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UNIT SHUT

DOWN
PROCEDURE

January 20, 2015

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Presentation outline
Planned Shut Down procedure
APH Washing
Hydrogen purging
ATT

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UNIT SHUT DOWN


Planned shutdown- For overhauling
Emergency shut down- Boiler tube leakage, major
problems in Turbine, Generator etc, Transmission
constraints.
Reserve shut down Low demand

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Planned shutdown
Preparation for shut down.
Mobilization of resources for overhauling- Manpower ,
Spares, consumables
Identification all Jobs to be carried out.
Carry out performance testing and identify performance
gaps, parameter deviations and action plan for rectification.
Necessary clearance from RLDC/bulk customers .

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Activities
All coal bunkers should be preferably made empty before
long shut down. Stop/ regulate coal feeding to bunkers
accordingly.
Charging of auxiliary steam from other unit.
Ensure availability of all oil guns.
Take trial run of all emergency equipments like Dc Scanner
air fan, DC EOP,DC SOP, DG set etc.

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Reduce coal firing in mills and bring down the unit


load to 160 MW
Gradually reduce boiler steam parameters (steam
pressure and temp.) for force cooling. Rate of
reduction to be controlled as per the permissible
limits. Ensure that the TSE margins are OK.
Carryout boiler soot blowing and APH soot blowing.

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Set turbine load gradient at 5 MW/min.


Bypass turbine steam temp. low protection.
Check HP/LP Bypass operation.
Charge D/A pegging steam from CRH.
Cut out the top mill .Make the bunker/feeder belt
empty before stopping the mill.

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Cut out HP heaters 5&6


Reduce unit load to 120MW after taking oil support
in AB elevation.
Cut out one more mill and reduce unit load to 80
MW.
Ensure that turbine gland sealing steam temp.
>250o C and change over from leak steam control
to seal steam controller.

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Change over unit bus power supply from


UATs to station Bus .
Monitor and record all turbine supervisory
parameters like turbine bearing and shaft
vibrations, Diff expansion of HPT, IPT &
LPT ,Axial shift , Over all expansion Turbine
brg temp. at different loads.
Monitor boiler drum Top/Bottom differential
temp. while reducing pressure and load.

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One set of ID ,FD, PA fans and one BFP can be


stopped.
Cut out one more mill and reduce load to 50 MW.
Reduce load to 30MW. Open HP bypass to
maintain boiler pressure.
Cutout LP heaters.
Ensure change over of drum level control from high
range to low range.

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Trip the turbine through trip push button on desk


and open the HP/LP bypass.
Control boiler drum level.
Ensure the following after turbine trip.
Generator circuit breaker opened
Generator Field breaker opened.
Turbine AOP has taken start at 2850 RPM and Lub.
Oil pressure is normal.
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Turbine ESVs and IVs closed.


HP ,IP control v/vs closed
CRH NRV and all extraction valves and NRVs
closed
Monitor turbine speed, bearing vibrations, brg
temp. and turbine supervisory measurements
during coasting down.
Monitor hotwell level, D/A level,Cond vacuum.

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ENSURE opening of the following drains:


HP casing drain.
Drain after CRH NRV's
Drain before/after IV's. NRV's.
Drain before extraction NRV's
Seal steam header drain.
Drain before ESV's.

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Stop the last mill after ensuring the feeder is


empty.
Stop the PA fans and trip the boiler. (Boiler can be
tripped by checking any of the boiler protections.)
Ensure the closure of HOTV,LOTV
Close HP/LP bypass and close boiler stop valves

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Purge the boiler for 5 minutes and scavenge all the


oil guns which were in service
Isolate HFO ,LDO stations and all oil guns
Isolate SH/RH spray stations.
Fill boiler drum level upto max. level.
Stop ID /FD fans if boiler force cooling is not
required (During boiler cooling ensure that boiler
TOP Bottom differential is <50oc

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Ensure that scanner air fan emergency damper has opened


after stopping both FD fans.
Switch of all ESP fields and rapping system.
Ensure speed ref. zero
Ensure turbine has come on barring

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MOT level is normal and duplex filter not choked.


Open generator bkr isolators on 220 KV side.
Depressurize MS, HRH steam lines .open MS
,HRH strainer drains to IBD tank
Stop condenser vacuum pump and kill vacuum.
Open vac. Bkr at 200 mm of Hg condenser vacuum

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Isolate seal steam supply to turbine glands and


stop GSE.
Isolate generator Hydrogen coolers Stator water
and seal oil coolers.
Stop one CW pump.
Monitor LP turbine exhaust hood temp. and stop
CEP after 4 hours
CW system can be stopped after 4 hours from unit
shut down
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Stop BFP after drum top up requirement is


completed.
Isolate auxiliary steam header.
Isolate power supply to all HT drives and ESP.
Generator hydrogen can be purged after the turbine
coming to barring gear.
At 2ksc drum pressure open boiler drum vents, SH
vents and SH hdr drains

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Drain the boiler when the boiler water temp. is


below 90oC.
Stop APH and scanner air when flue gas temp.
below 100oC.
Isolate all steam supply to Deaerator and drain
Deaerator after opening the vents.
Monitor turbine expansions and casing temp.
during cooling down.

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Turbine barring gear can be stopped at HP


shaft/casing temp. less than 130 oC.
TG oil system can be stopped at turbine casing
temp. of 95oC after ensuring that hydrogen is
purged out from generator.
Seal oil system can be stopped after hydrogen
purging and stopping of barring.

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APH WASHING.
Purpose- for cleaning of baskets of air heater
High pressure water jet is used
Washing to be carried out when the air heater is in
hot condition (Temp.about 200oC).immediately after
boiler shut down
Open the duct drains of SA and PA ducts

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Start the APH water washing pumps


Open the water washing lines of the air heater .
Keep the air heater rotating.
Continue the washing till the PH of inlet and outlet
water is same.
Run the ID /FD fans to dry out the baskets

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Hydrogen Purging.
Ensure that the generator is tripped condition
Reduce the Hydrogen pressure to 0.5 KSC by opening the
purge valve.
Connect CO2 cylinders to the filling manifold.
Start filling CO2 through the CO2filling valve
Crack open the purge valve to maintain the casing pr. At 0.5
ksc
Continue filling CO2 till purity of 95% is achieved.

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Purge out CO2 by opening the air filling valve and


purge out valve.
Continue air filling till CO2 concentration is Nil.
Disconnect the air connection after purging.

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SHUT DOWN TO HOTSTAND BY


When the unit is to be shut down for short duration
the boiler can be kept in Hot stand by.
Shut down due to grid restriction
Shut down due to problems in electrical systems,
Generator , GT, UAT ,Turbine etc (problems which
requires short duration to attend )

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Boiler pressure and temp. are maintained substantially to


facilitate quick start up.
Turbine metal temp. can be brought down to reduce start up
time during re rolling.
Shut down procedure is similar to normal shut down except
reduction in pressure and temp.
Reduce the load to 120 - 140MW at rated steam parameters

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Subsequent load reduction along with pressure and


temp. drops should be decided by the turbine
limitations
Trip the boiler when the desired parameters
reached.
After tripping the boiler to be boxed up.
Close boiler stop valves

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Close all boiler drains and vents (CBD, IBD, EBD)


Stop ID/FD fans after boiler purging.
Close all dampers and gates in flue gas path.
APH can be stopped after the flue gas at APH inlet
is below 200oC

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SWITCHYARD OPERATION
Co-ordination with RLDC for unit synchronization,
line charging etc.
Line up of electrical systems
Ensuring healthiness of switchyard equipments like
transformers, breakers, isolators, CTs etc.

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SHUT DOWN OF TRANSMISSION


LINE

Obtain written message code for shut down of the feeder


from RLDC.
Intimate the other end station before opening the breaker.
Open the main bkr.
Ensure that the sequential isolator opened on auto
Open the remaining isolators (Bus and line isolators) of the
bay

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Give message to the other end about opening of


the isolators and confirm that the line is isolated at
their end.
See the line voltmeter and ensure that the voltage
has become zero
Ensure the earthing at both ends

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Charging of transmission
line

Ensure the PTW has been returned and inspect the


bay physically
Ensure that no Discharge rod/earthing connected
on that bay
Give message to the RLDC and other end station
and obtain clearance for charging the line.
Ensure opening of both end earthing

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After getting written confirmation from other end


close all isolators of the line and check their
alignment.
Synchronize the feeder through the main Bkr and
then close the tie bkr.
Check the line power flow .

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THANK YOU

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