凝结水精处理系统调试措施

1、BALCO EXPANSION PROJECT -1200 MW THERMAL POWER PLANT Commissioning procedurePROCEDURE FOR CONDENSATE WATER POLISHING SYSTEM凝结水精处理系统调试方案Complied by编写： 史勉 shimian Revised by审核： 冯荣彬 fengrongbin Approved by批准： 于心水 yuxinshui 目 录CONTENTS1系统概述 General41.1凝结水精处理的目的 Purpose41.2系统简介 Brief introduce42 设备介绍equi

2、pment introduce42.1 混床 Mixed bed42.2 树脂分离罐 SPT52.3 阴、阳再生罐 ART CRT53调试应具备的条件Precondition before commissioning63.1对土建施工的要求Requirements to civil engineering63.2对安装施工的要求Requirements to erection73.3对电厂生产准备的要求Requirements to preparation of plant production94.辅助系统的调试 Commissioning for assistant system104.1

3、酸碱系统水冲洗Flushing for acid and alkali system104.2热水箱系统水冲洗Flushing for hot water tank104.3再生及输脂系统水冲洗Flushing for regeneration system104.4混床系统水冲洗Flushing for mixed-beds114.5压缩空气系统吹扫Blowing the Compressed air system.114.6再生用电加热箱的试运Commissioning of electric hot water tank114.7再生用酸碱系统调试Commissioning of aci

4、d & alkali regeneration system124.8操作系统调试automatic program control125树脂装填及预处理Packing and pre-treating of resin125.1树脂的装填Loading of resin125.2树脂的反洗Back wash of resin136再生系统的调试 Regeneration of resin136.1 阳树脂的再生Regeneration of cation resin136.2 阴树脂的再生Regeneration of anion resin146.3置换Exchange146.4树

5、脂漂洗Wash146.5 树脂的混合147 高速混床的调试 Commissioning of high speed MB148安全事项Safety cautions159 附录Appendix171系统概述 General 1.1凝结水精处理的目的 Purpose火电厂凝结水精处理工作是为了对凝结水进行除盐和除浊处理，使水汽品质得到改善和提高，以保证机组安全稳定运行。Condensate polishing treatment system shall be used to improve quality of boiler feed-water so as to shorten the op

6、eration cycle and improve the operational safety and reliability of the unit, and extend the boilers service life.1.2系统简介 Brief introduce本套凝结水精处理设备用于印度BALCO电厂4×300WM发电机组。设备采用单元制，一台机组为一单元，配备两台高速混床。机组正常运行情况下，两台高速混床投运可满足机组100%凝结水处理。一套体外再生设备，阴、阳混合树脂分离采用国内目前较先进的高塔分离技术。These equipments will be used a

7、s generators of Electric Power Plant 4×300MW in Balco India. They are composed in units. One group as a unit is composed of two high speed mixed beds. Normally, two high speed mixed beds will meet the demand of 100% condensate polishing processing .A suit of outer regeneration device, air and w

8、ater mixed resin is separated by high tower separation technology, which can reduce the intersected pollution below to 0.1%. 每台混床正常运行时流速为100m/h，流量为400m3/h，最大流速120m/h，流量可达到435 m3/h。机组正常运行时，2台混床流量为800 m3/h，满足单台机组凝结水量的处理。设计温度为50，正常运行时50.The normal velocity of flow in each MB is 100m/h, highest to 120m/

9、h; the flux is 400m3/h, highest to 435m3/h. When two MB work well, the flux will reach to 800m3/h, meeting the demand of single condensate polishing processing equipment. Design temperature is 50, normal temperature50.2介绍equipment introduce2.1 混床 Mixed bed再生好的阳树脂和阴树脂混合后装入混床，投运后混床能去除凝结水中的盐分，而且能过滤去除凝结

10、水中的悬浮物，使锅炉补给水的矿物质和悬浮物达到最低水品，由于不但地去除盐分和悬浮物而使树脂最终达到失效，为了使失效树脂恢复处理能力，此时必须将失效的树脂送到再生单元进行分离再生。 Recirculated cation resin and anion resin get into the MB after mixed. This kind of MB not only can reduce the salt in the condensed water, but also can filtrate the suspended matter, to make the mineral matter

11、s in the boiler like Na+, Si02, sulphate, hydride and suspended matter (like the oxide of Cu, Fe and silt) reduced to the low level. Because the resin will lose its effect as it reduce the salt and suspended matter, we must get these resin to the regeneration unit to be separated and regenerated on

12、time. 2.2 树脂分离罐 SPT树脂分离罐是有直的筒体和倒立的锥形筒体组成。在反洗时有柱状的流动，反洗沉降及输送树脂时，内部搅动减到最小，在此情况下可以利用两种树脂的比重差、以及粒度差造成两种树脂不同的沉降速度，借反洗时反洗强度的调节来使阴、阳树脂完全分离，分离后的树脂交叉污染在0.1%以下，然后将阴、阳树脂分别用水输送到阴、阳再生罐进行再生。This tin is the key point of the technic, which will back wash and transport resin. Making use of specific gravity differenc

13、e of two resins, even granularity, we can make two kinds of resins have different critical sedimentation rate, and reduce the cross pollution down to below 0.1%. And then transport the cation resin and anion resin respectively to CRT and ART by water. 2.3 阴、阳再生罐 ART CRT分离罐分离出来的阴、阳树脂用水分别输送到阴、阳再生罐后，先后

14、加水灌注到树脂层面上200mm左右，进行空气擦洗，使树脂表面介质（即混床运行时所截留的悬浮物）与树脂分离，擦洗进行的同时，水由底部集水装置进入，使罐内水位上升并使树脂膨胀，相当于大约床层膨胀约50%水位，打开排气阀，从而在罐内形成一个圆顶的帽形空气室，停止进气及水，同时开启中排和底排，使介质和细碎树脂随水急速流出体外。上述步续重复十次以上，直到树脂被清洗干净为止，然后分别用5%的酸、碱进行再生置换，冲洗到排水导电度10s/cm。Put some water onto the resin layer above 200mm,use air to scrub to make the exterio

15、r matter apart from the resin, at the same time, make the water go from the catchment equipment at the bottom, let the water line rise and the resin expand. When it expend to about 50% of the water level, lose the air outlet valve. At the same time, open the water discharge valve of UP-SPT and water

16、 discharge valve of DOWN-SPT, to make the medium and the gabby resin out of the tin with the water. Repeat this procedure several times, until the resin is clean again. Then use the 5% alkali and acid respectively to regeneration as normal, until the outlet water conductivity10s/cm. At last, the cat

17、ion resin and anion resin regeneration procedure ends.再生好的阴树脂从阴树脂再生罐用水和压缩空气输送到阳树脂再生罐，进行阴、阳树脂的混合，然后再向阳树脂再生罐注满水后，进行大流量冲洗直到排水达到混床的出水指标后停止冲洗，树脂再生合格备用。Use water and compressed air to transport the regenerated anion resin from ART to CRT and mix them. After fulfill the water into the CRT, we should flush

18、them in large flux, until the outlet water meet the MB Outlet Water Quality Standardand then keep the eligible resin as spare used.So the CRT is not only for the cation resin regeneration, but also as a packet to deposit the eligible resin after regenerated.3调试应具备的条件Precondition before commissioning

19、3.1对土建施工的要求Requirements to civil engineering3.1.1凝结水处理设备运行间、再生设备间、水泵、风机、酸碱计量间、控制室的地坪、上下水、门窗、通风照明、内部粉刷、油漆等项工作按设计要求施工完毕，验收合格。Complete the construction of ground, water supply and discharge, doors and windows, vent and lighting, internal whitewash and painting of operating room for condensate treating

20、equipment, regenerating equipment room, water pump, air fan, acid and alkali metering room, control room and laboratory test room according to the requirement of design.3.1.2所有需要防腐的混凝土构筑物，地面、沟道、墙壁等按设计要求施工完毕，沟道清扫干净并盖好沟盖板。Complete the construction of ground, ditches and walls of all the concrete struc

21、ture requiring anti-corrosion as per the requirement of design. The ditches shall be cleaned-up with slab in place.3.1.3防腐完毕的中和池其质量应符合相关标准要求，灌水试验要求24小时不泄漏。The quality of the neutralization system, which has been finished with corrosion-resistance, should be conformed to the relative regulations. The

22、re should be no leakage in filling water test for 24 hours.3.1.4控制室和空调设施施工完毕，控制室具备防尘、防盗和恒温条件。Construction of control room and air conditioning facilities should be completed. The control room should be in conditions of dustproof, guard against theft and constant temperature.3.1.5化验间的地坪、平台、水源、排水和电源插座

23、按设计施工完毕并完好，化验间整体具备使用条件。In the laboratory test room, ground and construction of platform are completed; water supply and discharge facilities as well as the power sockets are completed and perfected. The laboratory test room is ready for using. 3.1.6所有转动设备基础二次灌浆工作结束，因安装工作需要而无法避免的建筑物局部破损修补完毕。Base seco

24、ndary grouting for all the rotating equipment has been finished. All of local disrepair of construction should be complete repaired.3.2对安装施工的要求Requirements to erection 3.2.1凝结水的主设备、附属设备及其管道的安装工作全部完成。Installation of the main equipment, attached equipment and their piping of the condensate have been f

25、inished.3.2.2在通水前对主设备、附属设备进行检查，确认设备内部无异常，并按质量标准完成设备与系统的水冲洗。The main equipment and attached equipment should be checked and then confirm there is no foreign matter inside the equipment prior to supplying water .Focus the check on whether the flange is fastened, whether the filter tip is damaged. The

26、foreign matters inside the pipe must be cleaned away. If all is finished and complete the flush of the equipment and system. 3.2.3本系统所有转动机械经分步试运合格。All the rotating machinery in this system should be qualified subject to pre-commissioning operation.3.2.4所有罐体和衬胶管道的电火花试验合格。Spark test should be conduct

27、to all the rubber lined pipe prior to installation and to all the rubber lined equipment after installation.3.2.5低压系统（再生系统）的水压试验，即按厂家设计要求完成工作水压试验，试验合格方可使用。Conduct hydraulic test to regenerating system (low pressure withstanding vessel) according to “Instruction for design and installation”. 3.2.6不承压

28、容器（酸、碱计量箱）进行灌水试验（同时检测液面计灵敏度），试验合格方可使用。Conduct water filling test to non-pressure-withstanding vessel (test the sensitivity of level indicator)3.2.7进行中压系统的水压试验，即按厂家设计要求完成工作水压试验，试验合格方可使用。Conduct hydraulic test to the operational system according to “Instruction for design and installation”. 3.2.8按设计规定

29、完成所有设备保温和油漆工作。Complete heat insulation and paint of all equipment according the regulations of the design.3.2.9凝结水系统的电气、热工（包括程控）所有安装工作结束，并进入调试阶段，本系统内所有电气、热工、化学在线仪表、就地仪表校验合格安装完毕，并具备投运条件。Complete all the electrical and thermodynamic (including program control) installation in condensate system and pro

30、ceed to commission stage. All the electrical, thermodynamic and chemical on line instruments and local instruments should be completed for installation and qualified subject to calibration as well satisfies the conditions of putting into operation.3.2.10完成空气系统的检查和试验，完成所有电动阀、气动阀的就地及远方操作试验（软手操）和手动阀的操作

31、试验。Complete local and remote operation test (soft manual operation) of all electric and pneumatic valves and operation test of manual valves.l 气动空压系统的吹扫，进行空气贮罐安全阀及减压阀的整定。Purge the pneumatic air compressed system and set the safety valve and relief valve on air storage tank.l 所有气动阀门充压后要求通气管道、电磁阀和气动阀门

32、本体没有漏气现象。Pipe, electromagnetic valves and pneumatic valve proper filling with gas of all the pneumatic valves are required without leakage after filling pressure. l 电动阀、气动阀的静态操作试验（包括就地和远方操作试验），确认模拟操作盘上阀门按钮的命名与开关位置和系统上阀门的实际状况一一对应。Static operation test (including local and remote operation test) of el

33、ectric valves and pneumatic valves should be conducted, and confirm the name of valve button and switch position on the panel is correspondent with the practical condition on valves.l 启动冲洗水泵进行低压系统气动阀的动态试验和手动阀的操作试验，要求工作压力下阀门开关自如、无泄漏。Start the flush water pump to conduct dynamic test to pneumatic valv

34、es and to switch test to manual valves in low-pressure system. Valves are required to open and close freely without leakage under the working pressure.l 启动凝结水泵进行中压系统所有碟阀和球阀的动态试验（阀门制造厂家应派专业人员对所有阀门进行逐一调试），要求在工作压力下阀门开关自如无卡涩、关闭无泄漏。Start the condensate pump to conduct dynamic test to all butterfly valves

35、 and ball valves in the systems (the valve manufacturer should appoint special person to commission the valve one by one).The valve is required to open and close freely without leakage under the working pressure.l 高速混床的隔离试验，启动凝结水泵维持中压试验系统的工作压力，所有电动阀前的手动阀全开，高速混床进出口电动总阀全开，被试验的混床充压后，剩余一台混床可以与之彻底隔离（不允许关

36、闭的混床有自动升压现象），同时要求中压系统和低压系统可以彻底隔离。For the isolation test of high-speed mixed-bed, start the condensate pump to maintain the working pressure of test system. Open the front and back manual valves of one mixed-bed and the inlet and outlet valves of mixed-bed are fully opened. After filling pressure to

37、the mixed-bed to be tested, the other one can be isolated from it completely (automatic pressure-up is not allowed for the closed mixed-bed). The operational system and regenerating system are also required in complete isolation.l 高速混床温度保护和差压保护的旁路试验Bypass protection test( temperature and difference

38、pressure protect)3.2.11通讯设施按设计要求安装完毕，并能满足试运工作的需要。The communication facilities have been installed according to the requirement of design and can meet the requirements of trail operation3.2.12在启动试运工作中热工（包括程控）机务等专业应有试运值班员，设备出现故障后应能及时消除。There should be trial operators of thermodynamic (including progra

39、m control) and steam turbine specialties on duty, who can eliminate the faults of equipment in time when it emerged.3.2.13酸碱储存间和计量间的安全水源可投入使用。The safe water supply of acid and alkali storage room and metering room should be in available.3.2.14再生药品及离子交换树脂的质量需符合设计要求及有关规程的规定。The quality of regeneration

40、 chemical and ion-exchange resin should conform to the regulations of contract and the relative codes. It can be prepared according to the following quantity.盐酸40吨。烧碱40吨。Hydrochloric 30% 40tSodium hydroxide 32% 40t3.3对电厂生产准备的要求Requirements to preparation of plant production3.3.1参加试运工作的值班员应经培训考试合格,明了

41、中压凝结水处理设备的特性,并能胜任本职工作。The personnel taking part in the trial operation should know clearly the performance of the intermediate-pressure condensate treating equipment and is competent for his work.3.3.2试运操作人员应具备熟练操作技能，试运操作记录要及时准确无漏项。The trial operator should be skillful in operation. The record of tr

42、ial operation should be correct and in time without omission.3.3.3化验分析仪器、仪表、药品、运行规程及记录报表准备齐全，化验间、操作间的桌椅备齐。Instruments and chemicals for analysis should be prepared. Lab test room and operation room are equipped with complete and enough desks and chairs and satisfy the conditions for chemical analysi

43、s3.3.4按有关规定完成对设备、阀门上的命名编号，管道上的走向标记也应同时完成，并备好各种运行状况的标志牌。All equipments, valves, local indicators (including level, flow, pressure and temperature indicators) and on-line chemical instruments have been installed and provided with correct KKS NO. Tags. The orientation remark of pipeline should be done.

44、 The marking signs for various operational conditions at the same time.3.3.5现场应悬挂凝结水处理系统图。There should hang condensate polishing treatment systematic diagram on site.4.辅助系统的调试 Commissioning for assistant system4.1酸碱系统水冲洗Flushing for acid and alkali system在将酸碱计量箱内杂物清理干净后，先用临时工业水分别冲洗至出水澄清，后整体冲洗至出水澄清，最

45、后用除盐水冲洗干净。排污阀打开，放尽存水后关闭。在冲洗过程中，可检查管路系统（法兰、焊接头）的严密性。酸碱计量箱用除盐水冲洗干净后，才能进浓酸、浓碱。Firstly, cleaning acid and alkali metering tank; secondly, flushing the tank and piping with DM water until discharging water is clear and checking the system for any leakage. After finishing these works, acid and alkali can

46、be put into it. 4.2热水箱系统水冲洗Flushing for hot water tank先用临时工业水冲洗至出水澄清，后用除盐水冲洗干净。排污阀打开，放尽存水后关闭。在冲洗过程中，检查管路系统（法兰、焊接头）的严密性。Flushing the tank with DM water until discharging water is clear. Filling the tank and checking flanges and joints for any leakage and then draining off the water.4.3再生及输脂系统水冲洗Flush

47、ing for regeneration system首先保证凝结水补水箱足够水量，自用冲洗水泵试运合格后，依次冲洗如下管道：DM water should be prepared in the condensate water storage tank and flush water pumps should be available.4.3.1冲洗混床的顶部、底部送脂水管、树脂管道冲洗管，污水从树脂捕捉器排污阀放入地沟。Flushing mixed-beds and appendix piping.4.3.2冲洗混床和再生系统之间的输脂管道，污水从阴再生塔底排放地沟。冲洗完后，整定树脂输送

48、管道上的安全阀。Flushing the piping for delivering resin between mixed-beds and regenerating system. After flushing ,the safety valve should be adjusted .4.3.3冲洗酸碱储存罐至再生塔管道系统，污水从再生塔底排放地沟。Flushing the piping from acid and alkali metering tank to regeneration vessel.4.3.4冲洗阳再生罐的正洗、反洗管道。Flushing the Anion/Cati

49、on resin regeneration vessels and appendix piping4.3.5启动罗茨风机，吹扫再生擦洗空气管道。Starting Roots blower to blow the piping of air.4.3.6冲洗树脂隔离罐。Flushing the Resin isolation vessel4.4混床系统水冲洗Flushing for mixed-beds先启混床罗茨风机吹扫空气管路，最后冲洗混床系统。Blowing the air piping with Roots blower and then flushing the mixed-beds.4

50、.5压缩空气系统吹扫Blowing the Compressed air system.4.5.1在全部精处理系统中共使用了两种气源，一为厂用压缩空气，另一个为罗茨风机气源。压缩空气吹扫必须进行到每个气动设备的进气管。There are two sources of air, one is from compressed air tank the other is from Roots blower. Compressed air system should be blown to every inlet pipe of pneumatic valves.4.5.2罗茨风机系统的调试Commi

51、ssioning of Roots blower先关闭系统内各进气阀，开启风机出口管放水阀及排空阀，启动风机，观察风机的运转情况，整定风机出口安全阀。 all the air inlet valves of the system were closed the Roots blower mail tube vent valve and the discharge valve were opened then runing the Roots blower and observe if work well,at last the safety valve should be adjusted.4

52、.6再生用电加热箱的试运Commissioning of electric hot water tank阴树脂再生时需通过电加热箱将水加热然后热水与碱液混合稀释到40左右，以提高再生效率，因此再生系统投入前应先启动电加热罐。In order to improve regeneration efficiency, Anion resin shall be regenerated with around 40. So water shall be heated in the electric hot water tank and then mixes with alkali enter into

53、Anion regeneration vessel. 4.6.1加热罐水源来自冲洗水泵，启泵时开启加热罐进水阀、放空阀向罐内注水，满水后关闭放空阀，充压至0.4MPa(正常运行时下部进水阀常开)。The electric hot water tank should be filled prior to use.（the inlet valve should be opened during running time）4.6.2在使用热水前4小时左右，使用电加热罐加热，通过温控元件控制水温在80左右，加热过程中应注意不要超压。Heating shall be done around 4 hour

54、s before starting the regeneration procedure. The hot water tank is provided with thermometer and temperature transmitter, with thermometer interlocked with electric heater. When temperature is above 80, all the electric heaters shall be stopped running. Pressure of tank should be checked during hea

55、ting time avoid exceeding limit. 4.6.3热水罐在正常使用时，应随时保持满水状态，在低液位或空罐的情况下严禁投加热电源进行加热。The electric hot water tank provided with level switch to prevent dry burning when water level is lower than the electric heater. So in normal situation it shall be confirmed that the tank is full DM water.4.7再生用酸碱系统调试C

56、ommissioning of acid & alkali regeneration system酸碱计量箱内应有足够用来进行试运的水量，切换好阀门系统，打开阴阳再生罐进酸进碱阀及底排阀，打开喷射器进水阀及出水手动阀，启动自用冲洗水泵，维持流量8t/h，打开计量箱出酸出碱气动阀，调节出酸出碱手动阀，观察计量箱就地液位计上液位下降速度，大于5cm/min即为合格。There should be enough water in the metering tank ，switch the system ，open ART alkali inlet valve，CRT acid inlet v

57、alve and the bottom outlet valve，open injetctor inlet valve and outlet hand valve，start the selfuse flushing pump ，keep 8t/h flux,open acid/alkali outlet valves of the metering tank,adjust the hand valve,observe the descend speed of local level indicator,more than 5cm/min is eligible. 4.8操作系统调试autom

58、atic program control在上述调试工作完成后，从上位机完成对现场气动阀、泵、风机的远操，并保证开、关反馈信号正确。然后用半自动方式走程控。用除盐水作试验。每一个程序步骤完成后，应保证阀门开关正确、到位，反馈信号正确，阀位保持时间正确，泵与风机的启停正确，启停反馈信号正确，液位联锁正确，温度联锁正确，光电检测及电导检测正确。半自动方式合格后，调试全自动方式。After finishing above work, complete remote operation test (soft manual operation) of all electric & pneumatic valves, pumps and fan, at the same time assure feedbacks are right. Full put the automatic program control into operation. Review, mo