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PROCEDURES DURING SHUTDOWN CFBT-582-1 1

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Power Generation RAPP PB3 PROJECT 1 (7)

Systems CFB MULTIFUEL BOILER

TABLE OF CONTENTS

8. PROCEDURES DURING SHUTDOWN ................................................................ 2

8.1 Measures during shutdown.................................................................................... 2
8.2 Boiler preserve procedures.................................................................................... 2
8.2.1 Scope of preservation............................................................................................ 3
8.2.2 Short preservation ................................................................................................. 3
8.2.3 Long preservation .................................................................................................. 4
8.3 Inspections during shutdown ................................................................................. 4

1 2005 - 08 - 30 Tuomo Keinonen

0 2005 - 02 - 10 Tuomo Keinonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder
1\08proceduresduringshutdown_rev1.doc
This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 2 (7)

Systems CFB MULTIFUEL BOILER

8. PROCEDURES DURING SHUTDOWN

8.1 Measures during shutdown

While the boiler is out of service there is time for protective and
inspection measures. When planning and listing measures to be
taken, pay attention to the following:

• length of the shutdown

• length of the operational period behind/measures taken care of

during the previous shutdown

• length of the uninterrupted operational period ahead

• inspections by authorities required.

In the following the matters which are the most important for a
circulating fluidized bed boiler are dealt with.

8.2 Boiler preserve procedures

When the boiler plant is taken out of service, the pressure falling
below the pressure of ambient air, air tends to penetrate through
valves and flanged joints into the boiler piping and dissolving in
water.

In this case the risk of oxygen corrosion increases inside the boiler
tubes which are in direct contact with water or condense.

For shutdown the boiler plant must be protected against the above-
mentioned corrosion, i.e. the boiler must be preserved. The
preservation method is chosen according to the length of the
shutdown and the available start-up time.

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 3 (7)

Systems CFB MULTIFUEL BOILER

8.2.1 Scope of preservation

The equipment of the boiler to be preserved:

• feedwater tank
• feedwater line
• economizer
• boiler drum
• evaporator (furnace walls and cyclones)
• superheaters
• main steam pipe up to main steam valve

8.2.2 Short preservation

If the shutdown is relatively short (< 5 days), the following

preservation method can be used:

The water and steam system of the boiler is kept at an overpressure

(over 2.0 bar) by ‘bottling’ the boiler immediately after the shutdown.

‘Bottling’ will be done mainly as follows:

1. Close all boiler main steam valves, start-up valves and feed
water valves.

2. Close all isolation valves on the drain and vent lines (including
double valves on the vent air collection funnel and on the blow-
down tank).

3. Close the continuous blow-down valves on the steam drum.

4. Close all sample water and steam lines taken from the boiler.

An excess of hydrazine, Azamine or similar chemical is added in the

water system in order to remove the residual oxygen. (At normal
operation the hydrazine content of feed water is 200...500 mg/m3).

If the pressure in the boiler drum is decreasing below 2.0 bar during
preservation, start the boiler with oil burners, let the pressure rise to
approx. 30…40 bar and do the ‘bottling’ again.

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 4 (7)

Systems CFB MULTIFUEL BOILER

The advantage of this method of preservation is a very short start-up

time.

8.2.3 Long preservation

If the shutdown is going to last longer than 2 weeks, the boiler

should be preserved normally wet.

It means that the boiler is filled with boiler water, to which a fairly
large amount of chemical for the removal of oxygen is added, and
boiler water is periodically circulated. In that case the boiler is
depressurized and requires an ‘open expansion vessel’ in the upper
part of the boiler house.

During a long shutdown, the preservation of the combustion air and

flue gas systems must also be taken care of. These systems must
be kept dry to avoid corrosion in the ducts and fans.

8.3 Inspections during shutdown

Perform visual examination for the internal and external parts of the
boiler from top to bottom. On the basis of observations take
necessary measures.

Necessary equipment suitable for the inspections of the defects

found during operation and at visual examination should be provided
on the site.

The inspections required by the pressure vessel regulations are

performed according to the time periods mentioned in them.

Reserve time particularly for testing of the boiler safety interlocks.

The safety interlocks must be fully tested and in order before start-
up.

Testing of the interlocks should be performed at the annual

shutdowns. The Operation Manager records the results of the
interlock tests performed and testing of the safety valves in a test
report book. Alarm lists and trend pages during tests must also be
printed out and saved in the same book.

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 5 (7)

Systems CFB MULTIFUEL BOILER

The following lists the most important objects of inspection,

which must be gone through following the operator's
instructions:

1. Inspection of fluidizing and loopseal air wind boxes

• observation of sand leaks and removal of sand if necessary
• inspection of fluidizing air nozzles , support beams and welding
seams

2. Inspection of fluidized bed sand

• Empty the bed containing plenty of stones, iron, sintered ash and
coarse sand. Clean the bottom and examine the condition of
nozzles and bottom piping.
• Loopseal sand is normally fine. Loopseals are not drained unless
the nozzle must be inspected

3. Internal inspection of the lower part of the furnace

• check that no blocks have loosened from the refractory (small
fissures in the refractory are normal)
• check that hard metal spraying coating has not damaged or worn
out and replace if necessary. Metal spraying is installed to areas
where biggest risk for erosion is assumed to exist and thus good
condition of hard metal coating is essential to protect pressurized
parts against wearing.
NOTE! Metal coating is porous and it should be protected
against getting wet. Rust between the tube and metal
coating loosens the coating from the tube surface.
• check that the secondary air nozzles are clean
• check that recirculation gas nozzles are clean
• check that the bed thermocouples and their protection tubes are
unbroken
• check that the chutes for bottom ash removal are not damaged.

4. Internal inspection of cyclones and loopseals

• Check the condition of refractory in cyclone inlet, cyclone
chamber, cyclone cone and loopseal
• Check the vortex tube condition
• If there is sand in loopseal windbox, the loopseals must be
drained and the nozzles must be checked

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 6 (7)

Systems CFB MULTIFUEL BOILER

• Check that there is no slagging in cyclone return duct, if any ,

remove it carefully
• Check that pressure taps are open and thermocouples are in
good condition

5. Inspection of burners
• check that the refractory in burner cone is unbroken and remove
deposits carefully if any
• check the condition of the lances either on the inside or pulling
the burner tubes out
• examine the condition of the burner air dampers and registers
• check that the burner tubes are directed according to
instructions.
• Check the condition of erosion protection plates of burner heads

6. Inspection of boiler support structures

• examine the tightness of the suspension rods and perform visual
examination of the support beams.

7. Inspection of heat surfaces

• inspect the cleanness of the superheaters, economizers and air
preheaters in order to determine the sootblowing required
• check that there is no unusual wear in the heat transfer piping.

8. Inspection of flue gas ducts

• check that in the last air preheater package there are no
indications of dewpoint corrosion
• check that the flow guiding plates of the ducts are unbroken and
there is no ash in the ducts
• examine the condition of the dampers in the flue gas ducts.

9. Inspection of air ducts

• examine the condition of the flow controllers in the ducts
• examine and trial run all the air dampers (make sure they can
move freely).

10.Inspection of recirculation gas ducts

• check that the flow controllers of the ducts are unbroken and
there is no ash in the ducts
• check that in the ducts there is no indication of dewpoint
corrosion

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 7 (7)

Systems CFB MULTIFUEL BOILER

11.Inspection of safety valves

• examine the condition and cleanliness of the safety valves
• check that the drain of the blow-down pipe is not plugged

12.Inspection of fuel conveyors

• empty the fuel silos and examine the condition of the silo
dischargers and remove ropes, etc.
• examine the condition of the drag conveyor chains and slide rails
and remove ropes, etc.
• examine the condition of the robbing, mixing and feeding screws
• examine the condition of the rotary feeder blades and adjust the
blade clearance to abt. 0.5 mm according to manufacturer’s
instructions.
• Check the condition of fuel chutes on rear wall side feeding to
the loopseals

13.Inspection of limestone injection system

• examine the condition of the limestone screw and rotary feeder
• check the limestone injection nozzle and clean if it is necessary

14.Inspection of bottom ash conveyors

• examine the condition of the drag conveyor.
• examine the condition of the bottom ash pneumatic valves

15.Condition of access doors

• check that the refractory of the doors and openings is unbroken
• examine and replace packings if necessary.

16. ESP
• Be sure the high-voltage rectifiers are switched off
• Check the earthing cable connected before opening mans doors
• Check the condition of electrodes, rappers, and insulators
• Check that the hoppers are empty and heating is working
• Check the condition of fly ash conveyors

17.Lubrication and changing of oils

• Service all the systems and parts which are not possible to
access during operation
• All the scheduled oil changing must be done according to
manufacturer’s manual of each individual components

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005