Auxiliary PRDS System

Auxiliary PRDS System: Basic Layout Technical Details Protections & Provisions

Auxiliary PRDS System: Basic Layout Technical Details Protections & Provisions

P & ID For Aux PRDS System

P & ID

Classification of System
The auxiliary PRDS system is basically divided into four parts
The inflow i.e the sources for steam to system HT PRDS i.e at higher temperature (15 Bar / 310 0C) LT PRDS i.e. at Lower temperature (15 Bar / 250 0C) The outflow i.e. the consumption ends

Layout for system

Inflow HT PRDS Unitised
Supply to LT PRDS
CEP Attemp

LT PRDS For station

VAM 1 & 2 Road oil Tanker SLOP Oil drain heater HFO heater Tank floor coil heater Suction heater

CRH
BFP Interstage attemperation

Mill inerting Deaerator initial heating Turbine Gland sealing

MS

APH soot blowing

Aux Boiler
Fuel oil atomising

Interconnected header for all 5 units

To CRH line for HP casing warmup

Auxiliary PRDS System: Basic Layout Technical Details Protections & Provisions

Acid Cleaning
Purpose: Steam will be required initially during the acid cleaning of the unit

Parameters:
Acid cleaning : 15 T/Hr / 10 Bar / 300 0C / Intermittent

Details:
Cleaning of all the internals of boiler and piping for making it free of foreign materials, grease, oil and dirt. For establishing a protective magnetite layer in the boiler internals Removal of thick debris and other foreign material which have been ingressed during construction phase

Fuel oil coil heater and suction heaters

Purpose: Steam will be required for heating of HFO for achieving the flow Tapping point: LT PRDS Parameters:
Bottom heaters : 1.2 T/Hr / 14 Bar / 250 0C / Continuous Suction heaters : 3.1 T/Hr / 14 Bar / 250 0C / Intermittent

Details:
Oil is heated in the HFO tanks to achieve the flowability at heater inlet In second step the heating is done in the suction heaters

Fuel oil heater

Purpose: Steam will be required for heating of HFO for achieving the flow Tapping point: LT PRDS Parameters:
Fuel oil heaters : 11 T/Hr / 14 Bar / 250 0C / Intermittent

Details:
Oil is heated in the oil heater to achieve minimum viscosity for getting effectieve and complete combustion in the boiler

Atomizing Steam
Purpose: Steam will be required for atomising fuel oil Tapping point: HT PRDS Parameters:
Atomising steam : 6.1 T/Hr / 14 Bar / 300 0C / Intermittent

Details:
The steam assists for effective atomisation as required in the application of low NOX burner. This also ensures for a safe operation

Fuel oil unloading

Purpose: Steam will be required for fuel oil unloading Tapping point: LT PRDS Parameters:
Fuel oil unloading : 2.0 T/Hr / 14 Bar / 250 0C / Intermittent

Details:
The HFO before unloading needs to be heated up above the flow point temperature The heating needs to be carried out in the truck tanker itself

Mill Inerting
Purpose: Steam will be required for mill inerting Tapping point: HT PRDS Parameters:
Mill inerting : 61 T/Hr / 14 Bar / 300 0C / Intermittent

Details:
During routine operation coal is transported to boiler with the help of hot air. The coal and hot air mixture forms a fire hazardous situation. The steam in such condition is utilised as an inerting media

Deaerator initial heating & pegging

Purpose: Steam will be required for deaerator initial heating and pegging Tapping point: HT PRDS Parameters:
Deaerator initial heating : 11 T/Hr / 2 Bar / 300 0C / Intermittent Deaerator pegging at 5% MCR flow : 12 T/Hr / 2 Bar / 300 0C / Intermittent Deaerator heating during SG under recirculation : 28 T/Hr / 2 Bar / 300 0C / Intermittent

Details:
During cold startup the heat will be sourced thorough aux PRDS header. Once the CRH parameter is established the source will be switched over to CRH and will be pegged upto 2.5 bar The changeover from CRH to normal source i.e. IPT extraction will be done at about 30% load During the turbine trip condition the deaerator will be pegged through CRH line upto 7.45 bar

Turbine Gland sealing

Purpose: Steam will be required for turbine gland sealing system Tapping point: HT PRDS Parameters:
Start up : 8 T/Hr / 13.7 Bar / 300 0C / Intermittent At 35% MCR : 1.89 T/Hr / 13.7 Bar / 300 0C / Intermittent At 60% MCR : 0.298 T/Hr / 13.7 Bar / 300 0C / Intermittent

Details:
During the normal operating conditions the HP-IP turbine will be self sealed and the leak off will be utilised for sealing of LP turbine. During startup the sealing steam will be taken from Aux PRDS in order to establish vacuum

Air Heater soot blower

Purpose: Steam will be required for air pre heater soot blowing Tapping point: HT PRDS Parameters:
APH soot blowing : 10 T/Hr / 14 Bar / 300 0C / Intermittent

Details:
During normal operation condition the soot blowing for APH alongwith furnace and economiser will be done from the steam tapped from outlet of LTSH header. During startup i.e. during oil firing the APH soot blowing will be done by the steam from Aux PRDS to avoid fire.

Turbine casing warm up

Purpose: Steam will be required for turbine casing warm up Tapping point: HT PRDS Parameters:
Turbine casing warm up : 12 T/Hr / 13.7 Bar / 300 0C / Intermittent

Details:
As per the OEM recommendation if the Inner metal temperature for first stage is less than 150 0C then turbine pre warming needs to be conducted prior to turbine startup. Normally the warming time will be approximately 4 to 5 hrs.

Vapour Absorption Machine

Purpose: Steam will be required for turbine casing warm up Tapping point: LT PRDS Parameters:
VAM : 1.8 T/Hr / 9 Bar / 176 0C / Continuous

Details:
There will be 2 AC plants each having 3 VAM (2W + 1S). For cooling unit control room. In VAMthe refrigerant is seperated from the low concentration low temperature absorbent in the generator by using steam. The tapping point for the same will be between the interconnection of aux header for unit 1, 2 & 3,4.

Points to be highlighted
The steam required for acid cleaning for Unit #1 will be taken from Aux boiler but units followed will be tapped of from Unit # 1. During hot startup i.e. after black out the steam for gland sealing purpose will be catered from MS line through PRDS in order to avoid startup of aux boiler. The Aux PRDS will be charged through MS once the MS parameter is achieved at 80 bar and 380 0C. The same will be changed from MS to CRH once the parameter is achieved to 23.2 bar which is at about 35% TGMCR The source for deaerator pegging will be changed from Aux PRDS to CRH once CRH pressure reaches 16 bar and 320 0C.

Auxiliary PRDS System: Basic Layout Technical Details Protections & Provisions

Protection and Provisions

The HT PRDS is provided with 3 safety valves having the total blowdown capacity of 55 T/Hr Also thee is a provision for a stub thorugh which a new connection can be stablished if required in future. The HT PRDS can be charged from Aux boiler through a motorise valve. Whereas the LT PRDS can be charged through a manual valve having a NRV in line. HT and LT PRDS are directly connected through a motorised valves and no manual isolation valves are provided on either side.

Thank You