OPERATION & MAINTENANCE MANUAL - Laughing · Web viewThis manual describes the operation...

Click here to load reader

  • date post

    06-Apr-2018
  • Category

    Documents

  • view

    246
  • download

    12

Embed Size (px)

Transcript of OPERATION & MAINTENANCE MANUAL - Laughing · Web viewThis manual describes the operation...

OPERATION & MAINTENANCE MANUAL

OPERATION & MAINTENANCE MANUAL

NOOTER/ERIKSEN

HEAT RECOVERY STEAM GENERATOR

FOR INSTALLATION AT:

Hopkins Unit 2

Tallahasee, Florida

NOOTER/ERIKSEN JOB NO. 064130

City Of Tallahasee CONTRACT NO. 1304

TABLE OF CONTENTS

1FOREWORD

A.SCOPE OF MANUAL1

1.0Purpose1

2.0Responsibilities1

B.CONTACTS2

C.WARRANTY PROCEDURE3

SECTION I: GENERAL DESCRIPTION5

A.SCOPE OF SUPPLY5

B.TECHNICAL DESCRIPTION6

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

A.INSPECTIONS15

1.0General15

2.0Valves15

3.0Control Devices16

4.0Level Control and Indication16

B.HYDROSTATIC TEST17

C.TUBESIDE CLEANING19

1.0General19

2.0Types of Cleaning19

3.0Considerations25

D.LIQUID VOLUMES28

SECTION III: OPERATING PROCEDURES29

A.STARTUP29

1.0General Information29

2.0Start Preparations and Suggestions30

3.0Cold Start-Up31

4.0Warm Start-Up33

5.0Hot Start-Up35

6.0Start-Up Utilizing A Bypass Damper35

7.0Start-Up after Periods of Extended Storage37

B.HRSG OPERATIONAL SAFEGUARDS38

1.0General Philosophy38

2.0Specific Recommendations38

C.WATER TREATMENT47

1.0Objectives47

2.0Developing and Carrying Out a Water Treatment Program48

3.0Effects of Deposition, Corrosion, & Carryover49

4.0Feedwater Treatment49

5.0Blowdown51

6.0Boiler Water Treatment51

7.0Carryover Steam Purity54

8.0Chemistry Guidelines For Feedwater and Boiler Water55

9.0Instrumentation and Control56

10.0Startup and Standby57

11.0Recommended Reading58

D.OPERATOR WALKDOWNS AND PROCEDURES70

1.0Walkdowns70

2.0Procedures71

E.PERFORMANCE PARAMETERS72

F.SHUTDOWNS73

1.0Prior to Shutdown73

2.0Normal Shutdown73

3.0Emergency Shutdown74

4.0Post Shutdown75

G.LAYOVERS76

1.0Corrosion Factors76

2.0Dry Lay Up76

3.0Wet Lay Up78

4.0Conditions and Suggestions79

H.FREEZE PROTECTION81

1.0General81

2.0Heat Tracing81

3.0Wet Freeze Protection82

4.0Dry Freeze Protection82

I.DRAINING84

SECTION IV:MAINTENANCE85

A.INSPECTIONS85

1.0Schedule and Check List85

2.0Minimum Requirements85

B.PROCEDURES88

1.0Casing Access Door Usage and Gasketing88

2.0Grease Fittings88

3.0Drum Manway Cover Usage and Gasketing88

4.0Pipe Flange Gaskets91

5.0Bolted Casing Connections91

6.0Packing Glands91

7.0Miscellaneous91

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

C.SCR CATALYST94

SECTION VIII: MISC. EQUIPMENT95

A.DAMPER95

B.DEAERATOR95

C.EXHAUST SILENCER95

D.CHEVRONS95

E.ELECTRIC CHAIN HOIST95

F.STACK BYPASS95

G.RECIRCULATION PUMPS / BYPASS95

SECTION IX: SPARE PARTS99

SECTION X: HRSG DRAWINGS100

SECTION XI: TECHNICAL BULLETINS101

FOREWORD

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).

1.0Purpose

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.

2.0Responsibilities

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.

B.CONTACTS

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.

Mailing Address:

Nooter/Eriksen

P.O. Box 66888

St. Louis, MO. 63166-6888

Aftermarket Services (636) 651-1000

Fax (636) 651 - 1505

Shipping Address:

Nooter/Eriksen

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.

C.WARRANTY PROCEDURE

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).

Initiated By:

Of:

(Company)

Date:

Approved By:

Of:

(Company)

Date:

Nooter/Eriksen Response By:

Date

Distribution: Vice-President Operations

Manager, QA

Director, Systems

Director, Engineering

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

IP Evaporator

Module 5HP/IP Economizer No. 1

LP Evaporator

Preheater

- 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

B.TECHNICAL DESCRIPTION

1.0

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