UNIT OPERATING PROCEDURES

TABLE OF CONTENTS DESCRIPTION

INTRODUCTION UNIT DESCRIPTION PRE-OPERATION PROCEDURES CLEAN-UP CHEMICAL CLEANING BLOWING STEAM LINES SETTING SAFETY VALVES COLD START-UP PREPARATION FOR LIGHT OFF INITIAL FIRING PRECAUTIONS LIGHT OFF-COAL FIRING NORMAL OPERATING-UNIT LOAD CHANGES-COAL FIRING DECREASING LOAD INCREASING LOAD NORMAL SHUTDOWN TO COLD NORMAL SHUTDOWN TO HOT STANDBY HOT RESTART EMERGENCY PROCEDURES REHEAT PROTECTION UPON LOSS OF LOAD TURBINE VALVE CLOSURE TURBINE TRIP POST TRIP PROCEDURE TURBINE PROTECTION UPON LOSS OF LOAD MASTER FUEL TRIP LOW WATER LEVEL HIGH WATER LEVEL TUBE FAILURES WATER WALL TUBES ECONOMISER TUBES SUPERHEATER AND REHEATER TUBES ILLUSTRATIONS AIR FLOW Vs LOAD CURVE EVAPORATION Vs STEAM TEMPERATURE (CONSTANT PRESSURE) START UP CURVES VALVE OPERATING DIAGRAMS

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2 2 2 2 3 3 3 3 3 5 8 11 11 12 13 15 17 18 18 18 18 18 18 19 20 21 22 22 22 22

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INTRODUCTION The procedures outlined in this section of the manual are intended to serve as a guide during initial stages of operation. The procedures include precautions which should be observed and the proper operating sequences of the unit, the fuel firing equipment and auxiliaries furnished by BHEL. Sequential procedures do not include detailed reference to equipment furnished by others i. e. feed pumps, condensate pumps, turbine, etc. Because the unit is only one part of the over all power station and since all equipment must operate in unison, specific procedures and detailed values cannot be included in this manual. As operating experience is gained and controls are fine tuned by the units characteristics and actual operating requirements will become evident to the operator. Reference should be made to the control vendors instructions for further operating details. Reference should be made to the manufacturer's instructions regarding operational and pre-operational procedures for their equipment. UNIT DESCRIPTION The unit is a Controlled Circulation plus Radiant Reheat (type CC + RR) boiler. Firing equipment consists of five elevations (20) of remotely controllable High Energy Arc igniters, five elevations (20) of retractable air or steam atomizing oil guns and ten elevations (40) of pulverised coal nozzles. The ten elevations of pulverised coal nozzles are supplied with coal from ten number type 1003 XRP pulverizers. Complete descriptions of the equipment provided can be found elsewhere in this manual. Control equipment provided consists of a Furnace Safeguard Supervisory System, Scanner Air Control System and a Secondary Air Control System. Major auxiliary equipment provided consists of Pulveriser Feeders and Scanner Air Fans and miscellaneous valves. Three Hayward Tyler boiler circulating pumps are provided to insure proper circulation of water in the furnace wall circuits. Coal is used as load carrying fuel for which startup procedure is given below: PRE-OPERATIOINAL PROCEDURES Clean-Up Before initial firing and prior to each subsequent cold start-up after maintenance has been done on the unit, the furnace should be inspected and cleaned both internally and externally. All foreign material should be removed from the pressure parts. Any grating, pipe lines, electric conduit etc. that might restrict normal expansion of the unit should be cleared. All personnel should be cleared and access doors closed. A complete check list should be prepared by the Operating Department.

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Chemical Cleaning Specific procedures for boiling out and acid cleaning are included elsewhere in this manual Firing and circulating pump operating procedures as outlined under Cold Start up, Lighting off" should be used as a guide when operating the fuel firing equipment. Blowing Steam Lines Prior to starting up a new unit or following major pressure parts repairs on an older unit, the main steam lines and the reheater steam lines should be blown out to remove scale and foreign matter thereby preventing damage to the turbine. This should be done after acid cleaning and prior to setting boiler and superheater safety valves. Consideration should be given to setting the reheater safety valves before removing the temporary blow out piping. Refer to "Steam Line Blowing Procedures" elsewhere in this manual for recommended operating procedures and precautions. Setting Safety Valves Setting of the Safety valves on the drum and superheater should be done prior to turbine rolling. Refer to the safety valve manufacturers instructions for setting procedures. A conservative firing rate should be maintained, limiting the furnace exit gas temperature to a minimum of 540DC. If the reheater safety valves were not set during the steam line blowing procedure, they may be set while the turbine is carrying a light load, by closing down on the intercept valves until a reheat steam pressure is reached high enough to lift the reheat safeties. (Consult the turbine manufacturer's instructions for allowable procedures). Popping pressure and blowdowns should be adjusted to conform to design values. COLD START-UP Preparations for Lighting off It is assumed that at this time the following preparatory work has been completed: 1. The unit has been chemically cleaned, that the steam lines have been blown, that the safety valves have been set and that the unit has been filled to slightly above the normal operating level with properly treated feedwater. All control systems have been checked out and are available for service. NOTE : Check all safety interlock systems prior to start up to insure proper functioning. Exercise the systems by creating the actual interlock actuating conditions. Simulate the activating conditions if the actual conditions cannot be created. 3. 4. All instrumentation and associated mechanical equipment has been checked out and is available for service. The oil firing equipment has been checked out to assure proper functioning. Recheck items such as :
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2.

a. b. c. d. 5.

Oil guns inserted and properly coupled. (Check gaskets between unions.) All oil gun and igniter quick disconnect couplings properly assembled. All fuel manual valves open. All fuel control valves closed.

The pulverizers and feeders have been checked out and are available for service. Recheck items such as: a. b. c. d. e. f. Pulverizer discharge valves open. Hot air gates closed; hot air control dampers closed. Cold air gates open; cold air control dampers open approximately 5%, Bunker outlet valves open; coal available to feeders. Pulverizer and feeder seal air valves open. All classifier vane settings identical.

6. The windboxes have been checked for proper damper positioning, tilts at horizontal, etc. 7. The feedwater system, instrumentation and equipment, has been checked out and is available for operation. It is recommended that during startups the feedwater be controlled remote-manually, until a continuous flow is established. See Lighting Off. To avoid the possibility of oxygen corrosion in the boiler, the USB of undeaerated feedwater (temperature less than 100oC) is not recommended. Refer to the "Water Treatment" instructions elsewhere in this manual. The boiler circulating pumps have been checked out that they have been properly filled and vented and that all pump instrumentation is available for service. It is imperative that the pump differential pressure switches are in service and that the proper trip settings have been made. All air handling equipment has been checked out and is available for service. All air and gas duct dampers should be in the start up position. (Refer to Note and Caution below.) a. I. D. Fan outlet shut off dampers open, inlet control dampers closed. b. F. D. Fan outlet shut off dampers and blade pitch open. (F. D. Fan blade pitch should be closed before the fan is started-see Note 1.) c. Primary air fan outlet shut off dampers and blade pitch closed. d. Air heater gas inlet and outlet, air inlet and outlet and primary air inlet and outlet dampers should be open. e. Overfire air dampers closed. f. Windbox (secondary) auxiliary air dampers open or modulating. g. One set of pulverizer seal air filter and booster fan shut off dampers open. NOTE: It is assumed that the unit will be started with two I. D. Fans, two F. D.
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8.

9.

fans, both Air Preheaters, and both Primary Air Fans in service. If the unit started with only one I. D., F. D. and P. A. fan and one air heater in service, the above damper positions apply to the equipment to be started. Dampers associated with the idle equipment should be closed. CAUTION: The I. D. Fans may be capable of developing drafts in excess of the furnace design pressure. Therefore, the operator must take care to establish and maintain an air flow path through the unit, prior to starting an I. D. Fan and prior to opening the I. D. Fan inlet control dampers, by insuring that other dampers in the system are in the start up positions indicated above. I. D. Fan inlet control dampers must be kept closed until after the fan is started. This procedure minimizes the possibility of developing excessive negative pressure in the unit during the starting procedure. The operator must take care to maintain the furnace draft within sate limits at all times. He must be especially careful when draft and air flow controls are in the Manual " mode. He must be alert at all times for possible malfunctions of automatic control equipment resulting in abnormal excursions in furnace pressure, either negative or positive. 10. Check that the Air Heaters have been prepared for service, that an adequate means of extinguishing air heater fires is available and ready for use. Refer to Air Preheater instructions for details. 11. The soot blowing equipment has been checked for proper operation and the system is in the start up conditions. (All blowers retracted, main steam supply valve open.) 12. All Desuperheater Spray Water Control Valves are closed. 13. All boiler Superheater and Reheater drain and vent valves are in the start up position. CAUTION : Prevent possible water damage to the turbine by using extreme care to eliminate all water from the main steam line(s), cold and hot reheat lines and superheater and reheater elements and headers before the turbine is rolled. Refer to the turbine manufacturer's instructions. 14. The furnace gas temperature probe is in working order and available for service. 15. The turbine - generator is available for service and has been prepared for service as described in the manufacturer's instructions, Initial Firing Precautions To insure a maximum safety margin during start-ups, it is mandatory that at least 30% of full load air flow be maintained in order to produce the following conditions: 1. An air-rich furnace atmosphere. This precludes the possibility of the accumulation
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of explosive mixtures in the event of poor or delayed ignition after fuel is introduced to the furnace. 2, High excess air through the air heater. This minimizes the dilution of combustion air by inerts, carried over by the air heater rotor.

Air flow should be increased when the boiler reaches a load where additional air is required to maintain the design operating excess air. Refer to "Air Regulation" in the section "Tilting Tangential Firing System". 1. Start two boiler circulating pumps in accordance with pump operating instructions. The pump starting recommendations anticipate a normal rate of hotter water temperature rise of about 110oC per hour (i e. 27oC in 15 minutes). Quick boiler starts can create temperature changes approaching 83oC in 15 minutes. Pumps should not be started during intervals of rapid boiler water temperature change. NOTE: It may be preferable to start only two pumps in order to minimize flashing in the downcomers (and the consequent piping vibration) when the boiler water is in the range of 95 to 125oC, The third pump should be started before the boiler drum pressure reaches 7 kgjcm2 to minimize pump starting temperature transients. 2. 3. 4. 5. Start both air heaters. (Refer to Air Preheater instructions "Placing Air Heaters in Service".) Start scanner air fan. Start two I. D. Fans (see "Caution" under Item 9, "Preparation for Lighting Off") Start two P. A. Fans (see Note) NOTE: Air flow must be maintained through the pulverizer whenever the unit is being fired. Therefore P. A. fans must be in service. Open the P. A. Fans outlet shutoff dampers of the selected fan. Bring the primary hot air duct pressure up to the set point by "Manually" opening the P. A. Fan inlet control damper. Then transfer to "Auto" control. When the pulverizers are out of service, their discharge valves must be fully open and the cold air inlet control dampers must be open to a minimum position. The discharge valves are closed for pulverizer maintenance or when the pulverizers are idle, full of coal and other pulverizers are being started after a unit trip. See "Emergency Procedures, Master Fuel Trip". 6. 7. 8. Start two F. D. Fans. Start the steam air heaters. Adjust the fan and windbox dampers to permit a purge air flow of at least 30% of total air flow and a furnace draft of approximately 12.5 mm w g. Refer to "Initial Firing Precautions". When the fans are started, the secondary air damper control (on "AUTO") should
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9.

modulate the auxiliary air dampers to maintain a programmed set point differential between the windbox and furnace. Check that all other purge permissives are satisfied. 10. Initiate a furnace purge. Upon completion of the purge cycle, check that all firing prerequisites are satisfied. 11. Place the gas temperature probe in service. 12. Initiate a light off sequence of the lower elevation of igniters and warm-up oil guns. Refer to the "Furnace Safeguard Supervisory System", "Igniter" and "Retractable Oil Gun" instructions for details. 13. During the warming period the economizer recircutating line valves are open. Blow down the unit as required to maintain the water level in sight in the gauge glass. 14. The firing rate should be controlled to keep the furnace exit gas temperature below 540oC until the HP - LP Bypass is cut in. When the drum pressure increases, position the superheater and reheater drains and vents and drum vents in accordance with step 21. During startups, lighting off is done with the lower igniters and warm up oil guns. Warming up can be accomplished with either the warmup oil guns or pulverized coal firing. In either case, the required firing rate must permit operation of an entire elevation of fuel nozzles without exceeding the furnace exit gas temperature limitation as described in the following paragraph. NOTE: To minimize the possibility of adverse visible stack emission, it if desirable to use the igniters and warm up oil guns to at feast 35 kg/cm2 (g) drum pressure and 175oC secondary air temperature before firing pulverized coal or heavy oil. During all start-ups the firing rate should be controlled to keep the maximum furnace exit gas temperature below 540C (as measured by the furnace outlet gas temperature probe) until the HP- LP Bypass is cut in. After rolling the turbine, the steam temperature and pressure rise at the turbine throttle should at all times be in accordance with the limits prescribed by the turbine manufacturer. NOTE: It is recommended that during initial start of a new unit a relatively slow rate of pressure increase be followed, in order to allow sufficient time for checking expansion movements and to permit the operators to become familiar with the characteristics of the unit and its auxiliaries. Once these characteristics have been established, subsequent start-ups may be made at the fastest possible rats consistent with maintaining the furnace exit gas temperature limitation of 540oC until the HP-LP is cut in. Superheater Steam Temperature Control (Prior to Unit Synchronization) During start-up of this unit the drain system serving the backpass (steam cooled) walls may be used to control the final superheater outlet steam pressure and temperature in case HP - LP Bypass is not in service.
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Opening the backpass drain valves (see Note), preferably in steps, will cause a reduction in the unit pressure. An increase in firing rate to maintain pressure will provide a subsequent increase in the superheater outlet steam temperature. EXERCISE CARE NOT TO EXCEED THE FURNACE EXIT GAS TEMPERATURE LIMIT OF 540o C, Modulating the steam pressure and temperature by this method permits the unit to attain the highest possible superheater outlet temperature, approaching the turbine metal temperature on a hot restart or 55o of superheat during a cold start. NOTE: Drain valves should be either open or fully closed, not throttled CAUTION: All backpass drain valves must be closed immediately after the unit is synchronized. Lighting off-Coal Firing 15. Increase the firing rare as required to raise pressure. Take care not to exceed the furnace exit gas temperature limit to 540o C until the HP-LP Bypass is cut in. When ready to fire coal, the pulverizer serving a lower elevation of coal nozzles should be prepared for operation and started in accordance with steps 24 through 27. Adjacent warm-up oil guns supply the required ignition energy. The feeder rating should be controlled to keep the furnace exit gas temperature from exceeding 540oC until the HP-LP Bypass is cut in. 16. While the unit is heating up frequent checks should be made of the boiler expansion movements. Special attention should be given to expansion of the lower part of the boiler (furnace inlet drums, pump suction manifold etc.) relative to building steel. Expansion movement should be recorded for comparison with future Start-ups. Refer to the Expansion Movement Diagrams, in the "Pressure Parts" section of the manual. 17. Maintain drum water level at normal and check boiler water concentrations and constituents as frequently as required to maintain proper boiler water conditions. 18. When continuous feed water flow is established the economizer recirculating line valves may be closed. 19. Before raising a vacuum in the condenser make sure that all reheater vents or drains that are open to atmosphere are closed. Leave drains or vents connected to the condensate open until the turbine is carrying a light load. 20. Start the third boiler circulating pump before the drum pressure reaches 7 kg/cm2 to minimize the temperature transients experienced by the pump casting. Two boiler circulating pumps must be in operation at all loads to avoid the possibility of a Master Fuel Trip in the event of the loss or one of two pumps. The third pump may be placed in service before are after unit synchronization, however, it should not be started during a rapid boiler temperature change (increasing or decreasing). It is preferable to keep three pumps in operation at all boiler ratings to provide more flexibility in load regulation. NOTE: Refer to the "Boiler Circulating Pump Operating Procedures" for operating recommendations when a pump is out of service for maintenance.
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21. As drum pressure increases, progressively throttle the superheater main steam line vent (Start Up Vent) and other start-up vents and drains used (main steam line drain, turbine drains, etc.). Sufficient steam flow must be maintained at all times to assure clearing the superheater elements of condensate. Increase the firing rate as necessary, without exceeding the furnace exit gas temperature limitation. Do not close start-up drains completely until steam flow through the turbine is established. The superheater backpass lower front inlet header and backpass rear inlet header drains should normally be closed immediately after steam is admitted to the turbine. 22. Start rolling the turbine as soon as the minimum permissible start-up pressure and temperature, specified by the turbine manufacturer are reached. Refer to turbine manufacturer's instructions. 23. When bringing the turbine up to speed, the firing rate should be controlled, to prevent the furnace exit gas temperature from exceeding 5WC until the HP-LP Bypass is cut in. When the turbine is up to speed, it may be synchronized. At this point the gas temperature probe may be withdrawn and the firing rate increased as required. In no case should the firing rate exceed that which is necessary to satisfy steam demand. NOTE: If the unit is put on the line before design operating pressure is reached, further increase of firing rate should be in accordance with a gradual rate of pressure increase consistent with increasing load. Do not allow steam temperature to exceed the values shown in drg. No. 4Q-BPE-1532 CAUTION: Operators should be alert to detect the symptoms of water carryover from the boiler and introduction of water into the turbine such as: a. A sudden unexplained drop in steam temperature in either the main steam or hot reheat line. b. Vibration in the steam piping resulting from water hammer. c. Abnormal vibration and differential expansion readings from the turbine supervisory instrumentation. Operators must be prepared to take actions necessary to prevent turbine damage upon detection of water introduction. Refer to turbine manufacturer's instruction for specific actions to be taken. 24. If coal was not fired previously (see Note), the pulverizer serving the lowest elevation of coal nozzles (adjacent to the warmup oil guns) should be prepared for operation so it can readily be started at this time. Refer to Section "Bowl Mills" and "Furnace Safeguard Supervisory System" for startup sequences and controls NOTE: If a pulverizer was started during the warming up period, increasing load requirements can be met by increasing feeder rating on this pulverizer. 25. When placing the first pulverizer in service, check that the pulverizer start permissives (ignition energy, etc.) are satisfied. Refer to the Furnace Safeguard
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Supervisory System instructions. The coal fuel-air dampers should remain closed until ignition is established. Refer to "Air Flow Control and Distribution" in the Section "Tangential Firing System". Check to see that the nozzle tilts ate horizontal. Place 3 second P. A. Fan in service if not done previously. 26. Start the pulverizer (see Note), Open the hot air shut-off gate and bring the pulverizer up to the required operation temperature without coal. Place pulverizer air flow and temperature control on Auto. When ready to fire coal, start the feeder at minimum rating (Manual control). Ignition of the pulverized coal should take place immediately. When the pulverizer is proven in service the fuel air dampers should open automatically. Maintain the fuel feed at a minimum consistent with stable ignition. Watch the fires. NOTE: If the unit start-up follows a Master Fuel Trip the pulverizer may not be empty. It must be operated to cleat it of excess coal before starting the feeder. During this procedure the pulverizer valves of all other idle pulverizers must be closed in order to prevent blowing hot furnace gases back into the idle pulverizers and coal piping. (See "Emergency Procedures".) When most of the coat has been removed from the pulverizer, the feeder can be started at minimum speed and then adjusted to a speed selected to give a stable flame or, as required to meet unit load requirements. Do not admit hot air to the pulverizer until the feeder is started. Be sure that the ignition energy is established before starting the pulverizer. If the ignition does not take place within 5 seconds after coal appears at the coal nozzles, stop the feeder. Determine the cause of ignition failure before attempting to restart the feeder. 27. Maintain proper coal / air temperature leaving the pulverizers. Regulate the hot and cold air dampers to hold between 70oC and 80o C for Bituminous (High volatile) coal at the pulverizer outlet. At no time should this temperature exceed 93o C. If it should exceed 93oC, the hot air gate must be closed. NOTE: Pulverizer start up will cause a sudden and sharp increase of steam pressure. This will level out rapidly as load is placed on the turbine. Check the pulverizer oil temperature and turn on the water to the oil cooler when the temperature approaches 65oC. The oil temperature should not exceed 70oC at any time. 28. Place the second pulverizer (supplying the adjacent (*) elevation of coal nozzles) in service in a similar manner when the feeder rating of the first pulverizer has reached approximately 80% of maximum. When the second pulverizer is proven in service, equalize the feeder rating of the two pulverizers. The warm-up oil guns and igniters must remain in service until the feeder rating of each of the two pulverizers exceeds 50% of maximum. *NOTE: If the adjacent pulverizer is not available for service, place the pulverizer serving the next closest elevation in service and do not remove warmup oil guns and igniters from service until two adjacent coal elevations are
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in service with feeder ratings on each associated pulverizer greater than 50%. 29. The Furnace Safeguard Supervisory System and Secondary Air Damper Controls should close the auxiliary air dampers serving compartments adjacent to coal nozzles which are out of service when the boiler reaches 30% of full load and increases the windbox to furnace differential pressure to approximately 100 mm. w.g. 30. It is essential that the air flow to the furnace is sufficient for the firing rate at all times. Automatic control equipment is normally arranged to maintain such a balanced condition. The O2 measuring devices, which are often tied in with the air flow control, should be checked periodically to assure continuous and dependable operation. 31. Place additional pulverizers in service as the unit loading demands. The pulverizer serving the lowest available nozzle elevation not already in service should be started when the feeders in service reach approximately 80% rating. As each pulverizer is placed in service the required associated ignition energy must be available. When the unit firing conditions are stabilized all warm up oil guns and igniters may be taken out of service. (Refer to the Furnace safeguard Supervisory System instructions.) 32. Place the steam temperature controls and combustion controls on "Auto" when firing conditions are stable and the temperature and pressure control set points have been reached. Refer to the control manufacturer's instructions for specific procedures 33. Adjust the feedwater supply to the boiler as necessary to maintain normal water level. Feedwater control should be placed on automatic as soon as possible and practicable after continuous feedwater flow is established. 34. Overfire air should not be utilized (for NOx control) below 50% load. The effective starting load must be determined during initial unit operation. Refer to operating recommendations in the "Tilting Tangential Firing System". NORMAL OPERATION - UNIT LOAD CHANGES (Coal Firing) During normal operation, with the unit on the line changes in pulverizer loading and/or the number of pulverizers in service may be required to accommodate unit load changes. A wide range of load control can be achieved with the pulverizers on automatic. NOTE: Refer to Furnace Safeguard Supervisory System instructions regarding pulverizer start and stop sequences, ignition energy requirements, etc. Decreasing Load If the unit load decreases to a point where the feeder rating of the pulverizers in service is reduced to 40% of maximum, a pulverizer should be taken out of service. This can be a pulverizer serving either an upper or lower coal elevation, at the discretion of the operator. To remove the pulverizer from service, proceed as follows:
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1. 2. 3. 4. 5. 6.

Start the igniter and warm up oil guns associated with the coal elevation served by the selected pulverizer. Gradually reduce the feeder rating of the selected pulverizer to minimum. When the feeder rating is at minimum (approximately 25%] close the hot air shut off gate. Allow the pulverizer coal-air temperature to drop to 50oC and take feeder out of service. Allow the pulverizer to run for at least two minutes to insure that it is completely empty, and then stop the pulverizer. The associated igniters and warm up oil guns may be shut down when furnace conditions have stabilized.

Additional pulverizers can be taken out of service in a similar manner when the feeder rating again drops to 40% of maximum. Every effort should be made to keep adjacent pulverizers in service. If, due to maintenance, a pulverizer is not available, skipping the coal elevation served by that pulverizer is permissible. Skipping of two coal elevations is not recommended and is only permissible with the use of auxiliary supporting fuel (associated igniters and warmup guns). If the unit load is reduced to a point where only two pulverizers are required, auxiliary supporting fuel (associated igniters and warmup guns) adjacent to the coal nozzles in service must be placed in service to assure positive ignition when the feeder ratings drop to 50% or less. NOTE: Auxiliary supporting fuel should be used at any time and under any conditions in which, in the operators judgment, stabilization of ignition is necessary. Increasing Load If after a load decrease, where pulverizers have been taken out of service, the unit load should increase to a point where the feeder rating of the pulverizers in service exceeds 80% of maximum an additional pulverizer should be placed in service as follows: 1. 2. 3. 4. 5. Establish the ignition energy required for the coal elevation served by the selected pulverizer. Start the pulverizer. Open the hot air shut off gate and bring the pulverizer up to operating temperature, (Refer to "pulverizer" instructions.) Start the pulverizer feeder; the feeder control should be on manual", at minimum feeding rating. When the pulverizer is grinding the coal ignition has been established, gradually increase the feeder rating until pulverizer loading equals that of the other pulverizers in service. Then place the pulverizer on Auto control.
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6.

The auxiliary supporting fuel (associated Igniters and warm up guns) may be taken out of service when furnace conditions have stabilized and at least two pulverizers are in service, each with a feeder rating of at least 50%. Place additional pulverizers in service in the same manner, as required by load increase demand.

7.

NORMAL SHUTDOWN TO COLD The following procedures for normal shutdown are based on the assumption that the unit is operating at full load on automatic control and that it is the intention to reduce the pressure to zero and cool the boiler completely. 1. Gradually reduce load on the unit; reduce the firing rate in line with the decreasing steam flow. Allow the pressure to drop with the reduction in load to accelerate cooling. Reduce the steam temperature at the rate prescribed by the turbine manufacturer. Steam temperature control, combustion control and feedwater control may be left on automatic until the point is reached where better control can be obtained on manual. CAUTION: Care must be exercised to prevent water from entering the main steam line(s), the hot reheat line(s) and the cold reheat line(s) to the turbine from any source during and after the shutdown process. This is to prevent possible water damage to the turbine during a subsequent restart. Possible sources of water are: a. Overflow from the drum into the superheater as a result of high water level. b. Water entering the superheater or reheater through the desuperheaters due to open desuperheater control valves or possible valve leakage with the feed pumps running, 2. When the feeder rating on all pulverizers is reduced to 40% of maximum, place the pulverizer supplying the upper coal elevation on manual control. Gradually reduce the feeder rating. When minimum rating is reached, close the hot air shut off gate. Stop the feeder when the coal-air temperature has dropped to approximately 60oC. It is advisable to close the coal shut off gate above the feeder and run the spout and feeders empty before stopping the feeder. Keep the pulverizer running for about 2 minutes 01 until it is completely empty, and then stop the pulverizer, Refer to shutdown procedures in section "Bowl Milts". Unless an emergency condition exists the pulverizer should always be emptied before being stopped. As pulverizers are taken out of service, the Secondary Air Damper Control System should close the associated windbox dampers and throttle other dampers as required to compensate for the reduction in firing rate. Take the second pulverizer supplying the next higher elevation of coal nozzles out of service when the feeder rating on all remaining pulverizers reaches 40%. Continue taking additional pulverizers at consecutive lower elevation(s) out of
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4.

service in the same manner. *When down to 2 pulverizers the adjacent warm up oil guns must be placed in service, prior to reducing the feeder rating of either pulverizer to below 50% maximum. *NOTE: It is recommended that the above consecutive elevation shut down sequence be followed. Firing coal at separated coal nozzle elevations without auxiliary supporting fuel is not permitted. 5. Discontinue admission of overfire air when the unit load has dropped below the predetermined effective starting load. Keep the overfire air dampers slightly cracked open to prevent the nozzles from overheating. Operate all sootblowers. Refer to manufacturer's instructions. Reduce the air flow in line with fuel reduction until 30% of maximum air flow is reached. Do not reduce the air flow below this rating until all fires are out and the unit is off the line. (See Figure 3.) To avoid firing instability during this period of high relative air flow, the auxiliary air dampers at all elevations should open and reduce the wind box to furnace differential pressure to its lower setting. Check the expansion movement of the unit as load is being reduced. After the last pulverizer has been shut down, remove the warmup oil guns and the igniters from service. Shut off the cooling water to the pulverizers. All fires should be removed when the unit is off the line.

6. 7.

8. 9.

10. Immediately after closing the turbine stop valves, open wide the superheater outlet vents and drains and all reheater vents and drains. Open other drains in the superheater system as required for further pressure reduction. Open steam line and turbine drains as described by the turbine manufacturer. 11. Open the economizer recirculating line valves. Close desuperheater isolating valves. 12. If during the shut down period, it is not necessary to enter the unit sooner, a slow rate of pressure and temperature decay may be desirable. This can be accomplished as follows : a. Purge the unit by running the induced draft and forced draft fans, for at least five minutes (at 30% air flow) after the fires are extinguished. b. Reduce the air flow through the unit to a minimum. Keep the fans and air heaters* in service until the unit has cooled to the desired temperature. c. Keep one boiler circuit circulating pump in service until the boiler water temperature is reduced to the desired point. Keep the water level near normal in the gage glass, add make up as required. *NOTE: Air heaters and fans should not be taken out of service until the air heater gas inlet temperature has dropped to below 205oC. 13. If it is desirable to accelerate the cooling process in order to permit entry into the unit for maintenance, proceed as follows:
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a. Purge the unit by running the induced draft and forced draft for at least five minutes (at a minimum of 30% air flow) after the fires are extinguished. b. Continue running the fans to cool the unit at the desired rate. The air heaters may be shut down when the gas entering temperature has dropped below 205oC (Refer to the Air Preheater instructions) NOTE: With the air heaters stopped and the fans running, deposits of fly ash may accumulate in the air heater resulting unbalance of the rotors. c. Keep one boiler circulating pump in service to increase recirculation. Maintain the water level near normal in the gage. Shut down the pump when the boiler water temperature is reduced to the desired level. 14. Open the drum vents when the unit pressure has been reduced to 2 kg/cm2g. 15. If the boiler is laid up wet, refer to "Lay-Up Procedures". 16. If the boiler will be emptied, the boiler water temperature should be reduced to at least 95oC before draining NORMAL SHUTDOWN TO HOT STANDBY It is assumed that the boiler will be shut down for a relatively short period of time and existing pressure and temperature conditions will be substantially maintained. A procedure similar to that for normal shutdown should be followed except: 1. Do not reduce drum pressure in line with unit load reduction. The rate or pressure drop should be much smaller than the rate followed during normal shutdown. When the desired pressure at which the boiler is to be held is reached - after the turbine is off the line-the boiler may be bottled up by closing all superheater drains and vents. Reheater drains and vents are kept open. CAUTION: Care must be exercised to prevent water from entering the main steam line(s), the hot reheat line(s) and the cold reheat line(s), to the turbine from any source during and after the shutdown process. This is to prevent possible water damage to the turbine during a subsequent restart. Possible sources of water are: a. Overflow from the drum into the superheater as a result of high water level. b. Water entering the superheater or reheater through the desuperheaters due to the open desuperheater control valves or possible valve leakage with the feed pumps running. NOTE: 1. If it is expected that the Unit will be restarted in a very short period of time, in which the turbine metal temperatures win not decrease appreciable, it may be desirable to cool the turbine metal to below 425oC, by reducing steam temperature end pressure, while the unit lead is being reduced. This will reduce the steam / turbine metal differential temperature upon restart. NOTE: 2. If the unit load is reduced rapidly utilizing sliding pressure it is possible for the cafe of an idle pump to remain at a higher temperature than the
Page- 15/23

baiter water. Opening the pump bypass valves wilt provide a moderate rate of cooling of the pump case. A pump should not be started if the pump casing temperature exceeds the down-comer temperature by more than 55oC. If load and pressure will subsequently be increased it is preferable to delay the starting of the pump until the downcomer temperature has increased to within 28oC or the pump casing temperature to minimize the effects of temperature transients. 2. It is not necessary to close the feeder inlet gates and to run the spouts and feeders empty. As each pulverizer is taken out of service, close the hot air shut off gate. Stop the feeder when the coal-air temperature drops to 50oC. Run the pulverizer until empty and stop the pulverizer. One boiler circulating pump should be kept in operation to insure adequate boiler water circulation which will prevent possible local overheating due to hot slag deposits, It is recommended that, after all fires are extinguished (see caution below) the I. D. and F. D. Fans and air heaters be kept running until the air heater gas inlet temperature has dropped to below 205oC. (See warning below.) Close all gas duct, secondary air duct and windbox dampers after the air heaters and fans are shut down. CAUTION: If it is known or suspected that combustible deposits are present in the air heater elements, the air heater gas temperature must be reduced to 205oC before shutting down the F. D. Fans, I, D. Fans, and air heaters. The air heaters must be thoroughly cleaned to remove any combustible products before they are shut down. WARNING: If it is elected to shut down the fans with the airheater gas inlet temperature above 205C, the airheater MUST be kept rotating However, running an airheater with the gas inlet temperature above 205oC and no air flow through it will result in seal damage and subsequent excessive leakage during operation. (Refer to airheater instructions) The decision to bottle up the unit above 205oC must be made with this in mind. 5. All boiler circulating pumps may be shut down after the unit has been bottled up. However, if a hot restart is anticipated at least one pump should remain in service to provide more effective warm up circulation for the idle pumps. The ideal pumps may be placed on "hot standby", that is; suction and discharge valves open. Refer to the "Pump Operating Procedures" for complete pump standby requirements. When all circulating pumps are shut down the drum water level will rise possibly out of sight in the gage glass. As the unit cools and the water shrinks, make up should be added intermittently to prevent the water from dropping out of sight in the gage glass. Adding the relatively cold feedwater will establish a reservoir of cooler water in the drum(s) and downcomers. If a pump is subsequently started this cooler water will produce a cycle of cool and hot temperature transients to the pump casing and other pressure parts of the boiler. At least one pump should be in operation during the period of make up addition.
Page- 16/23

3.

4.

6.

NOTE: The operator should observe the gage glass periodically so that he is always aware of the actual drum level and can take the appropriate action to re-establish water level when the unit is being restarted. HOT RESTART Assuming the boiler has been down for a comparatively short period of time and considerable drum pressure was maintained, the following procedures should be used in restarting the unit. 1. 2. 3. Make a general inspection of the boiler and check the points as mentioned under normal start-up. One boiler circulating pump should still be in service. If the airheaters and fans were shutdown at reduced temperature (see Step 4, Normal Shutdown to Hot Standby), start the air heaters and fans as outlined under "Cold Startup-lighting Off", If the unit was bottled up hot, with the air heaters still running, start the fans in the normal sequence. Open wide all superheater drains to allow complete draining of superheater headers and/ or elements. After draining close all drains, except the Superheater Backpass Front Inlet Header and Backpass Rear Inlet Header drains and the startup drains (Main Steam Line Vent and drains). Keep the Backpass Header drains open. Reheat drains and vents are open. Open the economizer recirculating line and the desuperheater isolating valves. (Desuperheater control valves must be closed.) CAUTION: Prevent possible water damage to the turbine by using extreme care to eliminate all water from the main steam line(s), cold and hot reheat lines and superheater and reheater elements and headers before the turbine is rolled. Refer to the turbine manufacturer's instructions. 5. 6. Initiate a furnace purge and normal light off sequence of the igniters and warm up oil guns. Close all reheater vents and atmospheric drains before pulling a vacuum in the condenser. Reheater condenser drains may be left open until the turbine is under light load. When steam is admitted to the turbine for rolling it is desirable to have a minimum steam/turbine metal temperature differential. This can be achieved by firing at a maximum rate within the furnace exit gas temperature limitation of 540oC. In order to reach the exit gas temperature limit, it may be desirable to start a pulverizer at this time. Stabilize the firing conditions to maintain the maximum furnace exit gas temperature without exceeding it. Proceed as during normal start up from cold, hems 20 through 35.

4.

7.

8.

During a hot restart, the turbine metal temperature will normally require a rapid reloading of the unit.
Page- 17/23

EMERGENCY PROCEDURES REHEATER PROTECTION UPON LOSS OF LOAD Stoppage of steam flow through the reheater when the entering gas temperature is above 540oC can result in overheating and damage to the reheater tubing. To prevent this condition, the following measures must be taken. A. Turbine Valve Closure If a loss of load should cause the turbine valves to close, all fuel should be tripped automatically either immediately or after a maximum time delay of ten seconds. Upon a Master Fuel Trip resulting from turbine control valve closure, an immediate restart is feasible in most instances, as the turbine is still rolling and will be available to take steam as soon as the governor has the turbine speed under control (See Note.) If immediate turbine restart is not possible and the turbine is tripped, the reheater condenser drains should be opened, as under "B" below. NOTE: Refer to turbine manufacturer's instructions for no-load operating procedures and limitations. B. Turbine Trip If a loss of load occurs in which the turbine is tripped, all fuel should be automatically and instantaneously tripped. The reheater safety valves will protect against overpressure in the reheater. The reheater condenser drains should be opened to evacuate the steam in the reheater. C. Post Trip Procedures Immediately following a Fuel Trip, the furnace must be purged. Any pulverizer containing coal must be emptied as soon as possible. See Master Fuel Trip, below. To permit firing during start-up, prior to opening the turbine valves, the initiating fuel trip circuits must be disarmed. They must be re-armed at a suitable point in the start-up sequence, such as when synchronizing the turbine. D. Turbine Protection upon Loss of Load Extreme care must be taken following a trip of the turbine and boiler to prevent water from being introduced into the turbine upon unit restart. Water may collect in the main steam Line(s) and cold reheat lines from condensation. Water may be introduced into the superheater due to overflow from the steam drum (inadvertent high water level). Water may be introduced into the superheater and / or reheater through the desuperheaters due to open or leaking spray water control valves. Refer to the turbine manufacturer's instructions. CAUTION: Operators should be alert to deduct the symptoms of water carryover from the boiler and introduction of water into the turbine, such as:
Page- 18/23

a. A sudden unexplained drop in the steam temperature in either the main steam or hot reheat lines. b. Vibration in the steam piping resulting from water hammer. c. Abnormal vibration and differential expansion readings from the turbine supervisory instrumentation. Operators must be prepared to take the actions necessary to prevent turbine damage upon detection of water introduction. Refer to the turbine manufacturer's instructions for specific actions to be taken. MASTER FUEL TRIP Under conditions requiring a master fuel trip through normal interlocks or operators action (manual trip); all fuel should be tripped instantaneously. If coal was being fired, the pulverizers should be tripped immediately. Tripping the pulverizers will automatically trip the feeders and close the hot air shut off gates. (Refer to emergency shutdown procedures in section "Pulverizers".) If oil was being fired, the trip valves and individual nozzle shut off valves should be closed immediately. The following steps should be taken immediately following an emergency fuel trip. 1. Maintain the unit air flow at pre-trip value for at least 5 minutes to purge the system. If a hot restart is anticipated the air flow (30% of full load air low) during the 5 minute purge. At least two boiler circulating pumps should remain in service to maintain uniform temperatures throughout the boiler circulation system and to facilitate lighting off. In no case should all the pumps be stopped (refer to the "Pump Operating Procedures"). IF oil guns were in service when the fuel trip occurred, check to insure that all individual nozzle shut off valves are closed. Oil guns should be retracted (See Note 1), removed, cleaned (See Note 2) and reinstalled, to be ready for a restart of the unit NOTE: 1. Refer to the Furnace Safeguard Supervisory System instructions for emergency oil gun shutdown sequencing. 2. If immediate restart of the unit is anticipated, oil guns do not require cleaning. 3. If during a fuel trip all auxiliaries are lost, refer to the Boiler Circulating Pump Operating Procedures" for handling of the low pressure cooling water. Flow must be maintained. If all auxiliary power sources are lost during a trip, upon restoration of power, start the fans, start air heaters (observe hot restart precautions in the air preheater instructions) and purge the furnace for five minutes If available, at least one boiler circulating pump should be placed in service during the purge period. (See pump operating instructions for restarting procedures.) If pulverizers were in service when the fuel trip occurred, all pulverizers containing coal should be cleared of coal successively, as soon as possible. Each pulverizer should be unloaded in the following manner:
Page- 19/23

2.

4.

5.

A. Close the pulverizer discharge valves on all other idle pulverizers that contain coal. This will prevent hot furnace gases from being carried back into these pulverizers in the event of a furnace pressure rise when a mill is started. B. Establish the required ignition energy for the pulverizer to be started (See Note 1.) C. Start the pulverizer and allow it to clear itself of coal (See Note 2). 1) If the pulverizer will be retained in service, start its feeder when the pulverizer amps begin to fall off. When the feeder is started, open the hot air shut off gate and bring the pulverizer upto normal operating temperature. (See Note 3). 2) If the pulverizer will no! be retained in service, stop the pulverizer after it is completely cleared of coat. The pulverizer discharge valves should remain open to allow a flow of cooling air through the empty pulverizer. D. An emergency trip subjects residual fuel in the pulverizers to conditions which may cause spontaneous combustion. If the unit cannot be re-fired within a reasonable time (45 minutes) to permit clearing the pulverizers, then the pulverizers should be cooled to ambient and manually unloaded or at minimum, they should be isolated and ail doors should be removed to prevent gases from entering the furnace. NOTE: 1. Refer to Unit Cold Startup procedures and Furnace Safeguard Supervisory System instructions for Ignition Energy requirements and permissives. 2. If due to load conditions and/or requirements of the Furnace Safeguard Supervisory System, it is impossible to establish pulverizer ignition permissive for all pulverizers and chat them of coal the discharge valves of all idle pulverizers (including those still containing coal) should be opened to allow a flow of cooling air through the pulverizer. The discharge valves should remain open until ready to unload and I or restart a pulverizer. Each time an additional pulverizer is placed in service or unloaded, any idle pulverizer containing coal should again be temporarily isolated, see Item A. 3. Following a pulverizer trip under load, the pulverizer should be operated with cold air only, until its feeder is started. LOW WATER LEVEL If the water level falls out of sight in the water gauge, due to failure of the feed water supply or neglect of the operator, except in the case of momentary fluctuations that might occur with extraordinary changes in load, appropriate action should be taken at once to trip the fuel. Any decision to continue to operate, even if only for a short time at a reduced rating, would have to be made by someone in authority who is thoroughly familiar with the circumstances that led to the emergency and positively certain that the
Page- 20/23

water level can be restored immediately without damaging the boiler. In the absence of such a decision: 1. 2. 3. 4. 5. 6. 7. Trip all fuel immediately. Shut of all steam being discharged from the unit, (trip turbine, steam driven auxiliaries, etc.) Leave the boiler circulating pumps in service as long as they are operating normally and do not loose suction due to the low water level. If feedwater has become available and the boiler circulating pump(s) are still running, gradually re-establish the level in the drum. If no boiler circulating pumps can be maintained in service, do not admit feedwater to the unit. Maintain a high air flow at first to hasten the cooling process. If pressure parts damage is suspected, reduce the steam pressure gradually by opening the superheater start up drains. Open the drum vents when the pressure drops below 2 kg/cm2g as the boiler cools reduce the air flow. Shut down the air heaters and fans as soon as the unit is cool enough for a man to enter. Drain the boiler when the drum metal temperature is 93oC following normal draining procedures. Determine the cause of low water and examine the boiler for the effects of possible overheating such as leaks and distortion of pressure parts. Repair any leaks, etc. Hydrostatically test the boiler at working pressure before putting the unit back in service.

8. 9.

HIGH WATER LEVEL Abnormally high water level should be avoided as it may lead to carryover and even priming. If the water level rises above the recommended normal operating range proceed as follows: 1. 2. Reduce the water level immediately by opening the intermittent blowdown valves. Reduce the steaming rate, if necessary, and place feedwater control on Manual.

If priming should occur, as indicated by rapid fluctuation in outlet steam temperature proceed as follows: 1. 2. 3. Reduce the steaming rate. If the water level is abnormally high, reduce the level by opening the intermittent blowdown valves and place feedwater control on manual. Investigate the water condition (alkalinity and solids)
Page- 21/23

4.

Investigate the condition of the drum internals as soon as an opportunity Is afforded.

TUBE FAILURES Water Wall Tubes In the event of failure of one or more water carrying tubes in a controlled circulation boiler, the best method for shutting down the unit will be dictated by the size of the failure, the ability to maintain normal water level and the demands for the service of the unit. The following instructions regarding tube failures are of a general nature. It must be understood that conditions may arise which will require exercise of judgment by the operators. In case of a leak or tube failure, which does not involve a serious drain on the feedwater supply, the water level should be maintained and the unit is taken out of service in a normal manner. Refer to Normal Shutdown Procedures. If the tube failure results in a loss of water so great that the water level cannot be maintained with the feedwater supply available, use the method outlined below: 1. 2. 3. 4. 5. 6. Trip all fuel. Shut down the last boiler circulating pump just before the water level goes out of sight after the fuel is tripped. Shut off feedwater to the boiler, Maintain only enough air flow to carry the escaping steam up the stack. Leave fans and airheaters in service until pressure is off the unit. After the unit has cooled enough to permit a man to enter it, make a thorough inspection of pressure parts for any indication of damage resulting from loss of water level. After the necessary repairs have been made, apply a hydrostatic test and obtain the approval of the proper authority before putting the unit back in service.

Economizer Tubes An economizer tube leak can be detected by sound and/or increased make up water requirements. The leak should be investigated at the earliest possible time and the unit shut down in a normal manner. Water leaks in the economizer can cause considerable erosion damage to adjacent tubes. Water carried over from an economizer tube leak may cause plugging of hopper and air heaters. Any decision to continue operation with known leaks should be made with this in mind. Superheater and Reheater Tubes A small leak in a superheater or reheater element should be investigated at the earliest possible time, and the unit should be shutdown in a normal manner. Steam leaks in the Superheater or reheater can cause considerable erosion damage to adjacent tubes.
Page- 22/23

Any decision to continue with known leaks should be made with this in mind. A major superheater or reheater tube failure may require an emergency unit shutdown. The operator must use his judgment to assess the seriousness of the failure and its consequences and then decide what type of shutdown is required.

Page- 23/23

BOILER PARAMETERS
( CONSTANT PRESSURE OPERATION)
LOAD DESCRIPTION 100% BMCR** HP Heater In HPHS Out

89.41%
BMCR

71.3%
BMCR 400MW*

53.9%
BMCR 300 MW*

500 MW*
MAIN STEAM Steam flow at SH Outlet Pressure at SH Outlet Temperature at SH Outlet t/h kg / cm2 (g)
oC

MAX. HEAT INPUT

1675.00 178.0 540.0

1498.53 176.2 540.0

1198.93 173.8 540.0

909.27 171.6 540.0

1447.22 175.7 540.0

REHEAT STEAM Steam flow at RH Outlet Pressure at HPT Outlet / RH Inlet Temperature at HPT Outlet / RH Inlet Pressure drop - RH Pressure at RH Outlet / IPT Inlet Temperature at RH Outlet / IPT Inlet FEED WATER Feed Water Temperature
oC

t/h kg / cm2 (g)

oC

1397.4 44.99 338.5 2.1 42.89 540.0

1335.15 42.99 337.4 2.01 40.98 540.0

1078.04 34.70 329.5 1.62 33.08 540.0

825.78 26.52 321.7 1.24 25.28 540.0

1445.5 46.18 352.3 2.17 44.01 540.0

kg / cm 2 kg / cm2 (g)
oC

255.2

253.4

242.7

229.6

171.5

REMARKS: 1) Boiler Parameters are based on Annexure-IV to MoM dated 7/7/2003 except for 60%BMCR 2) ** Maximum capacity Point 3) * Performance Guarantee points

Customer / Plant : NTPC / KAHALGAON STPP - STAGE II (2 X 500 MW) Engineer : BMM TITLE : Bolier Parameters Revd .with : ACR/SCS DWG NO : BPP-KAH-Ph I-02 Approved by : RKr SHEET : Page 2 of 4

REV :

01

BOILER PARAMETERS
( CONSTANT PRESSURE OPERATION)
LOAD DESCRIPTION HP Heater In

45.9% BMCR 250 MW *

MAIN STEAM Steam flow at SH Outlet Pressure at SH Outlet Temperature at SH Outlet t/h kg / cm2 (g)
oC

60%BMCR

772.78 170.9 540.0

1005 172.3 540

REHEAT STEAM Steam flow at RH Outlet Pressure at HPT Outlet / RH Inlet Temperature at HPT Outlet / RH Inlet Pressure drop - RH Pressure at RH Outlet / IPT Inlet Temperature at RH Outlet / IPT Inlet FEED WATER Feed Water Temperature
oC

t/h kg / cm2 (g)

oC

669.22 21.47 311.9 1.01 20.46 540.0

910 29.0 324 1.4 27.6 540

kg / cm 2 kg / cm2 (g)
oC

219.2

235

Remark: 1) Boiler Parameters are based on Annexure-IV to MoM dated 7/7/2003 except for 60%BMCR 2) ** Maximum capability Point 3)* Performance Guarantee Points

Customer / Plant : NTPC / KAHALGAON STPP - STAGE II (2 X 500 MW) Engineer : BMM TITLE : Bolier Parameters Revd .with : ACR/SCS DWG NO : BPP-KAH-Ph I-02 Approved by : RKr SHEET : Page 3 of 4

REV :

01

BOILER PARAMETERS
( SLIDING PRESSURE OPERATION)
LOAD DESCRIPTION HP Heater In

500 MW

400 MW

300 MW

250 MW

MAIN STEAM Steam flow at SH Outlet Pressure at SH Outlet Temperature at SH Outlet t/h kg / cm2 (g)
oC

1508.4 168.47 540.0

1193.5 134.59 540.0

895.1 101.72 540.0

753.3 85.73 540.0

REHEAT STEAM Steam flow at RH Outlet Pressure at HPT Outlet / RH Inlet Temperature at HPT Outlet / RH Inlet Pressure drop -RH Pressure at RH Outlet / IPT Inlet Temperature at RH Outlet / IPT Inlet FEED WATER Feed Water Temperature
oC

t/h kg / cm2 (g)

oC

1330.2 42.79 338.7 2.00 40.79 540.0

1060.7 34.17 340.2 1.59 32.58 540.0

801.8 25.77 342.2 1.20 24.57 540.0

660.0 21.18 340.4 0.99 20.19 540.0

kg / cm2 kg / cm2 (g)

oC

252.8

242.0

228.8

219.6

` Customer / Plant : NTPC / KAHALGAON STPP - STAGE II (2 X 500 MW) Engineer : BMM TITLE : Bolier Parameters Revd .with : ACR/SCS DWG NO : BPP-KAH-Ph I-02 Approved by : RKr SHEET : Page 4 of 4

REV :

01

VALVE OPERATING INSTRUCTIONS BOILER DRAINS AND VENTS SYSTEM : CIRCULATION BOILER COLD FILLING START UP C C O O C C C O O O C O O C O C C C C O(1) O(9) C C C(5) O O(10) C C C O C(6) O C(6) C(5) HOT START C C C C C C C(5) O O(10) C C C O C(6) O C(6) C(5) SHUTDOWN BOILER WITH REMARKS EMPTYING COOLING C O C O C(2) C C C C O C C C C O C O C C O(3) O(3) C(4) O C O O C O C O C O C O To be opened when main Line is not in use. B5 & B22 to be opened during N2 filling

SL NO TAG NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 E16, E19 E20, E21

SERVICE DESCRIPTION Eco Feed line drain, isolation & reg Eco inlet header drain isolation & reg

B1, B2, B23, B24 Drum air vent isolation B3, B4, B20, B21 Drum purge &Bleed vent isolation B05, B22 B119, B120 B114, B115 E23 E22 E17 B118 B123 B108 B109, B110 B111 B112, B113 B116, B117 Drum N2 filling isolation Rear WW header drain isolation & Reg Emergency drum drain isolation & reg. Eco recirculation line isolation Eco recirculation line regulating Eco filling line isolation Waterwall drain header drain Boiler filling line isolation Drum CBD isolation Drum CBD inlet isolation & blowoff Drum CBD Bypass isolation Drum CBD Bypass isolation & blowoff Bottom ring hdr blowoff isolation &reg

LEGENDS O C O( ) C( ) 1 2 3 4 5 OPEN CLOSE OPEN EXCEPT AS INDICATED IN THE NOTE BELOW CLOSE EXCEPT AS INDICATED IN THE NOTE BELOW Open till 2.0 ksc (g) pressure. Close when pressure is more than 2.0 ksc (g). Close till 2.0 ksc (g) pressure. Open when pressure is less than 2.0 ksc (g). Close while emptying under Nitrogen capping. Open while emptying under Nitrogen capping. Open to control drum level swell when required. 6 7 8 9 10 Open according to chemists requirements and directions. Close after HP bypass is opened. Close just before raising vacuum in the condenser. Close before starting of Boiler water circulating pump. Close after continuous feed starts.

VALVE OPERATING INSTRUCTIONS BOILER DRAINS AND VENTS SYSTEM : SUPERHEATER BOILER COLD FILLING START UP C O C C O C O C C O C C C O C O(1) O(1) O(1) C C O(1) C C O(1) C O(7) C C HOT START C C C C C C C C C C C O(7) C C SHUTDOWN BOILER WITH REMARKS EMPTYING COOLING C O C(2) C C C C C(2) C C C(2) C C C C O O O O C(4) O O O O C(4) C O C S19 to be open during N2 filling.

SL NO TAG NO 1 2 3 4 5 6 S88, S89 S15, S16, S17, S18 S86, S87 S84, S90, S85, S91 S19, S20

SERVICE DESCRIPTION SH roof inlet header drain isolation & reg. SH roof outlet header vent isolation. Backpass lower front header drains isoln & reg Backpass lower rear header drains isolation & reg. Backpass rear upper header vent

S21 BP UPPER REAR HDR N2 filling - isoln S26, S27, S28, 7 SH - DESH link/SH finish platen inlet Link vent isolation. S29 S82, S92, S83, 8 SH Division panel inlet header Drain isolation & reg. S93 9 S94, S95 SH Finish platen inlet hdr drain isoln & reg 10 S31, S32 SH outlet header vent 11 S33 SH PLATEN O/L HEADER - N2 Filling isolation. S34, S36, S35, 12 SH Start up vent isolation & reg. S37 13 S96 SH drain header drain isolation 14 S97 SH filling line isolation SYSTEM : REHEATER 1 2 3 4 5 R42, R43 R09, R10 R11 R12, R13 R44 RH finish spaced outlet hdr drain Isolation & reg. RH finish spaced outlet hdr vent RH N2 filling isolation RH outlet hdr Start up vent isolation & reg. RH filling line isolation

S31 to open during N2 filling

C O C C O

C O(8) C O(8) C

C C C C C

C C C C C

O O C(4) C C

R 42 to open during RH filling R09 to open during N2 filling

LEGENDS O C O( ) C( ) 1 2 3 4 5 OPEN CLOSE OPEN EXCEPT AS INDICATED IN THE NOTE BELOW CLOSE EXCEPT AS INDICATED IN THE NOTE BELOW Open till 2.0 ksc (g) pressure. Close when pressure is more than 2.0 ksc (g). Close till 2.0 ksc (g) pressure. Open when pressure is less than 2.0 ksc (g). Close while emptying under Nitrogen capping. Open while emptying under Nitrogen capping. Open to control drum level swell when required. 6 7 8 9 10 Open according to chemists requirements and directions. Close after HP bypass is opened. Close just before raising vacuum in the condenser. Close before starting of Boiler water circulating pump. Close after continuous feed starts.