Recommendation for the design of the boiler-turbine unit for faster load rejection specifically in the Captive Power

Plant
Abhisheik Malhotra AMIMechE, Deputy Manager - Mechanical at Lahmeyer International India Pvt. Ltd A!!iliate Member - Energy Institute, "# $e are presently %orking on the design engineering o! coal !ired captive po%er plant comprising o! t%o &'( units o! )** M$e capacity %ith sub-critical technology and provided %ith natural circulation, single reheat, vertical, t%o pass design, pulveri+ed coal !ired and balanced dra!t type boiler along %ith the emission control system vi+. "rea based ,-. &,elective -atalytic .eduction(, E,P &Electrostatic Precipitator( and Limestone base $/0D &$et /lue 0as Desulphuri+ation( ,ystem. /urther as the plant shall be constructed and installed in the smelting plant, -lient has speci!ied that the po%er plant shall be suitably designed to take care o! the smelter load re1ections, the !re2uency o! %hich has been mentioned as !ollo%s3 *-4 M$ 5 '* times6hour 4-)4 M$ 5 4 times6hour )4-'* M$ 5 )6hour and '*-'4 M$ 5 *.)6hour. -lient has e7plicitly stated that the load re1ections up to '* M$ shall have to be carried out %ithout operating the steam turbine bypass system and the resulting increase in the steam pressure in the boiler and piping net%ork must no result in the li!ting o! the pressure sa!ety valves. In vie% o! the above mentioned, %e believe such an operation mode o! the po%er plant, shall result in the over designing o! the boiler pressure parts so as to absorb the e7cess pressure transients and thermal stresses during the load re1ections up to '* M$ &%ith no steam turbine bypass operation and also considering comparatively, the slo% response o! the boiler !uel and combustion system during the load re1ection operation(. .e2uest the group member8s e7pert opinion on the sub1ect design and operation issue. Do share your e7perience i! you have come across such an operation scenario and design re2uirements considered in tackling the issue. I mysel! have %orked in the captive po%er plant operation department, but every time there %as a load re1ection, %e used to operate steam turbine bypass, and only in case o! prolonged load re1ection, boiler !uel and combustion system %ere being put into operation. /urther, also provide your opinion 6 advice %hether sliding operation shall be bene!icial !or this plant as it may result in reducing the e7cess pressure surges during the transient condition as compared to the constant pressure operation and also %hether once through evaporator design %ill be bene!icial !or this plant considering !aster load re1ection re2uirements.