SEC a Bekasi Design Spec

THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA

Project No.-PH-0331 & PH0332

TBW Document No.-

Commg/BP CCPP/O&M/01

OPERATION & MAINTENANCE MANUAL FOR

2 x 86 TPH SUPPLEMENTARY FFIRED HSRG

FOR

BEKASI POWER CCPP 1 X 130 MW

JABABEKA, CIKARANG

COUNTRY: INDONESIA

HRSG PH- 0331& 0332

Prepared, revised Checked Approved Remark, kind of revision

Name Date Name Name Date Status

PK 27-07-09 OSS USU 27-07-09 REV-0



TBW Document No.-


OPERATION AND MAINTENANCE MANUAL

FOR 2 x 86 TPH

SUPPLEMENTARY FIRED HRSG

SUPPLIED TO

BEKASI POWER CCPP 1 X 130 MW JABABEKA,CINARANG COUINTRY: INDONESIA

CONSULTANT: INTERNUSA TECHNICAL GROUP PVT LTD

TBW JOB NO. PH-0331& 0332

THERMAX BABCOCK & WILCOX, A DIVISION OF THERMAX LIMITED, PUNE, INDIA



TBW Document No.-


We are pleased to welcome you to the growing family of

THERMAX BABCOCK & WILCOX

THERMAX BABCOCK & WILCOX, a division of THERMAX LIMITED – INDIA,

are having technology tie up with BABCOCK & WILCOX – USA. Combining the

Engineering / Technology and experience of the two organisations to provide the

very best of services in the field of Industrial Boilers. THERMAX BABCOCK &

WILCOX quality management system is certified under ISO 9001 with design

and manufacturing standards approved and confirming to ASME & IBR.

THERMAX BABCOCK & WILCOX has in its product range:

• Oil / Gas fired BI-DRUM packaged FM boilers up to 100 TPH

• Oil / Gas fired BI-DRUM modular 'HC-FM' boiler up to 272 TPH

• Coal / Lignite / Agro waste (pith, coconut shell, coffee waste / industrial waste,

paper sludge etc.) fired ATMOSPHERIC FLUIDISED BED COMBUSTION (AFBC)

boilers up to 300 TPH

• Coal / Lignite / Agro waste / Industrial waste fired CIRCULATING FLUIDISED

BED COMBUSTION (CFBC) Boilers up to 500 TPH

• Oil / Gas fired single drum high pressure capacity RADIANT BOILERS up to 500

TPH

• Gas turbine exhaust, Unfired / Supplementary fuel fired / Fully fired HRSGs for

combined cycle power plants up to 500 TPH

• Coal / Lignite / Bagasse fired TRAVELING GRATE / DUMPING GRATE boilers up

to 200 TPH

• Waste heat recovery boiler WHRB / Process integrated boiler PIB / Waste gas

fired boiler up to 200 TPH

• Exhaust gas boiler up to 20 TPH

• Fired Heaters up to 100 mm kcal/hr

• Cogen & Captive power plants



TBW Document No.-


THERMAX BABCOCK & WILCOX, with their team of specialists offer the

following services for Boilers of (any make and size including utility boilers)

• Condition assessment to determine the remaining life of boiler components

(RLA)

• Pressure part replacement for Superheaters, Economisers and convection

tubes

• Fuel conversions to take advantage of the newer / cheaper fuels

• Technology upgrades for old boilers to get benefits of modern technology for

efficiency, economy and reliability

• FBC RETROFITS for old conventional coal fired boilers

• INSTRUMENTATION MODERNISATION to replace complicated and unreliable

instruments with user friendly systems

• EMMISION CONTROL SOLUTIONS to upgrade fuel firing system for emission

control

• UTILITY BOILER REVAMPS for renovation & modernisation services for Power

Utility Boiler

• EMERGENCY SERVICE to rectify forced boiler shut downs on top priority

You can contact us at:

THERMAX BABCOCK & WILCOX,

A Division of THERMAX LIMITED,

"Energy Building", Block D-1, Plot 7/2,

RD AGA Road, MIDC, Chinchwad,

Pune - 411 019, India.

Tel: +91-20-4126464,

Fax: +91-20-7478066

E mail for after sales & service - [email protected]



TBW Document No.-


Thermax Babcock & Wilcox

A Division of Thermax Limited

O&M MANUAL

PROPRIETARY

This operation and maintenance manual contains confidential and

proprietary information of TBW-A division of Thermax Limited

and is submitted upon the following conditions only for reference.

• To be used solely and exclusively for the purposes of Boilers and its

auxiliaries operation and maintenance.

• Not to be copied or reproduced in whole or in part, without the

express written consent of TBW-A Division of Thermax Limited

• Not to be disclosed or disseminated in whole or in part, to any

person or entity outside of the recipient’s organisation, without the

prior written consent of TBW-A division of Thermax Limited

• Not to be used for any purpose detrimental to the interest of TBW-

A division of Thermax Limited



TBW Document No.-


THERMAX B&W REPRESENTS THAT THE INFORMATION

CONTAINED IN THIS MANUAL HAS BEEN DEVELOPEDED

IN ACCORDANCE WITH THERMAX STANDARD TECHNICAL

PROCEDURES AND PRACTICES FROM LATEST

INFORMATION AVAILABLE AT THE TIME OF ISSUE OF

THIS MANUAL.

PLEASE READ AND FOLLOW

THE INSTRUCTIONS CONTAINED IN THE

MANUALS CAREFULLY FOR

SAFE OPERATION



TBW Document No.-


OWNER SHOULD REVIEW ALL THE OPERATING

INSTRUCTIONS & BE SURE THAT THE PERSONS

OPERATING & MAINTAINING THE EQUIPMENT ARE

FAMILIER WITH ALL THE INFORMATION PROVIDED,

INCLUDING MANUALS FROM VARIOUS SUPPLIERS OF

VENDOR EQUIPMENTS.



TBW Document No.-


WARNING

THIS MANUAL PROVIDES SIMPLE AND BASIC

INSTRUCTIONS ON BOILER OPERATION &

MAINTENANCE TO ASSIST THE OPERATING

PERSONNEL.

BOILERS & ACCESSORIES BY THEIR VARY NATURE

OPERATE AT HIGH PRESSURE AND TEMPERATURE

CAN BE DANGEROUS WHEN NOT PROPERLY

OPERATED AND MAINTAINED, THEREFORE OWNER

MUST PROVIDE ADEQUATE OPEARTING

MAINTENANCE AND SAFETY TRAINING FOR ITS

PERSSONEL. THE OPEARTING COMPANY MUST

PROVIDE QUALIFIED OPERATORS FOR OPERATION.

INDEX BEKASI POWER CCPP

SECTION A Page I

A. DESIGN SPECIFICATIONS OF HRSG 9

2 DESIGN CODE 9

3 MATERIAL SPECIFICATIONS – PRESSURE PARTS 10

4 HEATING SURFACE AREA 11

5 FUEL 11

ULTIMATE ANALYSIS FOR NATURAL GAS ( PRIMARY FUEL ) 12

6 CONTINUOUS BLOWDOWN. 12

7 HRSG FEED WATER ANALYSIS : 12

8 HRSG BOILER WATER ANALYSIS: 13

9 UTILITIES 13

ELECTRICAL POWER 13 COOLING WATER 14 INSTRUMENT AIR 14

10 CHEMICALS FOR DOSING 14

11 SITE CONDITION 14

11 FANS 15

12 HP HRSG FEED WATER PUMPS 15

13 DEARATOR CHEMICAL DOSING SYSTEM 16

14 CHEMICAL DOSING SYSTEM FOR HP BOILER 16

15 BURNERS 17

16 GAUGE GLASS 18

DRUM LEVEL 18 DEARATER LEVEL 18 BLOWDOWN TANK 18

17 SAFETY VALVES 19

THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.

A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332

SECTION A Page 9

NUMBER & TYPE OF BOILER : 2X86 TPH, nos. Natural Circulation,

integral dearater and pumps, Single Drum Supplementary Fired Heat Recovery Steam Generator

A. DESIGN SPECIFICATIONS OF HRSG

PARAMETERS UNIT VALUE

Boiler Rating [MCR] TPH 86

Steam Pressure at Main Steam Stop Valve Outlet from minimum Load upto MCR

bar (g) 92

Steam Temperature at the Main Steam Stop valve at MCR

Deg C 535

Boiler Feed Water Temperature at inlet to MUWH

°C 42

Feed water temperature at BFW pump outlet

°C 105

Gas Turbine Load % 50 - 100

Design Pressure Kg/Cm2 105

Fuel Firing Combination. • 100 % NG

Boiler Performance Testing Procedure ASME PTC 4.4 “Heat

Loss Method”

2 DESIGN CODE

Boiler & Economiser / Pressure Parts: ASME Section 1.



SECTION A Page 10

3 MATERIAL SPECIFICATIONS – PRESSURE PARTS

Description Details Size In Mm Material

Shell 1500 I.D. x 70 Thk

Steam Drum Dished end for S.D. (Hemispherical)

70 Thk SA 516 Gr.70

Riser Tube 150DN x SCH40 SA 106 Gr. B

Down comers Pipe 300DN x SCH 160 SA 106 Gr. B

HP Superheater I

Module No.1 Header 200DN X SCH.160

SA 335 P22

HP Superheater I

Module No.1 Finned tube 38.1 O.D. x 3.25Thk SA 213 T22

HP Superheater I

Module No.2 Header 200DN X 35 THK

SA 335 P22

HP Superheater I

Module No.2 Finned tube 38.1OD X 6.3THK SA 213 T22

HP Superheater II

Module No.3 Header 200 DN X 45 THK

SA 335 P22

HP Superheater II

Module No.3 Finned tube 38.1OD X 6.3THK SA 213 T22

HP Superheater II

Module No.4 Header 200 DN X 32THK

SA 335 P91

HP Superheater II

Module No.4 Bare Tubes 38.1 OD X 3.6 THK SA 213 T19

Evaporator Top & Bottom Header I & II

Header 150 NB X SCH.160 SA 106 Gr B

Evaporator Bank Tubes 3.8 O.D X 2.7 THK SA 210 Gr A1

HP Economiser III Top & Bottom Header

Header 150 DN X SCH 160 SA 106 Gr. B

HP Economiser III

Finned tube 38.1 O.D. x 2.7Thk SA210 GR.A1



SECTION A Page 11

Description Details Size In Mm Material

HP Economiser II Top & Bottom Header


HP Economiser II Finned tube 38.1 O.D. x 2.7Thk SA210 GR.A1

HP Economiser I Top & Bottom Header

Header 150 DN X 21.95 THK SA 106 Gr. B

HP Economiser I Finned tube 38.1 O.D. x 2.7Thk SA210 GR.A1

Integral dearater

Inlet/outlet header


Integral dearater

Finned Tubes 38.1 O.D. x 2.7Thk

SA210 Gr A1

Condensate Preheater Inlet/outlet header

Header 150DN X SCH 160

SA 106 Gr. B

Condensate Preheater

Finned Tubes 38.1 O.D. x 2.7Thk SA210 Gr. A1

4 HEATING SURFACE AREA

Zone Unit Value

HP Superheater I Sq.Mtr 1784

HP Superheater II Sq.Mtr 615

Evaporator bank Sq.Mtr 11692

Economiser Sq.Mtr 21254

Integral dearater Sq.Mtr 941

Condensate preheater Sq.Mtr 1634

Total Heating Surface Area Sq.Mtr 37920

5 FUEL

a) Main Fuels : NG



SECTION A Page 12

7 FUEL ANALYSIS:

Ultimate Analysis For Natural Gas ( Primary Fuel )

PARAMETER UNITS VALUE

Methane % volume 81.686 Ethane % volume 4.865 Propane % volume 3.656 n-Butane % volume 0.942 i-Butane % volume 0.697 n-Pentane % volume 0.160 i-Pentane % volume 0.329 Octane % volume 0.140 Nitrogen % volume 2.820 Carbon di oxide % volume 4.324 Oxygen % volume 0.265 Water % volume 0.015 NCV KJ/Kg 42415 Condition at Battery Limit: Temperature °C 35 Pressure Bar(g) 4.5

6 CONTINUOUS BLOWDOWN.

Normal : 1 % / Hr

7 HRSG FEED WATER ANALYSIS: General appearance Clear & colourless Total Hardness as CaCO3

ppm Commercial zero

Total Fe ppm < 0.01 Total Cu ppm <0.003 Oxygen ppm <0.02 Oil & organics ppm NIL PH value at 25°C 8.5-9.5 Total Dissolved solids

ppm <0.1

Electrical Conductivity

µs/cm <0.2

Silica SiO2 ppm <0.02 Condition at Battery Limit

Boiler Feed Water barg 7



SECTION A Page 13

Pressure at inlet to MUWH Boiler Feed Water Temperature at inlet to MUWH

°C 42

Application HRSG feed water

8 HRSG BOILER WATER ANALYSIS:

Sodium phosphate as PO4

Ppm 27 to 25

Alkalinity as CaCO3 Ppm 20 Sodium sulphite as SO3

Ppm 11 to 8

pH value 8.8- 11 Oil & organic Ppm NIL Total dissolved solids

Ppm 100

Silica SiO2 Ppm <6

9 UTILITIES

Electrical power

Parameters Units Value

For HT motor above 150kw Voltage V 6000 Frequency Hz 50 Combined Variation % 5 Type AC, 3 phase

For LT motor upto 150kw

Voltage V 380 frequency Hz 50 Combined Variation % 5 Type AC, 3 phase

For Instrumentation Voltage

V 110

Frequency Hz 50 Type AC 1 phase For field transmitters Voltage V 24 Frequency Hz NA Type DC



SECTION A Page 14

Cooling Water

Parameters Unit Value

Supply pressure barg 5 Return pressure barg 4 Supply temperature °C 34 Return temperature °C 42 Quality Soft Duty Sample cooling

Instrument Air

Parameters Unit Value

Pressure barg 7.0 Dew point °C -20 Temperature max ° c 40 Quality Dry & Oil free Duty Instruments

Nitrogen Parameters Unit Value

Pressure (min/normal/design)

barg 6/7/10

Temperature (min/normal/max/design)

°C 0/30/25/40

Quality 99.9% pure Duty HRSG preservation

10 CHEMICALS FOR DOSING

HP Dosing Tri sodium phosphate.

11 SITE CONDITION

Site Location Jakarta, INDONESIA

Ambient Temperature



SECTION A Page 15

Ambient temperature (min/max/design)

°C (21/35/33)

For Performance testing °C 32

Relative Humidity

Average % 80

For Performance testing % 95

Area classification Zone 2 Group IIA/IIB T3 within 3 meters from the fuel gas train.

Seismic coefficient Zone 4 of UBC

11 FANS

Duty conditions Unit Scanner Cooling Air Fan

Make Andrew Yule And Co. Ltd.

Quantity Nos. 2 Nature of medium Air

Capacity Kg/s 0.10

Density Kg/cu.m

1.1187

Air Temperature at Fan Inlet

Deg C 33

Absorbed power at inlet temp.

KW 7

Fan Speed Rpm 2900 Diff. Static pressure MmHg 670 Outlet Static Pressure mmHg 759.53 Bearing Lubrication Servogem; EP-2

Motor 7KW ,TYPE – SCR ,Voltage -380 VAC,

Starting - DOL

Coupling Model

Resilient type coupling with guard

12 HP HRSG FEED WATER PUMPS



SECTION A Page 16

Duty conditions Unit Duty conditions

Make SULZER INDIA LTD Model MC 80-260/ 14

Number 2 Type Centrifugal

Design capacity m3/hr 102 Design head MLC 1205

Speed RPM 2970 Feed water temperature

°C 105

Casing Material Cast Iron Impeller Material Cast Iron

Drive Motor Type of coupling Flexible

Motor rating KW 500 Protection IP 55

Insulation Class F

13 DEARATOR CHEMICAL DOSING SYSTEM

Make : Metapow Industries M.I.D.C Bhosari, Pune

Description LP

Number 1 Storage tank Capacity m3 0.30 Material of construction CS with rubber lining Pump

Type Reciprocating plunger Numbers 2 Design Capacity liters/hr 10 Design Head bar[g] 5 Speed RPM 1440 Drive Motor Type of coupling Flexible Motor rating KW 0.37 Protection IP 55 Insulation Class F

Fluid to be handled. Di- Sodium Phosphate

solution.

14 CHEMICAL DOSING SYSTEM FOR HP BOILER



SECTION A Page 17

Description LP

Make Metapow Industries M.I.D.C Bhosari, Pune

Number 1 Storage tank Capacity m3 0.30 Material of construction CS with rubber lining Pump

Type Reciprocating plunger Numbers 2 Design Capacity liters/hr 10 Design Head bar[a] 102 Speed RPM 1440 Drive Motor Type of coupling Flexible Motor rating KW 0.37 Protection IP 55 Insulation Class F

Fluid to be handled. Tri Sodium Phosphate

solution.

15 BURNERS

15.1 General Number of HRSG 2 Burner Location uncooled furnace Burner make Stork Thermeq BV Burner fuel Natural gas Ignition fuel Natural gas Guranteed Performance for HRSG at

GT Base Load with Natural Gas, 32 DegC Ambient-Maximum Continuous rating [MCR] in supplementary fired

GT Base Load with Natural, 32 DegC Ambient-Supplementary fired

GT Load condition Base Base Steam Generation HP, TPH

86 78

Steam Pressure HP, Bar(g)

92 92

Steam Temperature HP, DegC

535 535



SECTION A Page 18

16 GAUGE GLASS

Drum level

Description Details

Make High- tech systems & services ltd Tag No. LG-173D & 173E Location Drum Operating pressure. 100kg/cm2 Design Temperature 370˚C C/c distance 800mm Visibility range 314 mm Operating temp. Saturation

Dearater level

Description Details

Make Chemtrols samil (India) pvt ltd Tag No. LG-173B & 173C Location Dearater Operating pressure. 0.21-2.1/6.3 kg/cm2 Design Temperature 200 0C C/c distance 1700mm Visibility range 1324 mm Operating temp. Saturation

BLOWDOWN TANK

Description

Details

Type Vertical cylindrical Numbers 1 Design pressure bar[a] 3.5 Internal diameter Mm 1200 Overall height Mm 2800 Shell thickness Mm 8 Material ASTM



SECTION A Page 19

17 SAFETY VALVES

DESCRIPTI ON

APPLICATION

UNIT

DRUM LHS

DRUM RHS

SH

DEARATER

TYPE - SPRING LOADED

MAKE TYCO SANMAR TAG NO

- 176J 176K 176N

176D 176E

SIZE ORIFICE -

2” J 3”

2” J 3”

2” J 3”

2” J 3”

2” J 3”

SETPRESSUR. Kg/ Cm2

107

108

100

5

5

RELIEVING. TEMP.

DEG.C

Saturated

Saturated

540

Saturated

Saturated

VALVE CAPACITY

TPH

34.4

34.4

17.2

Suitable

suitable

QUANTITY - 1nos. / Boiler

1nos. / Boiler

1nos. / Boiler

1nos. / Boiler

1nos. / Boiler

FLUID -

Sat. Steam Sat. Steam

SH Steam

Water

Water

DESCRIPTI ON

APPLICATION UNIT

CPH OUTLET

HP ECONOMISER I OUTLET

TYPE - SPRING LOADED

MAKE TYCO SANMAR TAG NO

- 176C 176H

SIZE ORIFICE -

2” J 3”

2” J 3”

SETPRESSUR. Kg/ Cm2

10

128

RELIEVING. TEMP.

DEG.C 250

saturated

VALVE CAPACITY Kg/Hr.

102888

88500

QUANTITY - 1nos. / Boiler

1nos. / Boiler

FLUID -

water

water

SEC a Bekasi Design Spec

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Transcript of SEC a Bekasi Design Spec