ADHI – JEPOE JO
SPECIFICATION/DATASHEET
Rev. : A
Document No.
Auxiliaries Instruction Page Number
Q6001N-SM10(e)T1 Page 1 of 16
OWNER : PT. PLN (Persero)
PROJECT NAME : PLTU LAMPUNG (2 X 100 MW)
PROJECT TITLE : PLG
JOB NUMBER : 07908
LOCATION : TANJUNG SELAKI, LAMPUNG
PLTU LAMPUNG (2X100 MW) CIVIL
CONTRACTOR DOCUMENT REVIEW R
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LOG DATE V ELECT
IN COMM. NO I I&C
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T WORKING DOC. 2
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BY : DATE : T
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LOG DATE:
O
OUT COMM NO: N
PT. PERUSAHAAN LISTRIK NEGARA (PERSERO)
AGENCY OF THE MINISTRY OF MINES AND ENERGY
GOVERMENT OF THE REPUBLIC OF INDONESIA
PLTU LAMPUNG (2 X 100 MW)
CONTRACT NO. : [Link]/041/DIR/2007
PT PLN (PERSERO) JASA ENJINIRING
PLN
Doc.
No
A Issued For Approval
CCJEC CCJEC AK CCJEC AK
REV DATE DESCRIPTION
PREP’D CHK’D APP’D
PLTU Lampung Unit 5 & 6 (2 x 100 MW)
Auxiliaries Instruction
Contents
1. Scope -----------------------------------2
2. Thermal system --------------------------------2
3. Condenser -------------------------------------3
4. Low pressure heater------------------------4
5. Gland heater ---------------------------------6
6. Installation and commissioning of SQ series
steam trap device ----------------------------6
7. Applicable standard for product -----------8
Auxiliaries Instruction
1. Scope
The auxiliaries contained in the thermal system are only applicable to
type N110-8.83/535 steam turbine.
2. Thermal system
2.1 Main steam and reheat steam system
The initial high temperature and high pressure steam enters the high
pressure main steam regulating valve via two electric valves and two
main steam pipes, and then enters high pressure casing via four high
pressure main steam pipes. The steam will expand to do work after
entering the turbine through steam distribution, then the steam done
work in high pressure casing enters low pressure casing to do work
continuously via connecting pipe, finally discharged to the condenser to
be condensed into water; the condensate will be pumped to the gland
heater by the condensate pump, and pumped to the high pressure
heater to enter the boiler through pressurizing by feed-water pump via
low pressure heater and deaerator, and used circularly (see
Q6001N0004(e) thermodynamic system drawing).
2.2 Extraction system
This turbine is provided with six stages of regenerative extraction steam,
among them, the first and second stage regenerative extraction steam
shall be supplied to two stage high pressure heaters and the third stage
extraction steam to high pressure deaerator. The forth, fifth and sixth
stage extraction steam shall be supplied to three low pressure heaters
separately. Except the fifth and sixth stage extraction steam pipeline, the
extraction check valves shall be provided. If closing the main stop valve,
the solenoid starting valve will act to control pressure water and close
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the extraction check valve automatically, which can take the isolation
effect. (See Q6001N0004 (e) Thermodynamic system drawing for
details).
2.3 Gland system
The steam gland system of the turbine is mainly used for preventing the
steam from leaking outwards along the HP and LP casing shaft end,
even flowing into the bearing box to mix with the lube oil, as well as
preventing the air from leaking into the casing to break the vacuum of
the unit.
Self-sealing system is the turbine’s steam seal system, whose steam is
supplied as LP shaft end steam seal leaking from HP and LP casing
shaft end through spray desuperheater under normal running of the unit.
The superfluous leaked steam passes through overflow station to
exhaust device. At the stage of unit’s startup or running with low load,
the steam of steam seal is supplied by external steam. From startup till
full load running of the unit, the steam seal system may switch over
automatically as per steam supply requirement of unit’s steam seal
during whole procedure.
Self-sealing steam seal system possesses various characteristics,
including simplicity; safety, reliability, with good suitability of working
condition, etc. (see Q6001N-SM13(e) Self-sealing steam seal system for
details.
2.4 Drainage system of steam turbine body and pipeline
The drainage system is composed of steam turbine body drainage and
pipeline drainage, namely, the drainage of main steam valve and the
pipeline between valve and turbine body, the drainage of pipeline
between each extraction check valve and casing. The system is
provided with high pressure and low pressure drainage flash tanks. The
high pressure drainage flash tank is used to contain drainage of turbine
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body and its pipeline, high pressure main steam pipe drainage, the first
and second stage extraction drainage. The low pressure drainage flash
tank is used to collect drainage of gland pipeline and the third, forth and
fifth stage extraction pipeline drainage. The drainage valve and throttle
orifice will be equipped on turbine body and Its pipeline(see
Q6001N0032(e) Thermodynamic system drawing for details).
3．Condenser (NQ76.01)
3.1 Technical Data
Cooling area 7600m2
Design capacity of cooling water 19524t/h
Cooling water pressure 0.25MPa
Design temperature of cooling water 30ºC
Steam pressure 0.008MPa
Pipe dimensions φ25×0.5×9515
Pipe material TA2
Pipe quantity 10172 pieces
3.2 Structure and function
Type N-7600-I condenser is composed of upper of left condenser and
right condenser, lower of left condenser and right condenser, cover
plates of upper and lower water chamber, cooling pipes, middle baffle
plates, compensation device, connecting pipes and condensate collector,
which is of full welded construction(see drawing NQ76.01condenser).
the two ends of heat exchange pipes are expanded and fixed on tube
plates and supported by baffle plate in the middle. A compensation
device is provided between the rear water chamber of condenser and
steam chamber, which can compensate longitudinal expansion
difference between the shell of condenser and heat exchange pipes,
Auxiliaries Instruction
accordingly reduce vibration of heat exchange pipes. The two end water
chambers are connected with steam chamber by flange, the manholes
are arranged at condenser throat and cover board of water chamber for
convenience inspection and maintenance. The net weight of 174t of the
condenser shall be supported by 8 spring supporting seats. Welding or
flange connection shall be adopted for all connecting pipes of condenser
and connection with exhaust port of turbine. The thermal expansion of
upper and lower of the condenser shall be compensated by spring too.
The cooling water is pumped to the lower of front water chamber by
circulating water pump, after double-flowing, it will be drained from the
upper of water chamber, which forms double-path and double-flow
arrangement.
The steam drained from exhaust port of turbine enters condenser and
make heat exchange with pipe wall thoroughly when passing through
the pipe bundle to condense the exhaust steam. The partial
uncondensed steam and air shall flow along the internal passage to the
middle air cooling zone for heat exchanging again. Finally a small
quantity of steam and air mixture shall be ejected by air ejector.
In the lower of pipe bundle, the condensate drop flows to the
condensate collector through dripping device to make steam contact
condensate thoroughly and take effect of regenerative deaerating of
condensate. The gas separated shall be drained from extraction port via
air cooling zone.
Prior to steam turbine starting, put the condenser into operation as well
as put the air ejector into operation to form specific vacuum in condenser.
Before starting: close all water drain valves of the condense, open air
release valve on water chamber and then fill water into the water
chamber. Close the air release valve after all the air in cooling water
circulating pipeline water chamber of condenser is released. The steam
side of condenser shall be filled with condensate from water tank in
advance to start condensate pump. It is acceptable when the
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condensate level is within 1/2 to 3/4 of water gauge, then make
installation of recycle of condensate and water gauge according to the
drawing. If the water level in water gauge exceeds the high water level
during running of the unit, it shows that heat exchange pipes are
immerged in condensate. At this time, the operator should take
emergency measures to eliminate the phenomenon. The cooling water
in condenser shall be drained completely to avoid rust erosion if long
term shutdown required.
After installation of condenser, the tightness of welds on connection with
exhaust connecting pipe and other pipes shall be inspected strictly.
The heat exchange pipes should not be immerged in condensate during
normal operation to avoid super-cooling of condensate. The air tightness
of equipments, water tightness of condenser, and salt content,
hardness, alkalinity in water shall be inspected regularly during running.
It is allowed to operate half of the condenser when running with low load
and clean half of condenser with no shutdown of the unit.
4. Low pressure heater
Low pressure heater is one of the main equipments using extraction
steam of turbine to heat feed water of boiler. It is the important part in
turbine’s regenerative system. The low pressure heater can increase
condensate temperature effectively so as to meet the requirements for
inlet temperature of deaerator and well deaerating, which is important for
power plant to improve operation economical efficiency.
Three stage low pressure heaters are adopted in this unit, which are
vertical type RJD190.01, RJD190.02 and RJD190.03 respectively.
Auxiliaries Instruction
4.1 Technical data:
RJD190.01
Index
Description Tube side Shell side
Design pressure 1.2 1.0
MPa
Design 200 300
temperature℃
The maximum 1.2 1.0
working pressure
MPa
Medium name Water Steam
Corrosion allowance 1.0 1.0
mm
Weld factor 0.85 0.85
Hydraulic test 2.0 1.62
pressure MPa
Number of path 6 1
Heat exchange area 190
m2
Cubage m3 2.4
Vessel class Class I
Auxiliaries Instruction
RJD190.02、RJD190.03
Index
Description
Tube side Shell side
Design pressure 1.2 0.5
MPa
Design 200 300
temperature℃
The maximum 1.2 0.5
working pressure
MPa
Medium name Water Steam
Corrosion 1.0 1.0
allowance mm
Weld factor 0.85 0.85
Hydraulic test 1.65 1.62
pressure MPa
Number of path 6 1
Heat exchange 190
area m2
Cubage m3 2.4
Vessel class Class I
4.2 Function and structure
The heating steam enters the space at steam side from upper side of
the heater shell, flows cross the outer surface of the pipe and transfers
the heat to the water flowing through the pipe; by this heat exchange,
the steam is finally condensed into water, which is discharged from
lower part of the shell. The heater is vertical type surface heater with
cylindrical structure shell which is welded by steel sheets. The U-shape
tube adopts yellow brass (HSn70-1) tube, and two ends of the pipe are
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expanded on pipe plate. the outside of sheet is connected with water
chamber by bolts, forming pipe bundle, which can be free to expand in
shell. Two in/out pipes for condensation water are welded on the water
chamber, which is divided into 6 water flows with baffle plates (6 flow
passages).
There are 4 horizontal baffle plates in pipe bundle to guide the flow and
prevent vibration. The shell at the lower part of pipe bundle has nipples
for discharging non-condensing gases, which are guided to condenser.
The inlet of heating steam is equipped with baffle to prevent pipe from
the erosion of steam. In order to monitor water level inside the shell after
the heated steam is condensed, a magnetic-float level gauge is
equipped with. The pressure gauge shall be installed at water chamber
of heater and pressure vacuum gauge mounted in the steam admission
pipe.
5. Gland heater
Type JQ-60-1 gland heater is the auxiliary equipment which make use of
main condensate to condense leaked steam from high pressure and low
pressure casing gland as well as heating partial main condensate. It is
composed of pipe bundle, shell, tube plate, baffle plate and water
chamber. The pipe bundle is composed of 288 pieces of U-shape
HS70-1 copper tubes with dimension ofφ19x1 and various length. The
copper tubes shall be expanded and fixed on tube plates and the
thermal expansion of the pipe bundle can be compensated by itself due
to the U shape of pipe. The shell and water chamber are of welded
structure(see QR060.03 Gland heater).
When putting the gland heater into operation, first connect to the water
side, then the steam side. When connecting to the water side, first open
the air release screw plug on water chamber, then open the water
admission valve gradually. When water outflows from the air release
screw plug, close it and open the valve on water outlet pipeline at the
Auxiliaries Instruction
sane time. Close slightly the valve on bypass pipeline and then open the
valve on extraction pipeline and valve on drainage pipeline in sequence,
finally open the valve of steam admission pipe, then the gland heater is
put into operation completely.
After the main condensate enters into the water chamber during
operation, the water flows through the pipe bundle in series and shall
be drained from the water chamber. The steam enters along the upper
pipe of the shell, flows along the guide baffle plate. The steam shall
contact the surface of heat exchange pipes for heat exchanging so as to
be condensed. The condensate flows to the lower of the shell and is
drained. The small quantity of steam and air mixture which is not
condensed shall be drawn out by gland fan.
To monitor the running of the gland heater, bimetallic thermometers
shall be equipped at inlet/outlet of the main condensate and inlet/outlet
of the steam. The level gauge is mounted on shell. Observe the
inlet/outlet temperature of the main condensate, the inlet/outlet
temperature of steam and the condensate level regularly during running.
When deviation of these parameters occur，the matter should be found
at once and take measures to eliminate it.
When the gland heater is damaged and needs to be cut off, first open
the valve of the pipeline which leads the steam admission to low
pressure heater. To decrease the water pressure in pipe bundle, open
the air release valve on water chamber. After the condensate in the shell
is drained completely, close the valve on drainage pipeline, at this time,
the gland heater is cut off fully and can be disassembled for
maintenance.
6. Installation and commissioning of SQ series steam trap device
Outline dimension：length×width×height 414 × ф300 ×485
6.1 Requirements:
(1) Clear indication and exact signal of local water level gauge;
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(2) Stable and reliable protection acting for the heater;
(3) Stable running of the unit and with load rise and decrease
condition;
(4) No leakage in valves and pipes of the drain system.
6.2. Working principle: the drained water enters from the inlet valve; the
regulated steam (led in from normal water level of the heater) enters the
inside of the valve body from the signal tube; the draining water quantity
will be reduced due to decrease of effective drainage area, so as to take
effect for adjusting the drainage. At this time, the drainage flow is
determined by the regulated steam flow, and the regulated steam
quantity is determined by the liquid level of the low pressure heater,
which is collected by the signal tube.
6.3 Installation of the adjuster:
(1) Installation direction: ① The arrowhead “→” direction indicated on
the adjuster body should be consistent with drainage flow direction; ②
levelly install the adjuster.
(2) Installation position: ① The adjuster should be installed nearby the
vessel body as near as possible (make the signal tube short as
possible). ② The inlet valve should be mounted in front of the adjuster;
there should be a more than 100mm straight tube section prior to
mounting of the inlet valve. The part behind the valve can be directly
connected with adjuster flange, and also connected by ≤250mm straight
tube section. The valve specification shall be selected by the user based
upon system pressure, and the gate valve should be used as inlet valve.
③ There should be no other equipment in front of or behind of the
adjuster installed (such as pump valve, drain cooler and etc).
(3) In overall installation process, the welding slag and sundries should
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be cleared away from heater and pipe.
6.4. Commissioning steps: it must be commissioned within normal
load:
Heater
Fully open inlet valve(DN150)and steam
Signal
valve(DN50)and fully close bypass
tube
valve(DN150); water level should rise
Steam slowly to signal tube interface normally.
valve
Water level is stable and conforms to
Stop
valve
Adjuster working parameter; if water level is lower,
operation as follows: slowly close inlet
valve a little, stop operation when water
level rises up to normal water level. If
water level is higher, operation as follows:
Bypass gradually open bypass valve, stop
valve
operation when water level drops down to
normal water level; observe water level
fluctuation and properly adjust it.
Figure1 Steam trap view
6.5 Regulating property and low load test
Gradually reduce the load to observe the water level kept condition: if no
water for a long time, properly close the bypass valve (or inlet gate valve)
till there is water level to maximum load, the test is successful when the
rising water level does not exceed alarm limit, otherwise, properly adjust
it (open the bypass valve or inlet valve, find out the balance point) (if the
water level is instable, namely, not enter the self-regulating state,
regulate again and again till stable).
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6.6. All commissioning works should be agreed by the person in charge
on duty. If the turbine watcher find out other malfunction in the unit, stop
the test and exit the site.
Note: never operate the valve at will, so as to avoid the affect on normal
operation.
(If the running is normal after completing the commissioning, it is
unnecessary to commission generally when starting and shutting down.)
7．7. Product standard for manufacture and acceptance of auxiliary
equipment：
Pressure Vessels Safety and Technical Supervision Regulation
issued by State Bureau of Quality and Technical Supervision
GB150-1998 Steel pressure vessel
GB151-1999 Steel shell and tubular heat exchanger
JB/T9629-1999 Specifications for hydraulic test of steam turbine
pressure parts
JB/T8184-1999 Specifications for low pressure heater of steam
turbine
JB/T10085-1999 Specifications for condenser of steam turbine
Q/CCFJ3404-1999 Specifications for machining and assembling of
condenser
