Escolar Documentos
Profissional Documentos
Cultura Documentos
Rev.
Date
Compiled by
Review
Approval
Document No
PROJECT
OWNER
OWNERs
ENGINEER
EPC
CONTRACTOR
CONTRACTOR
s ENGINEER
2150MW
300 MW(2150MW) Coal Fired Power Plant at Maamba, Zambia
TATA
TATA CONSULTING ENGINEERS LIMITED
Catalogue
1..............................................................................................................................3
Overview.......................................................................................................................3
2.....................................................................................................3
Main equipment technique specification....................................................................3
3.......................................................................................................17
Commissioning basis and standard..........................................................................17
4...................................................................................................................17
Commissioning purpose.............................................................................................17
5...................................................................................................................18
Commissioning range.................................................................................................18
6..........................................................................18
Commissioning condition and checking content.....................................................18
7..........................................................................................18
Commissioning process, procedure and method.....................................................18
8......................................................................................24
Commissioning quality targets and assess standards.............................................24
9..........................................................................24
Environment, occupational health and safety control procedure..........................24
10.................................................................................................................26
Organization and division.........................................................................................26
11......................................................................................................................28
Appendix.....................................................................................................................28
1.
Overview
ZMTP 2150MW
2510t/h
The project is Zambia ZMTP 2150MW coal fired power plant, located at
Maamba coal mine, Sinazongwe, Southern Province. The boiler is produced by
Dongfang Boiler Company, which is 2*510t/h high temperature, super high pressure
circulating CFB boiler. Here the procedure is for the boiler ash removal system
commissioning.
2.
Main equipment technique specification
2.1
Boiler specification
Zambia MCL 2150MW Coal Fired Power Plant 2 510t/h
150MW
Zambia MCL 2150MW Coal Fired Power Plant is provided with two sets of
510t/h super high pressure, natural circulating CFB steam drum boilers, which is
single furnace, single medium reheating, thermal isolation cyclone separator, tubetype air preheater, balanced draft, end part double flue, suspension structure, halfunsheltered layout, solid state deslagging, complete steel structure, matched with
150MW condense turbine-generator. The boiler adopts CFB combustion and
limestone desulfurization technique that low pollution and high efficiency.
Item
Unit
BMCR
BECR
Main steam flow
LP RH inlet pressure
LP RH inlet temp.
HP RH inlet pressure
HP RH inlet temp.
RH flow
Feed
water
temp.
exclusive all HP
#1
Feed
water
temp.
exclusive #1 HP
#2
Feed
water
temp.
exclusive #2 HP
(LHV)
Boiler
guaranteed
efficiency (LHV)
Boiler
desulfurization
efficiency
T/H
510
485.73
MPa
14.32
14.32
540
540
MPa
2.85
2.85
334
334
MPa
2.7
2.7
540
540
T/H
420.42
400.4
248
248
171
228.6
207.3
90
92.3
Range of Coal
Analysis
%
%
%
45.3 to 53.27
19.6 to 18.05
33.7 to 27.47
Coal Analysis
Performance
Worst
48.3
18.8
31.55
53.27
18.08
27.44
1.4 to 1.21
1.9 to 2.1
4059 to 2990
1.35
1.9
3500
1.21
2.1
3110
42.8 to 37.06
2.81 to 2.33
0.93 to 0.72
6.45 to 6.08
1.0 to 2.0
1.43 to 1.24
45.3 to 53.25
4039 to 3191
37.5
2.45
0.85
6.20
1.7*
1.90
49.4
3580
33.26
2.33
0.72
6.34
1.7*
2.1
53.55
3191
59
59
61.08
30.52
4.10
3.1
0.43
61.13
30.89
3.63
3.44
0.37
59
61.7 to 61.13
31.0. to 30.89
4.8 to 3.63
3.00 to 3.44
0.50 to 0.37
2.2
Ash removal system regulation and main equipment technique data
2.2.1
Ash removal system regulation:
MCR 230%
1
Ash removal system adopts positive pneumatic dense phase ash conveying
system, which the conveying capacity is not less than 230% ash discharging quantity
under MCR working condition. Dust precipitator is single channel ESP, each hopper
of precipitator and APH is provided with one set of pneumatic pump.
2 7 14
2
2120m3 31.8m
Precipitator hopper is provided with gasification air system, matching with
gasification air fan, electric heater and hopper gasification plate. 2 public ash silos are
matched for two boilers, and each boiler is provided with 7 ash pipes, total 14 for two
boilers. Each ash pipe can be converted between two ash silos through change-over
valves on silo top. The design can satisfy two boilers operation simultaneously, or
single boiler operation, and two boilers ash removal systems will not affect each other
and guarantee the output. Volume of reinforced concrete ash silo is 2120m 3, with top
height of 31.8m.
~25%
Gasification device is installed at bottom of ash silo, and ash removal box,
exhaust filter (bag dust collector), pressure vacuum release valve, level gauge and
other equipment are installed on ash silo top. Two ash removal mode are used under
each ash silo with three dumping outlets, in which the first outlet to discharge dry ash
to tank truck to outside users; the second to discharge dry ash to humidification mixer
to produce wet ash with 25% water content, which is also used by outside user; the
third is standby.
1
234
Precipitator fly ash conveying system (including APH) is designed as one boiler
as a unit, from under outlet flange of precipitator and APH hopper to inlet flange of
silo top discharging box, including silo and pump assembly (pressure conveying
device), pneumatic conveying pipe, pipe change-over valves, pipe expansion joints,
pipe blowing devices, etc.
2.2.1.2
Control air usage and bag pulse cleaning air usage system
Used air by pneumatic elements and bag pulse cleaning of top exhaust filter is from
compressed air center of the plant for instrument system.
2.2.1.3
System of silo discharging, exhaust and level indication
Including silo top discharging box, silo top exhaust filter (bag dust collector), pressure
vacuum releasing valve, silo top pipe change-over valves, level gauge and other
equipment and accessories.
2.2.1.4 PLC
Control system of pneumatic ash removal system (except PLC control cabinet)
All magnetic valves box and monitoring instrument required by the entire pneumatic
ash removal control system. All equipment can be controlled locally by auto and
manual, also controlled in control room by remote, and local control can lock the
other control modes.
Coal category
Unit capacity
(t/h)
Design coal
Checking coal
1150
(t/h)
Ash quantity per hour
Ash
Slag
Ash and slag
44.02
44.02
88.04
2150
88.04
88.04
176.08
1150
53.59
53.59
107.18
2150
107.18
107.18
214.36
1. 50% 50%
Note: slag quantity is calculated as per proportion of 50% of total ash and slag,
as well as ash.
2. q4 4.27%
Mechanical imperfect combustion loss: q4 4.27%
3. 3%
Sulfur ARB: 3%
Discharging point
Hopper
quantity
Precipitator
electric field
Precipitator
electric field
Precipitator
electric field
Precipitator
electric field
Precipitator
electric field
Precipitator
electric field
APH hopper
22
22
1.731 4=6.924
2.48 4=9.92
22
0.4556 4=1.822
0.6525 4=261
22
0.2734 4=1.0936
0.3915 4=1.566
22
0.1367 4=0.5468
0.1958 4=0.7832
22
0.04556 4=0.1822
0.06525 4=0.261
0.911 4=3.644
1.305 4=5.22
II
III
IV
VI
2.2.2
Pump thickness
Manufacturer
6.0E/8
DN200
0.20 M3
DN100
Clyde
Pressure conveying device of electric field fly ash (filling for various fields)
Conveying pump
Type
Inlet diameter
Capacity per set
Outlet diameter
Design pressure
Device weight
Output
Working temperature
Usage temperature
range
Material
Gasification plate
material of
transmitter
Gasification plate
service life of
transmitter
/
Transmitter inner
diameter/wall
I field
80/8
II field
80/8
III field
9/8
IV field
8.0/8
V field
8.0/8
VI field
8.0/8
DN200
DN200
DN200
DN200
DN200
DN200
2.50
2.50
0.33
0.30
0.30
0.30
DN150
DN150
DN150
DN150
DN150
DN150
1.0MPa
0.35
1.0MPa
0.35
1.0MPa
0.35
1.0MPa
0.35
1.0MPa
0.35
1.0MPa
0.35
1300Kg
85.24t/h
1300Kg
22.81t/h
750Kg
710Kg
710Kg
710Kg
6.003t/h
3.602t/h
1.801t/h
0.6t/h
150
150
150
150
150
150
0150
0150
0150
0150
0150
0150
16MnR
16MnR
16MnR
30
30 years
30
30 years
30
30 years
Ductile
cast iron
30
30 years
Ductile
cast iron
30
30 years
Ductile
cast iron
30
30 years
No
No
No
No
No
No
No
No
No
No
No
No
8mm
8mm
6mm
15mm
15mm
15mm
thickness
Pump thickness
Manufacturer
Quantity
8mm
8mm
6mm
15mm
15mm
15mm
Clyde
8
Clyde
8
Clyde
8
Clyde
8
Clyde
8
Clyde
8
120.06t/h
System output for each boiler: (system output: 120.06t/h)
85.24th
22.81-85.24th
6.003-22.81th
3.602-6.003th
1.801-3.602th
0.6003-2.401th
6.003th
120.06t/h
Average proportion of conveying ash and air (system output: 120.06t/h)
39.7
kgkg
39.7
kgkg
31.7
kgkg
31.7
kgkg
Proportion of conveying ash and air of V
field
31.7
kgkg
31.7
kgkg
30.1
kgkg
38.2
kgkg
Design pressure
Temperature tolerance
Material
Compensation
Manufacturer
I field
II field
No
APH
Flexible
joint
8
Flexible
joint
8
DN200
DN200
Normal
pressure
200
Normal
pressure
200
Stainless
steel
40mm
Stainless
stee
40mm
Clyde
Clyde
No
I field
II field
APH
200x200DN200
Q235
Quantity
Specification
Material
Manufacturer
200x200DN200
Q235
Clyde
Clyde
Clyde
Clyde
4
200x200DN200
Q235
Driving mode
Valve body
material
Valve plate
material
Seal ring
material
Manufacturer
Quantity
I field
II field
Pneumatic
dome valve
DN200
Fields of III,
IV, V and VI
Pneumatic
dome valve
DN200
Pneumatic
dome valve
DN200
APH
Pneumatic
dome valve
DN200
Pneumatic
Ductile cast
iron
Ductile cast
iron
Special rubber
Pneumatic
Ductile cast
iron
Ductile cast
iron
Special rubber
Pneumatic
Ductile cast
iron
Ductile cast
iron
Special rubber
Pneumatic
Ductile cast
iron
Ductile cast
iron
Special rubber
DN200
DN200
DN200
DN200
Clyde
8
Clyde
8
Clyde
8/
8 per field
Clyde
4
I field
II field
III field
No
No
No
Specification
Driving mode
Manufacturer
Quantity
Fields of IV, V
and VI
Pneumatic dome
valve
DN150
APH
Pneumatic
Special rubber
DN150
Clyde
6
No
Pneumatic air admission valve, including silo pumps various valves and
components (including air admission components on main ash conveying pipe and
discharging pipe)
Quantity
Driving mode
I field
II field
Pneumatic
butterfly
damper
4
Fields of III,
IV, V and VI
Pneumatic
butterfly
damper
8
Pneumatic
butterfly
damper
4
Pneumatic
APH
Pneumatic
butterfly
damper
2
Pneumatic
Pneumatic
Pneumatic
Specification
Valve body
material
Valve plate
material
Seal surface
material
Manufacturer
DN65
DN65
DN50
DN50
Cast steel
Cast steel
Cast steel
Cast steel
Cast steel
Cast steel
Cast steel
Cast steel
Hard seal
Hard seal
Hard seal
Hard seal
Clyde
Clyde
Clyde
Clyde
Pneumatic exhaust valve, including various valves and components of silo pump
exhaust components, classified by use in different ESP and filled as per different pipe
diameter and pressure.
I field
Driving mode
Pneumatic
DN80
Specification
Valve body
Ductile cast iron
material
Valve plate
Ductile cast iron
material
Seal ring
Special rubber
material
20000
II field
Fields of III,
IV, V and VI
No
APH
Pneumatic
DN80
Special rubber
20000
Pneumatic dome
valve
8
No
Service life of
valve body
and plug
Manufacturer
Clyde
Clyde
Mode and
type
Quantity
Driving
mode
Specification
Valve body
material
Valve plate
material
Seal ring
material
Manufacturer
I field
II field
III field
Damper
valve
2
Damper
valve
2
Damper
valve
2
Manual
Manual
DN150
Damper valve
APH
Damper valve
Manual
2/
2 per field
Manual
Manual
DN150
DN150
DN150
DN125
Cast
iron
Cast
iron
--
Cast
iron
Cast
iron
--
Cast
iron
Cast
iron
--
Cast iron
Cast iron
Cast iron
Cast iron
--
--
Clyde
Clyde
Clyde
Clyde
Clyde
Discharging valve
Mode and
I field
II field
III field
Ball valve
Ball valve
Ball valve
Ball valve
APH
Ball valve
type
4
4
2
Quantity
Driving
Pneumatic Pneumatic Pneumatic
mode
DN50
DN50
DN50
Specification
Valve body
Cast steel Cast steel Cast steel
material
Valve plate
Cast steel Cast steel Cast steel
material
Seal surface
Alloy
Alloy
Alloy
material
steel
steel
steel
Seal ring
No
No
No
material
Manufacturer
Clyde
Clyde
Clyde
Pneumatic
Pneumatic
DN50
DN50
Cast steel
Cast steel
Cast steel
Cast steel
Alloy steel
No
Alloy
steel
No
Clyde
Clyde
3.
Commissioning basis and standard
3.1
Relevant contracts, design drawings, manufacture introduction, technique agreement
and other documents
3.2
Relevant regualtion and rules of state and industry
3.3 MCL 2150MW
Commissioning outline of Zambia MCL 2150MW coal fired power plant project
4.
Commissioning purpose
4.1
Check all equipment manufacturing and erection quality of boiler ash removal system.
4.2
Check electric and I&C protections interlock and signal devices, and confirm the
action reliability.
4.3
Check system and equipment operation, test system performance, check out and
eliminate the possible failures.
4.4
Guarantee all equipment in normal condition and safe, stable and economic operation
through ash removal system commissioning.
5.
Commissioning range
2
3
4
5
6
Technique handover
Condition
commissioning
confirm
before
1. System
pipe
and
equipment
erection are completed, with
complete recording.
2. I&C and electrical instruments
erection
are
completed,
calibration is qualified, and it
can put into operation.
3. Single commissioning of system
equipment is qualified.
Open/close or change over ash removal valves through PLC to confirm local action
correction and flexibility. Channel check for important I&C signal points.
7.2.3
Gasification air system test of ash hopper:
1 1
Operation mode: one in operation and one in standby
When operating air fan trip caused by failure, interlock open standby air fan
outlet motor valve and alarm, start standby air fan.
7.2.4
When operating air fan trip caused by failure, interlock open standby air fan
outlet motor valve and alarm, start standby air fan.
7.2.5
Ash removal air compressor system
10 2
Operation mode: 10 in operation and 2 in standby
10
If pressure is low when 10 in operation, interlock start standby air compressor.
7.2.6
Cold dryer system
6 2
Operation mode: 6 in operation and 2 in standby
6 ,
When six sets in operation and one is trip by failure, interlock standby cold
dryer (firstly open outlet motor valves).
7.2.7
Check that lube oil, cooling water, dryers and other parts of air compressor
system shall conform to startup requirement; reversely operate air conveying
system as per regulated sequence, firstly start one cold dryer and then start air
compressors one by one.
Filers and gas tanks of started air compressors shall be cleaned up without
deposited water.
Manual butterfly valve of ash hopper shall be checked at closing position, put
positive pressure ash conveying system compressed air blowing into
operation; each group of ash silo pump shall be blown one time by manual,
and then put auto ash cleaning program into operation, after at least three
circulation, then into ash conveying operation.
I/ ,
Open manual butterfly valve of ash hopper, and put ash silo pump into
operation; as per principle of firstly less ash and then more ash, put ash
hopper pump of economizer, ash hopper pump of denitration, ash hopper
pump of ESP I/II field and ash hopper pump of bag dust collector into
operation.
When ash pumps into operation, check ash flow condition at all time, and
hammer it when it is necessary; if ash blocking is appeared, close inlet ash
valve and convert to compressed air blowing operation.
8
Before silo ash storage, all gasification pipes shall be checked without
blocking, and pipe temperature is a little hot; ash discharging shall be carried
out after 8 hours continuous storage to prevent deposit at silo bottom;
according to requirements of truck loading, put dry and wet ash discharging
devices, and one wet pump shall be started firstly before wet ash discharging
into operation.
b.
Shutdown sequence of ash system
After boiler blowing out, shutdown ash pump one by one until all ash in
hopper is completely evacuated according to ash deposit condition.
Deposit ash in silo shall be discharged completely.
60
Commissioning professional and supervisor shall enforce check and control for key
points of commissioning quality, and report to higher level leader when find out
problems to coordinate and solve to ensure successful startup commissioning.
9.
Environment, occupational health and safety control procedure
9.1
The system shall be organized and commanded coordinately, any change by personnel
is forbidden. The commissioning shall not affect unit safety, if any event that may
affect the unit safety and stability, stop commissioning at once and recover stable
operation of the unit. When the unit is confirmed in stable condition, restart
commissioning again. The commissioning shall be organized and commanded under
headquarter.
9.2
All commissioning staff shall strictly carry out Safety Regulation and on-site relevant
safety regulation to ensure the commissioning safety and reliability.
9.3
If find out abnormal condition during commissioning, timely regulate and report to
leader; if exists possibility that may endanger personnel and equipment, stop
commissioning at once or shutdown the unit when it is necessary.
9.4
If abnormal situation happens during the commissioning, instantly adjust it and report
it to headquarter.
9.5
Professionals shall be on site during the commissioning to ensure the safety of
running equipment and personnel.
9.6
When carry out equipment maintenance, relevant safety measures and working orders
shall be necessary.
9.7
Before ash silo to store ash, it shall be dried completely. Before silo pump starting,
ash hopper fluidization shall be checked to guarantee when ESP into operation, the
fluidization device shall be followed into operation.
9.8
When ash silo in operation condition, working condition of bag filter shall be checked
at all time to prevent deposit, which will cause high back pressure of ash silo to block
ash conveying pipe.
9.9
When system no-load, hopper blocking and other alarm signals does not work, timely
change to manual control and check whether exist ash deposit in all units in order to
handle.
9.10
When check and measure ash pipe and pumps, change to manual operation.
9.11
Working staffs and operators engaged in startup commissioning shall be familiar with
process flow and relevant technique standard of ash removal system.
10.
Organization and division
10.1
EPC unit
10.1.1
In charge of compiling commissioning report.
10.1.2
In charge of the system isolation and closing.
10.1.3
In charge of maintenance, overhaul and troubleshooting of commissioning equipment.
10.1.4
Prepare necessary overhaul tools and material.
10.1.5
Coordinate with the commissioning unit to carry out subsystem commissioning.
10.1.6
In charge of check and acceptance after subsystem commissioning.
10.1.7
10.2
Commissioning unit
10.2.1
In charge of supervisory work during starting and commissioning as per the contract,
supervise the procedure execution, engage in the commissioning, check and
acceptance.
11
Appendix
1
Appendix 1: Checking list before commissioning condition
machine
4
5
()
Erection is completed; secondary grouting
is completed; relevant pipes (including
suspension) erection is completed.
Rema
Time
Resu rk
lt
10
11
12
13
14
electrical
15
16
17
18
19
20
21
I&C
22
23
24
25
26
27
other
28
29
30
31
qualified.
32
33
34
35
Date: