Stage - 3 Steam Generator Operating Procedure

STEAM GENERATOR OPERATING PROCEDURES
NTPC Ltd /FarakkaSTPP STAGE-III -1 x 500 MW
TABLE OF CONTENTS
Page No.
INTRODUCTION 2
UNIT DESCRIPTION 2
PRE-OPERATIONAL PROCEDURES 2
• Clean-up
• Chemical Cleaning
• Lines Blowing Steam
• Setting Safety Valves
COLD START-UP 3
• Preparation for Lighting off
• Initial Firing Precautions
• Lighting off Coal Firing
NORMAL OPERATION - UNIT LOAD CHANGES - COAL FIRING 11
NORMAL SHUTDOWN TO COLD 12
NORMAL SHUTDOWN TO HOT STANDBY 15
HOT RESTART 16
EMERGENCY PROCEDURES 17
• Reheater Protection upon Loss of Load
• Master Fuel Trip
• Low Water Level
• High Water Level
• Tube Failures
• Ash Handling System
Bharat Heavy Electricals Limited Page No. 1

INTRODUCTION
The procedures outlined in this section are intended to serve as a guide line during initial stages
of operation. The procedures include precautions which should be observed and the proper
operating sequences of the unit, the fuel firing equipment and auxiliaries. Sequential
procedures do not include detailed reference to equipment such as feed pumps, condensate
pumps, turbine etc.
Because the unit is only one part of the over all power station and since all equipment must
operate in unison, specific procedures and detailed values cannot be included in this manual. As
operating experience is gained and controls are fine tuned by the units characteristics actual
operating requirements will become evident to the operator.
Reference should be made to the vendors instructions for further operating details.
Reference should be made to the manufacturer’s instructions regarding operational and

pre-operational procedures for their equipment.
UNIT DESCRIPTION
The unit is a Controlled Circulation Plus Radiant Reheat (Type CC+ RR) boiler. Firing equipment
consists of five elevations of remotely controllable high energy arc ignitors, five elevations of air
cooled, non retractable steam atomising oil guns and ten elevations of pulverized coal nozzles.
The ten elevations of pulverized coal nozzles are supplied with coal from ten number type XRP
1003 bowl mills. Complete descriptions of the equipment provided can be found elsewhere in this
manual.
Control equipment provided consists of a furnace safeguard supervisory system, scanner air
control system and a secondary air control system.
Major auxiliary equipment provided consists of pulverizers, feeders, fans and miscellaneous
valves.
Three number boiler circulating pumps are provided to ensure proper circulation of water in the
furnace wall circuits.
Coal is used as load carrying fuel for which start up procedure is given below.
PREOPERATIONAL PROCEDURES
Clean-up
Before initial firing and prior to each subsequent cold start-up, after maintenance has been done
on the unit, the furnace should be inspected and cleaned both internally and externally. All foreign
materials should be removed from the pressure parts. Any grating, pipe lines, electric conduit etc.
that might restrict normal expansion of the unit should be cleared. All personnel should be
cleared and access doors closed. A complete check list should be prepared by the Operating
Department.

Chemical Cleaning
Specific procedures for boiling out and acid cleaning are included elsewhere in this manual.
Firing and Circulating pump operating procedures are outlined under Cold Startup. Lighting off
should be used as a guide when operating the fuel burning equipment.
Blowing Steam Lines
Prior to starting up a new unit or after major pressure parts repairs on an older unit, the main
steam lines and the reheater steam lines should be blown out to remove scale and foreign matter
thereby preventing damage to the turbine. This should be done after acid cleaning and prior to
setting drum and superheater safety valves. Consideration should be given to set the reheater
safety valves before removing the temporary blow out piping.
Refer to “Steam Line Blowing Procedures” elsewhere in this manual for recommended operating
procedures and precautions.
Setting Safety Valves
Setting of the safety valves on the drum and superheater should be done prior to turbine rolling.
Refer to the safety valve manufacturer’s instructions for setting procedures. A conservative firing
rate should be maintained, limiting the furnace exit gas temperature to a maximum of 540 Deg.C.
If the reheater safety valves were not set during the steam line blowing procedure, they may be
set while the turbine is carrying a light load, by closing down the intercept valves until a reheat
steam pressure is reached high enough to lift the reheater safety valves. (Consult the turbine
manufacturer’s instructions for allowable procedures). Popping pressure and blowdowns should
be adjusted to conform design values.
COLD START-UP
Preparation for Lighting-off
It is assumed that at this time the following preparatory work has been completed:
1. The steam generator has been chemically cleaned, that the steam lines have been blown,
that the safety valves have been set and that the unit has been filled to slightly above the
normal operating level with properly treated feed water.
2. All control systems have been checked and are available for service.
Note
Check all safety interlock systems prior to start up to ensure proper functioning. Exercise
the systems by creating the actual interlock actuating conditions. Simulate the activating
conditions if the actual conditions 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 assure proper functioning. Recheck items
such as:
• Oil guns inserted and properly coupled. (Check gaskets between unions).
• All oil gun and ignitor quick disconnect coupling properly assembled.
• All fuel manual valves open.
• All fuel control valves closed.
5. The pulverisers and feeders have been checked and are available for service. Refer mill
starting sequence under mill operating procedure.
6. The wind boxes have been checked for proper damper positioning, tilts at horizontal etc.
7. The feed water system, instrumentation and equipment has been checked out and is
available for operation. It is recommended that during startups the feed water be controlled
remote-manually, until a continuous flow is established. To avoid the possibility of oxygen
corrosion in the boiler, the use of undeaerated feed water (temperature less than 100
Deg.C) is not recommended. Refer to water treatment instruction elsewhere in this manual.
8. The boiler circulating pumps have been checked; pump instrumentation is available for
service. It is imperative that the pump differential pressure switches are in service and that
the proper trip settings have been made.
9. All air handling equipment has been checked out and is available for service. All air and gas
duct dampers should be in the start up position. (Refer to Note & Caution below):
− ID Fan outlet shut off gates open. Inlet control dampers closed
− FD Fan outlet shut off dampers closed and inlet blade pitch in the minimum position.
− Primary air fan outlet shut off gates and inlet blade pitch closed
− Airheater gas inlet and outlet, secondary air inlet and outlet and primary air inlet and
outlet dampers should be open.
− Overfire air dampers closed
− Windbox (secondary) auxiliary air dampers open or modulating
− Scanner emergency air damper closed
− Pulveriser seal air fan shut off dampers open.

Note
It is assumed that the unit will be started with two I.D. Fans and F.D. Fans, both set of
airpreheaters and both primary air fans in service. If the unit is started with only 1 ID, 1 FD
and 1 PA fans and one set of airheater in service, the above damper positions apply to the
equipment to be started. Dampers associated with idle equipment should be closed.
Caution
The I.D. Fans are capable of developing drafts in excess of the furnace design pressure.
Therefore, the operator must take care to establish and maintain an air flow path through
the unit, prior to starting the I.D. Fan and prior to opening the I.D. Fan inlet control dampers
by ensuring that other dampers in the system are in the start up positions indicated above.
I.D. Fan inlet control damper must be kept closed until after the fan is started. This procedure
will minimize the possibility of developing excessive negative pressure in the unit during
the starting procedure.
The operator must take care to maintain the furnace draft within safe limit at all times. He must
be especially careful when draft and air flow controls are in the “Manual” mode. He must be
alert at all times for possible malfunctions of automatic control equipment resulting in
abnormal excursions in furnace pressure either negative or positive.
As the unit has been designed with low flue gas velocity, the following operational practices
should be followed to avoid ash settlement.
− Operate the unit with all passes of ESP at higher loads
− If the Unit load is less than 60% operate the unit with A&D or B&C passes of Electrostatic
Precipitator.
10. Check that the Airheaters has been prepared for service, that an adequate means of
extinguishing airheater fires is available and ready for use. APH fire detection system
should be commissioned and in service. Refer to Airpreheater instructions for details.
11. The soot blowing equipment has been checked for proper operation and the systems is in
the start up conditions. (All blowers retracted, main steam supply valve available for
remote/automated opening).
12. All desuperheater spray water control valves are commissioned and in closed position.
13. All boiler, superheater and reheater drain and vent valves are in the start up position.

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 superheater & reheater elements and
headers before the turbine is rolled. Refer to the turbine manufacturer’s instructions.
14. The furnace gas temperature probe is in working order and available for service.
15. The turbine-generator is available for service and has been prepared for service as
described in the manufacturer’s instructions.
Initial Firing Precautions
To ensure a maximum safety margin during start-ups, it is mandatory that atleast 30% of full load
air flow be maintained in order to produce the following conditions:
1. An air-rich furnace atmosphere. This precludes the possibility of an accumulation of
explosive mixture in the event of poor or delayed ignition after fuel is introduced to the
furnace.
2. High excess air through the airheater. This minimizes the dilution of combustion air by inert,
carried over by the airheater from gas side to air side of the APH on account of the rotation
of the APH rotor.
Air flow should be increased when the boiler reaches a load where additional air is required to
maintain the design operating excess air. Refer to “Air Regulation” in the section “Tilting
Tangential Firing System”.
During cold startups, lighting off is done with the light oil guns in lower elevation. Warming up can
be accomplished with the warm up oil guns. The required firing rate must permit operation of an
entire elevation of fuel nozzles with out exceeding the furnace exit gas temperature limitation as
described in the following paragraph.
Note
To minimize the possibility of adverse visible stack emission it is desirable to use the ignitors and
warm up oil guns to atleast 35 kg/cm2 (g) drum pressure and 175 Deg.C secondary air
temperature before firing pulverised coal or heavy oil.
During all start-ups the firing rate should be controlled to keep the maximum furnace exit gas
temperature below 540 Deg.C (as measured by the furnace outlet gas temperature probe) until
the HP-LP bypass is cut in. After rolling the turbine, the steam temperature and pressure rise at
the turbine throttle should be within the limits prescribed in the Manuals.

It is recommended that during initial start of a new unit relatively slow rate of pressure increase
be followed, in order to allow sufficient time for checking expansion movements and to permit the
operators to become familiar with the characteristics of the unit and its auxiliaries. Once these
characteristics have been established, subsequent startups may be made at the fastest possible
rate, consistent with maintaining the furnace exit gas temperature limitation of 540 Deg.C until the
HP/LP Bypass is cut in.
Lighting off - Coal Firing
1. Start two boiler circulating pumps in accordance with pump operating instructions.
Note
It may be preferable to start only two pumps in order to minimize flashing in the
downcomers (and the consequent piping vibration) when the boiler water is in the range of
95 to 125 Deg.C. The third pump should be started before the boiler drum pressure
reaches7 kg/cm2 to minimize pump starting temperature transients and may be shutdown
and kept as standby, if desired, once the Drum pressure reaches 40 kg/cm2 (g).
The pump starting recommendations anticipate a normal rate of boiler water temperature
rise of about 220 Deg.C per hour (i.e. 55 Deg.C in 15 minutes). Quick boiler start can
create temperature changes approaching 83 Deg.C in 15 minutes. Pumps should not be
started during intervals of rapid boiler water temperature change.
2. Start both sets of air heaters. (Refer to Air preheater instructions “Placing Airheaters in
service” ).
3. Start scanner air fan.
4. Start two I.D. Fans (see “caution” under item 9. “Preparation for Lighting off”)
5. Start two P.A. Fans (See Note)
Note
Air flow must be maintained through the pulveriser whenever the unit is being fired.
Therefore P.A fans must be in service. Open the P.A fans outlet shut off gate of the
selected fan. Bring the primary hot air duct pressure up to the set point by "Manually"
opening the P.A fan blade pitch control. Then transfer to "Auto" control. When the
pulverisers are out of service, their discharge valves must be fully open and the cold air inlet
control dampers must be open to a minimum position. The discharge valves are closed for
pulveriser maintenance or when the pulverizers are idle, full of coal and other pulverisers
are being started after a unit trip.
6. Start two FD Fans
7. Start the steam airheaters.

8. Adjust the fan and windbox dampers to permit a purge air flow of atleast 30% of total air
flow and a furnace draft of approximately 12.5 mm w.g. Refer to "Initial Firing Precautions".
9. When the fans are started, the secondary air damper control (on "AUTO") should modulate
the auxiliary air dampers to maintain a programmed set point differential between the
windbox and furnace. Check that all other purge permissive are satisfied.
10. Initiate a furnace purge. Upon completion of the purge cycle, check that all firing
prerequisites are satisfied.
11. Place the gas temperature probe in service.
12. Initiate a light off sequence of the lower elevation of warm up oil guns. Refer to the
“Furnace safeguard supervisory system”. “Ignitor” and “Air cooled oil gun” instruction for
details.
13. During the warming period the economiser recirculating line valves are open. Blow down
the unit as required to maintain the water level in sight in the gauge glass.
14. The firing rate should be controlled to keep the furnace exit gas temperature below 540
Deg.C until the HPLP bypass is cut in. When the drum pressure increases, position the
superheater and reheater drains and vents and drum vents in accordance with step 21.
15. Increase the firing rate as required to raise pressure. Take care not to exceed the furnace
exit gas temperature limit to 540 Deg.C until HP LP bypass is cut in. When ready to fire
coal, the pulveriser serving a lower elevation of coal nozzles should be prepared for
operation and started in accordance with steps 24 through 27. Adjacent warm up oil guns
supply the required ignition energy. The feeder rating should be controlled to keep the
furnace exit gas temperature not to exceed 540 deg.C until the HP LP bypass is cut in.
16. While the unit is heating up frequent checks should be made of the boiler expansion
movements. Special attention should be given to expansion of the lower part of the boiler
(furnace inlet drums, pump suction manifold etc.) relative to building steel. Expansion
movements should be recorded for comparison with future start-ups. Refer to the
expansion movement diagrams in the “Pressure Parts” Section of the Manual.
17. Maintain drum water level at normal and check boiler water concentrations and
constituents as frequently as required to maintain proper boiler water conditions.
18. When continuous feed water flow is established, the economiser recirculating line valves
may be closed.
19. Before raising a vacuum in the condenser make sure that all reheater vents or drains that
are open to atmosphere are closed. Leave drains or vents connected to the condenser
open until as recommended in the Turbine Manual.

20. Two boiler circulating pumps must be in operation at all loads to avoid the possibility of a
Master Fuel trip in the event of the loss of one of two pumps. If the third pump is to be
brought into service ,it shall be ensured that the pump is not started during a rapid boiler
temperature change (increasing or decreasing).
Note
Refer to the “Boiler circulating pump operating procedures” for operating recommendations when
a pump is out of service for maintenance.
21. As drum pressure increases, progressively throttle the superheater/ main steam line vent
(start up vent) and other start-up vents and drains used Sufficient steam flow must be
maintained at all times to assure clearing the superheater elements of condensate.
Increase the firing rate as necessary, without exceeding the furnace exit gas temperature
limitation. Do not close start-up vent completely until steam flow through the turbine/HPLP
by pass is established.
22. Start rolling the turbine as soon as the minimum permissible start up pressure and
temperature, specified by the turbine manufacturer are reached. Refer to turbine
manufacturer’s instructions.
23. When the turbine is upto speed, it may be synchronized. At this point (or when the HP-LP
bypass is cut in) the gas temperature probe may be withdrawn and the firing rate increased
as required. In no case should the firing rate exceed that which is necessary to satisfy
steam demand.
Note
If the unit is put on the line before design operating pressure is reached further increase of
firing rate should be in accordance with a gradual rate of pressure increase consistent with
increasing load. Do not allow steam temperature to exceed the values shown in startup
curves.
Caution
Operators should be alert to detect the symptoms of water carryover from the boiler and
introduction of water in the turbine such as:
a) A sudden unexplained drop in steam temperature in either the main steam or hot
reheat line.
b) Vibration in the steam piping resulting from water hammer.
c) Abnormal vibration and differential expansion readings from the turbine supervisory
instrumentation.

Operators must be prepared to take actions necessary to prevent turbine damage upon
detection of water introduction. Refer to turbine manufacturer’s instruction for specific
actions to be taken.
24. if the unit was started with one set of fans, then start the second set fans.
25. Place additional level of oil guns in service as the load demands; replace the warm up oil
guns with load carrying guns after the first level of main oil guns are in service and fire is
stable.
26. If coal was not fired previously (See Note) the pulverizer serving the lowest elevation. of
coal nozzles (adjacent to the warm up oil guns) should be prepared for operation so it can
readily be started at this time.
Note
If a pulverizer was started during the warming up period, increasing load requirements can
be met by increasing the feeder speed. When pulverizer is put into service ensure that the
seal air fan is also in service.
27. When placing the first pulveriser in service, check that the pulveriser start permissives
(ignition energy, etc.) are satisfied. Refer to the Furnace Safeguard Supervisory System
instructions. The coal fuel-air dampers should remain closed until ignition is established.
Refer to “Air flow control and distribution in the section “Tangential firing system”. Check to
see that the nozzle tilts are horizontal. Place a second Primary Air Fan in service, if not
done previously.
28. Start the pulveriser (See Note). Open the hot air shut off gate and bring the pulveriser upto
the required operation temperature without coal. Place pulveriser air flow and temperature
control on Auto. When ready to fire coal, start the feeder at minimum rating (Manual
control). Ignition of the pulverised coal should take place immediately. When the
pulveriser is proven in service, the fuel air dampers should open automatically. Maintain
the fuel feed at a minimum consistent with stable ignition. Watch the fires. If the ignition
does not take place within 5 seconds after coal appears to the coal nozzles, stop the
feeder. Determine the cause of the ignition failure before attempting to restart the feeder.
29. Maintain proper coal/ air temperature leaving the pulverizers . Regulate the hot and cold air
dampers to hold between 66 Deg.C and 90 Deg.C at the pulveriser outlet. At no time
should this temperature exceed 95 Deg.C . If it should exceed 95 Deg.C the hot air gate
must be closed. When the temperature falls below 66 deg c , the cold air gate can be closed
to improve the temp.
Note
Pulverizer start-up will cause a sudden and sharp increase of steam pressure. This will
level out rapidly as load is placed on the turbine.
30. Place the pulveriser serving the next closest elevation in service and do not remove oil
guns from service until two adjacent coal elevations are in service with corresponding mill
loading more than 50% (approx. 39 t/hr.) and unit load not less than 40% MCR.

31. The Furnace Safeguard supervisory System and Secondary Air Damper Controls should
close the auxiliary air dampers serving compartments adjacent to coal nozzles which are
out of service when the boiler reaches 30% of full load and increases the windbox to
furnace differential pressure as per set point graph provided.
32. It is essential that the air flow to the furnace is sufficient for the firing rate at all times.
Automatic control equipment is normally arranged to maintain such a balanced condition.
The Oxygen measuring devices which are often tied in with the air flow control should be
checked periodically to assure continuous and dependable operation.
33. Place additional pulverizers in service as the unit load demands. The pulveriser serving the
lowest available coal elevation not already in service should be started when the mill in
service reaches approximately 80% load (approx. 62 t/hr.). As each pulveriser is placed in
service the required associated ignition energy must be available. When the unit firing
conditions are stabilised all oil guns may be taken out of service. (Refer to the Furnace
Safeguard Supervisory System instructions).
34. Place the Steam Temperature Controls and Combustion Controls on ‘Auto’ , when firing
conditions are stable and the temperature and pressure control set points have been
reached.
35. Adjust the feed water supply to the boiler as necessary to maintain normal water level.
Feed water control should be placed on automatic as soon as possible and practicable after
continuous feedwater flow is established.
36. Overfire air should not be utilized (for NOx control) below 50% load. The effective starting
load must be determined during initial SG operation.
NORMAL OPERATION - UNIT LOAD CHANGES (Coal firing)
During normal operation, with the unit on the line changes in pulveriser loading and/ or the
number of pulverisers in service may be required to accommodate unit load changes. A wide
range of load control can be achieved with the pulverisers on automatic control.
Note
Refer to “Furnace Safeguard Supervisory System” instructions regarding pulveriser start and
stop sequences, ignition energy requirements etc.
Decreasing Load
If the unit load (with `n’ mills in service) decreases to a point wherein the load can be met by n-1
mills, then, one mill should be taken out of service. Ensure stabilisation fuel support at the
appropriate oil gun elevation serving the remaining coal elevation while cutting out mills,
especially at lower loads.

Additional pulverizer can be taken out of service in a similar manner.

Every effort should be made to keep adjacent mill in service. If, due to maintenance a pulverizer is
not available, skipping the coal elevation served by that pulveriser is permissible. Skipping of two
coal elevations is not recommended and is only permissible with the use of auxiliary supporting
fuel oil or when each of the separated groups are having adjacent coal elevation/mills in service.
If the unit load is reduced to a point where only one mill is/two mills are required, auxiliary
supporting fuel adjacent to the coal nozzle in service must be placed in service to assure stable
ignition .
Removing of oil guns from service can be done only when
i) Two adjacent coal elevations are in serivice with mill loading more than 50% (approx.39t/hr.)
and
ii) Unit load is not less than 40% MCR.
Note
Auxiliary supporting fuel should be used at any time and under any conditions in which, in the
operators’ judgement in stabilisation of ignition is necessary.
Increasing Load
Should the unit load increase, additional pulveriser should be placed in service as follows:
1. Establish the energy required for the coal elevation served by the selected pulverizer.
2. Start the pulveriser
3. Start the feeder corresponding to the pulveriser to be put into service at minimum rating.
4. Auxiliary supporting fuel (warm up oil guns) may be taken out of service when furnace
conditions have stabilized and atleast two adjacent pulverisers are in service with feeder
speed more than 50% (approx. 39 t/hr.) and the unit load more than 40% MCR.
5. Place additional pulverizers in service in the same manner, as required by load increase
demand or when the pulverisers have been loaded to about 90-95% of their capacity and at
the same time load increase is anticipated.
NORMAL SHUT DOWN TO COLD
The following procedures for normal shutdown are based on the assumption that the unit is
operating at full load on automatic control and that it is the intention to reduce the pressure to zero
and cool the boiler completely.
1. Gradually reduce load on the unit; reduce the firing rate in line with the decreasing steam
flow. Allow the pressure to drop with the reduction in load to accelerate cooling. Reduce the
steam temperature at the rate prescribed by the turbine manufacturer. Steam temperature
control, combustion control and feedwater control may be left on automatic until the point is
reached where better control can be obtained on manual.

Caution
Care must be exercised to prevent water from entering the main steam line(s), the hot
reheat line(s) and the cold reheat line(s) to the turbine from any source during and after the
shutdown process. This is to prevent possible water damage to the turbine during a
subsequent restart.
Possible sources of water are:

a) Overflow from the drum into the superheater as a result of high water level
b) Water entering the superheater or reheater through the desuperheaters due to open
desuperheater control valves or possible valve leakage with the feed pumps running.
2. When the feeder speed on all working mills is reduced to an extent wherein the load can be
carried with one mill/coal elevations less, then place the pulverizer supplying the upper coal
elevation on manual control. Required ignition energy must be provided while the mill is
taken out of service. Gradually reduce the feeder output when minimum rating is reached,
close the hot air damper. Stop the feeder when the mill loading reaches 70% (approx. 54
t/hr.). After five minutes, stop the pulveriser.
3. As pulverizers are taken out of service, the Secondary air damper control system should
close the associated windbox dampers and throttle other dampers as required to
compensate for the reduction in firing rate.
4. Continue taking additional pulverizers at consecutive lower elevation(s) out of service in the
same manner.
Removing of oil guns from service can be done only when
i) Two adjacent coal elevations are in service with mill loading more than 50% (approx.
39 t/hr.) and
ii) Unit load is not less than 40% MCR.
Note
It is recommended that the above consecutive elevation shut down sequence be followed.
Firing coal at separated coal nozzle elevations without auxiliary supporting fuel is not
permitted.
5. Discontinue admission of overfire air when the unit load has dropped below the
predetermined effective starting load. Keep the overfire air dampers slightly cracked open
to prevent the nozzles from overheating.
6. Operate all soot blowers. Refer to manufacturer’s instructions
7. Reduce the air flow in line with fuel reduction until 30% of maximum air flow is reached. Do
not reduce the air flow below this rating until all fires are out and the unit is off the line. To
avoid firing instability during this period of high relative air flow, the auxiliary air dampers at
all elevations should open and reduce the windbox to furnace differential pressure to its
lower setting.

8. Check the expansion movement of the unit as load is being reduced.

9. After the last pulveriser has been shut down, remove the warm up oil guns from service.
Shut off the cooling water to the pulverizers. All fires should be removed when the unit is off
the line.
10. Immediately after closing the turbine stop valves, open wide the superheater outlet
vents/drains and all reheater vents/drains. Open vents/drains in the superheater system as
required for further pressure reduction. Open steam line and turbine drains as described by
the turbine manufacturer.
11. Open the economiser recirculating line valve. Close desuperheater isolating valves.
12. If during the shut down period it will not be necessary to enter the unit, a slow rate of
pressure and temperature decay may be desirable. This can be accomplished as follows:
a) Purge the unit by running the induced draft and forced draft fans, for atleast five minutes
(at 30% air flow) after the fires are extinguished.
b) Reduce the air flow through the unit to a minimum. Keep the fans, and airheaters in
service till the unit has cooled to the desired temperature.
c) Keep one boiler circulating pump in service until the boiler water temperature is
reduced to the desired point. Keep the water level near normal in the gauge glass, add
make up as required.
Note
Airheaters and fans should not be taken out of service until the airheater gas inlet
temperature has dropped to below 200oC.
13. If it is desirable to accelerate the cooling process in order to permit entry into the unit for
maintenance, proceed as follows:
a) Purge the unit by running the induced draft and forced draft for atleast five minutes (at
a minimum of 30% air flow) after the fires are extinguished.
b) Continue running the fans to cool the unit at the desired rate. The air heaters may be
shut down when the gas entering temperature has dropped below 200oC. (Refer to
Airpreheater Instructions).
Note
With the airheaters stopped and the fans running, deposits of fly ash may accumulate in the
airheater resulting unbalance of the rotors.
c) Keep one boiler circulating pump in service to increase recirculation. Maintain the
water level near normal in the gauge. Shut down the pump when the boiler water
temperature is reduced to the desired level.
14. Open the drum vents when the unit pressure has been reduced to 2 kg/cm2(g).

15. If the boiler is laid up wet, refer to "Lay-up Procedures".
16. If the boiler will be emptied, the boiler water temperature should be reduced to atleast 95oC
before draining.
NORMAL SHUT DOWN TO HOT STANDBY
It is assumed that the boiler will be shut down for a relatively short period of time and existing
pressure and temperature conditions will be substantially maintained. A procedure similar to that
for normal shut down should be followed except:
Do not reduce drum pressure in line with unit load reduction. The rate of pressure drop should be
much smaller than the rate followed during normal shutdown. When the desired pressure at
which the boiler to be held is reached after the turbine is off the line the boiler may be bottled up
by closing all superheater drains and vents. Reheater drains and vents are kept open.
Caution
Care must be exercised to prevent water from entering the main steam lines the hot reheat lines
and the cold reheat lines, to the turbine from any source during and after the shut down process.
This is to prevent possible water damage to the turbine during a subsequent restart. Possible
soures of water are:
a) Overflow from the drum into the superheater as a result of high water level
b) Water entering the superheater or reheater through the desuperheaters due to the open
desuperheater control valves or possible valve leakage with the feed pumps running.
Note 1
If it is expected that the unit will be restarted in a very short period of time, in which the turbine
metal temperatures will not decrease appreciably, it may be desirable to cool the turbine metal to
below 425 Deg.C by reducing steam temperature and pressure, while the unit load is being
reduced. This will reduce the steam turbine metal differential temperature upon restart.
Note 2
1. If the unit load is reduced rapidly utilizing sliding pressure it is possible for the case of an
idle pump to remain at a higher temperature than the boiler water ; opening the pump
bypass valves will provide a moderate rate of cooling of the pump case. A pump should not
be started if the pump casing temperature exceeds the down comer temperature by more
than 55 Deg.C. If load and pressure will subsequently be increased it is preferable to delay
the starting of the pump until the downcomer temperature has increased to within 28 Deg.C
of the pump casing temperature to minimize the effects of temperature transients.

2. One boiler circulating pump should be kept in operation to ensure adequate boiler water
circulation which will prevent possible local overheating due to hot slag deposits.
3. It is recommended that after all fires are extinguished, the ID and FD fans and airheaters be
kept running until the airheater gas inlet temperature has dropped to below 200 Deg.C.
Close all gas duct, secondary air duct and windbox dampers after the airheaters and fans
are shut down.
4. All boiler circulating pumps may be shut down after the unit has been bottled up. However,
if a hot restart is anticipated atleast one pump should remain in service to provide more
effective warm up circulation for the idle pumps. The idle pumps may be placed on "hot
standby", that is discharge valves open. Refer to the Pump operating procedure to
complete pump standby requirements.
5. When all circulating pumps are shut down the drum water level will rise possibly out of sight
in the gauge glass. As the unit cools and the water shrinks, make up should be added
intermittently to prevent the water from dropping out of sight in the gauge glass. Adding the
relatively cold feedwater will establish a reservoir of cooler water in the drum(s) and
downcomers. If a pump is subsequently 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. Atleast one pump should be in operation during the period of make up addition.
Note
The operator should observe the gauge glass periodically so that he is always aware of the
actual drum level and can take the appropriate action to re-establish water level when the
unit is being restarted.
HOT RESTART
Assuming the boiler has been down for a comparatively short period of time and considerable
drum pressure was maintained, the following procedures should be used in restarting the unit.
1. Make a general inspection of the boiler and check the points as mentioned under normal
start up.
2. One boiler circulating pump should still be in service.
3. If the airheaters and fans were shut down at reduced temperature (See Step 4, Normal shut
down to Hot standby), start the airheaters and fans as outlined under "Cold Startup-lighting
off". If the unit was bottled up hot, with the air heaters still running, start the fans in the
normal sequence.
4. Operate superheater / reheater drains and vents as per the Valve Operating Instruction.

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 Turbine manufacturer's
instructions.
5. Initiate a furnace purge and normal light off sequence of the ignitors and warm up oil guns.
6. Close all reheater vents before pulling a vacuum in the condenser. Reheater condensate
drains may be closed soon after HPLP bypass has been cut into operation. (Refer valve
operating instructions).
7. When steam is admitted to the turbine for rolling it is desirable to have a minimum steam/
turbine metal temperature differential. This can be achieved by firing at a maximum rate
within the furnace exit gas temperature limitation of 540 Deg.C until HPLP bypass is cut in.
In order to not exceed the exit gas temperature limit, it may be desirable to put more oil
guns to start a pulveriser at this time. Stabilise the firing conditions to maintain the
maximum furnace exit gas temperature without exceeding it.
8. Proceed as during normal start up from cold, items 20 through 34.
During a hot restart, the turbine metal temperature will normally require a rapid reloading of the
unit.
EMERGENCY PROCEDURES
Reheater Protection upon loss of load
Stoppage of steam flow through the reheater when the entering gas temperature is above 540
Deg.C can result in overheating and damage to the reheater tubing. To prevent this condition,
the following measures must be taken.
A. Turbine Valve Closure
If a loss of load should cause the turbine valves to close, all fuel should be tripped
automatically either immediately or after a maximum time delay of ten seconds.
Upon a Master Fuel Trip resulting from turbine control valve closure, an immediate re-start
is feasible in most instances, as the turbine is still rolling and will be available to take steam
as soon as the governor has the turbine speed under control (See Note). If immediate
turbine restart is not possible and the turbine is tripped, the reheater to condenser drains
should be opened, as under “B” below:

Note
Refer to turbine manufacturer’s instructions for no-load operating procedures and limitations.
B. Turbine Trip
If a loss of load occurs in which the turbine is tripped, all fuel should be automatically and
instantaneously tripped.
The reheater safety valves will protect against over pressure in the reheater. The reheater
condensate drains should be opened to evacuate the steam in the reheater.
C. Post Trip Procedures
Immediately following a Fuel Trip, the furnace must be purged. Any pulveriser containing
coal must be emptied as soon as possible. See Master Fuel Trip, below:
To permit firing during start-up, prior to opening the turbine valves, the initiating fuel circuits
must be disarmed. They must be rearmed at a suitable point in the startup sequence, such
as when synchronising the turbine.
D. Turbine Protection Upon Loss of Load
Extreme care must be taken following a trip of the turbine and boiler to prevent water from
being introduced into the turbine upon unit restart. Water may be collected in the main
steam lines and cold reheat lines by condensation. Water may be introduced into the
superheater due to overflow from the steam drum (inadvertent high water level). Water may
be introduced into the superheater and/reheater through the desuperheaters due to open or
leaking spray water control valves. Refer to the turbine manufacturer’s instructions.
Caution
Operators should be alert to detect the symptoms of water carryover from the boiler and
introduction of water into the turbine, such as:
a) A sudden unexplained drop in the steam temperature in either the main steam or hot
reheat lines.
b) Vibration in the steam piping resulting from water hammer.
c) Abnormal vibration and differential expansion reading from the turbine supervisory
instrumentation.
Operators must be prepared to take the actions necessary to prevent turbine damage upon
detection of water introduction. Refer to the turbine manufacturer’s instructions for specific
actions to be taken.

MASTER FUEL TRIP
Under conditions requiring a master fuel trip through normal interlocks or operators action
(manual trip), all fuel should be tripped instantaneously. If coal was being fired the pulverisers
should be tripped immediately. Tripping the pulverisers will automatically trip the feeders and the
hot air shut off gate . (Refer to emergency shut down procedures in section bowl Mill). If oil was
being fired the trip valves and individual nozzle shut off valves should be closed immediately.
The following steps should be taken immediately following emergency fuel trip:
1. Maintain the unit air flow at pre-trip value for atleast 5 minutes to purge the system. If a hot
restart is anticipated the air flow may be gradually reduced to light-off air flow (30% of full load
air flow) during five minutes purge. Atleast two boiler circulating pumps should remain in
service to maintain uniform temperatures throughout the boiler circulation system and to
facilitate lighting off. In no case should all he pumps be stopped (refer to the pump Operating
Procedures).
2. If oil guns were in service when the fuel trip occurred, check to insure that all individual nozzle
shut off vales are closed. Oil guns should be retracted. (See Note 1) removed, cleaned (See
Note 2) and reinstalled, to be ready for a restart of the unit.
Note
Refer to the Furnace Safeguard Supervisory System instructions for emergency oil gun shut
down sequencing.
If immediate restart of the unit is anticipated, oil guns do not require cleaning.
3. If during a fuel trip all auxiliaries are lost refer to the “Boiler Circulating Pump Operating
Procedures” for handling of the low pressure cooling water. Flow must be maintained.
4. If all auxiliary power sources are lost during a trip upon restoration of power, start the fans,
start airheaters (observe hot restart precautions in the air preheater instructions) and purge
the furnace for five minutes. If available, atleast one boiler circulating pump should be placed
in service during the purge period. (See pump operating instructions for restarting
procedures). For emergency tripping of mills, refer instructions for Bowl Mills.
LOW WATER LEVEL
If the water level falls out of sight in the water gauge, due to failure of the feed water supply or
neglect of the operator, except in the case of momentary fluctuations that might occur with
extraordinary changes in load, appropriate action should be taken at once to trip the fuel. Any
decision to continue to operate, even if only for a short time at a reduced rating, would have to be
made by some one in authority who is thoroughly familiar with the circumstances that led to the
emergency and positively certain that the water level can be restored immediately without
damaging the boiler. In the absence of such a decision.

1. Trip all fuel immediately.

2. Shut off all steam being discharged from the unit (trip turbine, steam driven auxiliaries
etc.).
3. Leave the boiler circulating pumps in service as long as they are operating normally and
do not loose suction due to the low water level.
4. If feed water has become available and the boiler circulating pumps are still running,
gradually reestablish the level in the drum.
5. If no boiler circulating pumps can be maintained in service, do not admit feed water to the
unit.
6. Maintain a high air flow at first to hasten the cooling process.
7. If pressure parts damage is suspected, reduce the steam pressure gradually by opening
the superheater start up drains/vents. Open the drum vents when the pressure drops
below 2 kg/cm2(g). As the boiler cools, reduce the air flow. Shut down the fans as soon
as the unit is cool enough for a man to enter. Drain the boiler when the drum metal
temperature is 95 Deg.C following normal draining procedures. Determine the cause of
low water and examine the boiler for the effects of possible overheating such as leaks and
distortion of pressure parts.
8. Repair any leaks, etc.
9. Hydrostatically test the boiler at working pressure before putting the unit back in service.
HIGH WATER LEVEL
Abnormally high water level should be avoided as it may lead to carry over and even priming. If
the water level rises above the recommended normal operating range proceed as follows:
1. Reduce the water level immediately by opening the emergency blow down valves.
2. Reduce the steaming rate, if necessary and place feed water control on manual.
If priming should occur, as indicated by rapid fluctuations in outlet steam temperature, proceed as
follows:
1. Reduce the steaming rate.
2. If the water level is abnormally high, reduce the level by opening the intermittent blow
down valves and place feed water control on manual.
3. Investigate the water condition (alkalinity and solids)
4. Investigate the condition of the drum internals as soon as an opportunity is afforded.

TUBE FAILURES
Water Wall Tubes
In the event of failure of one or more water carrying tubes, in a controlled circulation boiler, the
best method for shutting down the unit will be dictated by the size of the failure, the ability to
maintain normal water level and the demands for the service of the unit.
The following instructions regarding tube failures are of a general nature. It must be understood
that conditions may arise which will require exercise of judgment by the operators.
In case of a leak or tube failure which does not involve a serious drain in the feed water supply,
the water level should be maintained and the unit taken out of service in the normal manner.
Refer to normal Shut-down Procedures.
If the tube failure results in a loss of water so great that the water level cannot be maintained with
the feed water supply available, use the method outlined below:
1. Trip all fuel.

2. Shut down the last boiler circulating pump just before the water level goes out of sight
after the fuel is tripped.
3. Shut off feed water to the boiler.
4. Maintain only enough air flow to carry the escaping steam up the stack.
5. Leave fans in service until pressure is off the unit.
6. After the unit has cooled enough to permit a man to enter, make a thorough inspection of
pressure parts for any indication of damage resulting from loss of water level. After the
necessary repairs have been made, apply a hydrostatic test and obtain the approval of
the proper authorities before putting the unit back in service.
Economiser Tubes
An economizer tube leak can be detected by sound and/or increased make up water
requirements. The leak should be investigated at the earliest possible time and the unit shut
down in a normal manner. Water leaks in the economiser can cause considerable erosion
damage to adjacent tubes. Water carried over from an economiser tube leak may cause plugging
of hopper and airheaters. Any decision to continue operation with known leaks should be made
with this in mind.

Superheater and Reheater Tubes
A small leak in a superheater or reheater element should be investigated at the earliest possible
time, and the unit should be shutdown in a normal manner. Steam leaks in the superheater or
reheater can cause considerable erosion damage to adjacent tubes. Any decision to continue
with known leaks should be made with this in mind.
A major superheater or reheater tube failure may require an emergency unit shutdown . The
operator must use his judgment to assess the seriousness of the failure and its consequences
and then decide what type of shut-down is required.
Ash Handling System
The ash handling system shall be properly maintained by operating personnel so as to

periodically evacuate the ash in Economiser, Airheater and ESP Hoppers. This is to avoid ash
build-up and consequent duct failures as Indian coals contain higher percentage of ash.
Sufficient care must be exercised to evacuate the Economiser hopper ash periodically. This will
reduce considerably the wear rate of AH elements/ seals and load of ESP due to less ash carry
over.

Stage - 3 Steam Generator Operating Procedure

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Stage - 3 Steam Generator Operating Procedure

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STEAM GENERATOR OPERATING PROCEDURES

NTPC Ltd /FarakkaSTPP STAGE-III -1 x 500 MW

Bharat Heavy Electricals Limited Page No. 1

Reference should be made to the manufacturer’s instructions regarding operational and

Bharat Heavy Electricals Limited Page No. 2

Blowing Steam Lines

Setting Safety Valves

Preparation for Lighting-off

Bharat Heavy Electricals Limited Page No. 3

− Overfire air dampers closed

− Windbox (secondary) auxiliary air dampers open or modulating

− Scanner emergency air damper closed

− Pulveriser seal air fan shut off dampers open.

Bharat Heavy Electricals Limited Page No. 4

− Operate the unit with all passes of ESP at higher loads

Bharat Heavy Electricals Limited Page No. 5

Initial Firing Precautions

Bharat Heavy Electricals Limited Page No. 6

Lighting off - Coal Firing

3. Start scanner air fan.

6. Start two FD Fans

7. Start the steam airheaters.

Bharat Heavy Electricals Limited Page No. 7

Bharat Heavy Electricals Limited Page No. 8

Bharat Heavy Electricals Limited Page No. 9

Bharat Heavy Electricals Limited Page No. 10

NORMAL OPERATION - UNIT LOAD CHANGES (Coal firing)

Bharat Heavy Electricals Limited Page No. 11

Additional pulverizer can be taken out of service in a similar manner.

NORMAL SHUT DOWN TO COLD

Bharat Heavy Electricals Limited Page No. 12

Possible sources of water are:

Bharat Heavy Electricals Limited Page No. 13

8. Check the expansion movement of the unit as load is being reduced.

Bharat Heavy Electricals Limited Page No. 14

15. If the boiler is laid up wet, refer to "Lay-up Procedures".

NORMAL SHUT DOWN TO HOT STANDBY

Bharat Heavy Electricals Limited Page No. 15

Bharat Heavy Electricals Limited Page No. 16

8. Proceed as during normal start up from cold, items 20 through 34.

Reheater Protection upon loss of load

A. Turbine Valve Closure

Bharat Heavy Electricals Limited Page No. 17

C. Post Trip Procedures

D. Turbine Protection Upon Loss of Load

b) Vibration in the steam piping resulting from water hammer.

Bharat Heavy Electricals Limited Page No. 18

MASTER FUEL TRIP

LOW WATER LEVEL

Bharat Heavy Electricals Limited Page No. 19

1. Trip all fuel immediately.

HIGH WATER LEVEL

3. Investigate the water condition (alkalinity and solids)

4. Investigate the condition of the drum internals as soon as an opportunity is afforded.

Bharat Heavy Electricals Limited Page No. 20

Water Wall Tubes

1. Trip all fuel.

Bharat Heavy Electricals Limited Page No. 21

Superheater and Reheater Tubes

Ash Handling System

The ash handling system shall be properly maintained by operating personnel so as to

Bharat Heavy Electricals Limited Page No. 22

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