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Second Issued
08.11.25
08.03.13
First Issued
Rev.
Date
Details of Revision
Client :
Contractor :
Sub Suplier :
Project Title :
Orig-Pc
08.11.25
Pc
Name
N/A
Scale
S.W.KANG DOC. TITLE
Type
Contents
Coordinated
Code
Checked
08.11.25
S.H.SONG
Approved
08.11.25
S.C.SONG
Dept.
BOILER BASIC
DESIGN TEAM
Document No. :
Owner Document No. :
Dept.
UNID
Reg. No.
Version
Rev
A
T07073-LBH-SY-M001
TCE.5146A-510-00-1309
Page-No.
1/43
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PAGE NO.
INTRODUCTION ...................................................................................................................... 1
PRE-OPERATIONAL PROCEDURES ...................................................................................... 1
Cleanup .......................................................................................................................... 1
Chemical Cleaning ........................................................................................................ 1
Steam Line Blowing ...................................................................................................... 1
Setting Safety Valves ................................................................................................... 1
COLD START -UP .................................................................................................................. 2
Cold Start Conditions ................................................................................................... 2
Preparations for Lighting Off ....................................................................................... 2
Warm Water Filling of the Boiler .................................................................................. 5
Water Recirculation via Boiler for Clean-up ............................................................... 6
Start of the Boiler Circulation Pump (BCP) ................................................................. 6
Initial Firing Precautions .............................................................................................. 6
Superheat Steam Temperature Control (Prior to Unit Synchronization) ................... 7
Air Pre-heater Protection During Unit Start-Ups On Oil ............................................. 7
Lighting Off .................................................................................................................... 8
Rolling and Synchronizing the Turbine ..................................................................... 13
Introducing Coal .......................................................................................................... 14
Initial Load Increase .................................................................................................... 15
NORMAL OPERATION -UNIT LOAD CHANGES ................................................................... 17
Decreasing Load ......................................................................................................... 17
Increasing Load ........................................................................................................... 18
NORMAL SHUTDOWN TO COLD .......................................................................................... 19
NORMAL SHUTDOWN TO HOT STANDBY .......................................................................... 21
WARM START -UP ................................................................................................................ 23
Warm Start Conditions ................................................................................................ 23
Preparations, Lighting Off, and Load Increase .......................................................... 23
Lighting Off .................................................................................................................. 23
Rolling and Synchronizing the Turbine ..................................................................... 26
Introducing Coal .......................................................................................................... 27
Initial Load Increase .................................................................................................... 28
HOT START -UP .................................................................................................................... 30
Hot Start Conditions ................................................................................................... 30
Preparations, Lighting Off, and Load Increase .......................................................... 30
Rolling and Synchronization the Turbine .................................................................. 32
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TITLE
PAGE NO.
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PRE-OPERATIONAL PROCEDURES
Cleanup
The furnace should be inspected and cleaned both internally and externally before initial
firing and prior to each subsequent cold start-up after maintenance. Remove all foreign
material from the pressure parts. Clear any grating, pipe lines and electric conduit which
may restrict normal expansion of the steam generator. All personnel should be clear and the
access doors closed. A complete check list should be prepared by operating personnel.
Chemical Cleaning
Specific pre-operational chemical cleaning procedures are included else where in this
manual. The fuel firing and circulating pump operating procedures, outlined under COLD
START-UP, Lighting Off, should be used as a guide when operating the fuel firing equipment.
Steam Line Blowing
Prior to starting up a new steam generator, or following a major pressure part repair, the
main steam and reheat steam lines should be blown out to remove scale and other foreign
matter. Steam line blowing, which prevents damage to the turbine, should be done after
chemical cleaning. Refer to Steam Line Blowing Procedures for recommended operating
procedures and precautions.
Setting Pneumatically Operated Safety Valves
The pneumatically operated SH safety valves serve the function of over-pressure protection
of the SH sections. It is important the complete checkout and verification of the pneumatic
power station operation and pressure sensing instrumentation be completed prior to firing
the boiler.
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The unit has been chemically cleaned, and the steam lines have been
blown(applicable for the first start-up only).
2.
All control systems have been checked and are available for service.
All safety interlock systems should be checked prior to start-up to ensure proper
functioning. Exercise the systems by creating the actual interlock actuating
conditions. Simulate the activating condition if the actual condition cannot be
created.
3.
All instrumentation and associated mechanical equipment has been checked out
and is available for service.
4.
The oil firing equipment has been checked out to ensure it is properly functioning.
Recheck the following items to make sure that:
5.
a.
Warm-up oil guns are inserted and properly coupled. Check gaskets between
unions.
b.
c.
d.
The pulverizers and feeders have been checked out and are available for service.
Recheck the following items to ensure that:
a.
b.
c.
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All hot air gates are closed and all hot air control dampers are closed.
e.
All cold air gates are open and the cold air control dampers are open
approximately 5%.
f.
All bunker outlet valves are open and coal is available to the feeders.
g.
h.
i.
6.
The windboxes have been checked for proper damper positioning and the tilts are
set at horizontal.
7.
The feedwater system and at least one feedwater pump, including the
instrumentation and equipment, has been checked out and is available for operation.
During a start-up, the feedwater flow should be controlled remote-manually until a
continuous flow is established.
8.
9.
The boiler circulating pump has been checked out, the suction and discharge
isolation valves are open, and all pump instrumentation is available for service. The
pump differential pressure transmitters must be in service. Ensure that the proper
trip settings have been made.
10. The steam generator start-up system valves are ready for operation (UG, WR, ZR
valves), with isolation valve open. The separator level control for WR and ZR valves
has been checked and is available for service.
11. The startup system drain transfer system is ready for operation. This system includes
WR and ZR valves, the flash tank, condensate drain transfer pump and connecting
pipe to condenser.
12. Auxiliary steam is available from another operating boiler for supplying the deaerator,
feedwater tank, and heavy oil atomization. When auxiliary steam is available, the unit
can be started with Heavy Fuel Oil firing. But even though the auxiliary steam is
available the Light Diesel Oil is introduced as an ignition fuel before HFO supplied
during Cold start-up. As soon as the steam parameters i. e. pressure and temperature
are available for the above requirements, they shall be put into service.
13. Cooling water system is in operation.
CAUTION: Before starting an ID fan and before adjusting the ID fan
inlet blade pitch, an airflow path through the unit must be established
such as ESP is in service, GAH in service and GAH inlet gas stream
damper open and maintained by placing other dampers in the system
in the start-up positions indicated below. The ID fan inlet blade pitch
must be kept closed or at the minimum open position until after the fan
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For the first draft group to be started (ID fan A and FD fan A), the fan outlet shutoff
dampers are closed and the inlet blade pitch is at minimum.
b.
For the second draft group (ID fan B and FD fan B), the outlet shutoff dampers
shall be kept closed to enable start up of the Fans.
c.
The PA fan outlet shutoff dampers and inlet blade pitch is closed or at the
minimum position.
d.
e.
f.
g.
One pulverizer seal air fan inlet shutoff damper is open with the associated fan
ready.
h.
15. The gas air heaters have been prepared for service and an adequate means of
extinguishing a gas air heater fire is available and ready for use. Refer to gas air
pre-heater protection during unit start-ups on oil, and to the gas air heater
instructions for details.
16. The soot blowing equipment has been checked for proper operation and the system
is in the start-up mode with all blowers retracted and the main steam supply valve
closed. Refer to the soot blower instructions.
17. All desuperheater spray water control and block valves are closed.
CAUTION: Prevent possible water damage to the turbine by taking
extreme care to eliminate all water from the main steam line(s), cold
and hot reheat lines, and the superheater and reheater elements and
headers before the turbine is rolled. Refer to the turbine manufacturer's
instructions for proper drain valve settings.
18. All boiler, superheater, and reheater drain valves are open, and all vent valves are
closed. The economizer and furnace wall drain valves are closed, and economizer
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4. After filling the water system, the feedwater pump is stopped. The water level in the
de-aerator must be re-established and maintained and water temperature at 105 reestablished.
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Temperature
Enthalpy
Saturation
[kg/cm2g]
9
11
14
15
17
[]
327
328
332
333
335
[kcal/kg]
743
743
743
743
743
[]
179
187
197
201
206
Superheated
by
[]
148
141
135
132
129
WARNING: The greatest danger, for developing an gas air heater fire,
is in the initial stages of boiler operation, i.e. boiler chemical cleaning
and boiler steam blowing. Experience has shown that during these
stages more than the normal precautions need to be taken. This is
because there is normally insufficient boiler steam capacity and/or soot
blowers are not available for use. Therefore, continuous plant visual
observations must be undertaken so the risk of a gas air heater fire
can be kept to its very minimum.
Once the unit has seasoned on coal, fly ash will have been deposited
in various areas of the boiler (especially in the assemblies of the back
pass). These ash deposits will absorb some of the vapor before it
reaches the gas air heater surfaces so the risk of gas air heater fires
will be somewhat diminished. It goes without saying that prolonged low
Ioad operation firing oil without blowing the gas air heaters should
always be avoided.
Water washing has no positive effects in removing oil unburned
particles / residue. Only soot blowing would be effective by knocking
off these particles. Therefore, when firing oil when sufficient blowing
steam is available, the gas air heater should be continuously cleaned
utilizing its soot blowers.
Gas air heater surfaces should only be water washed, during initial
stages of boiler operation and/or subsequent load operations, if heater
surfaces become plugged with fly ash (high delta-P) when soot blowing
was either ineffective or not available for use.
Gas air heater water washing must be in strict accordance with
vendor's instructions.
Frequent water washing of gas air heater surfaces is not a substitute
for the soot blowing process and should be avoided. Frequent washing
will decrease the life of gas air heater heating elements.
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Start the gas air heaters. Refer to the gas air heater instructions for operating details.
CAUTION: The ID fans are capable of developing drafts that exceed
the furnace design pressure. Therefore, an airflow path through the
unit must be established and maintained before starting an ID fan and
before opening the ID fan inlet blade pitch by ensuring that other
dampers in the system are in the start-up positions indicated in
Preparations for Lighting Off, page 2.
The ID fan inlet blade pitch must be kept closed or at the minimum
open position until after the fan is started. This minimizes the
possibility of developing excessive negative pressure in the unit during
start-up.
Furnace draft must be maintained within safe limits at all times.
Extreme care should be taken when draft and airflow controls are in
the manual mode. Be alert for possible malfunctions of automatic
control equipment resulting in abnormal excursions, negative or
positive, in furnace pressure.
2.
Start the first draft group: Start one ID fan, then the corresponding FD fan. Open the
outlet shut-off dampers. Adjust the ID fan for proper furnace draft, and set furnace
pressure control to automatic. Adjust unit air flow to minimum 35% air flow, and set
unit air flow control to automatic.
3.
4.
Adjust the fan and wind box dampers to permit a purge airflow of at least 35% of total
airflow and a furnace draft of approximately -12.0 mmw.g. Refer to Initial Firing
Precautions.
When lighting off an elevation on manual control, the fuel-air dampers should be
closed. Once ignition of the main fuel is established, the fuel-air dampers should be
opened in proportion to the fuel elevation firing rate. When the fuel-air dampers are
fully open, further damper adjustments should be made, if necessary, with the
auxiliary air dampers only. When changing the damper positioning, an entire elevation
should be treated simultaneously, that is, damper positioning at the same elevation
should always be identical in all wind boxes.
When the steam generator reaches a firing rate at which additional air is required to
maintain the design operating excess air, increase the airflow. Refer to the percent
excess air versus load curve.
5. When the fans are started, the secondary air damper control should modulate the
auxiliary air dampers to maintain a programmed set point differential pressure of
102mmw.g. between the wind box and furnace.
6. Check that all other purge permissives are satisfied.
7. Place the gas temperature probes in service.
8. Initiate a furnace purge.
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Upon completion of the purge cycle, check that all firing prerequisites are satisfied,
including the following control settings:
a.
Feed water control is on automatic maintaining minimum feed water flow rate of
approximately 5% TMCR.
b.
c.
Separator level control is on automatic, i.e. the WR, and ZR level control valves
are all in automatic.
d.
e.
Unit air flow is on automatic maintaining minimum 35% full load air flow.
f.
(1)
Set to "valve position control" and desired preset position of app. 10 - 12% open.
(2)
HP bypass valve is set to be controlled along with the pressure rising of boiler.
(3)
Pressure and temperature controls for HP bypass valves, HP bypass spray valves,
and Spray water pressure reducing valves are on automatic.
g.
(1)
Open LP bypass stop valve after establishing sufficient condenser vacuum and
water supply for de-superheating.
(2)
(3)
(4)
h.
i.
Open LTSH outlet vent valves, SH backpass drain valves, and RH outlet vent
valves.
11. Start one of the PA fans. After fan is started, open the PA fan outlet damper. Bring the
primary hot air duct pressure up to set point by manually adjusting the PA fan inlet
blade pitch. Then, transfer to automatic control.
10
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Elevation
AB oil
CD oil
AB oil
B coal
C coal
D coal
A coal
E coal
Notes
Light Diesel Oil
Heavy Fuel Oil
Heavy Fuel Oil
If coal elevation B not available, start coal elevation A
If coal elevation C not available, start coal elevation B
13. Initiate a light-off sequence of oil elevation AB start-up oil guns. Refer to the HEA
igniter, WRTE Retractable oil gun, and the Recommended Burner Management
System instructions for details.
To minimize the possibility of adverse visible stack emission, it is desirable to use
the warm-up oil guns until 35 kg/cm2(g) steam pressure is produced and 175
secondary air temperature before firing pulverized coal.
14. Set fuel oil flow(LDO) control to auto and adjust the set point to 7% of TMCR firing
rate. Stabilize the AB elevation for 35 minutes.
15. When elevation AB is in service, close the economizer vent valves.
16. Initiate an elevation start command for HFO elevation CD. Progressively increase
firing rate to 15%TMCR at a rate of 1.5% per minute for 5 minutes and Stabilize the
CD elevation for 30 minutes.
17. Stop firing LFO elevation AB by operator stop command after HFO elevation CD
firing stable and substitute HFO for LDO at elevation AB. Firing rate is reduced to
8%TMCR by stopping LDO elevation AB.
18. Initiate an elevation start command for HFO elevation AB. Progressively increase
firing rate to 15%TMCR again. Maintain the firing rate with 15% TMCR until the
introducing coal firing is stable.
19. To ensure stable operation of the water system and to ensure sufficient steam flow
through the superheater, firing rate should not be further increased until 8 kg/cm2g is
measured in the water separator.
20. As the pressure is raised, first the WR and then the ZR valves will open when
separator water level increases due to boiler water swell. As pressure further
increases, the WR and ZR valves will start to close as the water level decreases.
11
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12
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Confirm the steam conditions, i.e. pressure, temperature, and steam purity, at the
turbine are correct for turbine roll. (See turbine manufacturers Steam Purity
recommendations)
2.
Turbine roll, synchronization, and initial loading are all carried out using reheat
steam. Roll the turbine by opening the reheat stop and control valves to the IP
turbine per the Turbine manufacturers procedures. The HP turbine is maintained in
reverse flow using steam from CRH line. During this time, the total steam production
is passed through the HP bypass while it remains on "pressure control' mode.
3.
SH and RH steam temperatures are maintained by adjusting firing rate and airflow.
4.
Synchronize the generator and put on initial load of app. 6.5% according to
turbine/generator startup instructions. Initial load is produced by IP/LP sections of
the turbine. The HP section is still in reverse-flow mode.
5.
As steam is transferred to the IP turbine during turbine loading, the LP bypass will
close while maintaining RH pressure at 13 kg/cm2 (g).
6.
As turbine conditions permit, put feed water heaters into service per manufacturers
instructions.
7.
b.
c.
The firing rate should never exceed the rate necessary to match the total steam
generation.
13
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Start the second set of fans as required. Refer to the fan manufacturer's instructions
for operating details.
Introducing Coal
1.
Coal firing can commence when steam flow reaches app. 15%TMCR and LP bypass
is closed.
2.
3.
When placing the first pulverizer in service, make sure the pulverizer start
permissives are satisfied. Refer to the Recommended Burner Management System
instructions. The coal fuel-air dampers should remain closed until ignition is
established. Make sure the nozzle tilts are horizontal. PA fan/fans must be in service.
If the unit start-up follows a master fuel trip, the pulverizer may not be empty.
Operate the pulverizer to clear it of excess coal before starting the feeder. During
the pulverizer clearing procedure, the pulverizer discharge gates of all other idle
pulverizers must be closed. This prevents hot furnace gases from entering the coal
piping and the idle pulverizers. (See emergency procedures) When most of the coal
has been removed from the pulverizer, the pulveriser can be introduced as per
normal procedure Be sure the ignition energy in the furnace is established before
starting the pulverizer.
If 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 .
4.
Start the pulverizer. Open the hot air shutoff gate, adjust pulverizer airflow to 100%
by opening the hot air damper, and bring the pulverizer up to the required operating
temperature without coal. Place the pulverizer airflow and temperature control on
automatic. When ready to fire coal, manually start the feeder at minimum rating.
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 rate consistent with stable ignition. Watch the fires.
Pulverizer start-up will cause a sudden and sharp increase in steam pressure. The
pressure will level out rapidly as the HP bypass station responds.
Check the pulverizer oil temperature. When the temperature approaches 150
(66) turn on the water to the oil cooler or adjust the lube oil control system. The oil
14
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Maintain the proper coal/air temperature leaving the pulverizers. Regulate the hot
and cold air dampers to keep the temperature between 77 and 82 at the
pulverizer outlet. The pulverizer outlet mixed air temperature should be revised at
site during commissioning period based on coal characteristics which will be using.
6.
7.
Continue the transfer to forward-flow until the first three turbine valves are fully
opened and HP bypass valves are fully closed.
8.
9.
When the feeder rating of the first pulverizer has reached approximately 80%, place
the second pulverizer, which supplies the adjacent elevation of coal nozzles, in
service in a similar manner. When the second pulverizer is proven in service,
equalize the feeder rating of both. The warm-up oil guns must remain in service until
both feeders proven signal is achieved.
If the adjacent pulverizer is not available for service, place the pulverizer serving the
next closest elevation of coal nozzles in service. Do not remove the warm-up oil
guns from service until the two(2) adjacent coal elevations are in service with feeder
ratings greater than 50%.
10. Increase total fuel firing rate to 43% TMCR with second pulverizer. Also decrease
total oil firing rate to 10% TMCR by the operator decreasing command.
11. After reaching 43% TMCR load and firing is stable, oil firing load is maintained 10%
TMCR for coal firing stabilization.
12. The Burner Management System and secondary air damper controls should close
the auxiliary air dampers which serve compartments adjacent to the coal nozzles out
of service when the unit load reaches 35% TMCR load. These controls should also
gradually increase the windbox-to-furnace differential pressure to approximately 102
mm w.g. as load is increased per the prescribed curve.
13. The airflow to the furnace must be sufficient for the firing rate. Automatic control
equipment is normally arranged to maintain such a balanced draft condition. The
operation of the O2 measuring devices at economizer outlet, often tied in with the
airflow control, should be checked periodically.
The third pulverizer can be started after steam flow reaches 30-35% TMCR. Place
additional pulverizers in service in a similar manner. Pre-warm the pulverizer, and
initiate an elevation start command. After the coal elevation is proven in service
(signal from BMS), the feeder is put into automatic.
2.
Increase total firing rate to 43% TMCR. Oil elevation CD is issued an elevation stop
15
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After total firing rate reaching 65% TMCR load and firing is stable, oil elevation AB is
issued an elevation stop command by the operator .
4.
Before and after oil elevation AB is stopped, ensure coal elevation A or B shows
flame through flame scanner indications.
5.
After stable firing is established, put into service the second BFP(M) per the
manufacturer procedures.
NOTE: Before increasing the total firing rate above 35% TMCR,
feedwater quality must be verified to be within the limits for normal
firing as defined in Appendix A.
6.
7.
During load increase in automatic load control, the BMS shall be given a signal to
start the next available coal elevation. After a coal elevation is proven in service
(signal from BMS), the feeder is put into automatic.
8.
The steam temperature at the separator inlet will reach a stable superheated
condition at app. 35% TMCR, causing the level in the separator to decrease and
eventually disappear. The boiler is now in once-through mode(dry mode). The
BCP(Boiler Circulating Pump) will be stopped automatically.
9.
When the BCP stops, the warm-keeping system of the start-up system should be put
into operation.
10. The boiler/turbine is now ready for automatic load dispatch. The control system shall
monitor unit loading and will start/stop firing equipment by the automatic load
program.
11. Place additional pulverizers in service as the unit load demand increases. The
pulverizer serving the lowest coal nozzle elevation not already in service should be
started, if available, when the feeders in service reach the 50% rating. As each
pulverizer is placed in service, the required ignition energy must be available. When
the unit firing conditions are stabilized, all warm-up oil guns may be taken out of
service. Refer to the Recommended Burner Management System instructions.
12. Place the steam temperature control and combustion control on automatic when
firing conditions are stable and the temperature and pressure control set points have
been reached. Please refer to the steam temperature and combustion control logic,
ABC Logic.
13. Make frequent visual observations of furnace conditions to ensure that no excessive
slag build-up is developing. This is especially important when burning coal with low
ash fusion temperatures. Operate the soot blowers as required to keep the steam
temperature control (nozzle tilts, desuperheaters) within operating range. If
response to soot blowing is sluggish or insignificant, reduce unit load or increase
excess air to assist in lowering steam temperature and take steps to eliminate the
cause of the erratic steam temperatures.
16
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maintained clean such that a situation like hopper full of ash does not
occur.
Under no circumstances should the level of ash in the bottom ash
hopper be allowed to reach the level of the coutant opening, thus
blocking further removal of ash from the furnace.
Under no circumstances should ash or slag be allowed to bridge
across the coutant opening.
If bridging starts to occur, load should be reduced in an attempt to
shed the buildup.
If complete bridging across the coutant opening does occur, immediate
steps should be taken to shut the steam generator down to cold
following normal shutdown procedures. The ash should then be
removed by means which preclude damage to the water wall tubes.
Refer to "Preventing Furnace Bottom Overloading" for additional
operating recommendations.
If excessive slagging of furnace walls is experienced, make sure that
the bottom ash removal system is in good working condition to handle
the increased quantity of bottom ash that accompanies higher slagging
rates.
14. Overfire air is used for NOx control and is automatically controlled as a function of
total unit air flow. The effective starting load must be determined during initial unit
operation. Refer to the CCOFA damper characteristics furnishing the unit air flow Vs
OFA damper opening position under Tilting Tangential Firing system section in O &
M manual.
Decreasing Load
If the unit load decreases to a point at which the feeder rating of the pulverizers in
service is reduced to 40%, a pulverizer should be taken out of service. Normally the
17
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Ensure that pulverizer ignition energy is available in the furnace. Start the oil gun
elevation associated with the coal elevation served by the selected pulverizer.
2.
3.
When the feeder rating is at minimum, close the coal shut off gate above the feeder,
run the feeder until the spout and feeder are empty, and then stop the feeder.
4.
Make sure the pulverizer is completely empty by running it for at least 5 minutes.
5.
6.
Allow the pulverizer coal/air temperature to drop to 50 , and then stop the
pulveriser.
7.
The associated warm-up oil guns may be shut down when the furnace conditions
have stabilized.
Additional pulverizers can be taken out of service in a similar manner when the feeder
ratings again drop to 40%.
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 two(2) coal elevations is not recommended and is
only permissible through the use of the associated oil guns.
If the unit load is reduced to a point at which only two(2) pulverizers are required, the
associated oil guns adjacent to the coal nozzles in service must be placed in service to
ensure positive ignition when the feeder ratings drop to 65% or less. Auxiliary supporting
fuel should be used whenever, in the operator's judgment, ignition stabilization is
necessary.
Increasing Load
If, after several pulverizers have been taken out of service due to a load decrease, load
increases again to a point at which the feeder rating of the pulverizers in service
exceeds 50% of maximum, place an additional pulverizer in service as follows
1.
Establish the ignition energy required for the coal elevation served by the selected
pulverizer .
2.
3.
Open the hot air shutoff gate and damper to 100% airflow and bring the pulverizer
up to operating temperature.
4.
Start the coal feeder. The feeder control should be on manual and at minimum
feeder rating.
5.
When the pulverizer is grinding and coal ignition has been established, gradually
18
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The associated oil guns may be taken out of service when the furnace conditions
have stabilized and at least two(2) pulverizers are in service, each with a feeder
rating of at least 65%.
7.
1.
a.
b.
Reduce the unit load at a rate of 2% per minute following the prescribed sliding
pressure vs. load curve. Hold pressure constant at app. 125 kg/cm2g until the
turbine is taken off line. Reduce the firing rate in line with the decreasing steam flow.
Reduce the steam temperature at the rate prescribed by the turbine manufacturer.
Leave the steam temperature, combustion and feedwater controls on automatic until
better control can be obtained on manual.
2.
When the feeder rating on all pulverizers is reduced to 40% put the upper elevation
of oil guns in service. Place the pulverizer supplying the upper coal elevation on
manual control. Gradually reduce the feeder rating. When minimum rating is
reached, close the coal shutoff gate above the feeder, run the feeder until the spout
and feeder are empty, and then stop the feeder. Make sure the pulverizer is
completely empty by running it for at least Five (5) minutes. Close the hot air shutoff
gate. When the coal/air temperature has dropped to approximately 50,then, stop
the pulverizer. Unless an emergency condition exists, the pulverizer should always
be emptied before being stopped.
3.
As pulverizers are taken out of service, the secondary air damper control system
should close the associated windbox damper and adjust the other dampers to
compensate for the reduced firing rate.
4.
Take the second pulverizer supplying the next highest elevation of coal nozzles out
of service when the feeder rating on all remaining pulverizers reaches 40%.
Continue taking additional pulverizers out of service in the same manner. When only
two(2) pulverizers remain in service, the adjacent oil guns must be placed in service
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Overfire air will be reduced automatically as the unit load drops per the prescribed
control curve. Stop admitting overfire air when the unit load drops below the
predetermined starting load. Keep the overfire air dampers at minimum open
position to prevent the nozzles from overheating.
6.
Operate all soot blowers. Refer to the soot blowing philosophy section and to the
soot blower manufacturer's instructions.
7.
Reduce the airflow in line with the fuel reduction until 35% BMCR airflow is reached.
Do not reduce the airflow below this rating until all fires are out and the unit is off the
line (Refer to Figure 1, typical air flow curve of this section, and the percent excess
air versus load curve. To avoid firing instability during this period of high airflow, the
auxiliary air dampers at all elevations should open and the windbox-to-furnace
differential pressure reduced to its lower setting per the prescribed control curve.
Refer to the auxiliary air damper characteristics furnishing the unit load Vs windbox
to furnace differential pressure under Tilting Tangential Firing System section in O &
M manual.
8.
9.
At app. 35% steam flow, open the HP and LP bypass valves. Remove the turbine
from service following the turbine operating instructions. Boiler steam production will
be transferred to HP/LP bypass operation.
10. At app. 35% TMCR steam flow, the steam temperature at the separator inlet will fall
below the superheated region, and a water level will develop in the separator. The
boiler must now be returned to recirculation mode, and the BCP must be started to
provide minimum water wall flow when a water level in the separator reaches over 3
meters.
11. After the last pulverizer is shut down, remove the oil guns from service. Shut off the
cooling water to the pulverizers. All fires should be extinguished when the unit is off
the line. With no pulverizers in service, the PA fans and the pulverizer seal air fans
may also be shut down. The PA fans should not be shut down if the gas air heater
gas inlet temperature is above 400(205).
12. After all fuel firing is removed, close the HP and LP bypass valves.
13. Immediately after closing the HP/LP bypass valves, open all superheater outlet
vents and drains and all reheater vent and drains. Open the steam line and turbine
drains per the turbine manufacturer's instructions.
14. Close the de-superheater isolating valves.
15. Do not exceed the following cool down rates referenced to saturation temperature in
the separator: For pressure above 35 bar: 83per 15 minutes; for pressure less
than 35 bar: 42 per 15 minutes.
16. If the steam generator will not be entered during the shutdown period, a slower rate
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Purge the unit by running the ID and FD fans for at least Five(5) minutes at 35%
TMCR airflow after the fires are extinguished.
b.
Reduce the airflow through the unit to minimum. Keep the fans and gas air
heaters in service until the unit has cooled to the desired temperature. Gas air
heaters and fans should not be taken out of service until the gas air heater gas
inlet temperatures have dropped below 400 (205).
Keep the boiler circulating pump in service until the boiler water temperature is
reduced to the desired point ( 300 i.e. app. 15 less than the saturation
temperature corresponding to the SHO pressure at 35 % TMCR load). Keep the
water level near normal in the separator, adding makeup water as required.
c.
17. If the cooling process must be accelerated to permit entry into the steam generator
for maintenance, proceed as in step 16, except:
a.
Continue running the fans at the desired rate to cool the unit. The gas air
heaters may be shut down when the gas entering temperature has dropped
below 400 (205). Refer to the gas air heater instructions.
With the gas air heaters stopped and the fans running, deposits of fly ash may
accumulate in the gas air heater and cause a rotor unbalance. Therefore before
stopping the GAHs, fans should be stopped.
b.
Keep the boiler circulating pump in service to increase recirculation. Keep the
water level near normal in the separator. Shut down the pump when the boiler
water temperature is reduced to the desired level, which is differential
temperature, 20C, between separator outlet water temperature and economizer
inlet water temperature.
18. Do not shut down the scanner air fan until the furnace temperature has dropped to
below 140 (60C).
19. If the boiler is to be laid up wet, refer to Lay-up Procedures.
20. If the boiler is to be emptied, the boiler water temperature should be reduced to at
least 200 (93) before draining.
b.
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Reduce steam pressure in line with unit load reduction, following the prescribed
sliding pressure curve. After the turbine is off the line and fires removed and HP/LP
bypass closed, the boiler may be bottled up by closing all superheater drains and
vents. Reheater drains and vents are kept open.
If the unit will be restarted soon enough to prevent turbine metal temperatures from
decreasing appreciably, it may be desirable to cool the turbine metal to below 800
(427) by reducing the steam temperature and pressure, while the unit load is
being reduced. This will reduce the steam/turbine metal differential temperature
upon restart.
2.
It is not necessary to close the feeder inlet gates and run the spouts and feeders
empty. As each pulverizer is taken out of service, gradually reduce the feeder rating.
To minimum and then stop the feeder. Make sure the pulverizer is completely empty
by running it for at least Five (5) minutes. Close the hot air shutoff gate. When the
coal/air temperature has dropped to approximately 50,then, stop the pulverizer.
3.
The boiler circulating pump should be kept in operation to ensure adequate boiler
water circulation. This will prevent possible local overheating due to hot slag
deposits.
WARNING: If the fans are shut down with an gas air heater gas inlet
temperature above 400 (205), the gas air heater must be kept
rotating. However, running an gas air heater with the gas inlet
temperature above 400(205) and no air flow through it will cause
seal damage followed by excessive leakage during operation. (Refer to
gas air heater instructions.) The decision to bottle up the unit above
400 (205) must be made with this in mind.
CAUTION: If combustible deposits are present in the gas air heater
elements, the gas air heater gas inlet temperature ,must be reduced
to 400 (205) before the FD fans, ID fans and gas air heaters are
shut down. The gas air heaters must be thoroughly cleaned to remove
any combustible products before they are shut down.
4.
After the fires are extinguished, keep the ID, FD and PA fans and gas air heaters
running until the gas air heater gas inlet temperatures have dropped to below 400
(205). Close all gas duct and secondary air duct dampers after the gas air heaters
and fans are shut down. Keep the scanner air fan running.
5.
Shut down the boiler circulating pump after the unit has been bottled up. However, if
an immediate hot restart is anticipated, keep the boiler circulating pump in service
for more effective warm-up circulation.
CAUTION: The differential temperature between the feed water and
boiler metal must never exceed 200(111) (separator during initial
filling or separator and superheater outlet header during filling for
hydrostatic test).
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The operator should observe the separator level periodically so that he is always
aware of the actual level and can take the appropriate action to re-establish the
water level when the unit is being restarted.
When the boiler circulating pump is shut down, the water level will rise. As the unit
cools and the water shrinks, makeup water should be added intermittently to prevent
the water from dropping below normal level. Adding relatively cold feed water will
establish a reservoir of cooler water in the system. If a boiler circulating pump is
then 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 operating when makeup water is added.
WARM START-UP
Assuming that the unit has been down for a short period of time (less than app. 36
hours), the unit can be re-started in a similar sequence to Cold Start-up procedure as
outlined below:
Warm Start Conditions
1
2
Make a general inspection of the steam generator and check the points outlined in
the Preparations for Lighting Off for Cold Start-Ups.
2.
Verify that the boiler is filled with water and properly vented of air per the points
outlined for Cold Start-ups.
3.
Verify that the boiler water quality is within specified limits per the points outlined for
Cold Start ups.
4.
Start the Boiler Circulating Pump per the points outlined for Cold Start-ups.
5.
Observe the initial firing precautions and gas air heater protection per the procedure
for Cold Start-ups.
Lighting Off
1.
Start the gas air heaters. Refer to the gas air heater instructions for operating details.
2.
Start the first draft group: Start one ID fan, then the corresponding FD fan. Open the
outlet shut-off dampers. Adjust the ID fan for proper furnace draft, and set furnace
pressure control to automatic. Adjust unit airflow to minimum 35% TMCR air flow,
and place unit air flow control to automatic.
3.
Start the second draft group: After closing the outlet shut-off dampers, start the
other ID fan, then the corresponding FD fan. Open the shutoff dampers and adjust
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5.
Place the gas air pre heater temperature control (steam coil air pre heaters) to
automatic.
6.
Adjust the fan and wind box dampers to permit a purge airflow of at least 30% of
BMCR airflow and a furnace draft of approximately negative 12.0 mmwg. Refer to
Initial Firing Precautions.
7.
When the fans are started, the secondary air damper control should modulate the
auxiliary air dampers to maintain a programmed set point differential pressure
between the wind box and furnace.
8.
9.
10. Initiate a furnace purge. Upon completion of the purge cycle, check that all firing
prerequisites are satisfied, including the following:
a.
Feed water control is on automatic maintaining minimum feed water flow rate of
approximately 5% TMCR.
b.
c.
Separator level control is on automatic, i.e. the WR, and ZR level control valves
are all on automatic.
d.
e.
Unit air flow is on automatic maintaining minimum 35% TMCR air flow.
f.
1) Set to "valve position control" and desired preset position of app. 10 - 12% open.
2) HP bypass valve is set to be controlled along with the pressure rising of boiler.
3) Pressure and temperature controls for HP bypass valves with safety function, HP
bypass spray valves, and Spray water pressure reducing valves are on
automatic.
g.
1)
Open LP bypass stop valve after establishing sufficient condenser vacuum and
water supply for de-superheating.
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j.
11. Start two(2) PA fans per the points outlined for Cold start up.
12. For warm start-ups, the fuel startup sequence should follow this table:
Sequence
Step
1
2
3
4
5
6
7
Elevation
Notes
CD oil
AB oil
B coal
C coal
D coal
A coal
E coal
13. Initiate a light-off sequence of oil elevation CD warm-up oil guns by using HFO in
case of atomizing steam is available. Refer to the HEA igniter, WRTE Retractable oil
gun, and the Recommended Burner Management System instructions for details.
To minimize the possibility of adverse visible stack emission, it is desirable to use
the warm-up oil guns until 35 kg/cm(g) steam pressure is produced and 175
secondary air temperature before firing pulverized coal.
14. Set fuel oil flow control to auto and adjust the set-point to 1.5% of TMCR firing rate.
Stabilize the CD elevation for 15 minutes.
15. When elevation CD is in service, close the economizer vent valves.
16. To ensure stable operation of the water system and to ensure sufficient steam flow
through the superheater, firing rate should not be further increased until 8kg/cm(g)
is measured in the water separator.
17. Initiate an elevation start command for oil elevation AB. Stabilize the AB elevation.
The total oil firing rate will be kept for coal firing support.
18. As the pressure is raised, the WR and ZR valves will open when separator water
level increases due to boiler water swell. As pressure further increases, the WR and
ZR valves will start to close as the water level decreases.
19. During all start-ups, control the firing rate to keep the maximum furnace exit gas
temperature below 1000 (538 ), as measured by the furnace outlet gas
temperature probe(s) until approximately 10% steam generation or the turbine is
synchronized. Sufficient steam flow must be maintained at all times to assure
clearing the superheater and reheater elements of condensate. Do not close the
startup drains completely until steam flow through the HP/LP bypass is established.
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Confirm the steam conditions, i.e. pressure, temperature, and steam purity, at the
turbine are correct for turbine roll. (See turbine manufacturers Steam Purity
recommendations)
2.
Turbine roll, synchronization, and initial loading are all carried out using reheat
steam. Roll the turbine by opening the Reheat Stop and Control Valves to the IP
turbine per the Turbine manufacturers procedures. The HP turbine is maintained in
reverse flow using steam from CRH line. During this time, the total steam
production is passed through the HP bypass while it remains on "pressure control'
mode.
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SH and RH steam temperatures are maintained by adjusting firing rate and airflow.
4.
Synchronize the generator and put on initial load of app. 6.5% according to
turbine/generator startup instructions. Initial load is produced by IP/LP sections of
the turbine. The HP section is still in reverse-flow mode.
5.
As steam is transferred to the IP turbine during turbine loading, the LP bypass will
close while maintaining RH pressure at 13kg/cm(g).
6.
As turbine conditions permit, put feedwater heaters into service per manufacturers
instructions.
7.
8.
The firing rate should never exceed the rate necessary to match the total steam
generation.
9.
If the unit was started with one set of fans in service, start the second set of fans as
required. Refer to the fan manufacturer's instructions for operating details.
Introducing Coal
1.
Coal firing can commence when steam flow reaches app. 8%TMCR and HP bypass
and LP bypass should be regulated in order that the turbine can accept the
produced steam conditions.
2.
3.
When placing the first pulverizer in service, make sure the pulverizer start
permissives are satisfied. Refer to the Recommended Burner Management System
instructions. The coal fuel-air dampers should remain closed until ignition is
established. Make sure the nozzle tilts are horizontal. Both PA fans must be in
service.
If the unit start-up follows a master fuel trip, the pulverizer may not be empty.
Operate the pulverizer to clear it of excess coal before starting the feeder. During
the pulverizer clearing procedure, the pulverizer discharge gates of all other idle
pulverizers must be closed. This prevents hot furnace gases from entering the coal
piping and the idle pulverizers. (See EMERGENCY PROCEDURES) When most of
the coal has been removed from the pulverizer, the pulveriser can be introduced as
per normal procedure. Be sure the ignition energy in the furnace is established
before starting the pulverizer.
If ignition does not take place within five(5) seconds after coal appears at the coal
nozzles, stop the feeder. Determine the cause of ignition failure before attempting to
restart the feeder.
4.
Start the pulverizer. Open the hot air shutoff gate, adjust the hot air damper to 100%
pulverizer airflow, and bring the pulverizer up to the required operating temperature
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Maintain the proper coal/air temperature leaving the pulverizers. Regulate the hot
and cold air dampers to keep the temperature between 77 and 82 at the
pulverizer outlet. The pulverizer outlet mixed air temperature should be revised at
site during commissioning period based on coal characteristics which will be using.
6.
7.
Continue the transfer to forward-flow until the first three turbine valves are fully
opened and HP bypass valves are fully closed.
8.
9.
When the feeder rating of the first pulverizer has reached approximately 50%, place
the second pulverizer, which supplies the adjacent elevation of coal nozzles, in
service in a similar manner. When the second pulverizer is proven in service,
equalize the feeder rating of both. The warm-up oil guns must remain in service until
both feeders proven signal is achieved.
If the adjacent pulverizer is not available for service, place the pulverizer serving the
next closest elevation of coal nozzles in service. Do not remove the warm-up oil
guns from service until the two(2) adjacent coal elevations are in service with feeder
ratings greater than 50%.
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The third pulverizer can be started after steam flow reaches 35-40% TMCR. Place
additional pulverizers in service in a similar manner. Pre-warm the pulverizer and
Initiate an elevation start command. After the coal elevation is proven In service
(signal from BMS), the feeder is put on automatic.
2.
3.
After reaching 45% TMCR of steam load and firing is stable, oil elevation CD is
issued an elevation stop command by the operator.
4.
After oil elevation CD is stopped, ensure coal elevation C or D shows flame through
flame scanner indications.
5.
6.
Reduce oil firing to minimum after starting pulverizer A. Oil elevation AB is issued
an elevation stop command by the operator.
7.
After stable firing is established, put into service the second BFP(M) per the
manufacturer procedures.
NOTE: Before increasing the total firing rate above 35% TMCR, feed
water quality must be verified to be within the limits for normal firing as
defined in Appendix A.
8.
9.
During load increase, the BMS shall be given a signal to start the next available coal
elevation. After a coal elevation is proven in service (signal from BMS), the feeder is
put on automatic.
10. The steam temperature at the separator inlet will reach a stable superheated
condition at app. 35% TMCR, causing the level in the separator to decrease and
eventually disappear. The boiler is now in once-through mode. The BCP will be
stopped automatically.
11. When the BCP stops, the warm-keeping system of the start-up system should be put
into operation.
12. The boiler/turbine is now ready for automatic load dispatch. The control system shall
monitor unit loading and will start/stop firing equipment by the automatic load
program.
13. Place additional pulverizers in service as the unit load demand increases. The
pulverizer serving the lowest coal nozzle elevation not already in service should be
started, if available, when the feeders in service reach the 50% rating. As each
pulverizer is placed in service, the required ignition energy must be available. When
the unit firing conditions are stabilized, all warm-up oil guns may be taken out of
service. Refer to the Control Logic of Burner Management System for start-up
sequences and controls.
14. Place the steam temperature control and combustion control on automatic when
firing conditions are stable and the temperature and pressure control set points have
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HOT START-UP
Assuming the unit has been down for a comparatively short period of time (<8 hours)
and considerable steam pressure has been maintained, use the following procedures to
restart the unit:
Hot Start Conditions
1. SH outlet header metal temperature >= 300
and
2.Main steam pressure 30 kg/cm2(g) and < 120 kg/cm2(g)
Preparations, Lighting Off, and Load Increase
1.
Make a general inspection of the steam generator and check the points outlined in
the Preparations for Lighting Off for Cold Start Ups.
2.
3.
If the gas air heaters and fans were shut down at reduced temperature(see
NORMAL SHUTDOWN TO HOT STANDBY, step 4), start the gas air heaters and
fans as outlined under COLD START -UP, Lighting Off. If the unit was bottled up
hot with the gas air heaters still running start the fans in the normal sequence.
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 for the proper drain valve settings.
4.
Open wide all superheater drains to allow complete draining of superheater headers
and/or elements. After draining, close all drains the start-up drains (main steam line
vents and drains). Keep the start-up drains open. Reheater drains and vents are
open. Open the de-superheater isolating valves (de-superheater control valves
must be closed).
SH backpass drain valves are open after 5 minutes from light-up and close after 10
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6. For hot start-ups, the fuel startup sequence should follow this table:
Sequence
Elevation
Notes
Step
1
CD oil
Heavy Fuel Oil
2
AB oil
Heavy Fuel Oil
3
B coal
If coal elevation B not available, start coal elevation A
4
C coal
If coal elevation C not available, start coal elevation A
5
D coal
6
A coal
7
E coal
7.
Initiate a furnace purge and a normal light off sequence of the warm-up oil guns
following the sequence noted above.
8.
Set fuel oil flow control to auto and increase oil flow set point to 8% of TMCR firing
rate.
9.
10. Progressively increase firing rate to 15% TMCR at a rate of 1.5% per minute.
Stabilize the CD elevation for 5 minutes.
11. When steam pressure at HP bypass begins to increase, the HP bypass valve is
released to "pressure ramp" mode. The valves will then control the boiler pressure
ramp-up to 84 kg/cm(g).
12. As the HP bypass opens, the reheater will be pressurized as steam is passed
through the reheat vents and drains. Set the LP bypass station to minimum set-point
in auto mode. The LP bypass will open in response to increasing reheat pressure.
Close the reheat vents and drains to transfer flow and pressure control to the LP
bypass station.
13. Initiate an elevation start command for oil elevation AB and stabilize.
14. Progressively increase coal firing rate to 25% TMCR at a rate of 1% per minute.
15. Increase the firing rate, as prescribed, to raise the pressure and steam production.
The rate of pressure rise should follow the prescribed start-up curves.
16. When boiler pressure reaches 84 kg/cm(g), the HP bypass valve is released to
"pressure control" mode, and maintains a constant pressure during turbine rolling,
synchronization, and initial loading.
17. After a pressure of 84 kg/cm(g) is attained, the firing rate can be adjusted to
achieve the correct steam temperature for turbine rolling. Target steam conditions
are: 15%TMCR steam flow, SH = 450,RH = 460. In case actual produced steam
flow is over 6.5% BMCR and 6.5% BMCR steam flow is required at the turbine
synchronization, the surplus steam flow bypasses through HP bypass valve.
18. When steam is admitted to roll the turbine, there should be a minimum steam-to-
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Confirm the steam conditions, i.e. pressure, temperature, and steam purity (See
turbine manufacturers Steam Purity recommendations), at the turbine are correct
for turbine roll.
2.
Turbine roll, synchronization, and initial loading are all carried out using reheat
steam. Roll the turbine by opening the Combined Reheat Valves to the IP turbine
per the Turbine manufacturers procedures. The HP turbine is maintained in reverse
flow using steam from CRH line.
3.
SH and RH steam temperatures are maintained by adjusting firing rate and airflow.
4.
Synchronize the generator and put on initial load of app. 6.5% according to
turbine/generator startup instructions. Initial load is produced by IP/LP sections of
the turbine. The HP section is still in reverse-flow mode. During this time period,
boiler steam production is passed through the HP bypass.
During a hot start, the turbine metal temperature will normally require a rapid
reloading of the unit.
5.
As steam is transferred to the IP turbine, the LP bypass will close while maintaining
RH pressure at 13 kg/cm(g).
6.
As turbine conditions permit, put feed water heaters into service per manufacturers
instructions.
7.
8.
9.
Continue the transfer to forward-flow until the first three turbine valves are fully
opened and HP bypass valves are fully closed.
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Maintain the unit airflow at the pre-trip value for at least 5 minutes to purge the
system. If a hot restart is anticipated, the airflow may be gradually reduced to a lightoff airflow (35% of TMCR load airflow) during the purge. The boiler circulating
pumps should be started to maintain uniform temperatures throughout the boiler
circulation system and to facilitate lighting off. (Refer to Boiler Circulating Pump
manufacturer's Operating Procedures).
2.
Procedure after Master Fuel Trip when all ID and FD Fans are off:
The ID and FD fans discharge dampers shall be opened to allow natural ventilation
of the unit. Opening of fan(s) dampers shall be timed or controlled to avoid
excessive furnace pressure excursions during fan(s) coast-down. The fans
discharge dampers shall remain open for a period of at least 15 minutes.
During this 15-minute period, the ID and FD fans shall not be started.
At the end of the 15-minute period, the ID/FD fans may be started in accordance
with ID/FD fan(s) start-up procedures.
If the unit is not possible to restart for an extended time, a flow of air through the
unit shall be maintained.
3.
If oil guns were in service when the fuel trip occurred, make sure the individual
nozzle shutoff valves are closed. If an immediate restart is anticipated, the oil guns
will not require cleaning. Otherwise, the oil guns should be retracted, removed,
cleaned and then re-installed. Refer to the Recommended Burner Management
System instructions for emergency oil gun shutdown sequencing.
4.
If all auxiliaries are lost during a fuel trip, refer to the Boiler Circulating Pump
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If all auxiliary power sources were lost during a trip, start the fans and gas air
heaters when power is restored to purge the furnace for five(5) minutes. Observe
the hot restart precautions in the gas air heater instructions. The boiler circulating
pump, if available, should be placed in service during the purge. (See Boiler
Circulating Pump manufacturer's Operating Procedures for restarting procedures).
6.
If pulverizers are in service when the fuel trip occurs, successively clear all
pulverizers containing coal, as soon as possible in the following manner
a.
Close the pulverizer discharge gates on all other idle pulverizers containing coal.
This prevents hot furnace gases from being carried back into the pulverizers in
the event of a furnace pressure rise when a pulverizer is started.
b.
c.
(1) If the pulverizer will be retained in service, start the associated feeder when the
pulverizer amps begin to falloff .When the feeder is started, open the hot air
shutoff gate and bring the pulverizer up to normal operating temperature.
Following a pulverizer trip under load, the pulverizer should be operated with
cold air only until the associated feeder is started.
(2) If the pulverizer will not be retained in service, stop it after completely clearing
the coal. The pulverizer discharge gates should remain open to allow a flow of
cooling air through the empty pulverizer.
d.
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2.
Shut off all steam being discharged from the unit (trip turbine, steam driven
auxiliaries, and such).
3.
4.
5.
If the boiler circulating pump cannot be kept in service, do not admit feed water to
the unit.
6.
7.
8.
9.
Hydrostatically test the boiler at operating pressure before putting the unit back in
service.
Tube Failures
If any water or steam carrying tube fails, the best shutdown method will be dictated by
the size of the failure, the ability to maintain a normal water level and the demand for the
unit to remain in service.
The following instructions are general since most of the conditions will require the
judgment of the operators.
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2.
Switch the combustion control equipment to manual control and proceed to reduce
the firing rate and air flow in a normal manner.
3.
When all fires are extinguished continue the air flow through the unit at a reduced
rate to purge all combustible gases, vapors, etc. Shut down the fans when the unit is
cooled sufficiently.
4.
Feed water to the boiler by manual. To hasten cooling, boiler pressure can be
reduced by opening the superheater outlet drains.
5.
Allow the boiler to cool at least to 200 (93) (separator metal temperature);
before draining.
If there is a serious water loss and the water level cannot be maintained with the
feedwater supply available. use the following method:
1.
2.
3.
Maintain only enough airflow to carry the escaping steam up the stack.
4.
Leave the fans and gas air heaters in service until pressure is off the unit.
5.
Once the unit is cool enough to enter, inspect the pressure parts for damage caused
by the loss of water level. After the necessary repairs have been carried out, apply a
hydrostatic test and obtain the approval of the proper authorities before putting the
unit back in service.
ECONOMIZER TUBES
An economizer tube leak can be detected by sound and/or increased makeup water
requirements. Check the leak as soon as possible. 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 hoppers and gas air heaters. Any decision
to continue operation with known leaks should be made with this in mind. The unit
should be shut down in a normal manner.
SUPERHEATER AND REHEATER TUBES
A small leak in a superheater or reheater element should be checked as soon as
possible. Steam leaks in the superheater or reheater can cause considerable erosion
damage to adjacent tubes. Any decision to continue operation with known leaks should
be made with this in mind. The unit should be shut down in a normal manner .
A major superheater or reheater tube failure may require an emergency unit shutdown.
The operator must judge the degree of failure, its consequences, and then decide what
type of shut down is required.
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42973.56133.9304.42216_200811260047
Units
Conductivity at 25 measured
After cation-exchanger in H+ form and /
after Co2 removal
(2)
pH-VALUE(25)
(3)
Oxygen
(4)
ppb
Silica
(5)
ppb
Iron (susp. + dissolv.)
ppb
Copper (susp.+ dissolv)
ppb
Sodium
ppb
General requirements
Normal Operation
Alkaline
Combined
Water
Water
Treatment Treatment
Short Periods
Start-up
Procedures (1)
max. 0.2
max. 0.5
max. 1.0
min. 9.0
max. 100
max. 20
max. 20
max. 3
max. 10
clear and
colorless
8.0-8.5
30-150
max.20
max.20
max.3
max.10
clear and
colorless
min. 9.0
max.100
max.100
max.50
max.10
max.50
clear and
colorless
(1) Values specified in this column may be tolerated for max. 2 hours. However, they
must approach the limits for normal operation and should attain them within 6 hours
after ignition.
(2) If the contamination measured with the conductivity in the feed water are only soluble
salts such as sodium chlorides, sodium sulfates etc., they will concentrate in the
(circulating) water and dissolve in the steam in the evaporating area. They have a
corrosive effect only, if they can settle into the pores of deficient magnetite layers or
already existing corrosion pits formed e.g. through oxygen corrosion during shutdown.
The case is different when the contamination in the feed water consist of hardness
constituents (calcium and magnesium compounds) or free acids from cooling water
leakage. Therefore, observance of the conductivity limit value of 0.2 / is still no
guarantee for a proper feed water quality. Rather care should be taken that the
conductivity can be kept at the practically lowest possible level, and at each increase
of this value the reason for the conductivity increase should be sought.
(3) If copper materials are present in the water/steam circuit, the pH-value should be
kept within the limits of 9.1 0.2 in order to prevent undue copper corrosions.
(4) If Combined Water Treatment is practiced the specified oxygen level is controlled by
oxygen dosing into the condensate line between the condensate polishing
plant(CPP) and the low-pressure pre heaters.
(5) The max. allowable silica content should in any case not be higher than the limits
specified by the turbine manufacturer for the turbine steam.
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42973.56133.9304.42216_200811260047
42973.56133.9304.42216_200811260047
100
PURGE
AIRFLOW
90
80
70
60
50
40
30
20
10
0
0
LIGHTING
OFF
WARMING ON THE
UP
LINE
10
20
30
40
50
60
70
80
39
90
100
110