BOILER COOLING GUIDELINE for KTPS U #1,2,3 &4 (AS PER FAX MASSAGE FROM K.

ADITYA, Manager (R&D), Alstom Projects India Ltd.dated 14.11.2008)

OFF Bar with lower operating pressure, keeping turbine inlet parameters always within permissible limits. This process of lowering load should be slow, say around 20 to 30 minutes. During this process drum to be flushed with feed water, keeping water upto max. Visible range. Boiler Drum water level to be made up to very high, but visible level after Turbine Trip. This minimizes temperature differential. Open the Wind Box door with both FD Fans in isolated condition. Keep the bottom three row air registers full open. Penthouse doors to be opened optionally if ash accumulation is not very high. This is to ensure faster drum cooling. AIR FLOW CONTROL (a) One ID Fan will run with minimum vane opening. (b) Another ID Fan vane damper to be made shut. (c) One FD Fan vane, Bypass Damper to be kept open till Boiler & Wind Box door opening only. Second FD Fan vane & dampers to be made shut. (d) After opening Boiler & Wind Box doors, the FD Fan vane & dampers to be made shut. So only one ID Fan will run with minimum vane opening. Close monitoring is Needed over Drum metal temperature if the TOP-BOT temp. Diff. exceeds 600C. ID Fan vane opening to be lowered if the temperature diff. exceeds 700C then stop the fan & natural draft to be maintained. Temperature limits mentioned above is indicated on the assumption that Turbine is OFF Bar at 100 Kg/ sq. cm, keeping Turbine inlet parameters in healthy condition. For pressure below than that temperature regime is slightly lenient. After Turbine tripping, Superheater outlet valve to be closed. Keep circulating drain valve crack open. circulating drain valve further opening to be continued (say 1 turn after half an hour) till full open, keeping in mind that pressure falls gradually and maintains the Drum temperature under limit. Start up vent also to be opened 10% and then closed for every hour intervals. This process allows to maintain differential temperatures at check.

FORCED BLOW DOWN At 6-8 Kg/sq. cm Boiler outlet pressure, forced blow down to be carried out. All ring header valves, Economiser drain valve along with Master drain valve to be opened. No Superheater drain to be opened at this stage. Boiler to be vented at 2-2.5 Kg/cm2. Boiler draining start time to be noted. Just after the draining starts, Boiler must be on Natural cooling. After 1.5 hour or suitable time draining of Boiler draining to ensure no water available in Boiler Drum, ID Fan to be started again with minimum vane opening and monitor the Drum metal Top- Bottom temperature diff. If the diff. is less than 600C then increase vane opening very slightly. Maintain furnace Draught Max. upto -20 to -30 mm of wcl, if possible. No ESP Pass isolation to be carried out during boiler cooling process. One special log sheet to be maintained to monitor temperatures with time. This sheet will further indicate the final tuning process. The above process is indicative only & may vary from plant to plant but basic drum differential temperature criteria should be strictly followed.

BOILER COOLING GUIDELINE for KTPS U #1,2,3 & 4(ALSTOM) (Boiler Drum Thickness-82 mm)
OFF Bar with lower operating pressure, keeping turbine inlet parameters always within permissible limits. This process of lowering load should be slow, say around 20 to 30 minutes. During this process drum to be flushed with feed water, keeping water upto max. Visible range. Boiler Drum water level to be made up to very high, but visible level, after Turbine Trip. This minimizes temperature differential. Open the Wind Box door with both FD Fans in isolated condition. Keep the bottom three row air registers full open. Penthouse doors to be opened optionally if ash accumulation is not very high. This is to ensure faster drum cooling. AIR FLOW CONTROL (After machine desynchronisation): (a) One ID Fan will run keeping suction & discharge damper full open condition with a draught of -20 mm to -30 mm of wcl. (b) Another ID Fan suction & discharge damper to be made shut. (c) One FD Fan vane, Bypass Damper to be kept open till Boiler & Wind Box door opening only. Second FD Fan vane & dampers to be made shut. (d) After opening Boiler & Wind Box doors, the FD Fan vane & dampers(of both FD Fan) to be made shut. So only one ID Fan will run keeping suction & discharge damper full open condition with a draught of -20 mm to -30 mm of wcl. Close monitoring is needed over Drum metal temperature if the TOP-BOT temp. Diff. exceeds 600C, then ID Fan scoop position is to be lowered. If the temperature diff. exceeds 700C, then stop the ID fan & natural draft is to be maintained. Temperature limits mentioned above is indicated on the assumption that Turbine is OFF Bar at 100 Kg/ sq. cm, keeping Turbine inlet parameters in healthy condition. For pressure below than that temperature regime is slightly lenient. After Turbine tripping, Superheater outlet valve to be closed. Keep circulating drain valve crack open. Circulating drain valve further opening to be continued (say 1 turn per half an hour) till full open, keeping in mind that pressure falls gradually and maintains the Drum temperature under limit. Start up vent also to be opened 10% and then closed for every half an hour intervals. This process allows to maintain differential temperatures at check.

FORCED BLOW DOWN At 6-8 Kg/sq. cm Boiler outlet pressure, forced blow down to be carried out. All ring header valves, Economiser drain valve along with Master drain valve to be opened. No Superheater drain to be opened at this stage. Boiler to be vented at 2-2.5 Kg/cm 2 & all Superheater drains to be opened. Boiler draining start time to be noted. Just after the draining starts, Boiler must be on Natural cooling i.e. ID Fan to be stopped and suction & discharge dampers of ID Fan are to be kept open. After 1.5 hour or suitable time draining of Boiler draining to ensure no water available in Boiler Drum, ID Fan to be started again and monitor the Drum metal Top- Bottom temperature diff. If the diff. is less than 600C then increase scoop position very slightly. Maintain furnace Draught Max. upto -20 to -30 mm of wcl, if possible. One special log sheet to be maintained to monitor temperatures with time. This sheet will further indicate the final tuning process. The above process is indicative only but basic drum differential temperature criteria should be strictly followed.

Water filling for Boiler Hydro-test

Water filling may be started when the maximum drum metal temp. comes below 1200 C by CTP.