INTRODUCTION: This section describes about the method to be adopted for systematically

shutting down the unit from full output to the cold condition. On a number of occasions
boiler and/or its auxiliaries while in operation develops defects / trouble which by itself may
not be very serious in nature but if left on its own will subsequently cause major failures
resulting in plant to remain off the grid for extended period. Example: ( 1) Minor tube
leakages, (2) Turbine side problems / vibrations. 3) Generator Problems or for Unit
overhauling. On such occasion it is imperative to start shutting down sequence of the unit in
normal way.

STATUS OF PLANT
 M/C on Load.
 SH/RH steam temperature control on AUTO.
 Feed Water control on AUTO.
 Furnace draft control on AUTO.
 Aux. Steam pressure/temp. Control on AUTO.
 Mill outlet temperature & air flow control on AUTO.
 Primary Air Header Pressure control on auto. SADC on AUTO.
 Combustion Control on AUTO.
 Air Flow Control on AUTO.
 Fuel Flow Control on auto.
 AB, CD, EF elevation oil guns are available.
 Burner Tilt operation OK.
 HP /LP bypass on auto.
 EBD is available for operation.
 FRS 30% & 100% lines are available.
 Fire fighting equipments are available.
 Wall blowers & APH Soot blowing system is available.

NORMAL SHUTDOW N OF BOILER TO COLD

Note: In shutting down the boiler, the reduction of firing rate is determined by the
requirement of the turbine.
 Do soot blowing before reducing load or keeping load more than 75 %.
 Check HP / LP bypass operation is O.K. (to be ensured)
 After soot Blowing gradually reduce load on the unit by reducing firing in the Mills.
 Steam flow will be reduced, allow the pressure to drop with the reduction in load.
 Reduce the temperature with the rate prescribed by the manufacturer for turbine but
never exceeding the forced cooling rate of boiler work has to be done on turbine then
maintain MS and HRH temperature constant. (Even if force cooling is required should be
done with proper clearance and written procedure to be made before start of shutdown
activities).
 Reduce coal firing to 70 % of load.
 Put SADC on manual to maintain wind box to furnace DP more than 70mmwc..

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 Take HP / LP bypass into service and reduce steam flow to 60%. (Keep HP by pass at
least 25 % open to facilitate flow through Reheater.)
 Take oil support for lower most mills (A, B, C, and D). Do APH soot blowing.
 Reduce firing in the top most mills to minimum feeder rate, open cold air damper
fully and close HAG after closing hot air damper. When mill outlet temp falls below 60
deg. C, stop feeder. Then stop mill after completely emptying it. Close all the
dampers fully.
 Adjust air flow for required Oxygen %.
 Reduce firing further in top mill by reducing feeder rate. Load 80 MW and throttle
pressure.
 Stop bottom feeder and mill after emptying it; load 50 MW, pressure 60kg/cm².
Change over FRS from 100% to 30%. Ensure mill in service is having oil support.
 Open economiser recirculation valves E-23.
 Close CBD if in open condition.
 Start reducing firing in last mill, stop feeder and mill by emptying mill and feeder.
 Reduce load to 30 MW and pressure 50 kg/cm². Stop both PA fans.
 Note: If required to work in feeder then feeder can be made empty by closing bunker
gates and tripping the feeder on ‘NO COAL ON BELT’.
 Trip the boiler. Turbine will trip and generator breaker will open.
 PA fan will trip automatically if not stopped earlier
 Ensure closing of all oil valves, LDO trip valve and stopping of all feeders and mills.
 Close boiler stop valves, SH/RH spray all isolating valves to avoid passing.
 Do boiler purging.
 See no flame inside the furnace.
 Keep close watch on HP bypass spray.
 Ensure drain opening before / after stop v/v.
 Close HP bypass, LP bypass close on auto, If not close LP bypass.
 Make ESP fields off & run Rapping motors (Collecting & Emitting) for 6 hours then
stop rapping & isolate flushing water (after ID fan stopping).
 When APH inlet gas temp falls below 205°C, shut down the FD & ID fans. (ID to FD
protection can be checked.) Ensure natural circulation.
 Close Aux. Steam Control valve, isolating v/v and spray line isolating v/v and control
valve.
 Close atomising and heating steam line.
 Close LDO station inlet manual isolating valve.
 Open RH & CRH drains (after vacuum is killed)
 Maintain drum level by BFP.
 Open drum & SH air vents, SH start-up vents, SH header drains when drum pressure
falls to 2 kg/cm².
 When drum metal temp. Comes to 85°C close FRS control valves and isolating V/V.
Stop BFP.
 Open low point drain header drains to blow down tank.
 Stop Clinker Grinder.
 Isolate HP / LP water.

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 EMERGENCY SHUT DOW N DUE TO SEVERE TUBE LEAKAGE

Always small tube leakages are detected by hissing sound and increased make- up water
requirement. After investigation at the earliest possible time unit should be shutdown in
a normal manner. A sudden major tube leakage indicate by reduction in load, sudden
furnace pressurisation, increased ID fan loading and sudden increase in make-up
water requirement. D/A level could not be maintained after opening normal & emergency
make-up. The sequence of operation in this case will be as follows:
 Reduce load as fast as possible to 70% of MCR.
 If feed water flow cannot be maintained by two BFP’s take third BFP in service if
available. Check leakage area. Inform SCE & Maintenance engineer.
 Take oil support for lower most mill.
 Reduce feeder speed of top most mill and ensure mill is empty completely. Reduce load
to 40% of MCR. Reduce Pressure gradually.
 Similarly reduce feeder speed of second top most mill, stop mill.
 Load – 30%of MCR, Take HP / LP bypass into service. Try to maintain MS& HRH temp.
 Open economizer recirculation valves. Close CBD if in open condition.
 Stop bottom most mill after emptying mill. Load 30 MW, pressure 50 kg/cm².
 Stop second bottom most mill after emptying it.
 Trip boiler. Ensure tripping of PA fans, LOTV, mills and feeders. Close all dampers
HAD, CAD, HAG. Close all oil valves.
 Close boiler stop v/v. Close HP /LP by pass.
 Open RH air vent & start up vents
 Open drain after boiler stop valves.
 Maintain drum level.
 Stop one set of ID and FD fans. Stop ESP fields, do the rapping. Purge the
boiler.
 Run the fans till gas temp. falls to 205°C at APH inlet. Then stop ID and FD fans, only
allow natural cooling.
 When drum pressure comes to 2 Kg.cm², open SH, drum air vents and SH start-up vents.
 Open SH header drain to blow down tank.
 When drum pressure comes to zero or drum metal temperature is approx. 100°C
start one set of ID and FD fan for force cooling. (Cooling rate should not exceed as
recommended.)
 Rest follows same procedure as per planned shutdown.
 In case tube leakage is major and water level cannot be maintained, then trip the
boiler immediately. Follow same procedure as per Emergency shutdown.
NORMAL SHUT DOW N TO HOT STANDBY

It is assumed that the boiler will be shut down for a relative short period of time. It is
expected that the unit will be restarted in a very short period of time, when the turbine
metal temp will not decrease appreciably. Here the normal procedure for normal shut down
should be followed except in reduction in MS pressure to 120 kg/cm² and temp almost
constant.
 Mills should be stopped one by one after emptying mill. During this process take HPBP &
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 LPBP in service.
 Feeder should not be made empty except particular requirement.
 Boiler stop valve should be closed after tripping the boiler.
 Boiler side drain should not be opened. Purge the Boiler.
 Open only RH vents & RH Start-up vents after closing HP/ LP bypass.
 One set of ID and FD fan to be kept in service till APH inlet temperature falls 205°C.
After 205°C, stop ID and FD fan. Leave the boiler natural cooling. Efforts to be made to
preserve the Boiler heat.
 APH washing may not be done due to short shut down.
 ESP fields maybe just made of and keeping rapping motors in normal position.
 Ensure closing of all oil valves, trip valves, and all mill and feeders. LDO may be
kept in recirculation.

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