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THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
OPERATION & MAINTENANCE MANUAL FOR
2 x 86 TPH SUPPLEMENTARY FFIRED HSRG
FOR
BEKASI POWER CCPP 1 X 130 MW
JABABEKA, CIKARANG
COUNTRY: INDONESIA
HRSG PH- 0331& 0332
Prepared, revised Checked Approved Remark, kind of revision
Name Date Name Name Date Status
PK 27-07-09 OSS USU 27-07-09 REV-0
THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
OPERATION AND MAINTENANCE MANUAL
FOR 2 x 86 TPH
SUPPLEMENTARY FIRED HRSG
SUPPLIED TO
BEKASI POWER CCPP 1 X 130 MW JABABEKA,CINARANG COUINTRY: INDONESIA
CONSULTANT: INTERNUSA TECHNICAL GROUP PVT LTD
TBW JOB NO. PH-0331& 0332
THERMAX BABCOCK & WILCOX, A DIVISION OF THERMAX LIMITED, PUNE, INDIA
THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
We are pleased to welcome you to the growing family of
THERMAX BABCOCK & WILCOX
THERMAX BABCOCK & WILCOX, a division of THERMAX LIMITED – INDIA,
are having technology tie up with BABCOCK & WILCOX – USA. Combining the
Engineering / Technology and experience of the two organisations to provide the
very best of services in the field of Industrial Boilers. THERMAX BABCOCK &
WILCOX quality management system is certified under ISO 9001 with design
and manufacturing standards approved and confirming to ASME & IBR.
THERMAX BABCOCK & WILCOX has in its product range:
• Oil / Gas fired BI-DRUM packaged FM boilers up to 100 TPH
• Oil / Gas fired BI-DRUM modular 'HC-FM' boiler up to 272 TPH
• Coal / Lignite / Agro waste (pith, coconut shell, coffee waste / industrial waste,
paper sludge etc.) fired ATMOSPHERIC FLUIDISED BED COMBUSTION (AFBC)
boilers up to 300 TPH
• Coal / Lignite / Agro waste / Industrial waste fired CIRCULATING FLUIDISED
BED COMBUSTION (CFBC) Boilers up to 500 TPH
• Oil / Gas fired single drum high pressure capacity RADIANT BOILERS up to 500
TPH
• Gas turbine exhaust, Unfired / Supplementary fuel fired / Fully fired HRSGs for
combined cycle power plants up to 500 TPH
• Coal / Lignite / Bagasse fired TRAVELING GRATE / DUMPING GRATE boilers up
to 200 TPH
• Waste heat recovery boiler WHRB / Process integrated boiler PIB / Waste gas
fired boiler up to 200 TPH
• Exhaust gas boiler up to 20 TPH
• Fired Heaters up to 100 mm kcal/hr
• Cogen & Captive power plants
THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
THERMAX BABCOCK & WILCOX, with their team of specialists offer the
following services for Boilers of (any make and size including utility boilers)
• Condition assessment to determine the remaining life of boiler components
(RLA)
• Pressure part replacement for Superheaters, Economisers and convection
tubes
• Fuel conversions to take advantage of the newer / cheaper fuels
• Technology upgrades for old boilers to get benefits of modern technology for
efficiency, economy and reliability
• FBC RETROFITS for old conventional coal fired boilers
• INSTRUMENTATION MODERNISATION to replace complicated and unreliable
instruments with user friendly systems
• EMMISION CONTROL SOLUTIONS to upgrade fuel firing system for emission
control
• UTILITY BOILER REVAMPS for renovation & modernisation services for Power
Utility Boiler
• EMERGENCY SERVICE to rectify forced boiler shut downs on top priority
You can contact us at:
THERMAX BABCOCK & WILCOX,
A Division of THERMAX LIMITED,
"Energy Building", Block D-1, Plot 7/2,
RD AGA Road, MIDC, Chinchwad,
Pune - 411 019, India.
Tel: +91-20-4126464,
Fax: +91-20-7478066
E mail for after sales & service - [email protected]
THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
Thermax Babcock & Wilcox
A Division of Thermax Limited
O&M MANUAL
PROPRIETARY
This operation and maintenance manual contains confidential and
proprietary information of TBW-A division of Thermax Limited
and is submitted upon the following conditions only for reference.
• To be used solely and exclusively for the purposes of Boilers and its
auxiliaries operation and maintenance.
• Not to be copied or reproduced in whole or in part, without the
express written consent of TBW-A Division of Thermax Limited
• Not to be disclosed or disseminated in whole or in part, to any
person or entity outside of the recipient’s organisation, without the
prior written consent of TBW-A division of Thermax Limited
• Not to be used for any purpose detrimental to the interest of TBW-
A division of Thermax Limited
THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
THERMAX B&W REPRESENTS THAT THE INFORMATION
CONTAINED IN THIS MANUAL HAS BEEN DEVELOPEDED
IN ACCORDANCE WITH THERMAX STANDARD TECHNICAL
PROCEDURES AND PRACTICES FROM LATEST
INFORMATION AVAILABLE AT THE TIME OF ISSUE OF
THIS MANUAL.
PLEASE READ AND FOLLOW
THE INSTRUCTIONS CONTAINED IN THE
MANUALS CAREFULLY FOR
SAFE OPERATION
THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
OWNER SHOULD REVIEW ALL THE OPERATING
INSTRUCTIONS & BE SURE THAT THE PERSONS
OPERATING & MAINTAINING THE EQUIPMENT ARE
FAMILIER WITH ALL THE INFORMATION PROVIDED,
INCLUDING MANUALS FROM VARIOUS SUPPLIERS OF
VENDOR EQUIPMENTS.
THERMAX BABCOCK & WILCOX (A Division of THERMAX Limited) Pune-19, INDIA
Project No.-PH-0331 & PH0332
TBW Document No.-
Commg/BP CCPP/O&M/01
WARNING
THIS MANUAL PROVIDES SIMPLE AND BASIC
INSTRUCTIONS ON BOILER OPERATION &
MAINTENANCE TO ASSIST THE OPERATING
PERSONNEL.
BOILERS & ACCESSORIES BY THEIR VARY NATURE
OPERATE AT HIGH PRESSURE AND TEMPERATURE
CAN BE DANGEROUS WHEN NOT PROPERLY
OPERATED AND MAINTAINED, THEREFORE OWNER
MUST PROVIDE ADEQUATE OPEARTING
MAINTENANCE AND SAFETY TRAINING FOR ITS
PERSSONEL. THE OPEARTING COMPANY MUST
PROVIDE QUALIFIED OPERATORS FOR OPERATION.
INDEX BEKASI POWER CCPP
SECTION A Page I
A. DESIGN SPECIFICATIONS OF HRSG 9
2 DESIGN CODE 9
3 MATERIAL SPECIFICATIONS – PRESSURE PARTS 10
4 HEATING SURFACE AREA 11
5 FUEL 11
ULTIMATE ANALYSIS FOR NATURAL GAS ( PRIMARY FUEL ) 12
6 CONTINUOUS BLOWDOWN. 12
7 HRSG FEED WATER ANALYSIS : 12
8 HRSG BOILER WATER ANALYSIS: 13
9 UTILITIES 13
ELECTRICAL POWER 13 COOLING WATER 14 INSTRUMENT AIR 14
10 CHEMICALS FOR DOSING 14
11 SITE CONDITION 14
11 FANS 15
12 HP HRSG FEED WATER PUMPS 15
13 DEARATOR CHEMICAL DOSING SYSTEM 16
14 CHEMICAL DOSING SYSTEM FOR HP BOILER 16
15 BURNERS 17
16 GAUGE GLASS 18
DRUM LEVEL 18 DEARATER LEVEL 18 BLOWDOWN TANK 18
17 SAFETY VALVES 19
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 9
NUMBER & TYPE OF BOILER : 2X86 TPH, nos. Natural Circulation,
integral dearater and pumps, Single Drum Supplementary Fired Heat Recovery Steam Generator
A. DESIGN SPECIFICATIONS OF HRSG
PARAMETERS UNIT VALUE
Boiler Rating [MCR] TPH 86
Steam Pressure at Main Steam Stop Valve Outlet from minimum Load upto MCR
bar (g) 92
Steam Temperature at the Main Steam Stop valve at MCR
Deg C 535
Boiler Feed Water Temperature at inlet to MUWH
°C 42
Feed water temperature at BFW pump outlet
°C 105
Gas Turbine Load % 50 - 100
Design Pressure Kg/Cm2 105
Fuel Firing Combination. • 100 % NG
Boiler Performance Testing Procedure ASME PTC 4.4 “Heat
Loss Method”
2 DESIGN CODE
Boiler & Economiser / Pressure Parts: ASME Section 1.
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 10
3 MATERIAL SPECIFICATIONS – PRESSURE PARTS
Description Details Size In Mm Material
Shell 1500 I.D. x 70 Thk
Steam Drum Dished end for S.D. (Hemispherical)
70 Thk SA 516 Gr.70
Riser Tube 150DN x SCH40 SA 106 Gr. B
Down comers Pipe 300DN x SCH 160 SA 106 Gr. B
HP Superheater I
Module No.1 Header 200DN X SCH.160
SA 335 P22
HP Superheater I
Module No.1 Finned tube 38.1 O.D. x 3.25Thk SA 213 T22
HP Superheater I
Module No.2 Header 200DN X 35 THK
SA 335 P22
HP Superheater I
Module No.2 Finned tube 38.1OD X 6.3THK SA 213 T22
HP Superheater II
Module No.3 Header 200 DN X 45 THK
SA 335 P22
HP Superheater II
Module No.3 Finned tube 38.1OD X 6.3THK SA 213 T22
HP Superheater II
Module No.4 Header 200 DN X 32THK
SA 335 P91
HP Superheater II
Module No.4 Bare Tubes 38.1 OD X 3.6 THK SA 213 T19
Evaporator Top & Bottom Header I & II
Header 150 NB X SCH.160 SA 106 Gr B
Evaporator Bank Tubes 3.8 O.D X 2.7 THK SA 210 Gr A1
HP Economiser III Top & Bottom Header
Header 150 DN X SCH 160 SA 106 Gr. B
HP Economiser III
Finned tube 38.1 O.D. x 2.7Thk SA210 GR.A1
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 11
Description Details Size In Mm Material
HP Economiser II Top & Bottom Header
Header 150 DN X SCH 160 SA 106 Gr. B
HP Economiser II Finned tube 38.1 O.D. x 2.7Thk SA210 GR.A1
HP Economiser I Top & Bottom Header
Header 150 DN X 21.95 THK SA 106 Gr. B
HP Economiser I Finned tube 38.1 O.D. x 2.7Thk SA210 GR.A1
Integral dearater
Inlet/outlet header
Header 200 DN X SCH 120 SA 106 Gr. B
Integral dearater
Finned Tubes 38.1 O.D. x 2.7Thk
SA210 Gr A1
Condensate Preheater Inlet/outlet header
Header 150DN X SCH 160
SA 106 Gr. B
Condensate Preheater
Finned Tubes 38.1 O.D. x 2.7Thk SA210 Gr. A1
4 HEATING SURFACE AREA
Zone Unit Value
HP Superheater I Sq.Mtr 1784
HP Superheater II Sq.Mtr 615
Evaporator bank Sq.Mtr 11692
Economiser Sq.Mtr 21254
Integral dearater Sq.Mtr 941
Condensate preheater Sq.Mtr 1634
Total Heating Surface Area Sq.Mtr 37920
5 FUEL
a) Main Fuels : NG
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 12
7 FUEL ANALYSIS:
Ultimate Analysis For Natural Gas ( Primary Fuel )
PARAMETER UNITS VALUE
Methane % volume 81.686 Ethane % volume 4.865 Propane % volume 3.656 n-Butane % volume 0.942 i-Butane % volume 0.697 n-Pentane % volume 0.160 i-Pentane % volume 0.329 Octane % volume 0.140 Nitrogen % volume 2.820 Carbon di oxide % volume 4.324 Oxygen % volume 0.265 Water % volume 0.015 NCV KJ/Kg 42415 Condition at Battery Limit: Temperature °C 35 Pressure Bar(g) 4.5
6 CONTINUOUS BLOWDOWN.
Normal : 1 % / Hr
7 HRSG FEED WATER ANALYSIS: General appearance Clear & colourless Total Hardness as CaCO3
ppm Commercial zero
Total Fe ppm < 0.01 Total Cu ppm <0.003 Oxygen ppm <0.02 Oil & organics ppm NIL PH value at 25°C 8.5-9.5 Total Dissolved solids
ppm <0.1
Electrical Conductivity
µs/cm <0.2
Silica SiO2 ppm <0.02 Condition at Battery Limit
Boiler Feed Water barg 7
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 13
Pressure at inlet to MUWH Boiler Feed Water Temperature at inlet to MUWH
°C 42
Application HRSG feed water
8 HRSG BOILER WATER ANALYSIS:
Sodium phosphate as PO4
Ppm 27 to 25
Alkalinity as CaCO3 Ppm 20 Sodium sulphite as SO3
Ppm 11 to 8
pH value 8.8- 11 Oil & organic Ppm NIL Total dissolved solids
Ppm 100
Silica SiO2 Ppm <6
9 UTILITIES
Electrical power
Parameters Units Value
For HT motor above 150kw Voltage V 6000 Frequency Hz 50 Combined Variation % 5 Type AC, 3 phase
For LT motor upto 150kw
Voltage V 380 frequency Hz 50 Combined Variation % 5 Type AC, 3 phase
For Instrumentation Voltage
V 110
Frequency Hz 50 Type AC 1 phase For field transmitters Voltage V 24 Frequency Hz NA Type DC
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 14
Cooling Water
Parameters Unit Value
Supply pressure barg 5 Return pressure barg 4 Supply temperature °C 34 Return temperature °C 42 Quality Soft Duty Sample cooling
Instrument Air
Parameters Unit Value
Pressure barg 7.0 Dew point °C -20 Temperature max ° c 40 Quality Dry & Oil free Duty Instruments
Nitrogen Parameters Unit Value
Pressure (min/normal/design)
barg 6/7/10
Temperature (min/normal/max/design)
°C 0/30/25/40
Quality 99.9% pure Duty HRSG preservation
10 CHEMICALS FOR DOSING
HP Dosing Tri sodium phosphate.
11 SITE CONDITION
Site Location Jakarta, INDONESIA
Ambient Temperature
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 15
Ambient temperature (min/max/design)
°C (21/35/33)
For Performance testing °C 32
Relative Humidity
Average % 80
For Performance testing % 95
Area classification Zone 2 Group IIA/IIB T3 within 3 meters from the fuel gas train.
Seismic coefficient Zone 4 of UBC
11 FANS
Duty conditions Unit Scanner Cooling Air Fan
Make Andrew Yule And Co. Ltd.
Quantity Nos. 2 Nature of medium Air
Capacity Kg/s 0.10
Density Kg/cu.m
1.1187
Air Temperature at Fan Inlet
Deg C 33
Absorbed power at inlet temp.
KW 7
Fan Speed Rpm 2900 Diff. Static pressure MmHg 670 Outlet Static Pressure mmHg 759.53 Bearing Lubrication Servogem; EP-2
Motor 7KW ,TYPE – SCR ,Voltage -380 VAC,
Starting - DOL
Coupling Model
Resilient type coupling with guard
12 HP HRSG FEED WATER PUMPS
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 16
Duty conditions Unit Duty conditions
Make SULZER INDIA LTD Model MC 80-260/ 14
Number 2 Type Centrifugal
Design capacity m3/hr 102 Design head MLC 1205
Speed RPM 2970 Feed water temperature
°C 105
Casing Material Cast Iron Impeller Material Cast Iron
Drive Motor Type of coupling Flexible
Motor rating KW 500 Protection IP 55
Insulation Class F
13 DEARATOR CHEMICAL DOSING SYSTEM
Make : Metapow Industries M.I.D.C Bhosari, Pune
Description LP
Number 1 Storage tank Capacity m3 0.30 Material of construction CS with rubber lining Pump
Type Reciprocating plunger Numbers 2 Design Capacity liters/hr 10 Design Head bar[g] 5 Speed RPM 1440 Drive Motor Type of coupling Flexible Motor rating KW 0.37 Protection IP 55 Insulation Class F
Fluid to be handled. Di- Sodium Phosphate
solution.
14 CHEMICAL DOSING SYSTEM FOR HP BOILER
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 17
Description LP
Make Metapow Industries M.I.D.C Bhosari, Pune
Number 1 Storage tank Capacity m3 0.30 Material of construction CS with rubber lining Pump
Type Reciprocating plunger Numbers 2 Design Capacity liters/hr 10 Design Head bar[a] 102 Speed RPM 1440 Drive Motor Type of coupling Flexible Motor rating KW 0.37 Protection IP 55 Insulation Class F
Fluid to be handled. Tri Sodium Phosphate
solution.
15 BURNERS
15.1 General Number of HRSG 2 Burner Location uncooled furnace Burner make Stork Thermeq BV Burner fuel Natural gas Ignition fuel Natural gas Guranteed Performance for HRSG at
GT Base Load with Natural Gas, 32 DegC Ambient-Maximum Continuous rating [MCR] in supplementary fired
GT Base Load with Natural, 32 DegC Ambient-Supplementary fired
GT Load condition Base Base Steam Generation HP, TPH
86 78
Steam Pressure HP, Bar(g)
92 92
Steam Temperature HP, DegC
535 535
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 18
16 GAUGE GLASS
Drum level
Description Details
Make High- tech systems & services ltd Tag No. LG-173D & 173E Location Drum Operating pressure. 100kg/cm2 Design Temperature 370˚C C/c distance 800mm Visibility range 314 mm Operating temp. Saturation
Dearater level
Description Details
Make Chemtrols samil (India) pvt ltd Tag No. LG-173B & 173C Location Dearater Operating pressure. 0.21-2.1/6.3 kg/cm2 Design Temperature 200 0C C/c distance 1700mm Visibility range 1324 mm Operating temp. Saturation
BLOWDOWN TANK
Description
Details
Type Vertical cylindrical Numbers 1 Design pressure bar[a] 3.5 Internal diameter Mm 1200 Overall height Mm 2800 Shell thickness Mm 8 Material ASTM
THERMAX BABCOCK & WILCOX Project: INTERNUSA TECHNICAL GROUP PTE Ltd.
A Division of THERMAX LIMITED A/C BEKASI POWER CCPP PUNE, INDIA Job No.: PH-0331 & PH-0332
SECTION A Page 19
17 SAFETY VALVES
DESCRIPTI ON
APPLICATION
UNIT
DRUM LHS
DRUM RHS
SH
DEARATER
TYPE - SPRING LOADED
MAKE TYCO SANMAR TAG NO
- 176J 176K 176N
176D 176E
SIZE ORIFICE -
2” J 3”
2” J 3”
2” J 3”
2” J 3”
2” J 3”
SETPRESSUR. Kg/ Cm2
107
108
100
5
5
RELIEVING. TEMP.
DEG.C
Saturated
Saturated
540
Saturated
Saturated
VALVE CAPACITY
TPH
34.4
34.4
17.2
Suitable
suitable
QUANTITY - 1nos. / Boiler
1nos. / Boiler
1nos. / Boiler
1nos. / Boiler
1nos. / Boiler
FLUID -
Sat. Steam Sat. Steam
SH Steam
Water
Water
DESCRIPTI ON
APPLICATION UNIT
CPH OUTLET
HP ECONOMISER I OUTLET
TYPE - SPRING LOADED
MAKE TYCO SANMAR TAG NO
- 176C 176H
SIZE ORIFICE -
2” J 3”
2” J 3”
SETPRESSUR. Kg/ Cm2
10
128
RELIEVING. TEMP.
DEG.C 250
saturated
VALVE CAPACITY Kg/Hr.
102888
88500
QUANTITY - 1nos. / Boiler
1nos. / Boiler
FLUID -
water
water