THERMAL POWER PLANT SIMULATOR TPP 200 LABORATORY EXERCISE TUTORIAL N4: INTRODUCTION TO THE HEAT PRODUCTION SYSTEM

Transcription

1 EKV THERMAL POWER PLANT SIMULATOR TPP 200 LABORATORY EXERCISE TUTORIAL N4: INTRODUCTION TO THE HEAT PRODUCTION SYSTEM Master of Science Thesis Division of Heat and Power Technology 2003 Department of Energy Technology Royal Institute of Technology Stockholm, Sweden

2 TABLE OF CONTENTS INTRODUCTION 3 EXERCISE N4.1: HANDLING THE SIMULATOR 4 EXERCISE N4.2: CO-GENERATION MODE 6 Set burners on plane C into operation 6 Prepare operation of hot condensers 7 Operation of hot condenser 7 Prepare back pressure operation 8 Change to coal firing 9 Set FO system in standby mode 9 Controlling the DHW- system 9

3 INTRODUCTION Tutorial N4 consists of two exercises: the first exercise is for training with the TPP simulator software, which makes the students familiar to the simulator system gives a practical feeling of running a thermal power plant. The second exercise is for increasing the understanding of the heat production system at a cogeneration plant. Following exercises are available in the tutorial: 1. Exercise N4.1 for training: General handling of the TPP simulator 2. Exercise N4.2: Start up of heat production - Cogeneration mode

4 Exercise N4.1: Handling the simulator 1. Press Initial Conditions on the keyboard. [Shift F6] 2. Select Block connected. 3. Start the simulator with Running [F1]. Check that the clock is running (top of the left corner). 4. Press Picture Directory on the keyboard [Home]. 5. Select picture MD 260, Main Steam Lines". 6. Check that steam data in the steam main line is approx. 30 bar, 330 o C Main Steam Line take the steam from superheater 3 in the boiler to the main team valve at the HP- turbine. Read and write down the data on the line close to the HP- turbine. 7. Select picture MD 300 (Between IP- and LP- turbines on MD 260). 8. Check that the power is about 30 MW. (Numbers on the Generator) 9. Press Picture Directory at the keyboard [Home]. 10. Select picture MD Check that all four burners on level D are running and that the pressure in the furnace is close to -20 mm H 2 O. 12. Go to picture MD 180. (On the right side from the Coal Silo ) Take in the flames by pressing the button on Plane D in the display module. 13. Open the controller for O 2 in flue gas by pressing C in Oxygen Controller [CTR1801]. Check that the set point is 2 % and that the actual value is stable. 14. Read and write down the contents of CO in flue gas on the display for Carbon Mono Oxide and note the value. 15. Decrease the set point for O 2 to 1 % (set value and press Enter ) and find out how much the content of CO will Increase. Press F8 to go to Alarm Log Summary Display. Click on the blinking value to reset the alarm for high content of CO. Note the value of CO when it is stable. Reset the set point for O 2 to 2.1 % 16. Freeze the simulation [F2]. 17. Go to Initial Conditions [Shift F6] and select Cold Plant. 18. Start the simulation with Running [F1]. 19. Press Picture Directory [Home]. Select picture MD 100, Fuel Oil system.

5 20. Start preheating of the oil in the tank by opening (right click) the valves V01023 and V01024 (bottom of the left corner: to check mouse over) and switch the temperature controller into Auto. 21. Drain some water from the tank by opening HFO service tank bottom drain valve (at the bottom of Fuel Oil Service Tank). 22. Read the oil temperature in the tank. Check that the temperature is slowly increasing. 23. Stop simulation with Freeze [F2]. 24. Go to Initial Conditions, select Block Connected and start the simulation with Running [F1]. 25. Read and note steam pressure and generator power on picture MD 300 and fuel consumption (at the bottom: fuel oil flow G01850) on MD Start all four burners on plane C (MD 160). Be careful with the pressure in the furnace (should not be high). Do not ignite a new burner (wait some time) if the pressure is high on the positive side. Start with burner 1 (press start on the control panel) and followed by Select Initial Conditions and freeze the simulation. Increase the simulation speed to 5. Start simulation again with Running [F1]. 28. Press Picture Directory [Home] 29. Select Pen Recorder (MD 130). 30. Click on 'Tagname' and write the tagnumber (P03006) Note: Block Letters. The Variable will be searched in the database. 31. Select the limits 0 and 100 bar and start the plotting of the variable by clicking at the button for Channel 1. Repeat the procedure for variable E03812 (Generator Power) on Channel Increase the firing intensity to 25 % on picture MD 190. The increasing takes place by writing the value for fuel oil (25 %) on BLM (Block Load Master Controller Output). Check that the value for fuel oil increase from 9 t/h into15 t/h. 33. Read the fuel consumption on page MD Follow how the steam pressure and the generator power will increase. Look at page MD 300 and the plotting on Pen Recorder. Read the values when the plant is stabilized. 35. Freeze the simulation [F2].

6 Exercise N4.2: Co-generation mode It is early in the starting process. The generator has just become connected to the grid and the HP- preheaters are not yet started. Preheater 3 is not equipped with a level controller but is connected to preheater 1. Preheater 1 and 2 has their own level controller that led the drain to preheater 1. The drain from all the preheaters is led through the preheater 1 into the feed water tank or is reticulated to the LP- preheater Load Initial Condition Block connected and set the simulation Pic. Dir. speed 5 2. Open the ventilation valves on the HP feed heaters 1 and 2 MD440 (V14401/V24401) 3. Open drain valves (V24420/V14420) MD Set the level controllers to AUTO MD Line up return to feed water deaerator tank and to LP feed MD420/MD430 heater 3 6. Open the steam extraction valves (V34402/V34402 to HP feed MD440 heater 7. Check that the level controllers start to operate MD Open steam supply from ext. 4 (V04330) to feed water deaerator MD430 Set burners on plane C into operation 1. Start the flue gas fan 2 (R02260) MD Check the furnace pressure control MD Ignite the burners on Plane C in correct sequence MD Start the feed water Pump 2 (R24351) and set feed water MD430 Pump 3 (R34352) in standby (Set up to REMOTE mode (Z34379), start up oil pump (R34352) and set up pump 3 to auto mode (X34350). 5. Increase the firing to 30 % in BLM MD Check the combustion control system included the oxygen MD180/MD190

7 content controller Prepare operation of hot condensers 1. Open drain valve (V06053) between hot condenser 1 and 2. MD Start filling hot condenser 2 with water by opening V04134 valve MD Set level controller for hot condensers 1 and 2 to AUTO (Z26023) MD Line up drain return lines from hot condensers to condensate tank MD410 Operation of hot condenser 1. Check that 'Multi block operation' is selected at page 6300 in the Var. List Variable List 2. Change ambient temperature to - 5 o C Var. List 3. Read DHW supply temp recommendation and note the value Var. List 4. Switch DHW pump speed control from REMOTE to LOCAL MD Adjust the speed that the DHW flow is approx m 3 /h MD Check the DHW- flow through the direct heaters MD 610 (Min. flow is 1100 ton/h). 7. Close (0 %) the Hot Condenser 2 outlet control valve (V06088) MD 600 and open Hot Condenser 1 inlet shut off valve (V06065). Reset the alarms 8. Line up and start the hot condensate pump 2, and set pump 3 MD600 in standby mode. 9. Read the DHW supply line temperature and note the value MD Open DHW Flow adjust valve (V06087) to 100% and establish MD600 flow to hot condensers. 11. Set DHW temperature (bypass) controller (CTR6010) to AUTO MD Read the DHW supply line temp. and note the value MD Check that the hot condenser 1/2 level control is working properly MD600

8 Prepare back pressure operation 1. Reduce the LP turbine steam dampers gradually from 100% MD300 to 30% open position by closing the valve (V03200) 2. Read the DHW supply line temperature and note the value MD Check extraction flows and functioning of the hot condenser 1 and 2 MD Reduce the LP steam damper position from 30% to minimum MD300 opening 5. Check that the LP turbine house cooling system is activated at MD300 low steam flow 6. Read the DHW supply line temp. and note the value MD Ignite the burners on Plane B in correct sequence. MD Increase the firing up to 40 % MD Check the (V05025) in order to take the LP- Steam Generator MD500/MD120 into operation 10. Change the position of a drain valve (V11254) into AUTO MD Open the LP primary steam shat off valve (V01270) MD Set the pressure control valve (CTR1200) to AUTO MD Open the LP heating steam shat off valve (V01204) MD Reset the alarms F8 15. Open the LP second water make up inlet valve (V01273) MD Set the LP water level control valve (V11234) to AUTO MD Wait until water level reaches certain level and pressure is P 3,45 MD Open the LP second steam outlet valve (V01277) MD Open the LP drain pump discharge valve (V01287) MD Start the drain pump (R01288) MD Open the LP second drain return valve (V01274) MD Set the LP tank level control valve (V11274) to AUTO MD120

9 23. Close the Steam Cooling Tank FO heater x- over valve (V01217) MD120 Change to coal firing 1. Open the primary air fan shut-off valve. Set the electric air heater on MD Activate the start sequence for coal mill on Plane D on the MD170 operator-panel (wait some time) 3. Observe and adjust the oxygen controller O 2 set point 3,5-4 % at MD180 coal firing 4. When the start sequence is finished and all burners are operative on MD170 coal, then shut off oil burners 1 to 4 5. Repeat the procedure for burner planes B and C MD150/MD160 Set FO system in standby mode 1. Line up and start the FO circulation pump MD Stop the FO supply pump (R01060) MD Set the fuel oil control valves (plane B-D) to proper heating MD150/160/170 position 20 % 4. Check recirculation of fuel oil MD100 Controlling the DHW- system 1. Control manually the DHW- temperature into recommended MD300/MD600 value 2. Note the Line Power, the DHW- power and Block Load Master MD 190 Controller output 3. Check the values in page 6300 in the Variable List Var. List