Thermal Power Plant: Pre-Operational Activities

476 Pages·2016·10.69 MB·English

by  Dipak K. Sarkar

Thermal Power Plant
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Thermal Power Plant
Pre-Operational Activities
Dipak K. Sarkar
AMSTERDAM (cid:129) BOSTON (cid:129) HEIDELBERG (cid:129) LONDON (cid:129) NEW YORK (cid:129) OXFORD
PARIS(cid:129)SANDIEGO(cid:129)SANFRANCISCO(cid:129)SINGAPORE(cid:129)SYDNEY(cid:129)TOKYO
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Dedicated to my grandparents
Nalini Prabha-Rajani Kanta
and
Surabala-Surendra Nath
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Contents
Preface............................................................................................................xv
Acknowledgments ............................................................................................xxi
List of Acronyms/Abbreviations........................................................................xxiii
Chapter 1: General Description of Thermal Power Plants ......................................1
1.1 Introduction............................................................................................................1
1.1.1 Nuclear Power Plant..........................................................................................2
1.1.2 Hydel Power Plant.............................................................................................6
1.1.3 Renewable Energy Power Plant........................................................................8
1.1.4 Integrated Gasification Combined Cycle (IGCC)..........................................10
1.1.5 Magnetohydrodynamic (MHD) Generator......................................................11
1.1.6 Fuel Cell Power Plant......................................................................................11
1.1.7 Thermal Power Plant.......................................................................................12
1.2 Steam Power Plant...............................................................................................14
1.2.1 Steam Generator..............................................................................................16
1.2.2 Steam Turbine..................................................................................................23
1.3 Gas Turbine Power Plant.....................................................................................27
1.4 Diesel-Generating Station....................................................................................29
Reference....................................................................................................................31
Chapter 2: Quality Assurance and Quality Control
(Applicable to Preoperational Activities)............................................................33
2.1 Introduction..........................................................................................................33
2.1.1 Quality Assurance............................................................................................34
2.1.2 Quality Control................................................................................................35
2.2 ISO 9000:2015—Quality Management Systems—Fundamentals
and Vocabulary....................................................................................................36
2.2.1 Definitions.......................................................................................................37
2.3 ISO 9001:2015—Quality Management Systems—Requirements......................39
2.4 Procedure.............................................................................................................41
References...................................................................................................................42
vii
viii Contents
PART 1 PREOPERATIONAL CLEANING OF VARIOUS
SUB-SYSTEMS 43
Chapter 3: Alkali Flushing of Preboiler System...................................................45
3.1 Introduction..........................................................................................................45
3.2 Description of Preboiler System.........................................................................49
3.3 Precautions...........................................................................................................51
3.4 Prerequisites.........................................................................................................51
3.4.1 Typical List of Apparatus................................................................................53
3.4.2 Typical List of Safety Gadgets.......................................................................53
3.5 Preparatory Arrangements...................................................................................53
3.6 Operating Procedure............................................................................................55
3.7 Estimation of Clarified Water, DM Water, and Chemicals...............................59
3.7.1 Water-Holding Capacity..................................................................................60
3.7.2 Clarified Water Requirement..........................................................................60
3.7.3 DM Water Requirement..................................................................................61
3.7.4 Chemical Requirement....................................................................................61
3.8 Conclusion...........................................................................................................61
References...................................................................................................................62
Chapter 4: Flushing of Fuel Oil Piping System....................................................63
4.1 Introduction..........................................................................................................63
4.2 Description of Fuel Oil System...........................................................................68
4.2.1 Fuel Oil System of Steam Power Plant..........................................................68
4.2.2 Fuel Oil System of a Gas Turbine..................................................................71
4.2.3 The Fuel Oil System of a Diesel Engine........................................................72
4.3 Precautions...........................................................................................................73
4.4 Prerequisites.........................................................................................................74
4.4.1 Typical List of Bill of Materials.....................................................................75
4.4.2 Typical List of Safety Gadgets.......................................................................75
4.5 Preparatory Arrangements...................................................................................76
4.5.1 Protection of Equipment..................................................................................76
4.5.2 Mechanical Cleaning.......................................................................................76
4.5.3 Erection of Temporary Tank, Piping, and Valves..........................................78
4.5.4 Steam/Air Blowing or Water Washing of Fuel Oil Piping............................78
4.5.5 Installation of Fine Mesh Screen....................................................................80
4.5.6 Readiness of Auxiliaries..................................................................................81
4.6 Operating Procedure............................................................................................81
4.6.1 Oil Charge........................................................................................................81
4.6.2 Oil Circulation.................................................................................................82
4.6.3 Duration of Oil Circulation.............................................................................82
4.7 Estimation of Flushing Oil..................................................................................83
4.8 Conclusion...........................................................................................................83
References...................................................................................................................84
Contents ix
Chapter 5: Blowing of Fuel Gas Piping System....................................................85
5.1 Introduction..........................................................................................................85
5.2 Description of Fuel Gas System..........................................................................90
5.3 Precautions...........................................................................................................90
5.4 Prerequisites.........................................................................................................92
5.4.1 Typical List of Bill of Materials.....................................................................93
5.4.2 Typical List of Safety Gadgets.......................................................................94
5.5 Preparatory Arrangements...................................................................................94
5.6 Operating Procedure............................................................................................96
5.6.1 Natural Gas Blowing.......................................................................................97
5.6.2 Compressed Air Blowing................................................................................98
5.6.3 Compressed Nitrogen Blowing.......................................................................99
5.6.4 Steam Blowing................................................................................................99
5.6.5 Water Jet Flushing...........................................................................................99
5.6.6 Pigging...........................................................................................................100
5.7 Conclusion.........................................................................................................100
References.................................................................................................................100
Chapter 6: Chemical Cleaning of a Steam Generator.........................................103
6.1 Introduction........................................................................................................103
6.1.1 Drum-Type Steam Generator........................................................................112
6.1.2 Once-Through Steam Generator...................................................................113
6.2 Precautions.........................................................................................................114
6.3 Prerequisites.......................................................................................................115
6.3.1 Typical List of Apparatus..............................................................................117
6.3.2 Typical List of Safety Gadgets.....................................................................117
6.4 Preparatory Arrangements.................................................................................118
6.5 Operating Procedure..........................................................................................119
6.5.1 Drum-Type Steam Generators.......................................................................121
6.5.2 Once-Through Steam Generator...................................................................122
6.6 Estimation of DM Water and Chemicals..........................................................126
6.6.1 Water-Holding Capacity................................................................................126
6.6.2 Estimation of DM Water Requirement.........................................................127
6.6.3 Estimation of Chemical Requirement...........................................................128
6.7 Conclusion.........................................................................................................129
References.................................................................................................................130
Chapter 7: Flushing of Lube Oil Piping System.................................................131
7.1 Introduction........................................................................................................132
7.1.1 Purpose and Type of Lubrication..................................................................134
7.1.2 Oil Coolers.....................................................................................................135
7.1.3 Oil Filters.......................................................................................................136
7.1.4 Oil Pumps......................................................................................................136
7.1.5 Care and Supervision of a Lubrication System............................................137
ix