RAICHUR THERMAL POWER STATION

UNIT SHUT DOWN

PROCEDURES

By
SHAIKH FEROZ ALI
BE(Mech),MBA(Finance), BOE, CEM.
Assistant Executive Engineer
BEE Certified Energy Manager
 UNIT SHUT DOWNS

 Short Shut Down

 Long Shut Down or

Annual Shut Down

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 SHORT SHUT DOWN

 Coal Bunkers not to be

Emptied

 Boiler to be Boxed Up

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 LONG SHUT DOWN

AT UNIT LOAD 210 MW

 Ensure APRDS is availbale from neighbouring Units

 Take trial run of All Oil Elevations
 Plan for Emptying all Coal Bunkers
 Sequence of Bunker Emptying to be in the order of F, A,
E, B,D and C

Shut Down Procedures Shaikh Feroz Ali 4

 LONG SHUT DOWN

AT UNIT LOAD 210 MW

 Carry out Wall Blowing
 Carry out APH Soot Blowing
 Cut out top most mill ( E or F)-1/5,4 mills remain in
service
 Reduce Unit Load to 180 MW
 Load Reduction Rate 3 – 5 MW per Minute
 MS Temperature drop rate 83o C per hour
Shut Down Procedures Shaikh Feroz Ali 5
 LONG SHUT DOWN

AT UNIT LOAD 180 MW

 Establish Oil Support

 Cut out bottom most mill (A)-2/5, 3 mills remain in
service
 Reduce Unit Load to 150 MW

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 LONG SHUT DOWN

AT UNIT LOAD 150 MW

 Cut out HP Heaters

 Cut out another mill (D or C)-3/5, 2 mills remain in
service
 Take out Dearator pegging from Extraction-4
 Reduce the Unit Load to 100 MW

Shut Down Procedures Shaikh Feroz Ali 7

 LONG SHUT DOWN

AT UNIT LOAD 100 MW

 Cut out another mill (B)-2/5, 1 mill remain in service

 Take out Dearator pegging from Extraction-4
 Reduce the Unit Load to 50 MW
 Observe Condensor Vacuum
 Monitor TSE Margins

Shut Down Procedures Shaikh Feroz Ali 8

 LONG SHUT DOWN

AT UNIT LOAD 50 MW
 Cut out LP Heaters
 Stop Second Set of ID, FD and PA Fans
 Stop one BFP
 Stop one CWP
 Cut in Second CVP

Shut Down Procedures Shaikh Feroz Ali 9

 LONG SHUT DOWN

AT UNIT LOAD 50 MW

 Observe Condensor Vacuum

 Monitor TSE Margins
 Reduce Unit load to 30 MW
 Change Over Unit supply from Unit Bus (UATs) to
Station Bus (ST)

Shut Down Procedures Shaikh Feroz Ali 10

 LONG SHUT DOWN

AT UNIT LOAD 50 MW

Maintain
 Air Flow > 30%
 PA Header Pressur > 450 mmWCL
 Furnace Draft -10 mmWCL
 Drum Level, Dearator Level and Hot Well Level

Shut Down Procedures Shaikh Feroz Ali 11

 LONG SHUT DOWN

AT UNIT LOAD 30 MW

 Cut Out Last Remaining Mill

 Cut Out Remaining PA Fan
 Isolate ESP ECs
 Only Oil Elevation is in Service
 Reduce Unit Load to 20 MW

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 LONG SHUT DOWN

AT UNIT LOAD 20 MW

 Trip the Generator, Open GCB and Ensure MW

Indication is Zero
 Trip the Turbine and Ensure Trip Oil is Zero
 Trip the Boiler and Close MS Stop Valves

Shut Down Procedures Shaikh Feroz Ali 13

P
O
S POST TRIP ACTIVITIES
T

T  Close MS Stop Valves

R
I
 Close HP and LP Bypass Valves
P  Close Hydrogen Cooler Valves
A
 Reduce Stator Water Flow to 13 m3 per
C hour
T  Maintain Condensor Vacuum
I
V
 Open MS, HRH and CRH drains to Flash
I Tanks
T  Cloose SH and RH Spray Isolation and
I Block Valves
E
S Shut Down Procedures Shaikh Feroz Ali 14
P
O
S POST TRIP ACTIVITIES
T

T Ensure
R  AOP cut in at 2850 RPM
I
P  JOP cut in at 510 RPM
 Gate Valve Gearing cut in at 210 RPM
A
C  Adequate CST Level
T  Adequate Hot Well Level
I
V
 Adequate Dearator Level
I  Adequate CST Level
T
I
E
S Shut Down Procedures Shaikh Feroz Ali 15
P
O
S
T POST TRIP ACTIVITIES
T
R FOR SHORT SHUT DOWN
I
P
 Maintain Condensor Vacuum
A  Ensure Boiler Hot Box Up
C  Stop ID and FD Fans
T
I  Close all Gates and Dampers
V  Ensure TG is on Barring Gear
I
T
I
E
S Shut Down Procedures Shaikh Feroz Ali 16
P
O
S POST TRIP ACTIVITIES
T
FOR LONG SHUT DOWN
T
R  Stop ID and FD Fans
I
P
 Open all Gates and Dampers
 Kill Condensor Vacuum
A
 Stop Gland Steam Exhaust Fan
C
T  Stop CEP
I  Stop HWMP
V
I  Stop CVP
T  Open MS, CRH and HRH drains to IBD
I
E
S Shut Down Procedures Shaikh Feroz Ali 17
P
O
S POST TRIP ACTIVITIES
T
FOR LONG SHUT DOWN
T
R
I
P AT DRUM PRESURE 10 KSC

A
C  Fill the Boiler above normal Drum Level
T  Isolate FCV and Stop BFP
I
V
I
T
I
E
S Shut Down Procedures Shaikh Feroz Ali 18
P
O
S POST TRIP ACTIVITIES
T
FOR LONG SHUT DOWN
T
R
I AT DRUM PRESURE 5 KSC
P

A  Open SH and RH Start Up Vents

C
T  Start Hydrogen Purging in Generator
I Casing
V
I
T
I
E
S Shut Down Procedures Shaikh Feroz Ali 19
P
O
S POST TRIP ACTIVITIES
T
FOR LONG SHUT DOWN
T
R AT DRUM PRESURE 2 KSC
I
P

A
 Open Drum and Economiser Air Vents
C  Bottom Ash to be cleared
T
I
V
I
T
I
E
S Shut Down Procedures Shaikh Feroz Ali 20
P
O POST TRIP ACTIVITIES
S
T
FOR LONG SHUT DOWN
T
R
AT HPT SHAFT/CASING TEMP <120oC
I
P

A
 Switch off Gate Valve Gearing
C  Stop AOPs and JOPs
T  Stop Seal oil System
I
V  Stop Oil Vapour Extraction Fan
I
T
I
E
S Shut Down Procedures Shaikh Feroz Ali 21
 Title

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Shut Down Procedures Shaikh Feroz Ali 22