1 thermal power plant pre operational activities dipak k sarkar

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THERMAL POWER PLANT:
Pre-Operational Activities
Dipak K. Sarkar
Thermal Power Plant: Pre-Operational Activities is a complete guide to the pre-operational

activities of thermal power plants. Consolidating all pre-operational aspects, this book provides

guidance for new and existing power plants to help reduce outage time and work to a budget.

It explains how to handle the equipment safely and work efficiently, including chapters on

flushing various piping systems, various methods of cleaning steam generators, testing steam
turbines and drying out of generators.

Thermal Power Plant: Pre-Operational Activities is an invaluable reference text for utility
operators, professional engineers, power plant engineers and anyone working on the start-up
commissioning and operation of thermal power plants. It isa perfect companion book to
Sarkar’s Thermal Power Plant: Design and Operation.

Pre-Operation

Dipak K. Sarkar has over 40 years of experience in the field of Mechanical Engineering &

i

Power Plant Operation with rich experience in Diesel Generator Plants, Combined Cycle Power
Plants and Coal-fired Sub-critical and Supercritical Thermal Power Plants. During this time, he
has shared his experience with professional engineers under various training schemes, like training
programs for graduate engineers and operating personnel. He retired in the year 2014 as the

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Executive Director looking after Administrative & Technology Control of Various Power Projects.

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Sarkar was also a Guest Faculty and Guest Speaker in various technical institutes of repute.

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-ISBN-978-0-08-101112-6

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Contents
PFÍV1CØ.............
Go
9099999 999995065555 66 656 Họ H99 11 1 10066696 "——-... S999, S.SYSesssesessseeeese XXƯ
Acknowledgments ............ "
"
—...... A9 1966696611155 s.°ssss. xxỉ

List oƒ Acronyms/Abbreviatiows............... "1

1993616 9956 —.

S31

se xxiii

m

1

Chapter 1: General Description of Thermal Power Plants ....... —¬.
LL

Introduction... cessessesesssssscssssescsssseessssevscsssssecsassssesassesecsuessesssacscsssscacersacaseasacs 1
1.1.1 Nuclear Power PÏaT. . . . . . . . . . .
s5
St
g1 g1 816191 5115 8e ga segsre 2

1.1.2 Hydel Power PÏaTi(......................
tt HH
.........
TH Ti
cty 6

1.1.3 Renewable Energy Power PlAII...........
................
-s-sG2
SE Sex xe -srsrs 8
1:1.4 Integrated Gasification Combined Cycle (IGŒC) .......................
<< se .. 10

1.1.5 Magnetohydrodynamic (MHD) GeneratOr........................
-s- th sxsEsEEeexszsseszs 11
1.1.6 Fuel Cell Power Panií........
:--- c1
.............
HH nung g1 .....g1 8xx gressrssee 11
1.1.7 Thermal Power PÏ4HI(. . . . . . . . . . . . .
- có 6< vn
ng
xnxx 12
1.2 Steam Power PÏATi(. . . . . . . . . . .
Gà ch HH HH KH TT ng HT TT
gen cac 14
1.2.1 Steam i€TTAfOT......................... QC ng ng 18x se se 16
1.2.2 Steam TUTĐIT€.......................
(St 013151596 3H vn
n1 1 808815881 cex 23
1.3 Gas Turbine Power PÏari(.....
-ó- ...........
ng TH HT S0 HS
......
110183551585 se csx 27

1.4 Diesel-Generating StatiOn.....................

S50)

TT

nẽ ố

ố

.ố

co ch

.

HH HT HT HH TT ng ng

ee....KV..(

cea 29
31

Chapter 2: Quality Assurance and Quality Control
(Applicable to Preoperationall ACẸVỈEi@S)) ..........
cóc
.........
1 99. S9 90 91 96 se ee 33
2.

IntTOduUCfiOn.........................

2.1.1 5 QuaÏify ASSUTATIC€...................

-

H11 1011110111011 HH TH TT TH

Ú

19101101

TH

nà T1

ng re 33

ngu gen 34

2.1.2 Qualify COrITO] ..................
t1 9391 0101111101110 TH
ngu
2.2 ISO 9000:2015—Quality Management Systems—Fundamentals
and VOCAUÏaTY....................
h9 911111111111 01131111 1 HT TH HT cuc T1 cá
2.2.1 D€fÍinitiODS ....................
919141811111 1111 1110131
..........
nhàng
..
2.3 TSO 9001:2015——Quality Management Systems——Requiremenfs......................
2.4 PTOC€UT€.............................
Ăn
T TT TT TT TT H11 HT nà nàn
R©Í€T€TIC€S.....................
HH 0010111110111 1111111111111 TH Hà TT HE
vu cuc gu

vil

35

36
37
39
41
42


viii

Contents

Contents

PART 1 PREOPERATIONAL

SUB-SYSTEMS

CLEANING OF VARIOUS

43

Chapter 3: Alkali Flushing of Preboiler System....... 4999999999966568880 0601664 ¬¬ —
3.1
3.2
3.3.

3.4

ÍnTOUCHIOH.....................
TH HH HH HH no
HT
HH TH kn kg
Description of Preboiler Sysfem.........................
-- 5s
sssx ĐH
g1 gà g2 se
PT€CAUÍOIS......................
HH TH HH HT Hung HS gen keở "
Prerequisites ......cccccssssseccsssescesssesssessscsesssssesssesesssessossssssessacatsbasssesesasecsessenssers
3.4.1 Typical List of ADPATAEUS......................các
T115 HH
ng rersersree
3.4.2 Typical List of Safety Gadgets .......ccccssssssssssssssscssssscsessscsssvsvsesessssseseseessnenees
3.5 Preparatory Arrangement ........cccssessssseseccssscsesssesssesssssscsssessesscscssasseesssesseseseaees
3.6 Operating Procedure ......scesssssssssssssssesesssssssssscsssessesssessessssesssssscassssscasseeeceeeenees

45
45
49
51
51
53
53
53
55

3.7 Estimation of Clarified Water, DM Water, and Chemicals.......................
-.- s5: 59
3.7.1 Water-Holding CapaCity.....................
-- --s- 22x E141111111141511 7111101 1 tu ngu esee 60

3.7.2 Clarified Water R€quiT€m€I(.......................-cv hx2xE 111111131101 16 1xx receree 60
3.7.3 DM Water Requirement 0... cccssssesssssssscsssscscsessecsessesesssesesessescsssessssesaseseas 61
3.7.4 Chemical ÑeduireIm€ii(........................-+ se 4113 11181311130140111111 1111 101 xe 61

3.8 COncÏusion.........................
R©Í€T€TIC©S....................

c1
HH

1111 111111 11T. TT H011
1111 Hà
1 cán oke 61
11011111010 111141411 111111
101 1H11 01 111g
62

Chapter 4: Flushing oƒ Fuel Oil Piping System..........................ô mm"... ơ
4.1

TIntrodUCfiOH........................-

HT

nh

HT TT HT

gu TH TT

63

n1 1s5, 63

4.2 Description of Fuel Oil Sys†em......................
-¿ ch
HH ng vkg 68

4.2.1 Fuel Oil System of Steam Power. PÏarn(.........................
s5 co sex
revee 68
4.2.2 Euel Oil System of a Gas TurbÏne.......................
óc te.
giới 71
4.2.3 The Fuel Oil System of a Diesel Engine ...............................-5s scscscseserssessseree 72

4.3 Pr©CAUtiOPS.......................
HH H111 01110 111101011111 1111111011111 11g11 cà kgrske
4.4 PT€T€QU1SÏf€S...................
HH H111 1111 110111114111111 111111111 1511111 TH g6 vị
4.4.1 Typical List of Bill of ẶMateriS..........................-óc stcscn cưng
cung rvee
4.4.2 Typical List of Safety ŒGadgets.............................HH nh H HH nung cuc
4.5 PreDaTafOTV ATTATEITITIẨS.........................
5+ Sex 1111411211111 ch ng càng

4.5.1 Protection of EQuipIm€Ii(........................
-- 6-5 se S915 25x23 1233111 su xxx
4.5.2
4.5.3
4.5.4
4.5.5

Mechanical Cleaningg........................-.
-----< se 3 S3 3 3 3 59 629v
vn sex
Erection of Temporary Tank, Piping, and VaÏves.........................--5-ssssSteam/Air Blowing or Water Washing of Fuel Oil Piping............................
Installation of Fine Mesh Screen.........................-+ 5s san ng cưng se gvree

73
74
75
75
76
76

76
78
78
80

4.5.6 Readiness Of AUXỈÏÏAFlS,.................
-s ch
1 101011119 1h ng HH nung. 81
4.6 Operating

06000 0ý...
81
4.6.1 Oil CHhaTge............................setererrierererrrrerrrarsrrrrrreoere,
4.6.2. Oil CirCulatiOH.......................
6-Gc 1t h21 3 11x 1x HT. 101 011 T11
gay 82
4.6.3 Duration of Oil CirculafiOn.........................-s-s5s s2 St 2413 1911 HH cv 2 uy 82

4.7 Estimation of Flushing Oil,.........................--s-5-52 Sex
1g ersecrggy 83
4.8 COICÌUSIOT1........................
v3 1111511115 10231111 011113111 TH Tà TH TH Tà Hàn gen 83
l©ÍCTCTIC©............... HH4
HH1 1111101111111111111514111111 TH Hà TH ngàn gxki 84

Chapter 5: Blowing oƒ Fuel Gas Pipbing SŠVSE€IH......................
S.1
5.2
5.3
D.4

co

ix

HH4 1955155 0556556 65.

InffOUCfiOH............................S1 S111
11103 TH HT TH HC Tưng gu 85
Description of Fuel Gas System.....ccccccsesssesssesesssesssersessssssscsssssescscssassserssesaeeas 90

P€C2UIOS.........................
SH T111 13g10 HT HH TC TT
kh TT càng 90
PT€TÊ(UISI(€S.................
HH HH1 01111 1 Tà
TT TH KH TH ng gu 92
5.4.1 Typical List of Bill of Maf€TiaÌs..............................--o5 <<
S1
ve co 93

5.4.2 Typical List of Safety Giadgefs.............................HH
ng nude 94
5.5 Preparatory Arrangemenfs...................... ..:::
:94
5.6 Operafing PTOC@CUT©........................-t1 TH 1101111 1011111 nàng HH ng nrkc 96
5.6.1 Natural Gas Blowing............................ ——............... 97
5.6.2 Compressed Air BÏOWnE.......................
tt HH nh HH HT Hung
gko 98
5.6.3 Compressed Nifrogen BÏOWing........................
---scc canh HH HH
gen sec 99
5.6.4 Steam BÏOWINE,........................
tt
TH. HH
TH ng nung nen co 99
5.6.5 Water Jet Flushing... ssssccssssesesssssesssessssssscsssssssssesssssssvsssesscecscavacacseseaeae 99
5.6.6 Pig Qing ....ccsccsseecsceseceseseesscesssssessssscsesssessssssssssssscssscsoscsssseaesssessssscscssnssacasavece 100

5.7 COTICÏUSIOH1.........................

Ѐ̀T€TIC€S.........................

k1
1110111111011 01151 TH nu HH tưng
nh
H HH HT TT TH To TC HT TH TT ng cuc

100
100

Chapter 6: Chemical Cleaning of a Steam Generator........ dị H000 8 .....‹„ 103
Ĩ.Í IntfOduCfiOn.................................
cS Sàn
011011111 T1 1T
TT ng 113131 te 103

6.1.1 Drum-Type S(eam €I€TAfOT......................
co s25
HH Hye
112
6.1.2 Once-Through Steam eT€TAfOT-........................
--- ---GSu
ng nu
oxe 113

.2 PT€CAUfOTS........................
6.3 Pf€T€QUiSIf€S...........................

H1 919191111 1111 01T HH Họ nọ Hit ĐH ven 114
H110 0101 HT TH TT HH cà HT 3 cụ 115

6.3.1 'Typical List O ADDATAfUS.......................
se nàn ch
HH ngàng ky 117

6.3.2 Typical List of Safety Œadgefs..............................c.
nàn HH HH neo 117
Ó.4 PreparafOTY AITARBImTIS.......................-G- 6 ch nh
HH KH HS
Tung 118
6.5 Operating PTOC€CUTC........................
G1111 HH TH TH nh TC HH ky
119
6.5.1 Drum-Type Steam eTI€FAfOTS.....................
s55 5S v31
g gen gee 121
6.5.2 Once-Through Steam ieri©rafOT-..........................
s5.
nhưng gu pvc 122

6.6 Estimation of DM Water and ChetmiCaÌS............................
5 s3
cv gkrk 126

6.6.1. Water-Holding CapaCify......................-cá Án
T1 Hung go 126
6.6.2 Estimation of DM Water RequireimerIt.............................
o<< xe kg gecesee 127
6.6.3 Estimation of Chemical RequiremerI.............................
- - 5-5 5s cs se TH ky K60ke 128

.7 COnCÏUSION ............................. HH1 919191111411 1111 HH HH TT
TH nà
129
R€ÍGT€TIC€S...................
.
HH1 T1 14 1 11 TT TT Tà HT tu ve 130
Chapter 7: Flushing of Lube Oil Piping System ....... "..... "—....... 131
7.1
IntTOdUCfiOH..............................
SH
T 1111011101010 TH TH TH HH cưng
132

7.1.1 Purpose and Type of LuDriCAfiOH.........................--.ch
vs gee 134
7.1.2. Oil CCOOÏ€TS........................
H901 010114 1101010101
HT
cư ngu
135

7.1.3

Oil EiÏtETS. . . . . . . . . . . . .

ó0

HH

7,1,4 O1] PUTTIDS ......................... ó0 ST

1010111011131 111313151 11111103010
TH TH HH TH

HH nh nu

Hee

136

ngu ngu 8e 136

7.1.5 Care and Supervision of a Lubrication System..........................--‹-5cssssssxssscse 137

ix


x

Contents

Contents

xi

7.2 Description of the Lube Oil System ........csssssssssescsssssscstssscsssssscsssscsseseeeses 137

8.6 Operating Procedure ..ciicssescsessessstssessscscssecsssssesseessescssecsssssssssssssesssasssssavseses 180

7.2.2 Lube Oil System of Gas 'Turbinie..................... su
S SE vn coeezerses
7.2.3 Lube Oil System of Diesel Engine............................
-----s- Go St Ehn Sa cegecsesesees
7.3 PT€CAUÏOTNS........................
HH HT HH TH TT Tàn HH TH Hung 8x5
7.4 PT€T€QUISIIS....................
..
HH HH HT TH 0T n0 HT ng TH Hàng He gxg
7.4.1 Typical List of BIll of Materials...........................--- 55555555 ".
74.2 Typical List of ADDATA(US........................-óc ccn ncxsncnsexegksseceo
.
7.4.3 TypIcal List of Safety Ciadgefs.....................
nen HH HH. ng
ng geeey
7.5 Pr€paTaf†OFy ATTAIBGIN€IIES......................
.
tt 3 1939111111315 1 1H nhung ng ng
7.5.1 Mechanical Cleaning.............................
cv 1141914111111414110311 1011
nung

8.6.2 Compressed Air BÏOWNBE,.................. cư
cư nga
LY Ni ii 009), 0/1. /GEIIIIiiaiiaiiiiiầẳă...
8.8 Estimation of Fuel Oil. . . . . . . .
«co sa c1
ch HS TS 1T
pc
8.9 COTICÏUSIOT ........................ HS 9101111111314 0111 1 1H TH TH HT HH nh ng

rà
lЀ̀T€TIC€S,....................
HH" 91901810111 01101 011 TH HT HH ng pH TT ng ng

7.2.1 Lube Oil System of Steam Turbine ........cccsssssesssssseecsscsessessesssscsssesusence ........ 137

138
139
141
142
143
143
143
144
144

7.5.2 CHhemical Cleanirng..........................- ccc tt tt 9193931313811113 11 11T
nung. 144

7.5.3 Water Washing of Factory Pickled (Chemically Cleaned)

891004. .6...
nn
...............
146
7.5.4 Installation of Eine Mesh Scr€enn........................-c. nh nh nH HH ng nguy 147

7.5.5 Bypassing All Vulnerable Syst©mms.........................-csc+c+
se 22 1 EExErxExcsreeerrsrses 147

7.5.6 Heating of the Flushing Oil........................
ác tcvx939191 1111111111111 x2 seo 148
7.5.7 Erection of Temporary Piping and VaÏves ..........................s-cccccs55cccsccsrscccs 148

Ll; 8C... cối... nh ................ 149
7.6 Operating ốc... nh...
ốe
:‹+11ZŸ2
149
7.6.1 Oil Charge...........................c-cesseeecee ....................ÔỎ 149
I
ve. on nh e...............
150
7.6.3 Purification of Flushing Oil During Circulation.........................---5 5 55+ 55 c<: 151
7.6.4 Duration OŸ CirCulafiOT.....................
cv 1911193 1 1 th
ch HH ng ghe ngy 151

7.6.5 Inspection and Cleaning............ ...........

152

7.6.6 Fresh Ơi Filling and CirculafiOH........................-.ó
sóc cà 1 xxx eevee 153
7.7 Estimation of DM Water, Chemicals, and Flushing Oil................................«- 153

7.7.1 Details of Lube Oil Piping oc secssscsescsssescsenesescseseesscsescsescesesscesenesseseses 153
7.7.2 Estimation of DM Water Requirement ..........cscsssscsssesesesseesesssececscsessesseees 154
7.7.3 Estimation of Chemical Requirement ..........:scscscsesssssssscsscessesesesssessevensnseesees 154

7.7.4 Estimation of Flushing Oil Requirement ............ccceccessesesssesessessssesesssseees 154
7.8 COncÏuSiOHI..........................
HH
111111811111 1 11110101 1011111110011
13 s10 155
R€ÍGT€TIC€S.....................
HHHHHH1101110 8101111 1101110811111111101 0101111
H191 1511111 cengkt 156
Chapter 8: Steam/Air Blowing of Main Steam, Cold Reheat, Hot Reheat

and Other Steam Pibe Lines ............... sersccsseesecee mm... H411
688696 157
8.1 IntTOduCfiOn..........................
ch
1119111111110111111110111311 11 HH tiêu —- 157

8.6.1

Steam BÏOWing,..........................
nhàn H nu HH ch
ngu
ng St

180

185
188
189
190
191

PART 2 ACTIVITIES THAT MAKE CRITICAL EQUIPMENT
READY TO PUT THEM

IN SERVICE

193

Chapter 9: Hydraulic Test of Steam enerator......................ss‹- ¬—¬....
9.1
9.2
9.3
9.4

11 11101111113 01x nh TH TK TT HT TH nung
.
InÍTOUCfIOT.......................
HH HH1 HT ng TT TT TH TH HH 1k
ODJ€CEIV©.....................
HT H1 gy
S11 TT 0111 TT Hà TT HT
Pf€CAUfIOINS........................
HH HH1 0111 011110 HT Hà cu
PT€T€QUISIẨS....................
- s- «óc 1vư ke ưckckeEteeerereee
9.4.1 Typical List of Bill of MateriaÌS.......................
...

195

195
197
197
198
198

nhung.-gà 201
--9.4.2 Typical List of Safety Œadgefs...........................

1 nh Trà 201
12x
nà
9,5 Preparatory ATTanÿ€IHTS,..............
.....--G204
1T KH TH ng
31x
-G- c4
9,6 Filling of Steam G€TI€TAfOT....................

crre 204
1 26kg
54525 nh
9.6.1 Drum-Type Steam GTITAẨOFS.....................
.-Gke gk 206
HS 1E ng --G s4
9.6.2 Once-Through Steam GeTI€TAfOTS........................-

HH HH HT rưnkry 207
6 tt SE24 1 H11 1H ..........
9.7 Operafing PTOC€đUT€.................

«6-5 6E S4 1 Sex se se rxg 208
9.8 Estimation of DM Water and ChermiCal§..........................

ng Hee re 208
9.8.1 Estimation of DM W AI€T. . . . . . . . . . . chàng
5 G < <6 6x xe .. 209
9.8.2 Estimation of Chemical Reduir€1T\€TIK......................

9.9 COnCÏUSIOH...................
I€f€T€TIC€S...............

.

1111011111 111510111 11c HT TH TH ng ch T9 ky 209
gu ng 210
HH 9111411 11111101 1101 HH TT TH cọ TH TH

Chapter 10: Air-Tightness/Leakage Test of the Furnace, Air, and Flue Gas Ducts
Of a Steam @eHâFdOW....................oossssssss 5655555555 "... ơ....- se. sseee oe 277
ch 114191010111 TH TT TT nàng Tri, 211
10.1 IntrOducfiOH..........................
214
H910 0111141011101 01T TT HT ngu
10.2 OJ€CIV€.......................
nynkey 214
HH TH TH LH TT TT
111611111
Ú
10.3 Pr€CAU(ÍOTS.........................
215

nà
TT TH
HT 411 111111101 111kg
10.4 PPT€T€QUiSI(€S..................

«s5 5e 12x 25 x2 xe- 216
10.4.1 Typical List of Bill of MateriaÌs.........................
An sen co 217
10.4.2 Typical List of Safety Œadgets............................. HH

8.2 Description of Main Steam, Cold Reheat and Hot Reheat Steam,
and HP-LP Bypass ŠySfem..........................
tt
HH HH HH HH Hà HH
rec 169

ng HH1 111611, 217
E11
- --(
10.5 Preparatory ATTanỹ€ITTIẨS...............
...........

1š.

s2 v.v ks seo 218
10.5.2 Heat-Recovery Steam i€nI€TAfOT......--................
1111 1kg 11113 txe 218
11111111 kh. ........ch
10.6 Operating PTOC€dUT€.................

8.3 vn

ẽẽnx.. ae...

N6

ốố

6

--£+-

we 170
172

8.4.1 Typical List of BiI of MateriaÌs.........................5-5 5s sex
3 6 ke sec cveveg 174

8.4.2 Typical List of Safety Gadgets .....c.cccccssssscssscsesessesescssssssssessssssssssesssesssavarens 175
6.5 PT€pPATAf†OTY ATTAñBI€IIS.......................
thư
ng TT gen gyyg 175

10.5.1

5+ 5< cv seskeesseeeersssee 217
Fossil Fuel-Fired Steam GienerafOr...........................-----

10.6.1 i0‹ l0).
10.6.2 Kerosene 'T€§Ể. . . . . . . . . . . .

Tố

th

219
ad...
g1 xrg 220
ch ngu ng tư
1121111111011 01T


[

|
xii.

Contents

|

10.6.4 Noise Detectionn “T©S(. . . . . . . . . . . .
.-- --- cà TH 0081 e 221
Nhi
00.
nh
ố ốố.ố. ........
221
10.6.6 Pressure Drop 'Tê©S{ ......................... Ăn
TH

TH
nh HH TH Hàng ke 222

|

Reference TP...
..........ồỀẦa....... 223
11:5
G
Initial Firi
d Drying
Out of Insulati
225

.

10.7 COnc]usiOn...........................c5 chén
H01111011011110111 1011101 HH nhà HH, 222

Ch

apter

1:

team

enerator

Initial

Firing and

Drying

Out o

sua

na sessse mm

11.2.1

11100001000. 10111. 01..n1.n11TnHH0nnnnHHrriiiiiniiirriiiiiriiir 227

232

Clarified Water SŠySf€TH.............................- «tt HH TH g0 011 01 g1 01 01 10178 233
DM Water System... .e................. 233

:

11.5.6

Eire Water System.............................---ScchcchHHHH
HH H.01001210110101311 08110 00 236

:

Auxiliary Cooling Water (ACW) Sysiem.........................-Ă-Ă

sen
235
CCCCW Sysfem..............................
co
HH“ HH HH0 0010100101011 001 11116 235
Compressed Air ŠyS€M..............................
nàn n4 1111111111011110 1x56 235

Auxiliary Šteam SŠy§S†€I........................
.. - HH
HH 001018 1 1311180 cv. 237
Make-Up Water ŠYSf€I.......................
HH HH HH HH HH ng H081 t4 237

11.5.9. HP Chemical Dozing Šys(€m..............................-- «sen
238
11.5.10 Burner Managerient System (BÌMS)...........................-cà cành ie 238
11.5.11 Uninterrupted Power Supply (UPS) Šysfem.............................
se ceceeeeree 238

11.6 Preparatory Arrang€ITTIS.....................--5s + ké S*HE12111111001111..11111110101 1 238

i

11.7.1 Master Fuel Relay Trip (MET) Conditions ............................. --ccscssseceeses 242

ị

11.7 Operating Procedure... .cccsccsesssssssssesessescssescssseeesssstensseesesestessenesseneenees 240

{18 Conclusion vnc
oe
-............ 244

245
245
250
251
252

12.6.2 Lift-Assisted Valve ActuafiOn.........................se nh HH HH HH0 tr ru 258

s0.

Tố

ác

TH HH HH TH

ố ốốốốố ố.ốốốố

TH nàn

HH HH

H1 001115E 260
261

HH HH HH HH HH 269

Typical List of Apparatus/nstrumrifĐ......................
5s +5 se scsxcxsszxczsrscse 272

13.7 COnclusion HH...
RefârenCes.............
-s- ng
ng ng

274
276

Chapter 14: Condenser Flood and Vacuum Tightness Tests.................... ——

277

14.1.1 Circulating Water (CW) Cooled Conderiser..........................
--c- csc14.1.2 Air-Cooled Condenser (ACC)......ccsccscsssssssssssssssscsesscrsssesesesssesssessessessenes 281

14.1.3 Hybrid or Combination Water and Air Cooling..........................2 s-‹sscs«¿ 282
I9 .à 0n -“--‹-...
282
14.3
PreCaUtiOnS............................
ch th
HH
HH nà HH T111 0111k rrkg 283

14.4 Pf€T€QU1SIIS...........................

án

TH HH ng HH TH

1040 1111010101111 1k0 283

14.4.1 Typical List of BilI of Material and Apparatus/Instrumenfs...................... 285
14.4.2 Typical List of Safety Gadỹ€fS.........................
có HH HH HH ng tre 285

14.5 Preparatory Arrang©menfS.......................-..-‹‹cs286
14.6 Operating PTOC€đUTG.......................
s1 S1 HT SH HH TT n0 1 E01 HH Hee 287
14.6.1 Condenser Eloodd 'TSí.....................
-- -c--ccs tt
HH ng ng
cv rp 287
Le

14.6.2 Condenser Vacuum Test ....c.ccsecsesssssesssessessessessssssesssssssssssssecstesessasssssnenes 288
vn...

TR€ÍCT€TICCS...............

.

nh

HT H191411111 1111 11T H001

TT

TH

1 HT HH

289

k ke 290

:ị

Chapter
15: Generator Drying Out and Ai-Tịgieness
Tesd........e
co —ong 291291
15.1 Introduction.................................--ccetHh
HH HH
nàn

:
:
c

15.1.2 Generator Stator Cooling Wafter System.........................- 6s se ceccecrsceereeree
15.1.3 Generator Seal Oil System .....c.ccccscssssssssssssssssssssssssssssscsessesscssssvssssvenseneaes
P90.
nố ốốốốốố cố ốốốốố.e.............

{5.3 PT€CAU([OTS.........................
x91 111111 1110111111011 0111010013 cưng ni
15.4 Per©QỤSỈE€S....................... HH
HH K01 011111110114114111110111 1 1x6

ị

ĐỘ
4

12.6 Operating PTOC€đUTe........................s6 SH
HH TH TH HH TH
nh 255
12.6.1 Eull Set Pressure Valve Actuation (Popping)........................ôeeceeeeeierre 255
12.7 COncẽusiOn.........................





RfâTeICâS.................. net

12.4.1 Typical List of Bill of MateriaÌs................................----nhe
253
12.4.2 Typical List of Safety Gadgets................................eeeeereeirieiiie. 224
12.5 PreparatOTy ÀT1TAnE©INIIS.....................-- 6 k1
nh TH TH TH TH TH TH g0 g0 tà 0111 19 254

HH

14.1 IntrOducfiOn.................................
ch
HH HT HH HH T1 0111111111111 01 15 181 pkg 277

11.5.1
11.5.2

Chapter 12: Floating of Steam Generator Safety ValVes........................-.-.«---<--s«
12.1 (00h...
....................
I9). nh ố . ........ố.............
I6» cv, Na
-................
12.4 PT€T€QUiSIE€S..................
ó9
H4
HH HH1
1e.

HH HH

13.6 Operating Procedure ........sssssssssscssssssvessssessssscecsssssssssecesssssssseesssssssesessesssssvesseees 274

11.4.2 Typical List of Safety ŒGadgets.........................--csccccrretrtierrietriirrrierrriea 232

11.5.7
11.5.8

St th

12.3 Pf€CAU(IOTS......................
HH TH
TH TH
K1 1111111111111111x1xtx
treo 270
13.4 PT€T€QUISIES.........................
HT
TH HT Hàn TT Tá HT TT Cá Tàn Hành Hiện 270
13.5 Preparatory Arrangements .ccccccssssssssscsssssssssssssssccscsscssssssssssvssssssssssssssssssesessesee 273

11.3 Pr€CAUUOTNS...................
Ăn
TT HH nh HT 0
0 Đo Chư
09 228
11.4 PTr€T€QUISIICS....................... Ánh
HH
00181104411 010 1101011008838 228
11.4.1 Typical List of BIll of Mafteris................................-- che
232

11.5.3.
11.5.4
11.5.5

13.2 Oj©CfIV©......................

13.4.2 Typical List of Safety Gadgets ...c.ccsccccsssscscsssescecssessscssssssessssssseecssssssecesen 273

Boiler MOuUntTBS............................

-< s- <5 91H TH HH TH Tu ngu tà 227

11.5 Brief Description of Various SySÍ€TNS .......................- chua

xiii

Chapter 13: Clean Air Flow Test of a Pulverizer..................... “<<... } HH 9009880898689 263
13.1 IntroductiOn...............................5S Ăn HH HH n1 TT H0 H1 11031301115. 263
13.1.1 Classification Of Mills ốc
. . .............. 265

13.4.1

11.1 Introduction.......... Tan nang #hrerrerirreiie 225
11.2 Objective...

Contents

ị

i
1

op

15.1.1

Generator Air/Hydrogen Cooling Sysfem........................-.
-- co cccss s2sscrece 293

294
295
295
296
296

15.4.1 Typical List of Apparatus/Instruments..........ccccscsceceseseesccseeessessseseseseesesees 296
15.4.2 Typical List of Safety Œadge©fS........................ cty
-.... 298
15.5 Preparatory ATTARE©I€TIES.........................
vn
TH
HE ket 209

15.5.1 Generator Drying Out......cscsessessssecsecsessssesssssssssessssssssssssssssessissssessesens 299
15.5.2 Generator Air-Tightness 'Tesí ........................
- - sk eSeSke St ke Su sgk 301

15.6 Operating PTOC€CUT©.........................

Q.2 0n

Tu ch TT nh nh

ng cư ng 301

15.6.1 Generator Drying Out... esssssesessesessssessssesessesesssssescsesessseesscseeesseneees 301
15.6.2

Generator Air-Tightness Test ..........ccccsssssssscscssssscssesscsscsssssssessessssceessesees 303

xiv

Contents

15.7 COnCÏUSỈOT..........................
R€f€T€TC©S.............
Họ

6 5 <<
TH HT TT KH Tà Hàn TH TK 0804710 305
HH
TH TH HT
0 0 Tà TH 0111 18018005019150 305

Chapter 16: Filling of Generator With Hydrogen and Protection Stability Test
0ƒ Gener4aOF...............ssssss° "—¬"”............ 446566664545566556555 ... 307
16.1 InfrOđuCfiOH........................
c Ă
TH TH
HH HH 030030804101
16.2 ODJ€CEIV©.....................
Ác HH HH HH TH kh Hà TH TH TH TH
TỔ
gà Hư
16.3 Generator Hydrogen FElilling. ..........................
... -- ssnnkntHnHnHnHẰ Khu Hành tiệt
16.3.1
Prer€QISI{©S.............................-.

SH HH HH TH 01001 10T TH
0 HT
16.3.2 Typical List of Bill of Materials/Instrumens.........................................«
«se
16.3.3 Typical List of Safety Gadgefs............................ con
He
16.3.4 Hạ-CO SyS(€TH........................2. G4 0
TH TT
Hà HH Tá ng
1á 0000
6>» vo 8n nh ..............
16.3.6 Preparatory ÀTTAñB€ITTI(S...........................5c s 3 tt 91919211181104171111 1181 51

307
309
311
311
311
312
312
313
316

16.3.7 Operating PTOC©UTC.............................
ó2 s + H
Hy HH1 01 0101880101001 6031301580903 317

16.4 Protection Stability Test oŸ GenerAfOT ......................- ch
hưu 318
164.11 Prer€QISI(S............................

«sọ HT“
HH TT 4 080001 11 0000400041440044814 01008 318
16.4.2 Typical List of Ínsfru€nifS ................................-‹-c+«
s31
84101211 11g
rên 319
16.4.3

Pr€CaUfiOTIS...............................-QSH
TY HT Hà HH 4308041681411
319

16.4.4 Preparatory AITB€IH€TIS..........................--

cà

tà 99100 011001161 011101181 101011106 319

16.4.5 Test Procedure............................. _—.................

9i...
JL©ÍCTCIIC©S...............
cọ HT HH

..ằằẦằẦằồằẦằẦằốỐẦ.Ố..........
HH
H1 0141000080130014099 đe

319

326
327

Chapter 17: Completion Test of a Thermal Power Plant.................. 98919098585556895 329
17.1
17.2
17.3
17.4
17.5
17.6
17.7

IntroducfiOn..........................
c- cọ
TH
TH Tu Hà HE
0401010130309
OĐJ€CEIVC..................
..- HH
HT TH Ho nh nàn HH TH
0031111111011111700
PT€CAULÍOPS.................... GHI
T n T H ĐH
0181080 0130171119
Pr€T€QUISIfS...............
TY TH HT TH
HC kh Hà 10183007010
Miscellameous “T€SfS............................
«6 ch nh TH HH ĐH 0 1301301010
Reliability Run T€SỂ.............................

.sHà HH HH Hà HH HH g0 1101101101418 150

Performance Guarantee (PG)/Performance Acceptance (PA) Tests..............
17.7.1 General Đ€QT€TTI€TIS ............................
G- 0 <5 4
HC HU TH gnHI T E109 r4
17.7.2 Liquidated Damages (LDs) for Shortfall in Performance.........................
17.7.3 Performance Guarantee/Acceptance Test Codes........................
----c- 7-52
17.7.4 Performance Test PrOC€CUTCS.........................
nọ HH HH HH 010010181101 1g

329
330
330
330
331
333

340
340
342
346
350

17.8 COnCÏUSIOT.................................
5
TY TH TT THÍ HH TH TH Tàn Hà H4 0113141001844 04 100 351
R€ÍGTCTIC©S......................
Á HH. HH HH HH HH KH HH Hà

Lá 01801010 118715715 311030 352
Appendix A: Brief Description on Performance Guarantee/Performance
Accebtance mm"... m ",

Appendix B: General Safety Guidelines .....................-s--««s55sss1 sse sssssess.e„
Appendix C: Tagging Procedure.......... 959568649960468616% m1...
Appendix D: Conversion Factors........ mm
4449999940866009906006600996 4955559056665856
lndex................-««««s« "
4159999956 —............ ........

353

SEO
423
429
435

Preface
I worked in the premier engineering consultancy firm of India, M/S Development Consultants
Private Limited (DCPL), for more than four decades. During this long tenure I had the
opportunity to work in innumerable thermal power plants of various sizes and configurations.

The most important part of this association was my exposure to chronological development in
power plant technology, both within and outside India. Against this backdrop, when I was
executing various projects I observed that there is a dearth of published books wherein various

aspects of preoperational activities are consolidated. This was the starting point in getting
motivated to write this book, Thermal Power Plant—Preoperational Activities, in which I tried

my utmost to incorporate the state-of-the-art technology applicable to these activities.

Design of a thermal power plant is a desktop study, while operation of the plant falls exclusively
within the purview of field engineering. In between design and operation there are certain areas,
generally known in the industry as preoperational activities. The procedure for execution of

these activities is developed during desktop study, but is executed in field only. So these

activities act as a go-between for design and operation to ensure unruffled power generation as
far as the end user is concerned. Thus, this book may be construed as complemental to my

previous book, Thermal Power Plant—Design and Operation, published by Elsevier.

This book aims to address some of the essential preoperational activities which are extremely

important to carry out in line with the practice followed in the industry globally. Smooth,

trouble-free, and economic operation of thermal power plants can be ensured if preoperational
activities are carried out with the utmost care in order to establish that prior to the start-up of
various systems, equipment, and/or the plant as a whole, they would be ready in all respects in
accordance with manufacturers’ recommendations, and at the same time fulfill all requirements

of applicable statutory guidelines. The main purpose of addressing the essential features of
preoperational activities is to ensure economic generation from a plant. Hence, the primary
focus of this book is on professional engineers.

_ The contents of the book are such that the book should not be treated as a conventional textbook

used in technical institutes. For design engineers, this book would act as a reference to help

them develop project-specific precommissioning manuals of a new plant. It would also fulfill
the needs of commissioning engineers, suppliers, and utility operators during the execution

xv


xvi

Preface

Preface

period of new plants. While successful completion of preoperational activities is essentially to
be accomplished and certified prior to the start-up of new plants, areas addressed in this work
are applicable to running plants as well. In running plants, this book would be a tool to help
operation and maintenance engineers/suppliers (contractors) execute cleaning/testing activities

(eg, overhaul, critical inspection, major repair) successfully to comply with regulatory

requirements.

Degradation in the performance of major prime-movers—namely steam turbines, gas turbines,
and diesel engines—of running units is a common phenomenon in the industry. In order to arrest
the severity of degradation, it is generally recommended to undertake a major overhaul of these
prime-movers following a specified period of operating hours. In the case of steam turbines, this
period is usually 6 years, while for gas turbines and diesel engines, permissible operating hours
that are usually recommended by manufacturers are 48,000 and 8000, respectively. Steam
generators are generally inspected after about 12-24 months of operation to meet the statutory

requirements of the boiler inspectorate. Any defect observed during inspection needs to be attended
to before the boiler inspectorate extends permission to restart the steam generator.

In many countries initiatives have been undertaken to improve the efficiency and
environmental performance of their existing thermal power plants through refurbishment,
upgradation, rehabilitation, and modernization activities. Before putting these old plants into
service on completion of routine overhauls, on completion of renovation and modernization,
following a major repair, or after long shutdown of critical equipment or of the plant, it is
compulsory to carry out preoperational activities to meet statutory requirements; otherwise,
these plants would not be in a position to supply uninterrupted power.
Before discussing details of these activities, it is essential that readers are conversant with an
outline of a thermal power plant or that readers’ knowledge of a thermal power plant is
refreshed for the convenience of understanding various systems and equipment. Hence,
Chapter 1 addresses “General Description of Thermal Power Plants.” In addition, a generic
description of systems and equipment pertaining to specific types of preoperational activities or
thermal power plants is discussed substantially in various chapters.
Successful completion of a preoperational cleaning activity or a prestart-up activity depends on
how consciously each activity is carried out, such that a plant does not face any untoward
incident during normal running, lest generation gets perturbed. This is ensured by adhering to
the guidelines laid down by an internationally recognized quality management system (eg, ISO
9000). For the convenience of readers to adopt a foolproof quality management system,
guidelines on “Quality Assurance (QA) and Quality Control (QC) (Applicable to
Preoperational Activities)” are discussed in Chapter 2. Prior to conducting any preoperational
activity it is extremely essential to observe certain precautionary measures, and also to ensure

that certain activities/items are completed beforehand. These two aspects are addressed under
“Precautions” and “Prerequisites” in Chapters 3-17. The QA team must be responsible for

xvii

fulfilling these aspects. Thereafter the QC team takes over to ensure successful completion of
each p