OPERATOR

Hand Book

Book I

PT. HAMAN ENERGI INDONESIA

FOR
UNIT 2 - PLTU 2 NTB 2x25 MW
2018

1
 CONTENTS

Book I
BOILER
I. GENERAL ....................................................................................................................

II. BOILER
1. Specifications .......................................................................................................
2. Closing of the boiler drain & vent valves during start-up ..................................
3. HP Steam Bypass System .......................................................................................
4. Boiler Alarm and trip (OFT) ....................................................................................
5. Boiler Alarm and trip (MFT).....................................................................................
6. Boiler Alarm and trip (Boiler Trip) ...........................................................................
7. Operator Action if Trip Occurred..........................................................................

III. DRAFT SYSTEM

1. Specifications ........................................................................................................
2. ID FAN .....................................................................................................................
3. PA FAN.....................................................................................................................
4. SA FAN.....................................................................................................................

IV. FUEL SYSTEM

1. LDO service system ............................................................................................
2. COAL combustion system ...................................................................................

V. SLAG HANDLING SYSTEM

VI. CHEMICAL DOSING and SAMPLING SYSTEM

1. Chemical Feed System .......................................................................................
2. Water Sampling System ......................................................................................

VII. CONTINOUOS EMISSION MONITORING SYSTEM

2
Book II
TURBINE

I. STEAM TURBINE and ANCILLARY

1. Steam Turbine ......................................................................................................
2. Lubricating Oil System ........................................................................................
3. EHC System ..........................................................................................................
4. Gland Seal Steam System ..................................................................................
5. Turning Gear.........................................................................................................

II. CONDENSATE WATER SYSTEM

1. Condenser ...........................................................................................................
2. Condensate Extraction Pump (CEP) ................................................................
3. Condenser Vacuum Pump ................................................................................
4. LP Feedwater Heater .........................................................................................
5. Demin Transfer Pump. ........................................................................................
6. Flash Tank ............................................................................................................

III. FEED WATER SYSTEM

1. Feed water Tank and Deaerator ....................................................................
2. Feedwater Pump ..............................................................................................
3. HP Feedwater Heater .......................................................................................

IV. CIRCULATING WATER SYSTEM

1. CWP.....................................................................................................................
2. Screen Wash Pump ...........................................................................................
3. Debris Filter .........................................................................................................
4. Condenser Tube Cleaning System ..................................................................

V. CCW & COMPRESSED AIR SYSTEM

1. Closed Cooling Water Pump ...........................................................................
2. Service and Instrument Air Compressor...........................................................

3
Book III
ELECTRICAL System and GENERATOR

1. SUMMARY..................................................................................................................
2. STATOR COOLING AIR SYSTEM ...............................................................................
3. EXCITATION SYSTEM .................................................................................................
4. SYNCHRONIZE SYSTEM..............................................................................................
5. TRANSFORMER..........................................................................................................
6. 6.3KV & 400V CIRCUIT BREAKER..............................................................................
7. DC 220VDC SYSTEM..................................................................................................
8. ESSENTIAL AC POWER SUPPLY SYSTEM....................................................................
9. EMERGENCY DIESEL GENERATOR ..........................................................................

4
BOILER
I. GENERAL CHECK and ACTION
STEAM LEAKAGE CHECK
1. Checking the normal operating status (NORMAL SOUND) by listening to the
sound from each floor of boiler and turbine periodically every shift.

2. The operator should find out the source of the abnormal sound, if any.

3. At the boiler, Open the inspection door (if any) nearest from the abnormal
sound and check carefully the sound from the inside of the boiler.

4. The Boiler Soot Blowing System, Check if the steam supply is normal to the SOOT
BLOWING SYSTEM..

5. Make sure to check (visual inspection) if any leakage from the inside of the
BOILER during
the start-up & shut-down of it, for which the LDO burners are using and the
visual inspection of the boiler tubes. Especially do the inspection of the tubes
when it is shut-downed.

6. During the routine checking, if any clue of dropping water on the floor,
dewdrop, radiant heat, etc, regards it as leakage and check thoroughly.

7. Any white steam found by approaching Cold Metal or Glass Plate to the
suspected leakage point with care (for operator not to be hurt ), it could be
regarded as a steam leakage.

8. Use the rag & long stick (or pipe) to check, when it is not easy to approach to
the suspected leakage point.

9. Make sure to be in safe during the check of steam leakage, especially the
superheated high temperature steam, because it can’t be seen. The leakage
sound can be distorted by the reflection of the adjacent structure, so be
careful and don’t go jumping to the conclusion. ( i.e, when STEAM SAFETY
VALVE is popped )

10. Have a knowledge how it affects to the system ( i.e, to the SOOT BLOWING
OPERATION, SAFETY Vv, VENT VALVE, etc.) when the steam leaks

5
CHECKING : TEMPERATURE, VIBRATION, ABNORMAL SOUND

(1) TEMPERATURE (checking by hand)

- Be careful not to be hurt by holding too tight when check the temperature by
hand
- If touching by hand on the BRG HOUSING, MOTOR, etc,. can be kept for 20~30
sec with a feeling of not hot : the status is O.K
- Hot and not possible to keep touching it for more than 30 sec, then the temp
can be assumed as about 40~45℃
- Not possible to keep touching for 2~3 sec, then the temp can be assumed as
about more than 50℃
- Type of Thermometer
a. Stem thermometer with putty
b. THERMO TAPE
c. THERMO STICK
d. THERMO VISION

(2) ABNORMAL SOUND

- Be capable to distinguish the abnormal sound by being accustomed to the
normal sound.
- In case of the rotational equipment..Check by using the listening stick, check if it
is a metallic touching sound or periodical (repeated) sound or any influence of
the flow inside the pipe,
- Check the period of the occurrence of the abnormal sound.
- If it’s not easy to define the abnormal status, check and compare the adjacent
similar equipment on the same parts of it and try to point out their differences.
- Items to be considered
(1) Bearing Damage : radiant heat, abnormal sound
(2) Deficit of GREASE : radiant heat as time goes by (it can be the normal in
10~20 minutes after injecting GREASE)
(3) Surplus of GREASE : radiant heat shall be decreased as time goes by.

(3) VIBRATION
- Be capable to distinguish the abnormal vibration by being accustomed to the
normal status
- Check if the vibration comes from the whole equipment or any part of it.

6
MANIPULATING OF THE VALVES

(1) Manipulation of the VALVES

- Confirm the name, KKS No., of the VALVE and connected equipments.
- Confirm the status of the valve to be manipulated.
- Check the direction of the HANDLE (Clockwise : Generally CLOSE DIRECTION)
- Be sure not to be fluctuated rapidly on the Pressure, Temperature, flow when the
valve is manipulated
- Once VALVE is fully opened, close it by half turn to prevent “JAMMING STICK”
- Before manipulating, check lubricating status, any deformation on the screw
thread of the valve or any foreign material on it.
- If the valve is not fully closed (TIGHT CLOSE), crack open and try to close again
and also check the stroke(spiral ridge parts) of the valve. Be careful that surplus
tightening close could make opening of the valve adversely in some type of
valves,
- Be careful against steam leak from gland of the valve when manipulating
valves, like step aside safely.
- Operator keeps his/her balance when using “VALVE WRENCH” during the
manipulating of the valves, to avoid any biased force on the stem of the valve.
( if needed, use two VALVE WRENCHES on both direction(180°) )
- Use the correct size of VALVE WRENCH.
- Basically, don’t use the WRENCH when manipulate valves but use it carefully
under unavoidable condition only

(2) Counter-Action against The Leakage from the VV GLAND

- Leakage from the valves shall be prevented if it is wide opened in case that the
valve has the back seat according to the structure of the valves, so check the
type of the valves and make it wide opened.
- If the valve type is no leakage while closed due to its structure, close it after
reviewing carefully the affection of its closing.
- Do the emergency action like put the protection cover against any undesirable
affection the other equipments, in case that the manipulating of the valve
can’t stop or decrease the leakage.
- Put safety sign and safety barricade at the area around the leakage
equipment.

7
(3) Manipulating of the Double VALVES under High Pr.

(1) Purpose of Double VALVE

To protect the damage of 1st VALVE (DISC SEAT)
(2) Manipulating
OPEN : Open the 1st valve widely and then open the 2nd valve.
CLOSE : Close the 2nd valve tightly and then close the 1st valve
(3) Normal Status
- 1st valve : keep WIDE OPEN
- 2nd valve : CLOSE and manipulate it if needed

CHECKING PUMP & MOTOR before/after its STARTING

Pre-start Check
(1) Check the insulation of the motor.
For high voltage MOTORs, after long period of standstill, 7.5㏁ of insulation is O.K,
but below 100㏁ of it needs to be dried.
(2) Check the priming of the pump and the charge of the suction line of the pump
by manipulating the vent cock or vent valve. If air exit in those pump or suction
line, cavitations may occur during its running.
(3) Check if the casing drain valve and vent valve are closed.
(4) Check the assembling & tightening status of the rotation and stationary parts.
And check the smooth turning of the pump by hand.
(5) Check that the protection device is correctly assembled(no disassembled
devices)
(6) Check the correct settings of the protection devices
(7) Check the cooling fan of the motor : no obstacles for the suction side of the fan
(8) Check the L.O, cooling water system, each indicator (flow, etc,.), filters, line-up,
etc,.
(9) Check all VALVES’ position of the pump
- Check the minimum flow line
- Check the opening of the suction valve
- Checking of the Valves
• Centrifugal Pump
- Check closing of discharge valve, start pump and open discharge valve after start
• Axial / Diagonal Pump
- Check discharge valve opened, start pump
(or start pump and open discharge valve at the same time)
• Positive displacement Pump
- Check all valves opened, which are pressurized by the starting pump, and start
pump

(10) Breaker “On”.

(11) Confirm the return of the TAG(PTW, Safety Paper), make ready to start pump
with the present of the related staffs if needed.

Post-Start Check

(1) Check operation parameters ; ampere meter, flow meter, vibration, abnormal
sound, etc,.
(2) Check & monitor the operation parameters till reaching stable condition.
(3) If the parameters are changed or rapidly varied, stop immediately and find out
the cause.

8
Identification of the lubricating Oil Piping
Identify the in/out direction as below.

1. OUTLET LINE is larger than the INLET.

2. SIGHT GLASS is placed on the OUTLET.
3. The temperature of OUTLET LINE is higher than the INLET.

Identification of the leakage from the FW Heater

(1) Check the abnormal from the inside of the FW Heater sound by the listening
stick(steel), whose cause is leakage.
(2) Check if FW HTR DRAIN amount & level are increased
(3) If Drain Valve is not functioning or broken internally(disassembling of the disc,
plugging, etc,.), then the HEATER LEVEL can be increased or Dump Valve can be
opened.
(4) If FW HTR TUBE LEAKAGE is suspicious then do action(close Heater Steam Valve.
primarily to prevent Turbine Water Induction
(5) If leakage is confirmed, close the extraction steam and do the “heater by-pass
operation” and isolate the heater.
(6) When manipulate the “DRAIN, VENT system”, carefully consider how it affects on the
heater and vacuum system

Piping Support Checking

HANGER, SUPPORT : To support the weight of piping.
1. RIGID HANGER is used where the vertical displacement by the heat is very
small(<2mm).
2. SPRING HANGER(VARIADLE HANGER) is used where the vertical displacement is
(2~50mm) and the variable rate of the weight is (>25%)

RESTRAINT : To restrain the 3-demensional movement by the heat expansion.

1. ANCHOR fixes the part of the pipe.
2. GUIDE is used to prevent from rotating of the pipe followed along the axis.
3. RESTRAINT (STOP) is used where the pipe rotation is allowed but restrict the
rectilinear movement (simple motion).

BRACE : To restrict to move by “vibration, earthquake, water hammering, etc,.”

1. Anti-vibration-SPRING is used to prevent or reduce the vibration where the
displacement by heat expansion is small.
2. Anti-vibration device by hydraulic or mechanical, is used to prevent or reduce the
vibration where the displacement by the heat expansion is big
3. SHOCK ABSORBER is used to reduce the shock by the earthquake, HAMMERING,
etc,.

9
CHANGE OVER of the COOLER, STRAINER, FILTER
Pre-check :
1. Check the operating status (perform by two person)
- Position and direction of the TRANSFER VALVE HANDLE
- PRIMING status of the STAND-BY SIDE (check VENT VALVE, DRAIN Vv.)
- FLOW (SIGHT GLASS)
- LEVEL
2.Confirm again the PRIMING STATUS by opening slowly the AIR VENT OF
STAND-BY SIDE for 2~3 min with monitoring any change of pressure.
3.As having “STAND-BY (COOLER STRAINER FILTER)”’ in service parallel with together.
Monitor the operating parameters, any leakage, etc,.

If pre-check completed and condition normal,

4. perform TRANSFERING slowly (confirm the position of the TRANSFER LEVER.

5. Isolate certainly the IN/OUTLET VALVES of the one not in service.
6. Prepare STAND BY ONE
- Close DRAIN Valve
- Open “FILLING Valve” slowly
- Check the pressure as opening VENT Valve slowly
- Perform PRIMING for 2~3 min, then let it “STAND-BY”

7. TRANSFER LEVER should not be put in parallel position.

10
II. BOILER

1. Specification
(1) Type : CFB, Variable Pressure, Sub Critical,
Single Steam Drum, Natural Circulating
Water tube boiler.
(2) Boiler water rated load capacity : 55.5 m3
(Steam Drum : 10.8m3; Water wall : 18.9m3 ; Economizer : 13.3 m3)
(3) Steam Flow at BMCR : 130 t/h
(4) Steam Pressure at BMCR
- Outlet of the super heater : 9.81 Mpag
(5) Steam Temp. at BMCR
- Outlet of the super heater : 540 ℃
(6) Feed water Temperature at BMCR : 215 ℃
(7) Ambient Temperature : Ave. 20℃
(8) Blow Down rate :2%
(9) Evaporator : Vertical Tube
(10) Fuel : Bituminous Coal
(11) Combustion : Circulating Fluidize High-low Bed
Combustion
(12) Boiler Efficiency : 90 % (indonesian Coal)
(13) Slag Cooler : Adopted
(14) Exhaust gas Cyclone Separator : Adopted
(15) TBN By-Pass System : HP By-Pass
(16) Safety High Pr. Side : HP By-Pass Valve, PRV, Safety valves
(17) Soot Blowing : Steam
(18) Draft Fan : Centrifugal
(19) Electro Precipitator : Low Temp, dry
(20) Design Fuel : Coal

Symbol Unit Data

Car % 40.92

Har % 3.42

Oar % 13.902

Nar % 0.678

Sar % 1.08

Aar % 5

Mar % 35

Vdaf % 58.3

Qnet,ar KCal/kg 3611

Coal size：0-8 mm

11
 Method measurement of material bed thickness, and the drag characteristic curve of
air quantity :

When measuring material bed drag, put the material bed with a thickness of
>500mm on the grid plate, and measure the static pressure of air chamber under
different air quantity value.
Draw the characteristic curve about air quantity and pressure, then retest after
dropping every 100mm material bed in thickness and draw characteristic curve
until the thickness of grid plate is only 200mm.
At that time the air pressure of air chamber is equal to the value of grid plate drag
plus material bed drag, when debugging determine the air quantity parameter in
certain thickness of material bed according to the characteristic curve.
Air quantity is related to the granule size of material bed, gravity and freckle of
material bed heap, the detail could be found from the characteristic curve

Cyclone separator
Cyclone separator is separation devices non filter (dry scrubbers) that use the
principle of inertia to remove particulate matter from flue gases. Cyclone
separator is also known as pre-cleaner since they generally remove larger pieces
of particulate matter.
In a cyclone separator, dirty flue gas is fed into a chamber. The inside of the
chamber creates a spiral vortex, similar to a tornado.
The lighter components of this gas have less inertia, so it is easier for them to be
influenced by the vortex and travel it up. The cleaned flue gas escapes out the
top of the chamber. Contrarily, larger components of particulate matter have
more inertia and are not as easily influenced by the vortex.
Since these larger particles have difficulty following the high speed spiral motion of
the gas and the vortex, the particles hit the inside walls of the container and drop
down into a collection hopper. These chambers are shaped like an upside-down
cone to promote the collection of these particles at the bottom of the container.

Cyclone separator diagram :

CLEAN GAS

DIRTY GAS

DUST

12
 2. Closing & Opening of Drain & Vent Valve during Start-Up
2.1 Opening
(1) Vent Valve
- All SH vent valves --> will be closed if Hp Bypass system ready (steam
pressure around 1.8 Mpa)
- Steam Drum vent valves
- Saturated Steam Header vent valves
- Economiser vent valves

Note : All vent should be closed after steam pressure > 0.1 Mpa

(2) Drain Valve

- SH header drain valves
- HP Steam Bypass line drain valves (drain and warm up)
- Gland seai steam header drain valve

2.2 Closing
(1) Vent Valve
- Boiler Steam Header Exhaust MOV

(2) Drain Valve

- Boiler Side Water wall Down Header Drain Valves
- Boiler Front and Rear Water wall Lower Header Valves
- Boiler Front and Rear Embeded Down Header Valves
- Boiler Down comer Valves

3. HP Steam Bypass System

HP bypass system is for maintaining adequate steam flow for tube protection
while unit start up or if Steam Turbine tripped.

HP Bypass system line consist of :

- MOV Isolation valve L1BA20AA131 and L1BA20AA132
- Pressure Reducing and De-Superheating Control valve L1BA20AX001
- Water Spray control valve L1AD10AA100
- Pressure reducing Valve with IMPULSE SAFETY Valve (Opening Pressure
setting 0.6 Mpa)

ITEM DESIGN OPERATION

PRESSURE after PCV 0.8 Mpa Max 0.5 Mpa
TEMPERATURE 180 ℃ 150 ℃
CAPACITY 30 % ????

13
HP Steam Bypass System Operation Pre-Conditions :

- SH Steam Pressure : > 3.5 Mpa

- SH Steam Temperature : 250 ℃
- Steam Turbine T/G : In operation
- Steam Turbine gland /seal steam : In Operation
- Condenser vacuum pressure : < 0.075 Mpa
- HP Steam Bypass System line already warmed up (warm up started while SH
steam temp > 175 ℃)

HP Steam Bypass System Operation :

1) MOV Isolation valve L1BA20AA131 and L1BA20AA132
> AUTO OPEN if:
- Condenser Vacuum pressure < -0.075 Mpa, and
- Steam Turbine STOP /TRIP, and
- HP Bypass Interlock Push Button ON

> AUTO CLOSE if:

- Condenser Vacuum pressure > -0.075 Mpa

2) During unit start-up, Pressure Control Valve L1BA20AX001 will manually control
by operator.
If Steam Turbine TRIP, Pressure Control Valve L1BA20AX001 will directly open to
20% then controlling as given pressure setpoint.

Temperature Control valve L1AD10AA100 will auto controlling temperature as

given setpoint

3) In case of Turbine Trip and HP Bypass Fail to open, then

Steam Exhaust MOV H1AH10AA231 and H1AH10AA232at Boiler will

> Auto Open, If :

- Steam Turbine TRIP, and
- HP Bypass system fail to Open, and
- HP Bypass Interlock Push Button ON
OR
- If Main Steam Pressure ≥ 10 MPa

> Close manually by Operator

Note: Operator should aware of opening steam Exhaust valve to avoid too much
steam pressure drop

14
4. BOILER ALARM and TRIP : OFT (Oil Fuel Trip)
OFT Signals and Setting

Time
No OFT Signals Set Point Action
Delay
Oil Pressure Low
1 - Any Oil vlv Open, and - Chief Oil Close
〈0.9 Mpa 2 sec
- Header Oil Pressure - Low Bed 1(Vlv close, Ign gun out)
- Chief oil vlv Close, and - Low Bed 2(Vlv close, Ign gun out)
2 - Left Up Bed 1(Vlv close, Ign gun out)
- Any Oil vlv Open
- Right Up Bed 1(Vlv close, Ign gun out)
3 Boiler Trip(BT) Activated
- Left Up Bed 2(Vlv close, Ign gun out)
- Right Up Bed 2(Vlv close, Ign gun out)
4 Main Fuel Trip (MFT) Activated - Return Oil Regulating vlv to Open

5. BOILER ALARM and TRIP : MFT (Main Fuel Trip)

MFT Signals and Setting

Time
No OFT Signals Set Point Action
Delay
Bed Temperature
>900 ℃:
- H1AD01CT001
- H1AD01CT002
- H1AD01CT003
- H1AD01CT004

2OO3:
1 - H1AD01CT005
- H1AD01CT006 >900 ℃ 6 sec
- H1AD01CT007

2OO3:
- H1AD01CT008
- H1AD01CT009
- H1AD01CT010
- Boiler OFT Action
< 44000 - Coal Feeder 1 and 2 Stop
2 Total Air Flow <25% 5 sec
Nm3/h - Coal Feeder 1 and 2 Outlet Gate
Furnace Flame Loss: Close
- All oil vlv Close
- All Coal Feeder Stop, - STG Trp
3 AND 5 sec
Outlet gate vlv Close
- Bed Temp<650 ℃

15
 Bed Temp <650 ℃ AND
Oil Not in-service:

- H1AD01CT001
- H1AD01CT002
- H1AD01CT003
- H1AD01CT004
4 - H1AD01CT005
- H1AD01CT006
- H1AD01CT007
- H1AD01CT008
- H1AD01CT009
- H1AD01CT010
AND
- All Oil gun NOT
in-service
Steam Drum Level HH
2OO3:
- H1AA10CL001
>+150
5 - H1AA10CL002 5 sec
mm
- H1AA10CL003

-HH1AA10CL701

6 Boiler Trip(BT) Activated

7 Manual MFT Pb Activated

6. BOILER ALARM and TRIP : BT (Boiler Trip)

BT Signals and Setting

Time
No OFT Signals Set Point Action
Delay
Furnace Pressure HH :
- H1AD01CP201
1 - Boiler MFT Action
- H1AD01CP202
> +300 pa 2 sec - Boiler OFT Action
- H1AD01CP203
- Both IDF Stop
Furnace Pressure LL :
IDF Inlet damper Open 5%
- H1AD01CP204
2 < -300 pa 2 sec
- H1AD01CP205
- Both PAF Stop
- H1AD01CP206
- Both SAF Stop
Steam Drum Level LL : - 1st level DSH vlv 1 and 2 Close
2oo3 - 2nd level DSH vlv 1 and 2 Close
- H1AA10CL001 - All Boiler blow down vlv Close
< -150
3 - H1AA10CL002 5 sec
mm
- H1AA10CL003 - STG Trip
OR
- LH1AA10CL701

16
 4 Both IDF Stop
5 Any PAF Stop
Boiler Recyclone air
< 900
6 Flow Low
Nm3/h
- H1LA26F101
7 Main Boiler Trip (BT) Activated

7. OPERATOR ACTIONS if TRIP Occurred on Boiler :

ORDER ACTIONS
NO
a. MFT OCCURED

> Check MFT signal on MFT screen

> Check the stop of the fuel supply
- All FDR Trip (Motor Stop)
Check MFT Alarm and -All fuel oil Ignition retract
1
Status - All fuel oil valve close
- Fuel oil return valve open

> STG Trip (Check DEH screen)

> Check the operating status of PAF, IDF and SAF

> Check Fluctuation of furnace Pressure.
2 Check Draft System
- If needed, adjust fans damper to controlling furnace
pressure

> Check the operating status of CEP

> Check the operating status of Feed water Pump
- Feed water pump speed and other parameter
3 Check FW System - Min flow condition
> Check ECO. Inlet Feed WTR Flow
- Operating status of FW Control Valve
- FW Isolation Valve

> Check SH Spray Control Valve

IF BT occurred all valves Closed
4 Boiler Tube Protection
> Check Soot Blower is retracted

> Check Steam Turbine Speed Reducing

Normally, speed 3000 rpm -> 1500 rpm = ............ min
5 Check Turbine Status
1500 rpm -> 500 rpm = ............ min
500 rpm -> 0 rpm = ............ min

17
 > Check Lub Oil pump (AC, DC pump) status
> Check Turbine. Hood Spray Vv. Status
- Valve spray auto open if temperature > 75 ℃

> Check the Condenser Vacuum (< -600 mbar)

- Low Alarm ..... mpag,
- Lo-Lo Trip ≥ -0.06 mpag

> Check Seal Steam Header Pressure

- Low Alarm ......... mpa. High Alarm ...... mpa

> Check the operating status of T/G of Steam Turbine.

Check Generator and > Check GCB status is OPEN

6
Excitation system > Check Excitation FCB is OPEN

b BOILER TRIP OCCURRED

If BOILER TRIP occurred, all Boiler System will STOP

- ALL Fuel System STOP
- All Draft System STOP

> Analyze the cause of MFT, correct if any

Analyze the Cause
> Check again condition status of boiler and turbine
C > Prepare restart of the Unit
Restart if the system is
> Set the restart schedule with the coordination of
ready
dispatcher

> Boiler Purge Start

- When restart, perform rapidly to prevent the drop of
d BLR Purge Main Steam Temp.
> Do action as the needs according to the Unit Restart
Schedule

BOILER Safety Valve Setting :

Steam Drum Superheater Steam Header

12.058 Mpa 10.193 Mpa 10.2 Mpa
Pressure
12.3018 Mpa 10.403 Mpa

18
III. FANS DRAFT SYSTEM
1. SPECIFICATION

ITEMS ID Fan PA Fan

(1) QUANTITY 2 Sets 2 Sets
(2) FAN TYPE CENTRIFUGAL CENTRIFUGAL
(3) FAN MODEL QAY-1 No 20F
(4) VOLUME FLOW 164700 m3/h 39700 m3/h
(5) TOTAL PRESSURE 5100 Pa 21200 Pa
(6) FAN SPEED (MAX) 960 RPM 1450 RPM

(7) MOTOR TYPE YKK450-6 YKK400-4

(8) MOTOR SPEED 960 RPM 1450 RPM
(9)MOTOR OUTPUT 355 KW 400 KW
(10) MOTOR VOLTAGE 6.3 KV 6.3 KV

Variable Speed and

(11) CONTROLLING Inlet Damper Control
Inlet Damper Control

(12) LUBRICATING OF BRG

- Fan Oil Oil
- Motor Grease Grease
(13) BEARING COOLING Water Cooler Water Cooler

ITEMS SA Fan
(1) QUANTITY 2 Sets
(2)FAN TYPE CENTRIFUGAL
(3)FAN MODEL
(4)VOLUME FLOW 50000 m3/h
(5) TOTAL PRESSURE 13500 Pa
(6)FAN SPEED 1450 RPM

(7) MOTOR TYPE YKK400-4

(8) MOTOR SPEED 1450 RPM
(9) MOTOR OUTPUT 280 KW

19
(10)MOTOR VOLTAGE 6.3 KV

(11) CONTROLLING Inlet Damper Control

(6) LUBRICATING OF BRG

- Fan Oil
- Motor GREASE
(7) BEARING COOLING Water Cooler

2. INDUCED DRAFT FAN (ID FAN)

ID fan is always located between dust collector and chimney. ID fan will take the
hot flue gases from furnace via dust collector and will deliver to chimney.

ID fan will produce the negative pressure in the furnace to remove the flue gases
from furnace via electrostatic precipitators and to push the flue gases to
chimney.
The operation of ID Fan is to regulate boiler furnace pressure.

2.1 START-UP
(1) IDF START-UP CONDITION

>> To start IDF, the Permissive Start conditions should be fulfilled

(1) NOT “ID Fan Trip Condition”
(2) ID Fan motor electrical control "IN REMOTE" Condition
(3)ID Fan Parameter in NORMAL condition ( Temperature, Vibration and
Hydraulic Coupler Pressure )
(4) ID Fan Inlet Damper Position ≤ 5%

(2) OTHER CONDITIONS

(1) Cooling Water system Ready or in operation
(2) Close the manual damper on ducting between IDF and Chimney
(3) Hydraulic coupler actuator position 0%

2.2 STOP

IDF STOP and TRIP CONDITION :

>> IDF will stopped or Trip under below conditions.
- Manually Stop by Operator
- Any Parameter reached TRIP value
- Trip from Electrical MCC
- Boiler Trip occurred

20
2.3 ID FAN Operation Parameter :

Setting
Description Normal REMARKS
Start Alarm Trip

Motor Current

Pressure Furnace

Inlet damper

Hydraulic coupler
position

Alarm and Trip Signal

>85℃
Fan Bearing Temp >75℃
TD 3 sec
>90℃
Motor Bearing Temp >85℃
TD 3 sec
Motor
>130 ℃
Winding(U,V,W) >110℃ 2oo3
Temp TD 3 sec
>120 um
Fan Vibration >80 um
TD 1 sec
Hydraulic Coupler
< 0.30 Mpa < 0.35 Mpa
Outlet Oil Pressure
Hydraulic Coupler
Outlet Oil >80 ℃ >90 ℃
Temperature

Boiler trip Active

Electrical MCC Trip Active

Emergency Trip Pb Active

3. PRIMARY AIR FAN (PA FAN)

PA fan is used basically for providing the required quantity of hot air to the
furnace for smooth and uniform combustion of fuel and for fluidizing of material
bed.
PA fan will produce the positive pressure inside the boiler furnace.

21
3.1 START-UP
(1) PAF START-UP CONDITION

>> To start PAF, the Permissive Start conditions should be fulfilled

(1) PA Fan NOT Trip Condition
(2) PA Fan motor electrical control "IN REMOTE" Condition
(3)PA Fan Parameter in NORMAL condition ( Temperature, Vibration )
(4) ID Fan already Started
(5) NO MFT Occur
(6) PAF Inlet Damper Position ≤ 5%
(7) PAF Outlet Damper in CLOSE position

(2) OTHER CONDITIONS

(1) Cooling Water system Ready or in operation
(2) Close the manual damper on ducting between IDF and Chimney

3.2 STOP
PAF STOP and TRIP CONDITION :
>> PAF will stopped or Trip under below conditions.
- Manually Stop by Operator
- Any Parameter reached TRIP value
- Trip from Electrical MCC
- ALL ID Fan Stop
- Boiler Trip occurred

>> PAF Outlet damper Auto Close if PAF Stop or Tripped

3.3 PA FAN Operation Parameter :

Setting
Description Normal REMARKS
Start Alarm Trip

Motor Current

Min Air Flow =

Discharge Air Flow
........... t/h

Discharge Pressure

Alarm and Trip Signal

>85℃
Fan Bearing Temp >75℃
TD 3 sec
>90℃
Motor Bearing Temp >85℃
TD 3 sec
Motor Winding(U,V,W) >130 ℃
>110℃ 2oo3
Temp TD 3 sec

22
 >120 um
Fan Vibration >80 um
TD 1 sec

Boiler Trip Active

Electrical MCC Trip Active

Emergency Trip Pb Active

4. SECONDARY AIR FAN (SA FAN)

The SA fan allows for complete combustion of the fuel inside the furnace, and
when required the SA fan is used to increase the air flow to improve the
efficiency and avoid wastage of fuel.

4.1 START-UP
(1) SAF START-UP CONDITION

>> To start SAF, the Permissive Start conditions should be fulfilled

(1) SA Fan NOT Trip Condition
(2) SA Fan motor electrical control "IN REMOTE" Condition
(3) SA Fan Parameter in NORMAL condition ( Temperature, Vibration )
(4) PA Fan already Started
(5) ID Fan already Started
(6) NO MFT Occur
(7) SAF Inlet Damper Position ≤ 5%
(7) SAF Outlet Damper in CLOSE position

(2) OTHER CONDITIONS

(1) Cooling Water system Ready or in operation

4.2 STOP
SAF STOP and TRIP CONDITION :
>> SAF will stopped or Trip under below conditions.
- Manually Stop by Operator
- Any Parameter reached TRIP value
- Trip from Electrical MCC
- Boiler Trip occurred

>> SAF Outlet damper Auto Close if SAF Stop or Tripped

23
4.3 SA FAN ALARM and TRIP Signals :

Setting
Description Normal REMARKS
Start Alarm Trip
Motor Current
Minimum Air Flow
Discharge Pressure

Alarm and Trip Signal

>85℃
Fan Bearing Temp >75℃
TD 3 sec
>90℃
Motor Bearing Temp >85℃
TD 3 sec
Motor Winding >130 ℃
>110℃ 2oo3
(U,V,W) Temp TD 3 sec
>120 um
Fan Vibration >80 um
TD 1 sec

Boiler Trip Active

Electrical MCC Trip Active
Emergency Trip Pb Active

5. BOILER SOOT BLOWERS

A sootblower is a device for removing the soot that is deposited on the
furnace tubes of a boiler during combustion and prevent plugging of gas
passes and maintain boiler efficiency.

5.1 SPECIFICATION

ITEMS SPECIFICATION
Jianshan Keneng Boiler Auxiliary Machine
(1) MANUFACTURE
Equipping Co.Ltd
(2) MODEL G3A Fixed rotary

(3) QTY 8 (Superheater : 4, Economizer : 4 )

(4) OPERATING

- Blowing Medium Steam or Compressed Air

- Operating Pressure before valve 0.78 - 1.96 Mpa

24
 - Operating Temperature ≤ 350 ℃

- Steam Consumption (kg/h) 30 - 70 kg/min

- Motor Specification AO2 6324, 0.25 KW, 1400rpm

6.2 Boiler Soot Blower OPERATION

>> Soot Blower Operation Pre conditions :

- Boiler in Operation
- Boiler Load > 70 %
- Power Supply Soot Blower Panel ready and ON
- Power Supply for each Soot Blower Ready and ON
- Each soot blower coupling lever at "power" position
- Instrument Air for Pneumatic Control Valve ready
- No Fault indication on Soot Blower Control Panel

(1) Auto Operation

1) Open Soot Blower system Inlet Steam valve from CCR
2) Select AUTO MODE in Soot Blower Control Panel.
3) Select Soot blower No which is will be operate,
Put switch of selected Soot blower in AUTO,

4) Press START POGRAM push button ,

Start Program will automatically started.
5) Soot blower operation will stop after all sequence program finish

(2) Manual Operation

1) Open Soot Blower system Inlet Steam valve from CCR
2) Select MANUAL MODE in Soot Blower Control Panel
3) Open Discharge valve
4) Open Cut-Off valve and Control valve for warming up pipe line, till
temperature indication ON
5) Close Discharge valve
6)Perform blowing by Starting selected Sootblower

(3) LOCAL Operation

1) Open Soot Blower system Inlet Steam valve from CCR
2) Select MANUAL MODE in Soot Blower Control Panel
3) Open Discharge valve
4) Open Cut-Off valve and Control valve for warming up pipe line, till
temperature indication ON
5) Close Discharge valve
6)Perform blowing by Starting selected Sootblower at Local Soot Blower.

(4) DCS Operation

1) Open Soot Blower system Inlet Steam valve from CCR
2) Select DCS MODE in Soot Blower Control Panel.
3) Select Soot blower No which is will be operate,
Put switch of selected Soot blower in AUTO,

25
 4) Press START POGRAM push button at OWS SootBlower Screen,
Start Program will automatically started.
5) Soot blower operation will stop after all sequence program finish

IV. FUEL SYSTEM

This type boiler adopts off-bed oil lighting. Because the bed surface too big so
the off-bed oil lighting adopt single side main bed first start up, this boiler is main
bed right side for lighting area, then lighting, at last with forward vice bed.
Incorporate with forward vice bed because forward vice bed is dense
superheater layout when boiler output not get load that could not lighting
forward vice bed, the stationary bed material can protect dense superheater,
only when boiler get the load the steam can cooling dense superheater then
lighting up forward vice bed.

Off-bed boiler lighting up is fluidizing lighting up, the entire starting up process
should be done under fluidization.
- the bed of material (thickness 300~400mm) on the grid plate,
- the grain size should not exceed 3mm,
- the gas coal content of bed of material should not exceed 10~15 %,
- the calorific capacity of bed of material could not exceed 3000 KJ/kg.
Because the calorific capacity is delivered to the bed of material uniformly
below the grid plate, the entire heating process should be done in fluidization,
and would not get coked under low temperature or high temperature

Using light diesel fuel is in preference when lighting up, after firing, light diesel fuel
should be puffed into flue gas generator, the high temperature flame and the
cold wind in the side mixed into flue gas with a temperature of about 850 ℃ ,
which enter the right side main bed through air chamber and blast cap and
then heat the bed of material.

To avoid burning out the blast cap, the flue gas temperature must be controlled,
which is not allowed to exceed 900 ℃.

The rapid increase of temperature should be controlled to prevent cracks and

irregularity on the furnace wall, especially in the beginning of cold state, the
increasing speed could not exceed 5-10 ℃/min, the cold state starting up time is
about 4hr, while the hot state starting up time is 40-90 min

When starting up cold state, bed of material temperature should be slowly

heated to 300~400 ℃ from room temperature, while keep rising temperature, the
volatile matter in the coal release in bulk, the bed temperature would rapidly
increase at 450-550 ℃, the temperature scope of this stage is related to the coal
type used, when it is appeared, then add some coal into the main bed and
reduce the oil distributive value, when the bed temperature rise to 650-700 ℃,
the oil gun could be turn off.

26
1. Fuel Oil System
1.1 Fuel Oil Specification

(1) Fuel oil type : Light Diesel Oil

- Density :
- Viscosity (38℃) :
- Heat Value(High) :

(2) Fuel Oil Tank

- Quantity :2
- Capacity :
- Size :

(3) Light Diesel Oil Pumps

ITEMS LDO Feed Pump LDO Unloading Pump

PUMP
(1) QUANTITY 2 units 2 units
(2) PUMP TYPE CENTRIFUGAL CENTRIFUGAL
(3) PUMP MODEL SMH440R40E6.7W21 YCB-15/0.6
(4) VOLUME FLOW 15 m3/h 10 m3/h
(5) TOTAL PRESSURE 4 MPa 0.49 MPa

MOTOR YB2-200L-4
(6) MOTOR TYPE 380/660 V YB2-132S-4
(7) RATED VOLTAGE 57.6/660 V 380/660 V
(8) RATED CURRENT 57.6/33.3 A 11.5/6.7 A
(9) RATED CAPACITY 30 KW 5.5 KW
(10) PUMP SPEED 1450 RPM 1450 RPM

ITEMS DIRTY OIL Pump TO EDG

PUMP
(1) QUANTITY 2 units 1 unit
(2) PUMP TYPE CENTRIFUGAL CENTRIFUGAL
(3) PUMP MODEL YCB-15/0.6 100X80 FS JA
(4) VOLUME FLOW 10 m3/h
(5) TOTAL PRESSURE 0.49 MPa

27
 MOTOR
(6) MOTOR TYPE YB2-132S-4
(7) RATED VOLTAGE 380/660 V
(8) RATED CURRENT 11.5/6.7 A
(9) RATED CAPACITY 5.5 KW
(10) PUMP SPEED 1450 RPM

1.2 Fuel Oil Pumps Operation

> Fuel Oil Feed pump

- Operate Manually or Remotely from CCR

> Fuel Oil Unloading pumps

- Operate Locally

> Dirty Oil pump

- Operate Locally

> Fuel Oil Feed pump to EDG

- Operate Locally

1.3 Fuel Oil Tank Level Setting

- Top Level : mm
- High Level : mm
- Low Level : mm
- Low Low Level : mm

1.4 FUEL OIL BURNER

Boiler front Fuel Oil System :

- Working temperature : < 80 C for ignition equipment
- Total Flow fuel consumption : 4.4 T/h
- Oil gun number : 2 units at Lower Bed
4 units at upper bed

Fuel Oil Burner START and STOPSEQUENCE

Fuel Oil Burner Ignition Permissive start :

- Boiler Ignition Device in Remote Condition
- Any Boiler Oil burner Ignition NOT in Starting Sequence
- Oil valve is Close position
- Igniter gun NOT in Stop Sequence
- Boiler OFT NOT active
- Fuel Oil Pressure OK
- Purge valve is Close position
- Fuel Oil Chief valve i Open position

28
 (A) Fuel Oil burner START Sequence
1) Open Purge valve
2) after 30 sec Purge valve Close
3) Igniter Gun inserted then ignited
4) Igniter Gun inserted + 2 sec then Fuel Oil valve Open
5) Igniter gun Retracted after 15 sec Igniter Gun inserted
6) If within 10 sec NO fire detected then start FAULT indication coming
7) If Start sequence Fail, then continue with Stop sequence

(B) Fuel Oil burner STOP Sequence

1) STOP sequence will automatically start if NO fire detected
2) Oil valve Close
3) Purge valve Open
4)Purging time is 30 sec

5) Any FAULT of feedback valves, STOP sequence Fail alarm will come
6) If flame detected after Stop sequence completed, perform STOP sequence
again

2. COAL Combustion System

2.1 Coal Silo Specification

(1) Quantity 2 Silo / Boiler

(2) Density of Raw Coal kg/m3

Diameter : m
Height
(3) Size(m)
- Shell : m
- Hopper : m

(4) Capacity Effective : m3

2.2 Coal Feeder Specification

COAL FEEDER
XUZHOU HUANENG MEASURE & CONTROL EQ. Co.
(1) Manufacturer
LTD. CHINA
(2) Model NJG -30

(3) Capacity 20 ton/h

(4) Method of Output Control Microprocessor

(5) Matched Motor Capacity 5.5 kW

(6) Material in Contact with Coal Rubber

29
 CONVEYOR COAL FEEDER MOTOR

(7) MANUFACTURE Xuzhou Fangda Motor

(8) MODEL Y2-1325-4
(9) VOLTAGE 380 V
(10) CURRENT 11.7 A
(11) CAPACITY 5.5 KW
(12) ROTATION SPEED 1440 rpm
SCATTERED COAL FEEDER MOTOR
(12) MANUFACTURE Xuzhou Fangda Motor
(13) MODEL Y2-100L1-4
(14) VOLTAGE 380 V
(15) CURRENT 5.1 A
(16) CAPACITY 2.2 KW
(17) ROTATION SPEED 1420 rpm

SCATTERED COAL FEEDER GEAR BOX

(18) MANUFACTURE Worm Gear Reducer (Chen Chao)
(19) MODEL NMRV 130

2.3 Coal Feeder START

2.3.1 Coal Feeder Start-Up Condition

(1) Boiler in Normal Operation
(2) Bed Temperature > 650 ℃
If Bed temperature < 650 ℃ then any Oil gun should be In Service, otherwise MFT
will activated
(3) Coal Feeder Control No Fault Indication
(4) Coal Feeder Outlet Slide Gate Open
(5) Coal Feeder Inlet Side Gate Open
(6) Feeder Speed Set to Min ( <1 t/h )

2.3.2 Coal Feeder Manual Start

(1) Select “AUTO/MAN Select SW” MAN
(2) Check Coal FDR Start Condition
(3) Start Coal FDR "START", run it at MIN Speed
(4) Check boiler operation status ( Furnace pressure, Flame, Temperature )
(5) Continue increasing coal feeder speed as operation needed

2.3.3 Coal Feeder Manual Stop

(1) Select Coal FDR SPD CTRL "MAN"
(2) Decrease the Coal Flow manually till MIN SPD
(3) Check boiler operation status ( Furnace pressure, Flame, Temperature )
(4) Start Oil Firing for controlling boiler operation.
(5) After Coal Feeder completely stop,
Close Coal Feeder Outlet slide gate

30
2.4 Manipulating of Local Control PNL, The way to Check “Trip, Alarm”

KEY FUNCTION :

KEY FUNCTION DESCRIPTION

Normal run, press the key the corresponsive light is on. Integrator is
RUN
running.
Set the parameters. “Set” light is on when press the key. Display
SETUP shows prompt below the left; shows actual instantaneous flux
below the right.
ENTER Read indications or input digits
Zero the system. “Zero/Reset” light is on when press the key.
ZERO / RESET
Standby for zero. Press again, start the zero condition.
Automatically adjust the intervals (calibration coefficient). “adjust
SPAN interval” light is on when press the key. Standby for adjusting
interval. Press again, start the interval adjusting condition.
Test the digits on the display. Keep pressing the key, the digits will
LAMP
alternately blink. The broken digits cannot blink.
Clear key. Reset the integrator parameter or replace lithium
Start
battery.
C

Print Print key. Can print when connected with communication panel.
9
Clock key. When connected with communication panel,

Clock press the key can show current time, press again, return to the
2 condition.

31
 COAL FEDEER PARAMETER :

PAR NO. PARAMETER SETTING

1P Current Zero value 7695

2P Current interval Value 141000

3P Current scale capacity value 20.00

4P Pulse number of one minute 1757

5P Current Test time 1757

6P Current test tonnage 0.343

7P Current instantaneous flux filter coefficient 5

8P Current accumulative amount 6.86

9P Calibration amount in last time .000

10P Corresponding values of current flux -703

Inner check, display 2824 on above
11P 2.824 / 506.8
display 5232 on below
12P Eliminate error symbol or several error symbol NA
Current speed frequency - dividing value
13P 3
range 0 - 7
14P Current simulative electric current output method 4 - 20

15P Current calibration method 0

16P Current distance pulse frequency - dividing value 100

Amount (ton) by weighing system when
substantial demarcation
17P
(Change calibration coefficient,
Input new calibration coefficient(Interval Value))

V. BOILER SLAG HANDLING SYSTEM

Boiler Slag Handling System is for removing bottom ash, slag and for removing
material bed from the boiler

32
Main Equipment Specification :

SLAG COOLER

Jiangsu Jingkong Alloy Steel

MANUFACTURE
Machine Manufacturing Co. Ltd
MODEL SFA-II-03M
CONVEYING CAPACITY 0.5 - 3
MATERIAL GRAIN 0 - 30
MATERIAL FEED TEMPERATURE ≤ 850 - 900 ℃
MATERIAL DISCHARGE TEMPERATURE ≤ 80 ℃
COOLING WATER MEDIA Demin Water or Condensate
INLET TEMP. OF COOLING MEDIA ≤ 40 ℃
OUTLET TEMP. OF COOLING MEDIA ≤ 55 ℃
FLOW CAPACIT OF COOLING WATER 12 - 16 t/h
PERMISSIVE PRESSURE ≤ 1.39 Mpa
MATCHED MOTOR POWER 1.5 kW
QUANTITY 2 unit

SLAG COOLER GEAR BOX

MODEL BWY22-71-1.5
MOTOR POWER 1.5 KW
CURRENT 72 A
QUANTITY 2 unit

CHAIN BUCKET CONVEYOR

Qingdao Changlong Powewr

MANUFACTURE
Equipment
MODEL LD 350
DEVICE OUTPUT 0 -10 t/h
MOTOR POWER 7.5 kW
GEAR TYPE Xwed106-181-7.5 kW
ROTATION SPEED 1500 rpm

SLAG SILO

CAPCITY m3
HI : m
LEVEL SET
LO : m

33
 Boiler Slag System Operation Pre-Condition :
- Any Close Cooling Water Pump In Service
- Open Inlet and Outlet cooling water of Slag Cooler
Examine pressure drop of inlet and outlet cooling water < 0.02 Mpa

Boiler Slag System Start Sequence :

A. Operation with Chain Bucket Conveyor 1 and Slag Cooler 1

1. START Chain Bucket Conveyor No.1 E1BR01AF001
2. OPEN Valve E1BR01AA003
--> OPEN to Chain Bucket Conveyor No. 1
CLOSE to Chain Bucket Conveyor No. 2
3. START Slag Cooler No.1 E1DZ10LZ001
4. OPEN Slag tap valve E1DZ10AA130

B. Operation with Chain Bucket Conveyor 2 and Slag Cooler 2

1. START Chain Bucket Conveyor No.2 E1BR01AF002
2. OPEN Valve E1BR01AA004
--> OPEN to Chain Bucket Conveyor No. 1
CLOSE to Chain Bucket Conveyor No. 2
3. START Slag Cooler No.2 E1DZ20LZ001
4. OPEN Slag tap valve E1DZ20AA130

C. If Combine operation Chain Bucket Conveyor No.1 and Slag Cooler No. 2 or
Vise versa, it need to positioning the OPEN or CLOSE of valve E1BR01AA003 and
E1BR01AA004 to desire Chain Bucket conveyor.

Slag Cooler Interlock :

>AUTO STOP if
- Outlet water cooling Temperture > 80 ℃.
- Chain Bucket Conveyor STOP / TRIP
- All Close Cooling Pump STOP

VI. CHEMICAL DOSING and SAMPLING SYSTEM

Boiler water treatment is used to control alkalinity, prevent scaling, correct pH,
and to control conductivity.
The boiler water needs to be alkaline and not acidic, so that it does not ruin the
tubes. There can be too much conductivity in the feed water when there are too
many dissolved solids.

The correct alkalinity is protected by adding phosphates. These phosphates

precipitate the solids to the bottom of the boiler drum. At the bottom of the
boiler drum there is a bottom blow down to remove these solids.

Oxygen and Carbon Dioxide are removed from the feed water by deaeration.
Deaeration can be accomplished by using deaerators heaters
Corrosive compounds, especially O2 and CO2 must be removed, usually by use
of a deaerator. Residual amounts can be removed chemically, by use of oxygen
scavengers.
Hydrazine is an oxygen scavenger which works in conjunction with a mechanical
deaerator

34
 Chemical reaction of hydrazine and Oxygen :

N2H4 + O2 ->> N2+2H2O

Feed water is typically alkalized to a pH of 9.0 or little higher (high alkalized
solution causes caustic corrosion), to reduce oxidation and to support the
formation of a stable layer of magnetite on the water-side surface of the boiler,
protecting the material underneath from further corrosion.
This is usually done by dosing alkaline agents into the feed water, such as sodium
hydroxide (caustic soda) or ammonia.

Ammonia and hydrazine are use in LP dosing. where it was dosed in low pressure
side before BFP.
These both chemical used their own prominent, where Ammonia used for
boosting PH in feed water.
Chemical reaction of Ammonia and water :

NH3 + H2O <-> NH4+ +OH-

1. CHEMICAL FEED SYSTEM

Equipment Specification:

AMONIA INJECTION HYDRAZINE INJECTION

SYSTEM SYSTEM
MOTOR
(1) MANUFACTURE Zhejiang Waland Electric Zhejiang Waland Electric
(2) MODEL YVP-80MI-4 YVP-80MI-4
(3) VOLTAGE 380 v 380 v
(4) CURRENT 1.8 A 1.8 A
(5) CAPACITY 0.55 kW 0.55 kW
(6) ROTATION SPEED 1420 rpm 1420 rpm

PUMP
Hangzhou Dachao Hangzhou Dachao
(7) MANUFACTURE Petrochemical Equipment Petrochemical Equipment
Co.LTD Co.LTD
(8) MODEL JM-X354/1.6-IV JM-X354/1.6-IV
(9) PRESSURE 1.6 Mpa 1.6 Mpa
(10) FLOW 54 l/h 54 l/h

(11) VOLUME
1.0 M3 1.0 M3
SOLUTION TANK

INJECTED TO BFP SUCTION BFP SUCTION

35
 PHOSPATE INJECTION
MIXING TANK
SYSTEM
MOTOR
(1) MANUFACTURE Zhejiang Waland Electric
(2) MODEL YVP-90MI-4 Y2-80MI-4
(3) VOLTAGE 380 v 380 v
(4) CURRENT 4.1 A 1.57 A
(5) CAPACITY 1.5 kW 0.55 kW
(6) ROTATION SPEED 1400 rpm 1390 rpm

PUMP
Hangzhou Dachao
(7) MANUFACTURE Petrochemical Equipment
Co.LTD
(8) MODEL M-Z54/16-IV
(9) PRESSURE 16 Mpa
(10) FLOW 54 l/h

(11) VOLUME SOLUTION

1.0 M3 1.0 M3
TANK

INJECTED TO BOILER DRUM

2. WATER SAMPLING SYSTEM

2.1 SAMPLING WATER COOLING DEVICE :

SPECIFICATION :
(1) PUMP QUANTITY 2 SET
(2) MOTOR VOLTAGE 380 V
(3) MOTOR POWER 11 KW
(4) DESALTED WATER FLOW 50m3/h
(5) DESALTED WATER PRESSURE ≥ 0.3MPa
(6) INDUSTRIAL WATER FLOW ≥ 55 m3/h
(7) INDUSTRIAL WATER PRESSURE 0.5MPa
(9) INDUSTRIAL WATER TEMPERATURE ≤30 ℃
(8) HEAT EXCHANGER
- TYPE PLATE
- AREA 20m2
(9) WATER TANK CAPACITY 2.5m 3

36
 2.2 WATER SAMPLING RACK

Series SYF Water-Steam sample cooling device has two main types: Type I and
Type II. Type I is a kind of cluster only operated manually; Type II integrated
automatically and manually.
Type I consists of High Temperature Frame and Sampling Panel; Type II consists of
High Temperature Frame, Sampling Panel, On-Line Instruments and Constant
Temperature System etc.
Except for On-Line Instruments and Constant Temperature System, the principle
and structure of two types are the same.

Technical Specification of Water sampling Cooler at online analyzer panel:

1. Compressor : 3HP/380V/50Hz
2. Refrigerant : R22
3. Condenser : 1.32 m2
4. Standard temperature : 25℃±1℃
5. Power Source : 380 v/50 Hz
6. Total Power : 3.13 kW
7. Evaporator volume : 0.832 m3
8. Cooling water temperature : ≤ 30 ℃
9. Cooling water pressure : ≥ 0.3MPa
10. Cooling water flow : ≥ 4T/h
The water cooler will auto start if temperature > 26 ℃ and operation within 15
minutes and then stop,

Water sampling line of online Boiler water quality analyser :

1. Condensate pump Outlet : Cation Conductivy & Disolved O2
2. Deaerator Outlet : Disolved O2
3. Economiser Inlet : pH and Cation Conductivity
4. Left and Right side of boiler water : pH, Specific Conductivity and PO4
5. Left and Right side of Sat Steam line : Cation Conductivity
6. Left and Right side of SH Steam line : Cation Conductivity

the flow needed for each line of analyser instrument’s sampling is ± 10 ml/min;
the flow needed for each line of manual sampling is about 500 ml/min.

Water - Steam Quality Standard Value :

Saturated
CEP Outlet Deaerator Economizer Boiler Drum SH Steam
Steam
≤ 10 ≤ 10 ≤ 150 µs/cm ≤ 0.3 ≤ 0.3
Conductivity ≤ 10 µs/cm
µs/cm µs/cm µs/cm µs/cm
pH 8.6 - 9.6 8.8 - 9.6 8.8 - 9.6 8.8 - 9.6 9.0 - 9.6 9.0 - 9.6
Silica (SiO2) ≤ 20 ppb ≤ 20 ppb ≤ 20 ppb ≤ 2000 ppb ≤ 20 ppb ≤ 20 ppb
0.2 - 0.5
Chlorine
mg/l
10 - 50 10 - 50
Hydrazine
ppb ppb
Fe+ ≤ 30 mg/l ≤ 30 mg/l ≤ 20 mg/l ≤ 20 mg/l
Cu+ ≤ 5 mg/l ≤ 5 mg/l ≤ 5 mg/l ≤ 5 mg/l
Phosphate 0.3 - 3.0 ppm
Note: Saturated steam and Superheated Steam --> Cation Conductivity

37
Water Sampling Overview Screen :

Effect of pH on the corrosion of Steel curve :

38
VII. EMISSION MONITORING SYSTEM
Continuous Emissions Monitoring System with Extractive Methodology to
monitoring flue gas.

CEMS monitoring conditions of :

- Concentration of flue gas SO2
- Concentration of flue gas NOx
- Concentration of flue gas CO
- Concentration of DUST in flue gas
- Oxygen content in flue gas
- Flue gas FLOW
- Flue gas PRESSURE
- Flue gas TEMPERATURE

The Standard quality for ambient air shall refer to the Government Decree No. 41,
May 26,1999 concerning the National Ambient Level Standard of Air Pollutant the
parameters are as follow :

Measurement
No Parameter Standard
Duration
2 Hours 900 µg / Nm3
1 Sulfur Dioxide (SO2) 24 Hours 365 µg / Nm3
1 Year 60 µg / Nm3
1 Hours 30.000 µg / Nm3
2 Carbon Monoxide (CO)
24 Hours 10.000 µg / Nm3
1 Hours 400 µg / Nm3
3 Nitrogen Dioxide (NO2) 24 Hours 150 µg / Nm3
1 Year 100 µg / Nm3
PM10 (Particle < 10 µm) 24 Hours 150 µg / Nm3
4 24 Hours 65 µg / Nm3
PM25 (Particle < 2.5 µm)
1 Year 15 µg / Nm3
24 Hours 230 µg / Nm3
5 TSP (Dust)
1 Year 90 µg / Nm3
10 Ton/Km2/Month
(Dwelling Area)
6 Dust Fall 30 Days
20 Ton/Km2/Month
(Industry)
1 mg SO2/100 cm3
7 Sulfate Index 30 Days
From Lead Peroxide

39