By

Path Finder
Group – 2 & Group – 3
G.Rawat & P.K.Saha
 Drum metal temperature - 350 °C (At full load)
Required temperature – 100 °C

i.e. 250 °C to be reduced @ 1.8 °C/min

Time required to reduce 250 °C – 2 hrs 18 min.
But in actual it will take more time.
400

350

300

250

200

150
Temp
100

50

0
0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25
Time
 Technical Aspects:
 Plant / Unit forced outage hours will be more.
 PLF / PAF will be reduced.

 Financial Aspects:
0.25 MU/hr @ Rs: 6/Unit Loss.
250000 Units/hr x Rs: 6 = Rs: 1500000/hr
a) Before De-synchronisation
 Unit load reduced by cutting out top mills first.
 HP Heaters taken out as early as possible.
 Deaerator extraction closed when load is reduced below 80
MW, subsequently reducing temperature of water in
Deaerator.
 Maintain MS temperature & pressure as low as design criteria.
 Unit De-synchronised with least possible drum pressure.
b) After De-synchronisation
 Drum level is maintained by filling water frequently and
monitoring ∆T of Drum metal temperature.
 Increase the air flow by monitoring the decreasing rate of
Drum metal temperature @ 1.8°C /min.
16
14
12 10
10
8
6 2009-10
4
2 2008-09
0 2008-09
Boiler 2009-10
Cooling
Time
 After performing the above steps during shut
down of a unit, we have reduced the Boiler
Cooling Time from 16 hrs to 10 hrs.
 We have gained both Technical and Financial
Aspect,

a) Technical Aspect:
 Plant / Unit forced outage hours have
reduced.
 PLF / PAF have increased.
b) Financial Aspect:
0.25 MU/hr @ Rs: 6/Unit Loss.
250000 Units/hr x Rs: 6 = Rs: 1500000/hr
Then for 6 hrs (Boiler cooling time reduced from 16
hrs to 10 hrs) = Rs: 90,00,000
For every Boiler Leakage, we have saved
Rs: 90,00,000.
Total reduction of cooling time till date = 15 x 6
= 90 Hrs.
Cost savings for the F.Y. 09-10 = 9000000 x 15 =
Rs.13,50,00,000
 For optimum cooling/light up operation we
request C&I Dept. to provide Cooling / Rising
rate, Top Bottom Drum metal temp. diff. (∆T),
so that we can achieve a benchmark time for
cooling & light up.
 During hot summer cooling rate became very
slow down due to high ambient temp. To
facilitate the job external water washing by
BMD was advised by Operation Dept. below
100°C.
 Before identification of Boiler tube leak, furnace
cooling is required. If BMD allows us to drain
the boiler (at permissible condition), boiler
cooling can be achieved earlier.
THANK YOU