<8.8 or >9.3

pH(25) Without

copper9.0～9.6

<9.0 or >9.6

＜8.0

～

Electric

conductivity:μs/cm

≤0.3 0.3～0.4 0.4～0.65 ＞0.65

Supplied water

Dissolved oxygen:

μg/L

≤ 7 ＞7 ＞20 ～

Boiler water PH (25) 9～10 ＜9.0 ＜8.5 ＜8.0

Stop boiler instantly when PH of supplied water is less than 7.0 or sodium content in condensing

water is more than 400ug/l.

Note: Measure Cl-, Na+, conductivity and alkalinity of the boiler water when water quality is

abnormal to find out reasons and take measures for treatment.

12) Chemical specialty shall analyze accuracy of data and representation of sample firstly when

abnormal water vapor quality can reach the “primary treatment value” and report it to

supervisor instantly after comprehensive analysis and confirmation. Supervisor shall organize


Rev.: A



investigation and notify corresponding departments for treatment. (Ask integration control

personnel for system adjustment and ask maintenance department to solve equipment

problems.) In the meanwhile, it is required to add testing times and strengthen supervision

until it can be qualified. Supervisor shall report it to division heads and chemical supervision

engineer if abnormal water vapor quality can not be qualified after treatment of the staff.

13) Report detailed conditions to supervisor, chemical supervision engineer and relevant division

heads in a timely manner after confirmation of chemical specialty that water quality of

supplied water, boiler water or condensing water can reach secondary treatment value with

impossibility of restoration. The supervisor shall take corresponding measures for treatment

according to the detailed conditions of the unit and report it to leaders of the company if

abnormal water quality can not be qualified after treatment of the staff.

14) Report it to supervisor, chemical supervision engineer and relevant department managers

instantly when water quality of supplied water, boiler water or condensing water can reach the

“tertiary treatment value”, the supervisor and chemical supervision engineer shall report it to

leaders of the company at the same time and above people shall rush to the site instantly after

receiving the report and leaders of the company shall command uniformly and take emergent

measures.

15) Report it to the supervisor, chemical supervision engineer and relevant department managers

instantly if the condenser leaks or quality of condensing water or supplied water can exceed

the standard. Supervisor and chemical supervision engineer shall report it to leaders of the

company at the same time and above people shall rush to the site instantly after receiving the

report. Leaders of the company shall command uniformly and caulk in a timely manner and

strengthen sewage treatment of the boiler and monitor variation of PH value of the boiler

water. It is necessary to take measures such as reducing pressure and limiting load even

emergent shutdown measures to protect equipments and avoid accidents if the condenser

continues to leak and water quality deteriorates rapidly.

16) Stop equipments emergently for treatment without request if there are accidents which may

endanger safety of people and equipments and report it to relevant leaders instantly after the

event.

14.3.5 Supervision during repair phase of the unit

1) Responsible person of chemical supervision shall propose inspection items and requirements

with regard to water vapor quality before repairing thermodynamic equipments and inspect,

record, sample and analyze them with relevant personnel after inspection and disassembly of

equipments for comprehensive judgment and propose correction opinions by aiming to

existing problems. Sediments in the equipments can not be removed and it is not allowed to

repair in such parts before inspection of chemical supervision.

2) Inspect scale and corrosion of deoxidizer, economizer, water-cooled wall, super-heater,

impeller of turbine, baffle and copper tube of condensing tube and measure scale quantity.

3) Antisepsis management during shutdown and standby phase of the unit

4) Take corresponding antisepsis measures during overhaul, minor overhaul, temporary

inspection or standby periods of the unit and record detailed operation methods in the


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integration control and chemical manuals. Record antisepsis date, method and supervision

control indicators and operation department shall be responsible for it is discharging water by

hot boiler with protection of ammonia injection and hydrazine and nitrogen-filling protection

operation and equipment maintenance department shall be responsible for system installation.

5) Take antisepsis measures for equipments to prevent steam, water and oil in adjacent boiler or

public system from mixing and entering into the standby unit.


Rev.: A

Bop Operation Manual Qn1 Sec g 04 Tp 005(195) Dang Doc

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