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OPERATION & MAINTENANCE MANUAL
OPERATION & MAINTENANCE MANUAL
HEAT RECOVERY STEAM GENERATOR
FOR INSTALLATION AT:
Hopkins Unit 2
NOOTER/ERIKSEN JOB NO. 064130
City Of Tallahasee CONTRACT NO. 1304
TABLE OF CONTENTS
A.SCOPE OF MANUAL1
SECTION I: GENERAL DESCRIPTION5
A.SCOPE OF SUPPLY5
1.0 Module Layout and Flow Schematic6
2.0 Design Philosophy9
3.0 Definitions and Descriptions of Major Components10
4.0 Specific Boiler Design for Hopkins Unit 211
SECTION II: PREPARATION FOR SERVICE15
4.0Level Control and Indication16
2.0Types of Cleaning19
SECTION III: OPERATING PROCEDURES29
2.0Start Preparations and Suggestions30
6.0Start-Up Utilizing A Bypass Damper35
7.0Start-Up after Periods of Extended Storage37
B.HRSG OPERATIONAL SAFEGUARDS38
2.0Developing and Carrying Out a Water Treatment Program48
3.0Effects of Deposition, Corrosion, & Carryover49
6.0Boiler Water Treatment51
7.0Carryover Steam Purity54
8.0Chemistry Guidelines For Feedwater and Boiler Water55
9.0Instrumentation and Control56
10.0Startup and Standby57
D.OPERATOR WALKDOWNS AND PROCEDURES70
1.0Prior to Shutdown73
2.0Dry Lay Up76
3.0Wet Lay Up78
4.0Conditions and Suggestions79
3.0Wet Freeze Protection82
4.0Dry Freeze Protection82
1.0Schedule and Check List85
1.0Casing Access Door Usage and Gasketing88
3.0Drum Manway Cover Usage and Gasketing88
4.0Pipe Flange Gaskets91
5.0Bolted Casing Connections91
SECTION V: THERMAL DATA SHEETS92
SECTION VI: BOILER TRIM93
SECTION VII: ENGINEERED SYSTEMS94
A.DUCT BURNER (See Vendor O&M Manual)94
B.SCR SYSTEM (See Vendor O&M Manual)94
SECTION VIII: MISC. EQUIPMENT95
E.ELECTRIC CHAIN HOIST95
G.RECIRCULATION PUMPS / BYPASS95
SECTION IX: SPARE PARTS99
SECTION X: HRSG DRAWINGS100
SECTION XI: TECHNICAL BULLETINS101
Note: This Operation and Maintenance Manual is intended to provide general guidelines for the operation and maintenance of Nooter/Eriksen Heat Recovery Steam Generators. It is not intended to, and cannot, serve as a substitute for the sound judgment of experienced and qualified personnel operating the HRSG safely.
Nothing contained in this manual is to be construed as a warranty extended by Nooter/Eriksen. ALL WARRANTIES EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE SPECIFICALLY INCLUDED.
A.SCOPE OF MANUAL
This manual describes the operation and maintenance of a Nooter/Eriksen Heat Recovery Steam Generator (HRSG).
This manual should be used:
-to familiarize personnel with the equipment, not as a training manual.
-as a guideline for operating and maintaining the equipment.
-as a reference list to define the Nooter/Eriksen scope of supply.
-as an outline in helping to develop an extensive, site-specific operation and maintenance plan for the entire HRSG system.
The manual should be provided to startup, maintenance and operations personnel, allowing ample time for studying the manual before operating or performing maintenance on the HRSG.
The final responsibility for the safe and secure operation of this equipment lies with the operator. In no case should this manual be used as a substitute for the judgment of the boiler operator.
Nooter/Eriksen can provide engineering or field service personnel on a per diem basis. Contact the N/E office for current rate. It should be understood that the presence of a Nooter/Eriksen representative does not relieve the operator of his/her responsibility.
To discuss field services or for any inquiries regarding our equipment, contact Aftermarket Services at the address/phone/fax number below. Please have the N/E job number (064130) and as much detailed information as possible on the item to be addressed available.
P.O. Box 66888
St. Louis, MO. 63166-6888
Aftermarket Services (636) 651-1000
Fax (636) 651 - 1505
1509 Ocello Drive
Fenton, MO 63026
Nooter/Eriksens normal business hours are 7:30 - 4:15 CST, Monday through Friday.
Note: For emergency contacts after business hours or on Weekends, please call:
636 - 651 - 1000
The appropriate Nooter/Eriksen personnel will be notified and respond accordingly.
The following is provided, for your convenience, should an occasion occur which is applicable to Nooter/Eriksen warranty coverage.
All warranty claims are to be brought to the attention of Mike Grill, Nooter/Eriksens Warranty Manager, Telephone: (636) 651-1081; Fax: (636) 651-1505.
Nooter/Eriksens Warranty Claim form is included in this procedure. This form is to be completely filled out, for the benefit of all participants and submitted to Nooter/Eriksens Field Service Manager in a timely manner. Warranty claims will not be processed without this completed form.
The original equipment manufacturer/supplier will be notified by Nooter/Eriksen and have the opportunity to evaluate and, after Nooter/Eriksens concurrence on their plan of action, resolve the claim.
In seeking recourse for repair or replacement, please notify the Nooter/Eriksen Warranty Manager of any requirements. This notification should be performed by using the warranty claim form prior to committing an expense assumed to be chargeable to Nooter/Eriksen. N/E will not be responsible for any warranty repairs performed or expenses incurred before submittal of above notification and written approval by a Nooter/Eriksen representative.
WARRANTY CLAIM FORM
Warranty Claim No. Date:
Warranty Claim Information:
Description of Problem:
Operating Conditions Prior to, Or At Time Problem Occurred
(Operators log of HRSG operation for 30 days prior to problem showing operating hours by day with full or part load indicated).
Nooter/Eriksen Response By:
Distribution: Vice-President Operations
Supervisor of Operations Design
SECTION I: GENERAL DESCRIPTION
A.SCOPE OF SUPPLY
SCOPE OF SUPPLY BY NOOTER/ERIKSEN
- Inlet Transition Duct
- Supplemental Gas Fired Duct Burner
- Duct Burner Firing Duct with View Ports
- Duct Burner Fuel Train Skid
Five (5) HRSG Modules containing:
Module 1Reheater No. 3
HP Superheater No. 2
Reheater No. 2
Module 2HP Superheater No. 1
Reheater No. 1
Module 3HP Evaporator No. 1
HP Evaporator No. 2
HP Evaporator No. 3
Module 4HP Evaporator No. 4
IP Superheater No. 2
HP Economizer No. 2
IP Superheater No. 1
Module 5HP/IP Economizer No. 1
- CO Catalyst Frame
- CO Catalyst Blocks
- SCR Reactor Housing
- SCR Ammonia Injection Grid
- SCR Ammonia Skid
- SCR Catalyst Blocks
- HP Remote Steam Drum
- IP Remote Steam Drum
- LP Remote Steam Drum
- Platforms, Stairs & Ladders
- Interconnecting Piping & Valves
- Boiler External Piping & Valves
- Boiler Trim and Valves
- Field Seam Material
- Expansion Joint at Stack
- Exhaust Stack with EPA platform & Nozzles
- Code Stamping of each Pressure Level
Module Layout and Flow Schematic
The module layout drawings name and locate the major components of the HRSG. The elevation view shows the flow from coil to coil. The plan view shows flow within each c