Chapter 1 Operation Manual of Boiler

Indonesia 1×660MW Paiton
Coal Fired Thermal Power Plant
Operating and Maintenance Manual
Volume II: Operation Manual

Chapter 1: Operation Manual of Boiler
Harbin Power Engineering Company Limited
May 17th,2012
Content
1 Unit Overview
Overview........................................................................................................................................
........................................................................................................................................ 2
1.1 Unit Design Overview................................................................................................................. 2
1.2 Boiler’s equipment overview......................................................................................................4
2 Unit auxiliary equipment start and stop
stop.......................................................................................
....................................................................................... 26
.......................................................................................26
2.1 General rule............................................................................................................................... 26
2.2 Air preheater.............................................................................................................................. 28
2.3 Suction fan................................................................................................................................. 30
2.4 Force fan.................................................................................................................................... 33
2.5 Primary fan.................................................................................................................................35
2.6 Sealing fan................................................................................................................................. 38
2.7 Flame check cooling fan.......................................................................................................... 39
2.8 Boiler water pump..................................................................................................................... 39
2.9 Boiler-front fuel oil system shutdown..................................................................................... 39
2.10 Coal mill, coal feeder and its system.......................................................................................47
2.11 Use and stop for the drum two-color water level gauge.......................................................53
2.12 Intermitten blowdown and continuous blowdown outage.................................................... 54
2.13 Boiler soot-blowing system.......................................................................................................56
2.14 Air compressor start and stop.................................................................................................. 60
3 Unit start and stop ............................................................................................................................. 65
stop.............................................................................................................................
3.1 Boiler cold start..........................................................................................................................65
3.2 Other state start.........................................................................................................................83
3.3 Outage and maintenance of boiler......................................................................................... 84
4 Operation and maintenance of the unit
unit........................................................................................
........................................................................................ 91
........................................................................................91
4.1 Operation regulation and maintenance of the boiler............................................................91
5 Interlocking protection and test
test...................................................................................................
................................................................................................... 126
...................................................................................................126
5.1 Boiler interlocking protection................................................................................................. 126
5.2 Unit test........................................................................................................................142
6 Accident Treatment ..............................................................................................................150
Treatment..............................................................................................................150
6.1 Accident Treatment principle........................................................................................150
6.2 Boiler shutdown due to Failure............................................................................................. 151
Appendix:Curve and Table...........................................................................................................181
I
1 Unit Overview
1.1. Unit Design Overview
（Please Refer to40-F4821C-J04-01）
1.1.1. Unit overall design
Indonesia Paiton Coal Fired Thermal Power Plant will plan the coal-fired subcritical condensing
steam turbine-generator unit with the capacity of 1 × 660MW, which is scheduled for production in
December 2010. The boiler is HG-2187/17.5-HM14 provide by the People's Republic of China
Harbin Boiler Factory Co., Ltd; Steam Turbine is provided by the People's Republic of China
Harbin Steam Turbine Factory Co., Ltd, model: N660-16.7/538/538; generator is provided by the
People's Republic of China Harbin Electrical Machinery Plant Co., Ltd., generator’s model:
QFSN-660-2, three-phase synchronous turbo-generator. DCS system of the engineering,
including the control functions such as data acquisition (DAS), simulation quantity control (MCS),
sequential control (SCS), boiler furnace safety supervision (FSSS), steam turbine control (DEH),
feed pump turbine control (MEH), electric auxiliary power monitoring (ECS) and so on, it is the
control system with the sound control functions of the complete unit, which is provided by the
People's Republic of China Shanghai Westinghouse Co., Ltd.
The boiler is the Π--type coal fired drum boiler with the sub-critical pressure, primary intermediate
reheating, control cycle drum boiler, four-angle tangential combustion mode, single furnace
balanced ventilation, solid deslagging and all-steel framework, designed coal is the lignite. The
maximum continuous load (i.e., BMCR working condition) is taken as the design parameter of the
boiler. When the electric load of the unit is 693MW, the maximum continuous rating required for
the boiler is 2187t/h; when the electric load of the unit is 660MW, the boiler's rated evaporation
capacity is 2064.1t/h. The coal pulverizing system adopts the positive pressure direct blowing style,
each boiler is provided with a total of 6 HP1163 bowl-type medium-speed coal mill. In BMCR
condition, 5 coal mills are operating, a coal mill is used for the back-up. Each boiler is provided
with the sealing fan of the coal mill capacity of 2x100%, one is used for the operation, one is used
for the back-up. Each boiler has 6 coal feeders, pressure-proof type measurement coal feeder,
which is equipped with the frequency control motor, the amount of coal supply can be
automatically adjusted along with the boiler load. Two movable blade adjustable axial flow primary
air fan with the capacity of 50% are equipped, so as to provide the primary heat, cold wind for the
coal transportation. Blower adopts the movable blade adjustable axial flow fan with the capacity of
2x50%.
The suction fan adopts the static blade adjustable axial flow fan with the capacity of 2x50%. Boiler
adopts 2 Ljungstrom trisector air preheater. In order to prevent the low temperature corrosion, the
heating surface component at the preheater cold-side is manufactured by the corrosion-resistant
low-alloy steel plate. Burner assembly is set up the six layers of pulverized coal nozzles, eight
layers of secondary air nozzles, which the fuel nozzle is set up on the fourth layer, OFA air nozzle
is set up on the first layer. 24 burners are the four-corner arrangement, tangential firing, swing
direct flow burner, maximum swing angle primary air is ±27°, secondary air is ±30°, OFA air nozzle
can swing horizontally 12 °.
The superheated steam temperature of the boiler adopts two-stage spray desuperheating; the
primary spray-type desuperheater is arranged between the low temperature superheater and
division panel, and the secondary spray-type desuperheater is arranged between the
superheater’s back screen and final superheater, the desuperheater adopts the flute tube type.
The temperature of the reheater is mainly adjusted by swinging the burner, the inlet conduit of the
reheater is equipped with two atomizing nozzle-type spray-type desuperheater to prepare for the
emergency use.
Superheater system processes: drum →saturated vapour outlet pipe→ inlet header of the roof
tube →roof tube (roof by-pass tube ), (wall enclosure system bypass tube to the rear pass side
wall upper header) →outlet header of the roof tube → (two way, one way: from the rear pass roof
tube → rear pass’s rear wall tube→ rear pass’s rear wall lower header →rear pass’s side wall
lower header →rear pass’s rear side wall header→ rear pass side wall upper header; the other
way, rear pass front wall tube →rear pass front wall lower header →rear pass extension side wall
2
lower header (rear pass side wall lower header) →rear pass extension part side-wall tube (rear
pass front side wall tube) →rear pass side wall upper header) → low-temperature superheater’s
inlet connecting tube →level low-temperature superheater’s inlet header→ level low-temperature
superheater → vertical low-temperature superheater → vertical low-temperature superheater’s
outlet header →primary desuperheater inlet connecting tube → superheater’s primary
desuperheater→ primary desuperheater outlet connecting tube → division screen inlet header →
superheater’s division panel→ division panel outlet header→ division panel and rear panel
connecting tube→ rear panel inlet header→ superheater rear panel→ rear panel outlet header→
secondary desuperheater inlet connecting tube→ superheater’s secondary desuperheater→
secondary desuperheater outlet connecting tube→ final superheater inlet header→ final
superheater→ final superheater out header → superheater’s outlet conduit →steam turbine’s
high-pressure cylinder.
Reheater system process: steam turbine’s high-pressure cylinder → cold end reheater pipeline→
reheater’s spray-type desuperheater→ wall re-inlet header→ front (side) wall radiation reheater→
wall re-outlet header→ wall re-outlet header to the reheater front panel’s inlet header connecting
tube → reheater front panel’s inlet header→ reheater front panel→ final reheater → final
reheater’s outlet header→ reheater outlet conduit →steam turbine’s medium pressure cylinder.
The unit is provided with the steam turbine bypass system, capacity of 70% BMCR, the main
steam enters the boiler’s reheater through the high-pressure bypass and reheat cold section
steam pipeline, the reheater ‘s outlet steam flows into the condenser through the low pressure
bypass.
The vertical shaft lower header at the rear of the boiler is equipped with the start hydrophobic
bypass, capacity of 5%, can meet the requirements of the hot and cold state start of the unit. When
starting up the boiler, the bypass is used to drainage, so as to achieve the accelerated heating
purpose of the superheater.
Boiler water circulation system has three boiler water circulation pumps, two pumps can run with
full load, three pumps can also run. If a single pump is only put into operation, the boiler load must
be reduced to 60% MCR. When starting up the boiler, two pumps should be at least put in
operation.
134 different types of sootblowers are installed at the furnace, all levels of convective heating
surfaces and rotary air preheater, etc, in order to maintain the cleanliness of the heating surfaces,
the operation of the sootblower adopts the process control.
Unit mainly bears the basic load and with a certain of peak regulation capacity, the scope of peak
regulation:: rated output of 40% to 100%. Unit can meet all the automatic devices adopted by the
unit when the boiler load is 40% BMCR and above. Ignition and combustion-supporting adopt # 0
light diesel oil. 16 oil guns are designed to contribute with 20% BMCR load. The minimum stable
combustion load is 37% TMCR. Boiler’s life expectancy is more than 30 years.
When the boiler is running and starting at low load, it is recommend to use the sliding pressure
operation, in order to attain a higher economy.
Boiler is respectively set up with 2 suction fans, force fans and primary fans. The suction fan is the
adjustable static blade axial flow fan with the capacity of 2x50%, 2 blowers and primary fans are
the adjustable movable blade axial flow fan with the capacity of 2x50%. The blower and primary
fan are arranged in the blower room at the rear of the boiler, the suction fan is arranged in the
suction fan room at the back of the electric dust collector.
The unit is configured 6 oil-free screw air compressors, 3 are used to provide the compressed air
for the instrument; 3 are used to provide the compressed air for the maintenance. Along with the
air consumption change of the system, the air compressor will be loaded and unloaded
automatically in order to adapt to the air consumption of the conveyor system.
The ash and slag are respectively removed in the plant, dry ash and slag removal multipurpose
utilization; the slag is removed by the slag conveyor spoil tank system with the mechanical
deslagging scraper, the boiler bottom slag is removed by the continuous deslagging mechanical
transmission system with the water immersion-type scraper slag conveyor, after the bottom slag is
discharged by the water immersion-type scraper slag conveyor, it is directly transmitted to the
3
spoil tank for the storage, which is sent regularly from the automotive to the multipurpose
utilization user or storage yard. Gray system adopts the positive pressure dense phase pneumatic
ash handling system.
Boiler is equipped with 2 double-chamber four- electric field electrostatic precipitator, 32 ash
hoppers. The fly ash quantity is 90% of the total amount of boiler ash and slag, the efficiency of
electrostatic precipitator is more than 99.5%. One ash silo is set up, the fly ash is conveyed to the
ash silo for the storage by the positive pressure dense phase pneumatic conveying system,.
The coal sources are the Indonesian coal, the coal of the power plant adopts the sea
transportation. The coal is unloaded with the ship unloader, which is conveyed to the coal yard or
the raw coal bunker of the main building through the coal conveyer belt; Power plant uses the sea
water as the living and industrial water source; the reverse osmosis technology is used for the sea
water desalination;
This project is connected to the 500kVGIS distribution device of the old power plant by 500kV
isobaric line’s outgoing line, the standby power is connected to the 150kV distribution device from
the old power plant, high voltage auxiliary power voltage class uses the primary voltage of 6kV; the
machine, boiler, electricity are implemented the centralized control by the computer distributed
control system (DCS), the auxiliary workshop is controlled by the PLC system, the support system
control network consists of a number of auxiliary workshop PLC systems, the operator station is
arranged in the centralized control room.
The power plant uses the sea water direct flow cooling system; the circulating water of the power
plant adopts the partial open channel diversion program, the layout of the circulating water pump
room should be in conjunction with the pipeline construction technology and engineering
investment optimization; the anti- salt spray corrosion of the seaside power plant is considered,
the glass steel pipe, coating and cathodic protection are used for the pipeline and metal part in the
different occasions;
Fire system is designed in accordance with NFPA and local specification of Indonesia.
Boiler’’s equipment overview
1.2 Boiler
Type: subcritical parameters, controlled circulation, single furnace, four
corners tangential-firing type, single reheat, single furnace balanced draft,
dry slagging, semi-outdoor laid, complete steel structure hanging
construction, Π-type drum boiler.
Manufacturer: Harbin boiler group co. ltd (HBC)
1.2.1. General overview of the boiler
Boiler model：HG-2187/17.5-HM14
Boiler type: Π-type coal-fired drum boiler with the sub-critical parameter, control cycle, primary
intermediate reheating, four-corner tangential combustion mode, single furnace balanced
ventilation, solid deslagging, all-steel frame.
Boiler efficiency：93.28%
Electric precipitation efficiency： 99.6%
Standard coal consumption of power generation：310g/kW·h
Standard coal consumption of power supply：330g/kW·h
Manufacturer: Harbin Boiler Factory Co., Ltd.
Coal pulverizing system: positive pressure direct blowing type, with 6 HP1163 bowl -type
medium-speed coal mill
1.2.2. Main design specification of the boiler
4
No. Item Unit BMCR TMCR
1 Main steam flow t/h 2187.13 2064.1
2 Drum pressure MPa 19.00
3 Main steam pressure MPa 17.40 17.40
4 Main steam temperature ℃ 541 541
5 Reheated steam flow t/h 1839.8 1742.4
6 Reheated steam inlet pressure MPa 4.025 3.81
7 Reheated steam outlet pressure MPa 3.835 3.63
8 Reheated steam inlet temperature ℃ 338.1 332.3
9 Reheated steam outlet temperature ℃ 541 541
10 Boiler’s feed water temperature ℃ 281.4 282.7
Air preheater’s inlet primary wind

11 ℃ 36 36
temperature
Air preheater’s inlet secondary wind
12 ℃ 33 33
temperature
Air preheater ’s outlet primary hot wind
13 ℃ 378 377
temperature
Air preheater’s outlet secondary hot
14 ℃ 384 383
wind temperature
Exhaust gas temperature (air preheater
15 ℃ 148 153
outlet, uncorrected)
Exhaust gas temperature (air preheater
16 ℃ 141 145
outlet, after correcting )
17 Theoretical air amount Nm3/kg 4.327 4.196
18 Coal-fired quantity of the boiler t/h 375.9 358.6
19 Guarantee thermal efficiency of boiler % 93.28 93.01
20 Feedwater Pressure MPa 19.49 19.22
21 Total Air Amount Nm3/kg 2609.6 2489.3
1.2.3. Performance parameters of main components of boiler body

Please Refer to Volume I : Design Manual.Chapter 2: Boiler and Auxiliary Equipments
Name Relevant parameters
1 Drum
1.1 Amount 1piece
1.2 Centerline elevation of the drum 79018mm
5
1.3 Normal water level of the drum Below the centerline of the drum :-229mm
Drum’s inner diameter/ upper half
1.4 wall thickness/lower half wall Φ1778/182/153mm
thickness
1.5 Straight section length /total length 28450/30504mm
1.6 Material SA-299
1.7 Drum water capacity 66m3
Drum total weight (including internal
1.8 265.483t
device)
1.9 Drum design pressure 19.9MPa
Ring-shape sandwich structure, with the cyclone
Type of steam purification separator, vertical corrugated plate separator
1.10
equipment and louver separator
From, and blind separator
Diameter and quantity of the cyclone
1.11 Φ254mm,124 pieces
separator
1.12 Single cyclone separator output 17.64t/h
1.13 Material SA—299
Boiler’s allowable minimum cycle
1.14 1.33
ratio
Minimum calculated cycle ratio of
1.15 1.64
the boiler
Calculated cycle ratio in case of
1.16 2.183
boiler BMCR
Calculated cycle ratio in case the
1.17 2.363
boiler is BMCR of 60%
2 Furnace
Furnace size (width × height ×
2.1 20193×20052×64985mm
depth)
2.2 Roof elevation 88600mm
2.3 Furnace type Membrane, gas-tight, single-furnace
2.4 Furnace capacity m3
Calculated cross-sectional area of
2.5 404.91m2
the furnace design
2.6 Furnace Section Heat Load MW/m2
2.7 Furnace volume heat load 71.9 kW/m3
2.8 Furnace design pressure Pa
3 Combustion equipment
3.1 Burner type, layout Tangential firing direct flow, four-corner layout
Pulverized coal nozzle ± 27 °, secondary air
3.2 Swing angle of the burner nozzle
nozzle ± 30 °
6
OFA extinction whirlwind swing
3.3 Horizontal swing 12 °
angle
3.4 Secondary air rate / wind speed 70%/48m/s
3.6 一 Primary air rate / wind speed 25%/28m/s

Center distance of adjacent
3.7 1880mm
pulverized coal nozzle
Distance from the center of the top
3.8 22052mm
burner to the panel bottom
Size of the bottom burner center
3.9 from the upper edge of main ash 4380mm
hopper
Equal air distribution/ primary air hedge and
3.10 Burner arrangement mode secondary air concentric tangent and resection
(SBWL-CFS)
Steam atomization / pneumatic extension
3.11 Type of oil gun
mechanism
Number of gun oil (number of each
3.12 4×4=16 pieces
layer × layer numbers)
3.13 Output of single oil gun 2.4t/h
3.14 Oil supply pressure 1.5MPa
3.15 Design fuel capacity 20%BMCR
3.16 Steam purge pressure 0.6～0.8MPa
250℃
3.17 Steam purge temperature
4 Downcomer
4.1 Downcomer number 6pieces
4.2 Outer diameter / inner diameter Φ406×36mm
4.3 Material SA-106C
5 Water wall
5.1 Number of water-wall tube
Water wall’s tube outer diameter /
5.2 Φ51×6.5 mm、Φ51.8× 6.5 mm
wall thickness
5.3 Water wall tube’s material SA-210A1
5.4 Water wall tube type Bare tube and internally ribbed tube
Arrangement height of water-wall
5.5 21.8m~61.1m
internally ribbed tube
Circulation loop number of water
5.6
wall
5.7 Water volume of the water 242m3 (Include the drum)
7
circulation system
5.8 Furnace arch water wall Φ63×7.11 mm
Furnace extension side wall
5.9 Φ63×7.11 mm
water--wall
Roof tube on the upper part of the
5.10 Φ57×6.5mm
furnace
5.11 Material SA-213-T12
6 Horizontal low-temperature superheater
Pipe outside diameter / wall
6.1 Upper :Φ57×7、Lower:Φ57×8mm
thickness
Top SA-213-T12, bottom SA-210C, and vertical
Top, bottom and vertical sectional SA-20C
6.2
tubes
Outlet working substance

6.3 378℃
temperature
Maximum calculated working
6.4 378℃
substance temperature
Outlet metal wall temperature /
6.5 442/502℃
maximum metal wall temperature
6.6 Number of parallel connection tubes 132×6 pieces
7 Vertical low-temperature superheater
7.1 Φ63×7mm
thickness
Top, bottom and vertical sectional
7.2 SA-213-T12
tubes
7.3 383℃
temperature
7.4 384℃
7.5 442/502℃
7.6 Number of parallel connection tubes 132×6
8 Split panel superheater
8.1 Φ51×6.5mm
thickness
8.2 Material SA-213T22
8.3 435℃
temperature
8.4 437℃
8.5 Outlet metal wall temperature / 540/592℃
8

8.6 Number of parallel connection tubes 6×8×10 pieces
9 Rear plate superheater
Inner and outer ring tube diameter /
9.1 Φ57/10 mm, Φ51/8 mm
wall thickness
SA-213T22, SA-213TP347H
9.2 Material

9.3 505℃
temperature
9.4 507℃
9.5 575/648℃
10 Final superheater
10.1 Φ57×9mm
thickness
10.2 Material 12Cr1MoVG/SA-213 T91
10.3 541℃
temperature
10.4 541℃
10.5 582/603℃
10.7 Superheater system’s water volume 240m3
10.8
10.9
11 Wall-type reheater
11.1 Φ60×4mm
thickness
11.2 Material 15CrMoG
11.3 ℃
temperature
11.4 ℃
11.5 ℃
11.6 Number of parallel connection tubes 572 pieces (front wall: 280, two side walls : 292)
12 Panel reheater
9
12.1 Φ63×4，Φ63×7mm
thickness
12.2 Material 15CrMoG
12.3 ℃
temperature
12.4 ℃
12.5 566/651℃
12.6 Number of parallel connection tubes 52× 6 pieces
13 Final reheater
13.1 Φ63/4.5mm
thickness
13.2 Material SA-213 T91
13.3 541℃
temperature
13.4 541℃
13.5 634/676℃
13.6 Number of parallel connection tubes 78× 6 pieces
13.7 Reheater system water volume 238m3
14 Primary desuperheater of the superheater
14.1 Quantity 2, one on the left ,one on the right
14.2 Type Flute tube type
14.3 Installation location Low-temperature superheater outlet
14.4 Desuperheating water source Feed pump outlet
14.5 Designed water spray volume t/h
15 Secondary desuperheater of the superheater
15.3 Installation location Rear plate superheater outlet
15.4 Desuperheating water source Feed pump outlet
16 Reheater’s desuperheater
16.3 Installation location Wall-type reheater inlet
10
16.4 Desuperheating water source Intermediate tap of the feed pump
17 Economizer
Number of parallel connection tubes
17.1
(row × piece)
17.2 Tube diameter × wall thickness Φ51×5.5mm
17.3 Material 2G
Economizer’s supporting tube
17.4
number
17.5 Economizer system water volume 80m3
18 Blow down flash tank
18.1 Volume 40m³
18.2 Design pressure 1.0MPa
18.3 Working pressure 1.0MPa
Start and tripping pressure of the
18.4 1.7MPa
relief valve
18.5 Design temperature 380℃
18.6 Operating temperature 20~380℃
18.7 Water discharging temperature 60℃
18.8 Manufacturing Shandong Bei Chen Group Co., Ltd.
19 Continuous blow down flash tank
19.1 Volume 60m³
19.2 Design pressure 1.5MPa
19.3 Working pressure 1.3MP
Start and tripping pressure of the
19.4 2.25MPa
relief valve
19.5 Design temperature 380℃
19.6 Operating temperature 20~380℃
19.7 Manufacturing Shandong Bei Chen Group Co., Ltd.
1.2.4. Fuel Characteristics
Please Refer to F4821C-J04-01
Boiler is designed for the lignite, the coal characteristics are as follows:
Designed
Item Symbol Unit Check coal
coal
Elemental Fixed carbon F.Car % 31.5 27.8

analysis and
Received based carbon Cnet.nr % 45.48 43.59
industrial
11
Received based hydrogen Hnet.nr % 3.16 3.1
Received based oxygen Onet.nr % 16.86 15.28
Received based nitrogen Nnet.nr % 0.77 0.89
Received based sulfide Snet.nr % 0.23 0.24
Received based ash A % 3.5 3.9

Total moisture Mar % 30 33
Air-drying based moisture Mad % 18 18.9
Dry ash-free basis volatiles Vdaf % 50 52.69
Received basis gross heating value QHHV kcal/kg 4200 4070
Received basis low- calorie capacity Qnet.nr kcal/kg 3849 3706
Abradable coefficient HGI 60 50

Pulverized coal fineness R90 % 22 22
Silica SiO2 % 11.07
Aluminium oxide Al2O3 % 12
Ferric oxide Fe2O3 % 34
CaO CaO % 14
Ash Magnesium oxide MgO % 12
composition
analysis Potassium oxide K2O % 0.98
Sodium oxide Na2O % 0.19
Titanium dioxide TiO2 % 0.3
Sulfur trioxide SO3 % 13.67
Phosphorus pentoxide P2O5 % 1.15
Ash deformation temperature DT ℃ 1150
Ash melting Ash softening temperature ST ℃ 1200

point Hemispherical fusion temperature HT ℃ 1250
Flow temperature FT ℃ 1300
1.2.5. Fuel characteristics are as follows:
Please Refer toF4821C-J04-01
Ignition and combustion-supporting oil adopts the #0 light diesel oil, the characteristics data of the
oil quality is shown in the table below:
No. Composition Unit Designed value
1 Specific gravity (15℃) t/m3 ≥0.847
2 Movement viscosity (30℃) cst ≥5.2
3 Movement viscosity (100℃) cst ≥1.0
12
4 Pour point ℃ ≤0.5
5 Flash point ℃ ≤50
6 Sulfur content % ＜1.2
7 Moisture % 0.02
8 Sodium ppm 1.90
9 Potassium cst 2.40
10 Alum ppm ＜0.5
11 Graphite ppm -
12 Lower calorific value kJ/kg 42915
13 Ash content % Trace
1.2.6. Suction fan
Please Refer to Volume I : Design Manual.Chapter 2: Boiler and Auxiliary Equipments
Suction fan
Adjustable static blade
Type Quantity 2 sets
axial flow type
Air quantity 678.1/557.4/529.6
Model AN40(13)
(TB/BMCR/TMCR) m3/s
Total wind pressure
Speed 585r/min 4639/3568/3413Pa
(TB/BMCR/TMCR)
One class, 13
Impeller diameter 4000mm Blade quantity
pieces
Shaft power Efficiency
3672/2320/2112kW 85.1/85.5/85.4%
(TB/BMCR/TMCR) (TB/BMCR/TMCR)
Anti-clockwise
Adjustable range of
300～-750 Fan rotation direction rotation, observing
blade
from the motor side
Bearing Lubrication
Fan’s bearing Type Rolling bearing Grease lubrication
way
Forced cooling of the Chengdu Power
Bearing cooling way Make
cooling fan Machinery Factory
Suction fan motor
Model YKK Rated Power 3900kW
Rated voltage 6000V Rated Current A
Rated speed 590 r/min Rated Frequency 50Hz
Cooling way of the
Insulation class F Air-to-air cooling
motor
Cooling way of the Forced oil
Motor’s bearing type Rolling bearing
bearing circulation
Shanghai Motor
Oil grade designation L-TSA46 Make
Factory
13
Oil station of the suction fan’s motor
Pump rotating speed 1390r/min Pump’s motor power 1.1kW
Oil supply
Pump’s motor voltage 380V 40±3℃
temperature
Lubricating oil
0.4MPa Oil supply flow 16L/min
pressure
Electric heater
Electric heater power kW V
voltage
Cooling water
1.6MPa Cooling water flow m3/h
pressure
Cooling water Accuracy of the oil
℃ mm
temperature filtering
Shanghai
Tank volume 0.83 m³ Maker Lubrication
Equipment Co., Ltd.
Cooling fan of the suction fan bearing
Model G9-19№5A Quantity 2 sets
Air volume (standard
Power 7.5 kW 1610～3166m³/h
state)
Air pressure
Voltage 380 V 5697～5323Pa
(standard state)
1.2.7. Force fan
Force fan
Adjustable
Type movable blade Quantity 2 sets
axial flow type
Air volume
Model FAF26.6-13.3-1 242.55/207.62/164.16m3/s
(TB/BMCR/TMCR)
Total air pressure
Rotating speed 985r/min 3842/3341/3180Pa
(TB/BMCR/TMCR)
Impeller diameter 2660mm Blade number One class, 16 pieces
1055/783/612kW 87.12/87.6/84.41%
Action time of the
Regulating range of complete movable
－300 to ＋150 30～45s
the movable vane blade regulating
course
Anti-clockwise rotation,
First critical speed of
≥1281r/min Fan rotating direction observing from the motor
the fan
side
Bearing lubrication
Motor’s bearing type Rolling bearing Thin oil
mode
Forced-oil
Bearing cooling way Make Shanghai Blower Factory
circulation
14
Force fan’s motor
Model YKK560-6 Rated power 1120kW
Rated voltage 6000V Rated current 135A
Rated speed 990r/min Rated frequency 50Hz
Insulation Class F Make Shanghai Motor Factory
Force fan’s hydraulic oil station
Pump type Gear type Pump number 2 sets
Pump speed 1470r/min Pump outlet pressure 3.5MPa
Pump’s motor voltage 380V Control oil pressure 2.5MPa
Lubricating oil
0.80MPa Total oil supply flow 25L/min
pressure
Electric heater
Pump motor power 2.2kW 380V
voltage
Cooling water
0.3～0.6MPa Cooling water flow 2.25m3/h
pressure
≤38℃ 25μm
temperature filter
Tank volume 0.25m3 Electric heater power 2.2kW
Oil grade designation N68 Oil cooler type Multitubular
1.2.8 Primary air fan
Primary air fan
Adjustable movable
Type Model PAF20-12.5-2
blade axial flow type
Air amount 172.84/120.48/94.57 Total wind pressure

13870/10695/9965Pa
(TB/BMCR/TMCR) m³/h (TB/BMCR/TMCR)
Rotating speed 1470r/min Quantity 2 sets

Two class, 24 pieces
Impeller diameter 1996 mm Blade class number
each class
2984/1490/1097kW 80.36/87.22/86.67%
Action time of the
Adjustable range of complete movable
－300～＋200 30～45s
the blade blade regulating
course
Anti-clockwise rotation,
First critical speed of
≥1911r/min Fan rotating direction observing from the
the fan
motor side
Bearing lubrication
Motor’s bearing type Rolling bearing Thin oil
mode
Shanghai Blower
Bearing cooling way Forced-oil circulation Make
Factory
15
Primary air fan’s motor
Model YKK710-4 Rated power 3200kW
End cover type sliding
Insulation class F Motor bearing type
bearing
Bearing lubrication Bearing oil supply
Forced-oil circulation 16L/min
way flow
Oil grade designation 46 steam-turbine oil Make Shanghai Motor Factory
Primary air fan’s hydraulic oil station
Pump type Gear type Pump quantity 2 sets
Pump speed 1470r/min Pump outlet pressure 3.5MPa
Pump’s motor voltage 380 V Control oil pressure 2.5MPa
Lubricating oil
0.80MPa Total oil supply flow 25L/min
pressure
Electric heater
Pump motor power 2.2kW 380V
voltage
Cooling water
0.3～0.6MPa Cooling water flow 2.25m3/h
pressure
≤38℃ 25μm
temperature filter
Tank volume 0.25m3 Electric heater power 2.2kW
Oil grade designation N68 Oil cooler type Multitubular
1.2.9. Sealing fan
Sealing fan
Type Centrifugal type Quantity 2sets
Model 9-26,16D-4 Inlet air quantity 64032m3/h
Air pressure 6481Pa Rotating speed 960r/min
Sealing fan’s motor
Type Y355M2-6 Power 185kW
Voltage 380V Current A
Rotating speed 960r/min Air filter model 60M
1.2.10. Coal mill
Coal mill body
HP1163 bowl
Model type intermediate Item Designed coal Check coal
speed coal mill
16
Quantity 6sets Maximum output 99.6t/h 88.4t/h
Coal mill speed 27.7 r/min Guarantee output 89.64t/h 79.56t/h
Maximum ventilation
149.3t/h Calculated output 75.26t/h 78t/h
quantity
Ventilation quantity
under the guarantee 143.3t/h Minimum output 24.9t/h 22.1t/h
output
Minimum ventilation Calculated ventilation
104.5t/h 143.7t/h 142.3t/h
quantity quantity
Maximum ventilation Calculated ventilation
4500Pa 3663Pa 4086Pa
resistance resistance
Ventilation resistance
Inlet air temperature
under the guarantee 4147Pa 274℃ 304℃
of the coal mill
output
Unit power
Outlet temperature
65℃ consumption of the 9.2kW·h/t 9.8kW·h/t
of the coal mill
coal mill
Unit power
Sealed air volume of
98.22m3/min consumption under 8.7kW·h/t 9.83kW·h/t
the coal mill
the guarantee output
Unit wear rate of the
Coal mill’s shaft power 644kW 1.953g/t 19885g/t
coal mill
Grinding roll’s bearing Loading way of the
GP-6639 Spring variable loading
type coal mill
Pebble coal
Loaded spring type GP-3271-S 0.1%
discharge amount
Service life of grinding Raw coal particle size

roll sleeve, grinding 25000h into the coal mill 0～35mm(95%),35～50mm(5%)
bowl backing plate
Distributor type of the

Coal separator Static separator Centrifugal distributor
coal mill
Coal mill’s motor
Squirrel-cage type /
Mode Rated power 850kW
YHP630-6
Class number 6 class Insulation Class F class
Cooling way IC611( Air-air cooling ) Power Factor 0.79
Rated load efficiency 93% Bearing type Rolling Bearing
Starting current/rated Bearing’s lubrication

6.5 Self-lubricating
current way
17
Electric heater
Electric heater voltage of
380V power of the coal 1.0kW
the coal mill
mill
Gear reducer
Mode KMP360 Transmission ratio 35.6:1
Spiral bevel gear -planetary

Transmission mode gear + two class of vertical Gearbox oil capacity 850L
transmission
Lubricating oil station
Pump model OWTS11 Pump type Gear pump
Lubricating oil flow 287L/min Gearbox capacity L
Pump’s motor model Pump’s motor speed r/min
Pump’s motor voltage 380V Pump’s motor power 15kW
Oil supply pressure 0.45MPa Pump number 1set
Electric heater voltage 380V Electric heater power 1.7kW

Oil return pipe heat tape Oil return pipe heat
220V 35.5W/m
voltage tape power
Filter’s differential
＜0.1MPa Oil number ISOVG320
pressure
Lubricant oil cooler
Cooling water
Cooling water quantity 20m3/h 0.2～0.4MPa
pressure
Outlet water
Inlet water temperature ≤30℃ ≤35℃
temperature
Outlet oil
Inlet oil temperature 45℃ ＜45℃
temperature
Coal feeder
Mode EG2490 Quantity 6 sets
Electronic weighing
Main drive motor
Type pressure-proof belt coal Frequency control
type
feeder
Main drive motor
Main drive motor model Y3-4P 3.0kW
power
Main drive motor voltage 380V Output range 11～110t/h
Cleaning chain
Inverter model 196NTMPC Y0.37-4P
motor model
Sealing wind
Clean motor power 0.37kW 500Pa
pressure
sealed volume 10Nm3/min Raw coal warehouse m3
18
volume
Shenyang Shidaoke
Inlet and outlet coal gate
0.75kW Manufacturer Power Equipment
drive motor model
Co., Ltd
Coal hopper air cannon
Type Horizontal Mode KQP-B-220L

Compressed air supply
0.4～0.8MPa Air temperature 50℃
pressure
Each coal hopper is
Quantity Starting time ≤ 2 seconds
installed 20 air cannons
1.2.11. Boiler water pump
refer to Circulating Pump System and Accessories No.: F0310XH001D101
This boiler is equipped with 3 wet motor pumps (type LUVAc 350x2-500/1) by ShenYang
Turbo-machinery Corporation, China. Furthermore, the pump body, cooler for pump electric
machine, thermometer in pump electric machine chamber and thermocouple are all supplied by
ShenYang Turbo-machinery Corporation, China. Harbin Boiler Company Limited is in charge of
designing HP cooling water system of circulating pump system. The drawing of boiler circulating
pump system are shown in F001BMA001D101, and list of boiler circulating data are shown in
F0330SX001D101.
Boiler water pump

Wet motor boiler
Model LUVac350x2－500/1 Type water-circulating
pump
Quantity 3 sets 19.17MPa
Pump’s outlet
19.43MPa Single-pump flow 4768m³/h
pressure
Single-pump flow
Design total
32m when two pumps are 4086.8m³/h
pressure head
MCR
Design Pump working / design
22 MPa 33MPa
pressure pump temperature
Pump
Shenyang Water
Working/Desig 354.4/365℃ Manufacturer
Pump Factory
n Temp.
Boiler water pump motor
Wet Squirrel Cage
Model LUVAC2×350-500/1 Type
Induction Motor
Rated voltage 6000V Rated power 450kW
Rated speed 1477r/min Rated current 56A
Start-up time S Starting current 366A
19
Motor cavity
Motor cavity trip
alarm 60℃ 65℃
temperature
temperature
Water quality requirements of the low pressure cooling water
Clean, after softening, the
sediment is not produced Cooling water
Total quality under the operating suspended substance ≤ 5 ppm
requirements temperature, non-corrosive content (max)
Inlet
≤40℃ pH value 9 to 9.5
temperature
Pump high-pressure water filling and cleaning water quality requirements
Deoxidizing condensed Suspended substance
Water Quality 0.25ppm
water in the solution (max)
Inlet water Water quantity each
4 to 50℃ 0.8 to 1.0m3/h
temperature pump
Cleaning 0.21 to 0.275Mpa more than the pump outlet pressure
system
pressure
Low-pressure cooling water of the pump motor’s cooler
Rated cooling Cooling water inlet
11m3/h 30 to 39℃
water flow temperature
Cooling water ： Cooling water
0.2～0.3MPa 0.04MPa
inlet pressure pressure drop:
Low pressure cooling water of the pump insulator cooling
Rated cooling Cooling water inlet
2m3/h 30 to 39℃
water flow temperature
Cooling water Cooling water pressure
0.2～0.3MPa 0.02MPa
inlet pressure drop:
Cooling water booster pump of the boiler water pump
Type AZ50-200 Flow 58 m³/h
Pump lift 50M Speed 2900 r/min
Motor voltage 380V Motor power 15W
1.2.12. Air preheater
refer to Air Preheater Operation and Maintenance Manual F031OYY001D101
The Ljungstrom® Air Preheater absorbs waste heat from flue gas, then transfers this heat to
incoming cold air by means of continuously rotating heat transfer elements of specially formed
metal plates.
Thousands of these high efficiency elements are spaced and compactly arranged within
sector-shaped compartments of a radially divided cylindrical shell, called the rotor. The housing
surrounding the rotor is provided with duct connections at both ends and is adequately sealed by
radial and circumferential sealing members-forming an air passage through one half of the
preheater, and a gas passage through the other. As the rotor slowly revolves the mass of elements
alternately through the gas and air passages, heat is absorbed by the element surfaces passing
20
through the hot gas stream. Then, as these same surfaces are carried through the air stream, they
release the stored up heat, thus greatly increasing the temperature of the incoming combustion or
process air.
This air preheater is vertical inverted modular tri-sector design and internal supporting
bearing.
Air preheater body
Trisector, rotary type
Model : 33.5-VIT 33.5-VI(T)-2333-QMR Type
(Ljungstrom)
Quantity 2 sets Rotor diameter 14800mm
Cold section layer
Hot section layer height 1000mm 800mm
height
Hot section
intermediate layer 1000mm Speed 0.9r/min
height
Rotation speed of
frequency control slow Water cleaning Multi-nozzle fixed cleaning
speed shift rotor 0.23r/min
device tube
Air preheater’s motor

Y200L1-6B5 Double
Motor model Quantity 2 sets
shaft extension
Motor rated
Motor power 18.5kW 380V
voltage
Motor rated current 37.7A Motor speed 980r/min
1.2.13. Flame check cooling fan
Flame check cooling fan

Maximum inlet
Model ℃
temperature
Fan rated wind
Air flow 850L/s 9323kPa
pressure
Flame check cooling fan motor
Motor model Current 27.7A
Motor power 15 kW Voltage 380V
Speed 2940 r/min Make
1.2.14. Sootblower
Furnace sootblower
Mode V04 Stroke 255mm
Purge angle 360° Travel speed 510mm/min
Purge time 30s Quantity 64pieces
21
Effective purge Steam
~2.5m ≤350℃
radius temperature
Motor voltage 380V Motor Power 0.25kW
Starting current 5.2A Rated current 0.77A
Steam working Screen Reheater Inlet
0.8~1.5MPa Steam source
pressure Header
Long sootblower
Model PS-LL Stroke 9635mm
Blowing tube
Blowing Angle 360° 2000mm/min
travel speed
Purge time 5min Quantity 52pieces
Steam
Soot Temperature ≤350℃ 579-900kg
consumption
Motor voltage 400V Motor power 1.1W
Steam working Screen Reheater Inlet
10-15Kg/cm²g Steam source
pressure Header
Furnace temperature probe
Model TS-0 Type
Temperature
Quantity 2 ~540℃
range
Stroke 7000mm Walking speed 720mm/min
Motor voltage 380V Motor power 0.63kW
Starting current Rated current 1.5A
Air preheater’s sootblower
Model PS-AT Stroke 1.232m
Stepping
Purge angle 360°
distance
Step times Stop purge time
Effective purge
~2.0m Quantity 2
radius
Motor voltage 380V Motor power 0.55kW
Steam
Steam pressure 0.8~1.5MPa temperature 325℃
Shanghai Clyde
Steam consumption Make
Bergmann Company
1.2.15. Air compressor and its ancillary equipmen
The compressed air system of this project is divided to two systems, one is for instrument and
the other for maintenance, and they have separate air compressor. There are three 20Nm3/min
oil-free air compressors for 63 instrument with one of them standby to meet the maximum
22
continuous gas consume of gas-driven equipment of instrument and controlling. Two sets of 75m3
air tank will be set. There are three 10Nm3/min oil-free air compressors for maintenance with one
of them standby, and two sets of 25m3 air tank.
Instrument air compressor
Model D132 Type Oil-free screw air compressor

Dimension (L × W ×
2300×1500×1500mm Quantity 3 sets
H)
Rated discharge Rated discharge
20.59m3/min 0.80MPa
quantity pressure
Exhaust oil
Revolution 13598r/min 0 ppm
content
Exhaust dust Discharge
1.0μm ≤45℃
particle size temperature
Compressed air
dew-point 6℃ Cooling method Closed Cooling Water
temperature
Maximum flow of Cooling water
9.87m3/h 0.6MPa
cooling water inlet pressure
Centralized installation,
Installation mode foundation-free overall Manufacturer Wuxi Huada
installation
Instrument air compressor’s motor
Model Y315M-2 Type Squirrel-cage induction motor

Power 132kW Voltage 380V
Rotating speed 2980r/min Starting current 1480A
Shell / ventilation
Full load current 246A Totally enclosed / fan
way
Temperature rise
under the full load 30℃ Rotation direction Clockwise
operation
Shaft power 126kW Vibration value ≤ 6mm
/NU222EC-C3(SKF) Ball
Bearing RTD type/
bearing / NU222EC-C3 Lubricant model Esso T68
model
(SKF)
Plant service air compressor
Model D75 Type Oil-free screw air compressor
Dimension (L × W ×
2300×1500×1500mm Quantity 3 sets
H)
Rated discharge Rated discharge
11.25m3/min 0.80MPa
quantity pressure
Exhaust oil
Revolution 2980r/min 0 ppm
content
23
Exhaust dust Discharge
1.0μm ≤45℃
particle size temperature
Compressed air
dew-point 6℃ Cooling method Water cooling
temperature
Maximum flow of Cooling water
7.5m3/h 0.6MPa
cooling water inlet pressure
Centralized installation,
Installation mode foundation -free overall 家 Manufacturer Wuxi Huada
installation
Plant service air compressor’s motor
Model Y280R-2 Type Squirrel-cage induction motor
Power 75kW Voltage 380V
Rotating speed 8560r/min Starting current 1480A
Shell / ventilation
Full load current 177A Totally enclosed / fan
way
Temperature rise
under the full load 30℃ Rotation direction Clockwise
operation
Shaft power 126kW Vibration value ≤ 6mm
Bearing RTD type/ Ball bearing
Lubricant model Esso T68
model /NU222EC-C3(SKF)
Pre-filter
Dealing air
Equipment model SLAF-20HC ≥23.5m3/min
volume
Operating
Working pressure 0.80MPa ＜60℃
temperature
Inlet oil content ≤10 ppm Outlet oil content 5 ppm
Outlet Dust particle Water distribution
3μm 99.6 %
diameter efficiency
Filter element
Pressure loss 0.01 MPa Centrifugal, fiberglass
type and material
Filter element
Filter element life 8000 hours Hangzhou Li-shan
manufacturer
Refrigeration dryer
Rated processing
Mode SLAD-20NF 23.5m3/min
air capacity
Working pressure 0.8MPa Design pressure 1.1MPa
To adapt to the
Inlet air temperature ≤45℃ ambient ≤38℃
temperature
Normal pressure
Cooling method Air-cooling / pressure dew 1.7℃
point
24
Number of
Compressor type Piston type one
compressor
Compressor power 3.72kW Motor voltage 380V
Working
Rated current 7A 2 24-hour continuous operation
conditions
Design pressure
Fan power 2×180W 1.7℃
dew point
Origin of the
Pressure loss ≤0.02MPa Germany
compressor
Used refrigerant R22 Start-up mode Direct start
Fan’s motor power 360W Air pipe size DN65
Gas-liquid separator
Particulate matter and oil-water
Model SLAF-20HC Processing media
mixture
Inlet and outlet pipe Rated processing
DN65 23.5m3/min
diameter air capacity
Centrifugal type
Separation principle Working pressure 0.8MPa
Dehydration
Pressure loss 0.01MPa 99%
efficiency
Discharge time
Discharge interval Automatic Automatic
each time
Internal packing Glass fiber Packing life 8000h
Ultrafilter, degreasing filter
Particulate matter and moisture
Mode SLAF-20HT Dealing media
content
Rated processing air Inlet and output
23.5m3/min DN65
capacity pipe diameter
Centrifugal type
Separation principle Working pressure 0.8MPa
Pressure loss 0.007MPa Precision filter 1μm

Outlet air’s oil Outlet air dust
0 ppm 1μm
content particle size
Outlet air particle Filter element
0.1 mg/m3 Multi-layer glass fiber
concentration type
Filter element
Filter element life 8000h Hangzhou Shanli
manufacturer
Efficient precision filter
Particulate matter and water
Model SLAF20HA Processing media
content
Rated processing air Inlet and outlet
23.5m3/min DN65
capacity pipe diameter
25
Separation principle Centrifugal type Working pressure 0.8MPa
Pressure loss 0.01MPa Filter precision 0.01μm
Outlet air’s oil Outlet air dust
0 ppm 0.01μm
content particle size
Outlet air particle Filter element
0.01 mg/m3 Multi-layer glass fiber
concentration type
Filter element
Filter element life 8000h Hangzhou Shani
manufacturer
1.2.16 Auxiliary steam system
Aux. steam system will provide steam source for this plant. One set of aux.steam header will be
employed with pressure 0.9~1.1 MPa(a), temperature 245~340℃.
Aux. steam comes from the 4th extraction steam during normal operation and from the start-up
boiler during unit start-up. In order to enhance economy of the units during the long term running
period, the steam is supplied by low temperature reheat steam at low load condition, which is
different from the the contract which required that the auxiliary steam is from the main steam.
This system will provide steam for heating water in deaerator, commisioning and standby steam
for BFP turbine, turbine gland sealing, fuel oil atomization, mill fire fighting and etc.
This system refers to drawing no. F4821C-J04-11, P&ID of auxiliary steam system.
steam flow balance sheet of aux. steam system
No. Item Unit Start-up Operation Load rejection
A：Parameter of aux. steam
1 P=0.9～1.1MPa(a)，t=245~340℃
B：Steam consumption
1 Gland sealing steam t/h 5 10 10
Heating steam for water
2 in t/h 30 / 90
deaerator
Commisioning steam for
3 t/h 17* / /
BFP turbine
4 Mill fire control t/h 39* 39* 39*
5 Fuel oil atomization t/h 4 / /
6 Total t/h 39 41 41
C：Aux. steam source
From start-up steam of
1 t/h 39 /
boiler
2 From cold reheat steam t/h / （41） 131
3 From 4th extraction / 41 /
4 Total t/h 39 41 131
D Mass balance t/h 0 0 0
Note: 1 The symbol “*” shows short-term steam consumption, and will not be counted.
26
2. The steam for heating water in deaerator comes from aux. steam system during unit
start-up and low load.
3. Gland sealing steam comes from aux. steam during unit start-up and low load.
2 Unit auxiliary equipment start and stop

2.1 General rule
2.1.1. Notice on the equipment start and stop
2.1.1.1 Before the repaired auxiliary machine is implemented the preliminary operation, it must be
carried out the interlocking and protection test. Its control circuit, automatic device, thermal
interlock protection and mechanical device, pneumatic device should be can be carried out the
preliminary operation after passing the specified tests.
2.1.1.2. The repaired auxiliary machine is allowed to be put into operation or standby only after
passing the trial run. In case the trial run, the person in charge of the maintenance must preside
over it. If the motor has been repaired, it should be connected with the auxiliary machine after
testing the rotation direction rightly, 6kV power equipment shall be first carried out the static on-off
test or has the clear maintenance explanation.
2.1.1.3. Before the auxiliary machine is started for the trial run, it is must be checked on site to
confirm that it is started by the power transmission only after providing with the start condition
2.1.1.4. In case the motor may be damped or shut down for more than one week, the insulation
should be measured to qualify prior to the power transmission or starting up.
2.1.1.5. In case 6kV equipment and important 400V equipment are started, the special person
should be sent to monitor in situ. When starting, the local staff should stand at the emergency
button position, stop in time if the problem is found.
2.1.1.6. On the same bus, two or more auxiliary machines of 6kV can not be activated at the same
time.
2.1.1.7. The tripping occurs if the auxiliary machine is started, it may not be re-activated prior to
the elimination of failure.
2.1.1.8. In case the auxiliary equipment is equipped with the forced circulation lubrication system
or hydraulic control oil system, the oil system should be started within two hours in advance when
the unit is shut down in the winter for a longer time,
9. Must contact with the relevant staff before starting the auxiliary equipments.
2.1.1.10. The auxiliary equipments should be started up in accordance with the logic relations,
they should be avoided to start with the load as far as possible.
2.1.1.11. When the auxiliary machine is started, the special personnel should monitor the current
and start-up time, if the start-up time is in excess of the provision, the current has not yet returned
to the normal operation, he should stop it immediately.
2.1.1.12. Auxiliary equipment start and stop should generally be operated on the CRT
corresponding screen, it should be noted at this time that the control switch is placed on the
"remote" location. For the start and stop operation in-situ, the control switch should be placed on
the "in situ" position.
2.1.1.13. When the auxiliary machines are started or chosen for the back-up, should pay attention
to maintaining the uniform distribution of the auxiliary power loads, the load should be avoided to
centralize on a certain section as far as possible.
2.1.2. Inspection contents prior to starting the equipment
2.1.2.1 The work sheets related to the inspection and start of the equipment have been recovered,
inspect that all the staff withdraw from the scene. Inspect that there is no the debris at the device
and around the device and adequate lighting.
2.1.2.2. Inspect the appearance completeness of the equipment, reliable connection, the security
27
cover of the rotational part should be installed tightly. The manhole door is closed tightly, the foot
screw and connection bolts are not loosened. Meters of the equipment should be put into
operation.
2.1.2.3. Inspect that the equipment bearing has been injected the lubricating oil, the oil quality, oil
level and oil temperature can meet the requirements. The cooling water or sealed water of the
equipment have been put into normal operation, the temperatures of the auxiliary machine and
motor parts should be consistent with the requirements.
2.1.2.4. Check that the motor wiring is firm, with good grounding line, the insulation should be
measured and qualified.
2.1.2.5. Check that the field accident button wiring of the equipment is fine, the security cover is
complete.
2.1.2.6. Should implement a comprehensive inspection based on the system check card, and
inject the oil and water to the water system and oil system and pump body, empty the air.
2.1.2.7. For the auxiliary equipments to be rotated manually, should rotate the rotors, confirm the
rotation flexible, no blockage phenomenon.
2.1.2.8. Complete the inspection before starting the auxiliary equipment, should turn on the power
supply and control power for the auxiliary device and relevant system after confirming with the
start condition.
2.1.3. Inspection after starting the equipment
2.1.3.1. The bearing (W) of the rotating equipment, as well as temperature rise of the gearbox
shall be subject to the provisions of the manufacturer. In case there is not the provisions of the
manufacturer, in general, the sliding bearing shall not exceed 80℃, the rolling bearing shall not
exceed 100℃. (calculation based on 40℃ ambient temperature). The sliding bearing temperature
produced by Shanghai motor factory shall not exceed 90℃; the rolling bearing temperature shall
not exceed 95℃.
2.1.3.2. The vibration of the equipment parts should be in line with the provisions. Bearing
vibration is controlled generally in the table below:
Allowable value of bearing vibration
Rotating speed (r / min) 3000 1500 1000 750 and below
Allowable vibration double
0.05 0.085 0.10 0.12
amplitude value (mm)
2.1.3.3. Motor temperature rise and current indication should be in line with the provisions.
2.1.3.4. The oil level of the lubricating oil tanks are normal, oil leakage-free phenomenon in the
system.
2.1.3.5. The sealed part of the equipment should be sealed well.
2.1.3.6. The equipment and motor have not abnormal sound and friction sound.
2.1.3.7. The mechanical connection of the adjustment devices should be in good order,
non-shedding.
2.1.3.8. The inlet pressure, outlet pressure and flow of the equipment are normal.
2.1.3.9. Confirm that the interlocking and self-adjusting devices are put into operation and normal.
2.1.3.10. System of the equipment has not the water leaking, gas leaking, oil leaking
phenomenon.
2.1.4. Auxiliary equipment outage
2.1.4.1. The outage operation of the auxiliary equipment should be in accordance with the
equipment outage logic relationship.
28
2.1.4.2. The protection, interlocking relationship should be considered before the auxiliary
equipment is shut down, so as to prevent the unsafe situation such as linkage and tripping of the
relevant device.
2.1.4.3. It should also be monitored normally after the auxiliary equipment is shut down, it should
be immediately isolated in case the inversion occurs,
2.1.4.4. In case the relevant auxiliary equipment is stopped in the winter, the necessary antifreeze
measures should be made.
2.1.4.5. When making the isolation overhaul of the auxiliary machine, the isolation operation can
be implemented only after the auxiliary machine should be first shut down.
2.1.5. Emergency outage condition of the auxiliary equipment
2.1.5.1. There is the risk of damage to equipment if the severe vibration or axis movement occurs,
2.1.5.2. Bearing temperature does not abnormally increase or in excess of the specified value.
2.1.5.3. When the motor rotor and stator are seriously rubbed or smoke and on fire.
2.1.5.4. When the auxiliary machine’s rotor and shell are seriously rubbed or impacted.
2.1.5.5. When the auxiliary machine is on fire or flooded.
2.1.5.6. When endangering the personnel safety.
2.2 Air preheater（refer to PID F4821S-K0202-01 F4821S-K0203-02）
2.2.1. Inspection and preparation prior to the air preheater
2.2.1.1 Check that the air preheater and related maintenance work has come to an end, confirm
that no personnel and no other debris are in the air preheater, the handled work sheets are
recovered or ended. All the manhole doors and observation holes etc have been closed. The
scene health is cleaned out.
2.2.1.2 Check on site that the oil level of the driving slowdown gearbox is at 2/3 position of the oil
level gauge. The oil quality is good and non-emulsified phenomenon.
2.2.1.3 Check on site that the oil passage of the guide bearing and thrust bearing of the air
preheater are complete, without leakage oil phenomenon, the oil quality in the oil tank is good and
non-emulsified phenomenon, the oil level is at 2/3 position of the oil level gauge.
2.2.1.4 Check on site that the air preheater water washing and fire water pipeline valve are in good
condition, tightly closed. Sootblowing and water flushing devices are in good condition, the
sootblower can be normally put into operation at the withdrawing position, and the sootblowing
steam source and fire water source are normally supplied.
2.2.1.5 Check on site that the seal gap automatic adjustment device is in a good condition and
lifted to the maximum position. Inject the sealed cooling air of the air preheater seal gap probe.
The air preheater fire alarm device is put into operation by connecting the thermal power, the rotor
is stopped, and the alarm system is put into operation, check if there is no alarm on the control
panel.
2.2.1.6 Check on site that there are no leakage phenomenon in the lubricating oil cooling water
system pipeline, intercept valve and oil cooler, smooth cooling water at the positions. Inspect and
open the inlet and outlet valves of the lubrication system of the air presenter’s guide bearing and
support bearing. The bearing oil cooler of the air preheater is put into operation.
2.2.1.7 Check if the inlet flue gas baffle of the air preheater, primary and second hot air outlet
baffles can be flexibly turned on-off, the field local is on the full-closed position in line with the
shown location of the CRT screen.
2.2.1.8 Confirm that the main and auxiliary motor wiring of the air preheater are fine, the earthing
wire of the motor shell is complete. The anchor screws are complete and solid, the protection hood
of the coupling is complete, the field accident button is complete, the air preheater has the
transmission conditions.
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2.2.1.9 Check that the single interlocking and protection test are qualified
2.2.2. Air Preheater Starting Conditions
2.2.2. 1 Being in remote control mode;
2.2.2.2 Auxiliary motor stops;
2.2.2.3 Main motor without fault signal;
2.2.2.4 Without fire alarm;
2.2.3. Air Preheater Starting
2.2.3.1 Close secondary air baffle at the outlet of air preheater;
2.2.3.2 Close primary air baffle at the outlet of air preheater;
2.2.3.3 Close flue baffle at the inlet of air preheater;
2.2.3.4 Start the main motor of air preheater, check if its turning direction is correct and if the alarm
signal disappears when it stops; input the auxiliary motor for standby purpose;
2.2.3.5 Open the secondary air baffle at the outlet of air preheater;
2.2.3.6 Open the primary air baffle at the outlet of air preheater;
2.2.3.7 Open the inlet flue baffle;
2.2.4. Air Preheater Sequential Starting
2.2.4.1 Click the button for air preheater sequential starting;
2.2.4.2 Start the main motor, lasting for 5s, and start the auxiliary motor when the main motor does
not work;
2.2.4.3 Open flue inlet baffle, secondary air outlet baffle, primary air outlet baffle;
2.2.5. Operation and maintenance of air preheater
2.2.5.1. After the boiler is ignited, the air preheater has been sootblowed continuously with the
auxiliary steam until the oil is stopped. In the normal operation, the boiler is sootblowed once on
each shift. The sootblowing times should be added in case the following phenomena are found:
the oulet air pressure of the air preheater is reduced, the flue gas pressure difference is increased;
significant changes of the boiler load; instable combustion condition, significant changes of the
furnace draft. The rear heating surface is leaked;
2.2.5.2. In the start process of the unit, the seal gap automatic adjustment device is put into
operation automatically by connecting to the thermal power only after the unit load is greater than
50% MCR and has been continuously operating with the load for more than six hours. In the
process of unit outage, when the load is reduced to 50% MCR, the seal gap automatic adjustment
device should be turned off and lifted to maximum position manually.
2.2.5.3. In the course of the air preheater operation, should periodic inspect the air preheater,
which it is not less than twice on each shift, should strengthen the abnormal condition inspection,
there should be no abnormal noise, smooth operation of transmission device, no friction, the motor
current is stabilized within the normal range . If the current is abnormal swinging, should
immediately lift manually the seal gap automatic adjustment device, and take the other measures
such as flue gas temperature decrease and so on.
2.2.5.4. Monitor the changes of the inlet and outlet flue gas pressure difference, wind pressure
difference, inlet and outlet wind and smoke temperature of the air preheater, if the abnormal
condition is found, should analyze the reasons in time and take corresponding measures.
2.2.5.5. In case the inlet and outlet flue gas (wind) pressure of the air preheater increases, the air
preheater should be sootblowed in time.
2.2.5.6. The bearing lubrication system is not leaked, the oil level and oil temperature are normal.
In the operation, the any leakage is not allowable in the reducer, the oil temperature of the tank
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operation is not more than 90 ℃.
2.2.5.7. The "cold-side integrated temperature " (flue gas outlet temperature + air inlet temperature)
of the air preheater is not less than 138℃; flue gas inlet temperature of the air preheater is less
than or equal to 482 ℃.
2.2.5.8. The shell insulation of the air preheater is good, there are not the wind leaked, smoke
leakage phenomenon in the body.
2.2.5.9. The washing water system valve of the air preheater should be closed, the system is
leak-free.
2.2.5.10. Inspect that the support and guide bearing oil temperature of the air preheater are less
than 44℃.
2.2.5.11. when the oil temperature of the guide bearing and support bearing of the air preheater
are greater than 90℃, should alarm and interlock to stop the operation of air preheater.
2.2.6. Air preheater outage
2.2.6.1. Close the inlet flue gas baffle, outlet primary air baffle, outlet secondary air baffle of the air
preheater;
2.2.6.2. Close the back-up of the air presenter’s auxiliary motor, check that the corresponding
suction fan, primary fan are shut down and inlet flue gas temperature of the air preheater is less
than 150℃, close the main motor of the air preheater, air preheater stoppage signal alarm.
2.2.6.3. Air preheater outage process steps
2.2.6.3.1. Close the inlet flue gas baffle of air preheater;
2.2.6.3.2. Close the outlet primary air baffle of air preheater -;
2.2.6.3.3. Close the outlet secondary air baffle of air preheater;
2.2.6.3.4. Close the air presenter’s auxiliary motor standby, stop the air presenter’s main motor.
2.2.7. Air preheater water washing
2.2.7.1. Water washing should be implemented after the boiler is shutdown, it can be not
implemented when the suction fan is running.
2.2.7.2 Cleaning Device Inspection
For the element to remain clean and effective, the cleaning devices must function correctly.
The path of the cleaning device must be unobstructed and all heat transfer surface must be
subjected to the cleaning medium. Operate the cleaning device to verify that no interference exists
between the travel of the cleaning device lance and other air preheater structure. Verify that the
element surface is fully covered by action of the cleaning medium.
2.2.7.3. Prior to cleansing, should check the steam trap opening under the air preheater, the drain
pipe and flooding nozzle are not plugged.
2.2.7.4. Start the flushing pump for the washing.
2.2.7.5. The cold end and hot end of the air preheater should be washed at the same time, and is
used the auxiliary motor for the low-speed operation. After the alkaline flushing is completed, it
should be washed with the clean water once.
2.2.7.6. The washing can be stopped only after the heating surface is rinsed out, stop the washing
pump, close all the intake gate, close the drainage door after the remained water is emptied.
2.2.7.7. When entering the air preheater to inspect the cleaning effect, the air preheater must be
stopped, the power supply is off, should take the safety measures, otherwise, the staff is prohibited
to enter it.
2.3 Suction fan
2.3.1 Inspection and preparation prior to the Suction fan
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2.3.1.1. Inspect the suction fan before starting in line with the provisions of the general rule.
2.3.1.2. Confirm that the suction fan power is supplied. Check that the control power of the inlet
static blade of the suction fan is supplied.
2.3.1.3. Confirm that the power supply of the motor lubricant system, bearing cooling fan are
supplied.
2.3.1.4. Check and the motor oil station of the suction fan is put into operation:
2.3.1.4.1. Check that the oil level and oil temperature of the tank are normal.
2.3.1.4.2. Open the manual isolated valve of the pressure gauge.
2.3.1.4.3. Open the oil supply valve of the motor bearing for the suction fan, inlet and outlet oil
valves of the oil cooler and pump outlet valve, close the bypass valve of the oil cooler and
discharge valves.
2.3.1.4.4. The reverse flow valve of the oil filter is switched to the working position.
2.3.1.4.5. Check that the tank temperature is normal (30 to 40℃), in case the oil temperature is
below 20℃, the electric heater is automatic put into operation; in case the oil temperature is higher
than 40℃, the electric heater is automatically shutdown.
2.3.1.4.6. On the local control cabinet of the fan motor oil station, switch the oil pump select switch
to the #1 (or # 2) oil pump, start # 1 (or # 2) oil pump, the interlock test of the oil pump of the oil
station is normal.
2.3.1.4.7. Check that the outlet pressure of oil pump, differential pressure of the oil filter and outlet
oil pressure of the oil cooler are normal.
2.3.1.4.8. Inject the cooling water. of the oil cooler
2.3.1.5. Start the bearing cooling fan of a suction fan, the electrical interlock test of the bearing
cooling fan is normal.
2.3.1.6. The outlet baffles of all the off-duty suction fan and force fan are opened, the inlet
stationary blade and moving blade are opened, the natural ventilation channel is established.
2.3.1.7. Confirm that the fan interlock protection device is put into operation.
2.3.1.8. Check that the oil return of the motor bearing oil return window of the suction fan is
normal.
2.3.2 Suction fan start condition:
2.3.2.1. Suction fan adjustable baffle position ＜5%；
2.3.2.2. At least one cooling fan is normal operating;
2.3.2.3. Any one lubricating oil pump runs and oil pressure ＞2.0bar；
2.3.2.4. The inlet gas baffle of the suction fan is closed;
2.3.2.5 The outlet gas baffle of the suction fan is closed;
2.3.2.6. This side air preheater is operating normally, and inlet flue baffle of air preheater is
opened;
2.3.2.7. The motor bearing temperature of the suction fan is less than 60℃;
2.3.2.8. The bearing temperature of the suction fan motor is less than 60℃;
2.3.2.9. The coil temperature of the suction fan motor is less than 100℃;
2.3.2.10. The lubricating oil pump of the suction fan motor is running, and to check if oil system
works normally;
2.3.3 Suction fan start
2.3.3.1 Start suction fan and check if current is normal; check if the flue inlet/outlet baffle of such
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fan is automatically opened;
2.3.3.2 Slowly adjust the inlet stationary blade of the suction fan so that the furnace draft is
maintained around-50Pa.
2.3.4 Parallel start the suction fan steps:
2.3.4.1 Confirm that the outlet gas baffles of the parallel suction fans are opened, the inlet gas
baffles are closed, meet the start conditions.
2.3.4.2 Adjust the stationary blade of the running suction fan, so that the furnace pressure is
maintained around -50Pa.
2.3.4.3 Start the parallel suction fan and check if the inelt/outlet flue baffle is automatically opened;
2.3.4.4 Slowly open the stationary blades of the parallel suction fans, turn down the stationary
blades of the parallel suction fans, so as to maintain the furnace pressure around -50Pa
unchanged.
2.3.4.5 When the stationary blade opening, current of two suction fans are basic same, the suction
fans are paralleled, and the aspirating capacity is regulated in accordance with the load
requirements, the stationary blade of the suction fan is put into operation automatically.
2.3.5 Start suction fan process
Press the "suction fan start sequential control" button on the sequential control screen of the
suction fan, then process is carried out in the following steps:
2.3.5.1 Start oil station for the motor of suction fan, lasting for 300s;
2.3.5.2 Start any one of cooling air fans for suction fan;
2.3.5.3 Close suction fan adjustable baffle ＜5%;
2.3.5.4 Close suction fan inlet flue baffle;
2.3.5.5 Close suction fan outlet flue baffle;
2.3.5.6 Start the suction fan.
2.3.5.7 Open inlet/outlet flue baffle of suction fan;
2.3.6 Suction fan operation and maintenance
2.3.6.1 When adjusting the suction fan load, the load deviation of two fans may not be too large, to
prevent the fan from entering the unstable working condition for the running.
2.3.6.2. In the operation, carry out the regular inspection of the suction fan motor lubricant, cooling
water, bearing temperature, suction fan current, etc.
2.3.6.3 Check that the suction fan vibration is not more than 4.6mm/s (0.162mm). In case the
bearing vibration is high to alarm, should immediately check the fan operation in situ, if necessary,
can appropriately reduce the load and observe the operation; in case the bearing vibration
continues to rise to 7.1mm/s (0.198mm) and load decrease is invalid, should report to the shift
foreman and apply for the outage.
2.3.6.4 Check that the oil tank’s oil level and oil pipeline are no leaked, the cooler is no leaked.
2.3.6.5 Check that the filter screen differential pressure indication of the oil system is 0.10MPa, in
case the differential pressure is more than or equal to 0.10MPa, it is switched to the standby filter
screen work, contact the maintenance department to clean-up the filter.
2.3.6.6 Monitor the oil temperature indication of the tank at 30 to 45℃.
2.3.6.7 Check that the back-up oil pump are in good back-up state, the oil pump should be
regularly switched, should pay attention to the lubrication pressure of more than or equal to
0.4MPa when switching.
2.3.6.8 Alarm in case the bearing temperature of the suction fan is more than 80℃, connect and
start another bearing cooling fan.
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2.3.6.9 The suction fan may not be shut down before the boiler- front oil system is not completely
paralleled off.
2.3.7 Suction Fan Alarm Parameter
NO. Descriptions Parameters
1 Suction fan vibration ≥5kPa
Suction fan motor lubricating oil station – filter
2 ≥100kPa
differential pressure
3 Suction fan motor lubricating oil system – major failure
4 Suction fan motor lubrication oil system - normal
5 L Suction fan lubricating oil system outlet pressure low L ＜1bar
6 Suction fan lubricating oil system temperature high H 45℃
Suction fan motor lubricating oil system oil tank – low oil
7
level L
8 Suction fan motor lubricating oil system initial alarm
2.3.8 Suction fan outage

2.3.8.1 Gradually close the suction fan adjustable stationary blade ＜5%;
2.3.8.2 Close the inlet gas baffle of the suction fan
2.3.8.3 Close outlet flue baffle of suction fan;
2.3.8.4 Stop suction fan;
2.3.8.5 Stop all cooling air fans, after all suction fan bearing temperatures ＜ 60℃ and after
30min.since motor has stopped;
2.3.8.6 Stop lubricating oil station after all suction fan bearing temperatures ＜ 60℃ and after
30min.since motor has stopped;
2.3.9 Suction fan protection stops in the following cases:
2.3.9.1 MFT lasting for 3s,and 2/3 furnace pressure ＜﹣2540Pa
2.3.9.2 All air preheater stops with delay for 5s;
2.3.9.3 Suction fan has run for 20s without inlet flue baffle opened;
2.3.9.4 Suction fan has run for 10s without outlet flue baffle closed;
2.3.9.5 Suction fan bearing temp. ＞90℃
2.3.9.6 Suction fan motor bearing temp. ＞90℃
2.3.9.7 Suction fan motor stator coil temp. ＞130℃
2.3.9.8 All suction fan lubricating oil pumps stops with delay for 3s;
2.3.9.9 Vibration HH existed ＞7.1m/s;
2.3.9.10 All cooling air fans stops with delay for 10s;
2.4 Force fan
2.4.1 Preparation before starting
2.4.1.1. Inspect the force fan before starting in line with the provisions of the general rule .
2.4.1.2. Confirm that the force fan power is supplied.
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2.4.1.3. Confirm that the oil system power is supplied and used in the force fan oil system:
2.4.1.3.1. Check that the tank oil level is normal, no less than 75% mm.
2.4.1.3.2. Check that the tank temperature is normal at 35℃ to 45℃; the oil temperature is lower
than 30℃, the electric heater is put into operation.
2.4.1.3.3. Open the pressure gauges and hand-operated valves of the pressure switch, so as to
switch the filter screen reverse flow valve to the working position.
2.4.1.3.4. Start # 1 (# 2) oil pump, set up # 2 (# 1) oil pump as the "automatic", the interlocking
tests of two oil pumps are normal.
2.4.1.3.5. Inspect that the oil pressure and lubrication pressure are normally controlled.
2.4.1.3.6. Inject the cooling water of the cooler in accordance with the requirements.
2.4.1.4. Contact the heat power personnel, supply the power supply of the moving blade
adjustment device of the force fan.
2.4.1.5. Check the moving blade hydraulic regulating device of the force fan, dial (local and main
control room) indication is in line with the moving blade position, and then placed the moving blade
in the closed position.
2.4.1.6. Confirm that the fan interlock input protection device is put into operation.
2.4.2 Force fan start condition:
2.4.2.1 Suction fan works normally;
2.4.2.2 Air preheater runs with outlet baffle opened;
2.4.2.3 Forced draft fan (FDF) moving blade regulation ＜5%;
2.4.2.4 All outlet baffles closed;
2.4.2.5 Any one of lubricating oil pumps runs without oil pressure ＞2.5MPa;
2.4.2.6 All FDF motor bearing temp.＜80℃;
2.4.2.7 All FDF bearing temp. ＜75℃;
2.4.2.8 All FDF motor stator coil temp. ＜100℃;
2.4.3 Force fan startup
2.4.3.1 Start FDF lubricating oil station and check if oil circulation is normal;
2.4.3.2 Close FDF adjustable moving blade ＜5%;
2.4.3.3 Close FDF outlet baffle;
2.4.3.4 Start FDF;
2.4.3.5 Last for 5s, and FDF outlet baffle is automatically opened;
2.4.3.6 Open FDF outlet contact baffle and regulate the FDF moving blade openness as per
needed;
2.4.4 Start the blower steps side by side:
2.4.4.1. Confirm that the inlet moving blade and outlet baffle of the force fan to be started are
closed, meet the start condition.
2.4.4.2. Start the force fan to be paralleled, the outlet baffle is opened automatically after delaying
5s. Check that the outlet connecting baffle of the force fan is closed.
2.4.4.3. Slowly open the force fan ‘s moving blade to be paralleled, confirm the air quantity and
current increase of the force fan, correspondingly turn off the inlet moving blade of the operated
force fan, the total air quantity and thermal secondary air header pressure are maintained basically
unchanged.
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2.4.4.4. When the moving blade opening, current and air quantity of the two force fans are basic
same, the parallel are completed.
2.4.4.5. Set that the bellow / furnace differential pressure is at 380Pa, the auxiliary wind baffle is
set up as automatic operation.
2.4.5 Start force fan process
Press the “force fan start sequential control" button on the sequential control screen of the force
fan, then process is carried out in the following steps:
2.4.5.1. Start the force fan’s lubricating oil station, delay 300s.
2.4.5.2. Regulate FDF inlet moving blade ＜5%；
2.4.5.3 Close the force fan’s outlet baffle;
2.4.5.4. Start the force fan.
2.4.5.5. Open the force fan’s outlet baffle.
2.4.6. Force fan operation and maintenance
2.4.6.1. When adjusting the force fan load, the load deviation of two force fans may not be too
large, so as to prevent the force fan from entering the unstable working condition for the running.
2.4.6.2. Regularly inspect and monitor that the parameters are normal such as force fan lubricant,
oil pressure, oil temperature and oil quantity of the control oil system, as well as force fan bearing
temperature and so on.
2.4.6.3. Check that the force fan vibration and sound are normal. The normal operation bearing
vibration is not more than 4.6mm /s. In case the bearing vibration is high to alarm, should
immediately check the blower operation in situ, if necessary, can appropriately reduce the load
and observe the operation; in case the bearing vibration continues to rise to 11mm/s and load
decrease is invalid, should report to the shift foreman and apply for the outage.
2.4.6.4. Check that the tank oil level of the force fan is normal, the oil system is not leaked.
2.4.6.5. Check that the filter screen differential pressure indication of the force fan oil station is
0.35MPa, in case the differential pressure is more than or equal to 0.35MPa, it is switched to the
standby filter screen, contact the maintenance department to clean-up the filter.
2.4.6.6. Check that the instrument indication of the fan, wind system, oil system and cooling water
system are normal.
2.4.6.7. The standby oil pump should be regularly switched, should pay attention to the lubrication
pressure and control oil pressure when switching.
2.4.7 FDF Alarm Parameters
FDF hydraulic oil pump outlet/inlet filter differential
1 ≥3.5bar
pressure high
2 FDF hydraulic oil pressure OK ≥25bar
3 FDF hydraulic oil pressure low L ＜25bar
4 FDF hydraulic oil pressure low low LL ＜8bar
5 FDF lubricating oil volume low L ＜3L/min
6 FDF surge sensor differential pressure ＞2kPa
7 FDF hydraulic oil tank – oil temp. normal ＞35℃
8 FDF hydraulic oil tank – oil temp. low L ＜25℃
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9 FDF hydraulic oil tank – oil level L ＜243mm
2.4.8. Force fan outage
2.4.8.1. Gradually close down the FDF inlet moving blade ＜%5;
2.4.8.2. Shut down the force fan.
2.4.8.3 Stopping of single FDF linked to closing of FDF outlet baffle, and stopping of both FDF
linked to opening of FDF outlet baffle;
2.4.8.4 All FDF bearing temperatures ＜60℃ and lubricating oil station shut down after 30min
from motor stopping;
2.4.9 FDF protection stops in the following cases:
2.4.9.1 MFT lasts for 3s and 2/3 furnace pressure ＞﹢3234Pa;
2.4.9.2 All air preheaters stop with delay for 10s;
2.4.9.3 All suction fan motors stops with delay for 1s;
2.4.9.4 Suction fans on one side trip and the same on the other side start after 5s;
2.4.9.5 FDF runs for 20s with the outlet baffle not opened;
2.4.9.6 FDF bearing temperature ＞100℃;
2.4.9.7 FDF motor bearing temperature ＞95℃;
2.4.9.8 FDF motor stator coil temperature ＞130℃;
2.4.9.9 All FDF lubricating oil pumps stop with delay for 3s;
2.4.9.10 FDF vibration HH exist (higher than 11mm/s)
2.5 Primary fan
2.5.1. Preparation before starting the primary fan
2.5.1.1. Inspect the primary fan before starting in line with the provisions of the general rule.
2.5.1.2. Confirm that the primary fan power has been supplied.
2.5.1.3. Confirm that the oil system power has been supplied and used in the primary fan and
motor oil system:
2.5.1.3.1. Check that the tank oil level is normal, more than 75% mm.
2.5.1.3.2. Check that the fan tank temperature is normal at 3o℃ to 40℃; in case the oil
temperature is lower than 30℃, the electric heater is put into operation automatically; in case the
in case the oil temperature reaches to 30℃, the electric heater is shut down automatically. The
tank temperature of the fan motor is normal at 3o℃ to 45℃; in case the oil temperature is lower
than 25℃, the electric heater is put into operation.
2.5.1.3.3. Open the pressure gauges and hand operated valve of the pressure switch, so as to
switch the filter screen reverse flow valve to the working position, with filter differential pressure ＜
3.5bar.
2.5.1.3.4. Start # 1 (# 2) oil pump of the fan, set # 2 (# 1) oil pump as the "automatic", switch the oil
pump select switch to the “#1 main #2 auxiliary ” or “ #2 main #1 auxiliary”. Start # 1 (or # 2) oil
pump, the interlocking tests of all oil station pump are normal.
2.5.1.3.5. Inspect that the hydraulic oil pressure and lubrication pressure are normal.
2.5.1.3.6. Inject the cooling water of the cooler.
2.5.1.4. Contact the heat power personnel, supply the power supply of the moving blade
adjustment device of the primary fan.
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2.5.1.5. Check the moving blade hydraulic regulating device, carry out the full-open (+15°), full-off
(-30°) test of the adjustable moving blade, dial (local and main control room) indication is in line
with the moving blade position, and then placed the moving blade in the closed position.
2.5.1.6. Confirm that the primary fan interlock protection device is put into operation...
2.5.2 Primary fan start condition:
2.5.2.1 No MFT;
2.5.2.2 Any FDF runs;
2.5.2.3 Air preheater runs with primary outlet baffle opened;
2.5.2.4 Primary air fan (PAF) adjustable moving blade position ＜5%;
2.5.2.5 PAF outlet baffle closed;
2.5.2.6 Any hydraulic oil pump runs with oil pressure＞2.5MPa;
2.5.2.7 Any lubricating oil pump runs with all PAF motor bearing temperatures ＜70℃;
2.5.2.8 PAF bearing temperature ＜80℃;
2.5.2.9 PAF motor stator temperature ＜100℃;
2.5.3 Primary fan start
2.5.3.1 Start PAF motor lubricating oil station, and check if oil system is well established;
2.5.3.2 Start PAF hydraulic oil station, and check if oil system is well established;
2.5.3.3 Close PAF adjustable moving blade ＜5%;
2.5.3.4 Close PAF outlet baffle;
2.5.3.5 Start PAF, lasting for 5, and the outlet baffle and the primary cold air baffle to the main tube
are automatically opened;
2.5.4. Parallel start primary fan steps:
2.5.4.1. Confirm that the inlet moving blade and outlet baffle of the primary fan to be started are
closed, meet the start condition.
2.5.4.2. Start the PAF to be paralleled, lasting for 5s, and the outlet primary cold/hot air baffle are
automatically opened;
2.5.4.3Slowly open the primary fan’s moving blade to be paralleled, confirm the air quantity and
current increase of the primary fan, correspondingly turn off the inlet moving blade of the operated
primary fan, the primary air header pressure are maintained basically unchanged.
2.5.4.4. When the moving blade opening, current and air quantity of two primary fans are basic
same, the parallel is completed.
2.5.5 Start primary fan process
Press the "primary fan start sequential control" button on the sequential control screen of the
primary fan, then process is carried out in the following steps:
2.5.5.1 Start PAF lubricating oil station, lasting for 300s;
2.5.5.2 Start PAF hydraulic oil station;
2.5.5.3 Close PAF adjustable blade ＜5%;
2.5.5.4 Close PAF outlet baffle;
2.5.5.5 Start PAF;
2.5.6 Primary fan operation and maintenance
2.5.6.1. When adjusting the primary fan load, the load deviation of two fans may not be too large,
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so as to prevent the fan from entering the unstable working condition for the running.
2.5.6.2. In the normal operation, the outlet wind pressure of the primary fan shall not exceed
13kPa. In case the wind pressure can be not maintained due to the ash blocking in the air
preheater etc, the unit output should be reduced.
2.5.6.3. Regularly inspect and monitor that the parameters are normal such as primary fan
lubricant, oil pressure, oil temperature and oil quantity of the control oil system, as well as fan
bearing temperature and so on.
2.5.6.4. Check that the primary fan vibration is not more than 4.6mm /s. In case the bearing
vibration is high to alarm, should immediately check the fan operation in situ, if necessary, can
appropriately reduce the load and observe the operation; in case the bearing vibration continues
to rise to 11mm/s and load decrease is invalid, should report to the shift foreman and apply for the
outage.
2.5.6.5. Check that the tank oil level is normal, the oil system is not leaked.
2.5.6.6. Check that the filter screen differential pressure indication of the primary fan oil station is
less than 0.35MPa, as well as the filter screen differential pressure indication of the motor oil
station is less than 0.05MPa. In case the differential pressure is more than or equal to 0.35MPa or
0.04MPa, they should be switched to the standby filter screen, contact the maintenance
department to clean-up the filter screen.
2.5.6.7. Check that the instrument indication of the fan, wind system, oil system and cooling water
system are normal.
2.5.6.8. The standby pump should be regularly switched, should pay attention to the lubrication
pressure and control oil pressure when switching.
2.5.7 Primary Air Fan (PAF) Alarm Parameters
PAF hydraulic oil pump outlet/inlet filter differential
1 ＞3.5bar
pressure high
2 PAF hydraulic oil pressure normal ＞25bar
3 PAF hydraulic oil pressure low L
4 PAF hydraulic oil pressure low low LL ＜8bar
5 PAF lubricating oil flow low L ＜3L/min
6 PAF hydraulic oil tank – oil temperature normal ＞35℃
7 PAF hydraulic oil tank – oil temperature low L ＜25℃
8 PAF hydraulic oil tank – oil level low low LL ＜243mm
9 PAF surge sensor differential pressure ＞2kPa
10 PAF lubricating oil station works normal
11 PAF lubricating oil station – major failure
12 PAF lubricating oil station – minor failure
13 PAF lubricating oil station – pressure normal ＞0.2MPa
14 PAF lubricating oil station – differential pressure high
15 PAF lubricating oil station – oil flow low
16 PAF lubricating oil station – outlet oil temperature high
17 PAF lubricating oil station – pressure low
39
18 PAF lubricating oil station – oil level high
19 PAF lubricating oil station – oil level low
2.5.8. Primary fan outage
2.5.8.1 Close PAF adjustable blade ＜5%；
2.5.8.2 Stop PAF running;
2.5.8.3 All PAF bearing temperatures ＜60℃, and lubricating oil station and hydraulic oil station
stop after 30min from motor stopping;
2.5.9 PAF protection stops in the following cases:
2.5.9.1MFT
2.5.9.2 All FDF stops with delay for 1s;
2.5.9.3 All suction fans stop with delay for 1s;
2.5.9.4 PAF runs for 20s with the outlet baffle not opened;
2.5.9.5 PAF bearing temperature ＞90℃;
2.5.9.6 PAF motor bearing temperature ＞95℃;
2.5.9.7 PAF motor stator temperature ＞130℃;
2.5.9.8 All PAF lubricating oil pumps stop with delay for 3s, or low oil pressure and low oil flow;
2.5.9.9 All PAF hydraulic oil pumps stop with delay for 3s;
2.5.9.10 PAF vibration HH exists (higher than 11mm/s);
2.6 Sealing fan
2.6.1 Preparation prior to starting
2.6.1.1. Inspect the sealing fan before starting in line with the provisions of the general rule.
2.6.1.2. Confirm that the sealing fan power has been supplied.
2.6.1.3. Confirm the input of sealing fan interlock protection device;
2.6.2. Sealing fan start condition:
2.6.2.1 Any one PAF running;
2.6.2.2 Sealing fan outlet baffle is closed;
2.6.3 Start the sealing fan
2.6.3.1. Start the sealing fan, check if it runs normally with correct electric current, slowly open the
outlet baffle to make the difference of sealing air pressure and primary air pressure ＞1.85kPa;
2.6.3.2. After checking the stability of the sealing wind pressure, the automatic regulation of the
sealing fan is put into operation.
2.6.3.3. After checking that the wind pressure is normal, the back-up sealing fan is set up as the
"backup."
2.6.4 Sealed fan operation and maintenance
2.6.4.1. Under normal circumstances, a sealed fan is maintained for the operation, another sealed
fan is maintained as the back-up.
2.6.4.2. Air fan tripping occurrence or air pressure of main pipe lower than 12.5kPa, or sealing air /
primary air pressure difference ＜1.85kPa, are linked to starting of standby air fan;
2.6.4.3. Regularly check that the inlet regulating baffle of the sealed fan is in good automatic
condition, the sealing air pressure meet the operational requirements.
40
2.6.4.4. The lubricant oil level of the sealed fan bearing is normal, good oil quality.
2.6.4.5. The temperatures of the sealed fan bearing and motor bearing should be less than 75℃.
2.6.4.6. The temperatures of the sealed fan motor coil and iron core should be less than 100℃
2.6.5. Sealed fan outage
2.6.5.1. The seal fan can be shut down only after the coal mill is fully shut down.
2.6.5.2. Switch the sealing fan’s outlet regulating baffle from "automatic" to "manual."
2.6.5.3. Gradually close the sealing fan’s outlet regulating baffle.
2.6.5.4. Shut down the sealed fan.
2.6.6 Sealing air fan protection stops in the following cases:
2.6.6.1. MFT；
2.6.6.2. All PAF stop with delay for 3s;
2.6.6.3. Sealing air fan starts running with delay for 20s, and outlet baffle is closed;
2.7 Flame check cooling fan
2.7.1 Flame check cooling fan start
2.7.1.1 Inspect the flame check cooling fan before starting in line with the provisions of the
general rule.
2.7.1.2 Confirm that the flame check cooling fan power has been supplied.
2.7.1.3 Start the flame check cooling fan, check the automatic open of the outlet valve.
2.7.1.4 After checking that the flame check wind pressure is normal, the back-up flame check
cooling fan is put into operation as the "backup."
2.7.2 Flame check cooling fan operation and maintenance
2.7.2.1 Under normal circumstances, a flame check cooling fan is maintained for the operation,
another flame check cooling fan is maintained as the back-up.
2.7.2.2 If the running fan is tripped or header tube wind pressure is low, the back-up fan should
be linked.
2.7.2.3 After the boiler is extinguished, the flame check cooling fan is maintained for the
operation, the flame check cooling fan can be shut down only after the furnace outlet gas
temperature is less than 80℃.
2.7.2.4 Regularly check the inlet filter screen situation of the flame check cooling fan, when the
outlet wind pressure is less than 6.0kPa, should contact the maintenance personnel to clean-up
the filter screen.
2.7.2.5 The tripping of fire detection cooling air fan or outlet air pressure <5.6kPa is interlinked to
automatic operation of standby cooling air fan;
2.7.2.6 Check that the vibration is normal, the motor temperature is normal.
2.7.3 Flame check cooling fan outage
2.7.3.1 Inspect that the flame check cooling fan is in line with the outage conditions, the back-up
interlock of the flame check cooling fan is released.
2.7.3.2 Shut down the flame check cooling fan.
2.7.3.3 If the flame check cooling fan is switched for the operation, the running flame check
cooling fan can be shut down only after the back-up flame check cooling fan should be started and
flame check wind pressure is applicable, it is will be used for the "back-up" after shutting down
2.8 Boiler water pump
41
Please Refer toBoiler Instruction Volume Ⅸ: Circulating Pump System and Accessories No.:
F0310XH001D101）
2.8.1. Process
2.8.1.1 High-pressure Water Flow Process
Water filling or flushing:
Demineralized water to condensate make-up water main pipe → filter → high-pressure
flushing cooler → isolation valve → motor → motor cooler → motor → overflowing from
seal gap to pump body;
Normal operation (lower than 2MPa):
Motor chamber→ auxiliary impeller→ motor cooler→ motor chamber;
Emergency condition:
Superheater attemperating water main pipe→ filter→ high pressure flushing cooler→
isolation valve→ motor→ motor cooler→ motor→ overflowing from seal gap to pump
body;
2.8.1.2 Low-pressure Water Flow Process
Closed cooling water booster pump (or emergency cooling water pump) → motor cooler
→ isolator cooler → high pressure filling water cooler → backwater main pipe;
2.8.2. Operation Test of Boiler Circulating Pump and High/Low Pressure Cooling Water System
Valves
Conduct single operation test for boiler circulating pump and all system valves, ensure
the valve operation flexibly, switch direction correct and full opening & closing in place;
2.8.3. Flushing of High/Low Pressure Cooling Water System of Boiler Circulating Pump
2.8.3.1 Low pressure cooling water system flushing and operation (take one pump as example,
the same to the other two pumps) (see attached fig. 1)
2.8.3.1.1 Flushing of low pressure cooling water system is in the following procedures:
Disconnect respectively the inlet flanges of motor chamber cooler, isolator cooler and
high pressure flushing water cooler, which are connected respectively to a temporary
hose to a safe position of trench;
2.8.3.1.2 Flushing Process
A. Contact turbine specialty to open closed cooling water;
B. Launch a cooling water booster pump;
C. Open valve #20, observe the water quality at drain outlet, and closed the valve after
water satisfied;
D. Open valve #22, observe the water quality at drain outlet, and closed the valve after
water satisfied;
E. Open valve #28, observe the water quality at drain outlet, and closed the valve after
water satisfied;
After the inlet flushing completed, connect respectively the inlet flanges of motor
chamber cooler, isolator cooler and high pressure flushing water cooler;
F. Open valve #20 → open valve #30, totally exhaust air and close it →open valve #31,
totally exhaust air and close it → open valve #25 and #21 until water returned → close
valve #25 after water qualified, open valve #24 and adjust water flow to 2 m3/h;
42
G. Open valve #22 → open valve #32, totally exhaust air and close it →open valve #33,
totally exhaust air and close it → open valve #26 and #23 until water returned → close
valve #26 after water qualified, open valve #27 and adjust water flow to 11 m3/h;
H. Open valve #28 → open valve #34, totally exhaust air and close it → open valve #29.
2.8.3.1.3 Low-pressure Cooling Water Quality Requirements (Recommended Values)
General quality requirement: Cleaning, demineralizing, no sediments produced under
operation temperature, non-corrosive;
Suspended solids in solution: ≤5ppm
Inlet temperature: ≤38℃
PH: Normal 9.5
※Maintain a long term of low pressure water system operation, in case of system
shutdown due to leakage or other causes, confirm at first if conditions allow;
2.8.3.2 High pressure cooling water system flushing and operation (take one pump as example,
the same to the other two pumps) (see attached fig. 2)
2.8.3.2.1 Flushing Process
Flushing uses water from makeup main pipe of demineralized water to condensate
system (contact chemical specialty to maintain water pressure larger than 0.7Mpa);
A. Respectively launch electric feedwater pump and condensate pump;
B. Open valve #1 → open valve #4 → open valve #5 until water qualified → close valve
#1
C. Open valve #2 & #3 → open valve #4 → open valve #5 until water qualified → close
valve #2, #3 and #5
D. Open valve #2 & #3 → open valve #4 → open valve #14 → open valve #15 → open
valve #17 until water qualified → close valve #15 & #17 → open valve #12 until water
qualified
2.8.3.2.2 High-pressure Flushing Water Quality Requirements
Flushing requirement:
Suspended solids in solution: ≤0.25ppm(max.)
Temperature range: 21∼49℃
Recommended water flow for each pump: 0.7~1. 1m3/h
Cleaning system pressure: larger than pump outlet pressure 0.21~0.275MPa
※The valves of other high pressure systems are all closed in the process except the
valves mentioned above;
2.8.4 Water Filling of Motor Chamber
2.8.4.1 Fill water in motor chamber of boiler circulating pump after the flushing of high pressure
cooling water system is qualified. The filling water must be qualified condensate. Ensure
pump outlet valve #19 is closed before filling water;
2.8.4.2 Wear Filling Process:
A. Ensure low pressure cooling water for motor chamber cooler, isolator cooler and high
pressure flushing water cooler is in flowing status, and in normal flow and pressure;
B. Ensure pump outlet valve #19 is closed;
C. Close bypass valve #8;
D. Open bypass vent valve #18 and drain valve #6;
43
E. Open isolator drain valve #7;
F. Close drain valve #11, open valve #2, #3, #4, #14 and #12 to connect the water filling
pipeline, of which the valve #12 is used for discharging of oxide scale or other
impurities in the pipeline. Adjust the opening of valve #14 to discharge the cleaning
water in a flow approx. 1.5gallon (0.0057m3) per minute to the outside. After
adjustment of valve #14 completed, close valve #12 and open valve #9 and #16.
※Close valve #7 whenever the valve #16 and #9 are opened for water filling or water
outflow without air mixing is discharged from drain valve #18. Keep on filling water
until water outflow without air mixing is discharged from drain valve #6, then close
valve #18; Keep on filling water until water outflow without air mixing is discharge from
vent valve #6, then close valve #6.
Conduct water filling to three boiler circulating pumps as per above said.
2.8.5 Boiler Water Filling

2.8.5.1 Boiler water filling can be conducted after completion of pump water filling above said.
Switch flushing water to the main pipeline (superheater attemperating water main pipe) in
filing process: open valve #1, then close valve #2 and #3.
2.8.5.2 After boiler water filling completed, open boiler circulating pump outlet valve #19;
2.8.5.3 Inching for venting before startup of boiler circulating pump;
2.8.5.3.1 After boiler water filling completed, ensure the startup conditions of boiler circulating
pump are satisfied;
2.8.5.3.2 Inch the motor for 5s, stop for 15min; repeat the operation for three times;
※After motor venting completed, launch boiler circulating pump as normal;
2.8.5.4 The motor shall maintain in working state in the following circumstances:
2.8.5.4.1 In the process of boiler water filling;
2.8.5.4.2 In the process of boiler circulating pump inching and venting;
2.8.5.4.3 In the process of boiler hydraulic test, and before the boiler pressure under 2.00MPa;
2.8.5.4.4 In the process of boiler ignition startup, and before boiler pressure under 2.00MPa;
2.8.5.4.5 In the process of boiler acid cleaning;
※ Ensure the motor does not need water filling any more, close the valves in the sequence: valve
#8 and #14 at first, and then valve #16;
※ Stop flushing after boiler ignition pressure reaches 2mpa, open valve #12 and check the system
valve tightness, cold water outflow indicating the valve #14 on high pressure filling water side is
not tight enough, hot water outflow indicating the drain valve #11 is not tight enough, and no
water outflow indicating valve tightness satisfied. Close valve #12 after inspection completed;
※ Standby high pressure cooling water is provided up to vlave 14; in case of emergency condition,
open valve #14, #15 and #16 when high pressure is needed;
2.8.6 Inspection before Boiler Circulating Pump Startup
2.8.6.1 Ensure low pressure cooling water system is in normal operation state, valves in correct
positions and cooling water flow meeting requirements;
2.8.6.2 Ensure high pressure cooling water system is in normal operation state and valves in
correct positions;
2.8.6.3 Ensure boiler circulating pump has been fully filled with water and in the state of
continuous water filling;
44
2.8.6.4 Ensure differential temperature between suction header and pump casing is smaller than
55℃;
2.8.6.5 Ensure motor power is normal, and motor insulation is qualified;
2.8.6.6 Ensure measuring instruments of boiler circulating pump are complete and in correct
precision;
2.8.6.7 Ensure the outlet valves of boiler circulating pump are in full-open position;
2.8.6.8 Ensure the drum water level is in the highest visible level;
2.8.7 Startup and Stopping of Boiler Circulating Pump
2.8.7.1 After confirmation of boiler circulating pump startup conditions, launch the pump in startup
procedures. Close valve #8 after normal startup of boiler circulating pump.
2.8.7.2 Stopping of Boiler Circulating Pump
A. Stop boiler circulating pump;
B. Open bypass valve #8 and isolator drain valve #7;
C. Maintain pump outlet valve #19 and low pressure cooling water system valve is in
opened state;
2.8.8 Water Drainage of Boiler and Boiler Circulating Pump
2.8.8.1 Before draining water in boiler, maintain the outlet valve #19 of boiler circulating pump is in
closed state;
2.8.8.2 Before draining water in motor chamber, check if the boiler water has been drained and if
the motor chamber temp. ≤50℃;
2.8.8.3 Open valve #8, #18 and #6, confirm the water in pump and downcomer is all drained;
2.8.8.4 Open valve #10, #11, #12 and #13, drain the water in motor chamber;
2.8.9. Relevant Alarms and Protections of Boiler Circulating Pump

2.8.9.1 Relevant alarms of boiler circulating pump:
2.8.9.1.1 Alarm when motor chamber temperature higher than
2.8.9.1.2 Alarm when the low pressure cooling water flow is low, interrupted or lower than 70% of
rated flow;
2.8.9.1.3 Alarm when the temperature difference of pump casing and suction header is larger than
55℃;
2.8.9.1.4 Alarm when the boiler pump inlet/outlet pressure difference is low (smaller than
0.7kg/cm2; MFT action when the same of three pumps are all smaller than 0.7kg/cm2)
2.8.9.2 Tripping conditions of boiler circulating pump:
2.8.9.2.1 Tripping when motor chamber temperature is higher than 60℃;
2.8.9.2.2 All cooling water booster bump stopped and emergency cooling water pump stopped for
10s
2.8.9.2.3 Temperature different value between BCP cover metal and inlet pipe metal higher than
50℃ delay 5s
Fig.1 Low Pressure Cooling Water
45
34 28
29
31 33
30
水源 32
26 27
来自
除盐 25
水箱 24
闭式水泵事故
冷却 21 20 22 23
炉水泵水泵
冷却水
增压泵
Chinese English
闭式水泵 Closed water pump
Boiler water pump/Cooling water
炉水泵/冷却水增压泵
booster pump
水源来自除盐水箱 Water from demineralized water pump
事故冷却水泵 Emergency cooling water pump
46
4
5 1 3
2
去另两台泵
14 6
15
16
19 19
8
7
17 18
10
13
11
12
接自过热器减温水母管
接自除盐水至凝结水系统补水母管
Fig. 2 High Pressure Cooling Water
Chinese English
去另两台泵 To the other two pumps
From superheater attemperating water
接自过热器减温水母管
main pipe
From demineralized water to
接自除盐水至凝结水系统补水母管 condensate system makeup water main
pipe
47
2.9 Boiler-front fuel oil system shutdown
2.9.1 Inspection before the boiler-front fuel oil system is put into operation
2.9.1.1 The boiler-front fire equipment is complete and in good condition, the fire water system is
put into operation.
2.9.1.2 The fuel regulator valve, trip valve, oil gun feeding solenoid valve and recirculation valve
have been calibrated and qualified, normal action.
2.9.1.3 Close the oil gun feeding solenoid valves.
2.9.1.4 The oil fuel atomizing steam system is put into operation, with pressure of 0.6 to 0.8MPa
and temperature of 200-240℃.
2.9.1.5 Check that the compressed air pressure to the oil gun control gas sources are normal, the
gas source valves are opened.
2.9.1.6 Check that it is normal from the flame check cooling fan to the oil gun flame check cooling
fan.
2.9.2 Boiler-front fuel oil system is put into operation
2.9.2.1 Confirm that the fuel feed pump is functioning properly, the boiler-front fuel oil pressure is
normal.
2.9.2.2 Open the feeding and oil return manual main valves of boiler-front fuel header tube, open
the oil return recycling front and rear intercept valves, check that the bypass valves are closed.
2.9.2.3 Open the front and rear leaf-doors of the feeding and oil return flowmeter, check that the
bypass doors are closed. Open the front and rear intercept valves of the fuel header tube’s feeding
filter screen, check that the bypass valves are closed.
2.9.2.4 Open the front and rear intercept valves of the fuel layer pressure regulating valve, check
that the bypass valves are closed. Open the front and rear intercept valves of the oil gun atomizing,
purge steam manual main valve and baffle, check that the bypass valves are closed.
2.9.2.5 Open the oil feeding manual valves and atomization, purge steam manual valve to the oil
guns.
2.9.2.6 After the purge is completed 5 minutes prior to igniting the furnace, implement the fuel
header pipe leak test, open the fuel header tube trip valve, oil return trip valve.
2.9.2.7 Inspect that the fuel layer oil pressure is normal, good fuel oil automatic adjustment and
normal atomization steam pressure.
2.9.2.8 Inspect that the oil pressures of various layer oil guns are normal, the fuel system is no
leaked.
2.9.2.9 The boiler-front oil system should be maintained the continuous operation in the boiler
operation to ensure that the oil gun is used for the oil combustion at any time.
2.9.3 Boiler-front oil system parallel off
After the oil guns are shut down, purged and completed, close the fuel trip valve, front and
rear intercept valves, close the front and rear intercept valves of the oil return trip valve, shut down
the feeding manual intercept valves of the oil guns, close the boiler-front feeding and oil return
main tube manual intercept valve.
2.9.4 Oil gun shutdown
2.9.4.1. Inspection before the oil gun is put into operation
2.9.4.1.1 Inspect that the boiler-front fuel system operation is normal;
2.9.4.1.2 Inspect that the boiler-front atomized steam system is operating normally;
2.9.4.1.3 Inspect that the flame check cooling air system is operating normally;
2.9.4.1.4 Inspect that the oil guns are on the withdraw position and in good condition;
48
2.9.4.1.5 Inspect that oil gun flame check is in good condition, the flame check cooling wind is
normal.
2.9.4.2. Allowable conditions for oil gun operation:
2.9.4.2.1 MFT reset;
2.9.4.2.2 OFTresset;
2.9.4.2.3 Fire detection cooling air fan works normally (any air fan runs without pressure alarm) ＞
6.5KPa;
2.9.4.2.4 Atomizing steam pressure ＞0.8MPa；
2.9.4.2.5 Fuel oil supply pressure ≥1.5 MPa, and low fuel oil pressure switch not act (＜0.6 MPa)
2.9.4.2.6 Fuel oil trip valve is opened;
2.9.4.2.7 Purging air flow normal＞35%；
2.9.4.2.8 All burners are in the horizontal position (40～60)
2.9.4.3. Oil gun is put into operation
Under normal circumstances, the oil guns on each layer are set up on the "program-control ",
"remote" position.
2.9.4.3.1 Confirm that the oil gun operation condition is met.
2.9.4.3.2 Click the "program start fuel layer" button on the control screen of the fuel layer, # 1 angle
oil gun is put into operation, and then followed by # 3, # 2, # 4 angle oil guns every 15 seconds.
2.9.4.3.3 Click the " program start # 1, # 3 angle" button or " program start # 2, # 4 angle " button
on the control screen of the fuel layer, # 1 angle or # 2 angle oil guns are put into operation, # 3
angle or # 4 angle oil guns are put into operation every 15 seconds.
2.9.4.3.4 Click the "start" button of the corresponding angle oil gun on the control screen of the fuel
layer, the corresponding angle oil gun is put into operation.
2.9.4.3.5 Oil gun commissioning steps
2.9.4.3.5.1 Impel the oil gun;
2.9.4.3.5.2 Impel the igniter while igniting;
2.9.4.3.5.3 Open the steam atomized valve of the oil gun;
2.9.4.3.5.4 Open the angle valve of the oil gun.
2.9.4.3.6 In case there is the fire for the flame check within five seconds after the angle valve of
the oil gun is started, the oil gun is put into operation successfully.
2.9.4.3.7 If certain oil gun fails in igniting, the ignition only sustains for 25s;
2.9.4.4 Oil gun outage condition
2.9.4.4.1 The oil gun is not impelled in place after issuing the oil gun start instruction 10 seconds;
2.9.4.4.2 The oil gun angle valve is not started after impelling the oil gun oil 15 seconds;
2.9.4.4.3 There is not fire for the flame check after starting the oil gun 15 seconds;
2.9.4.4.4 The oil gun is impelled in place for 50s, but it does not run;
2.9.4.4.5 Fuel trip valve is closed;
2.9.4.4.6 Low fuel pressure ≤5bar
2.9.4.4.7 Low steam atomization pressure ＜4.8bar
2.9.4.4.8 There are the outage instructions;
2.9.4.4.9 There is OFT working condition or OFT relay is tripped.
49
2.9.4.5 Oil gun normal outage
2.9.4.5.1 Click the "program stop fuel layer" button on the control screen of the fuel layer, # 1 angle
oil gun is stopped, followed by # 3, # 2, # 4 angle oil guns every 30 seconds.
2.9.4.5.2 Click the " program stop # 1, # 3 angle" buttons or " program stop # 2, # 4 angle " buttons
on the control screen of the fuel layer, # 1 angle or # 2 angle oil guns are stopped, # 3 angle or # 4
angle oil guns are stopped every 30 seconds.
2.9.4.5.3 Click the "stop" button of the corresponding angle oil gun on the control screen of the fuel
layer, the corresponding angle oil gun is stopped.
2.9.4.5.4 Withdraw after purging the oil gun.
2.9.4.6 Oil gun purge
Under the allowable conditions of the fuel ignition, as long as the oil- gun program stop command
is issued, then the request purge signal of oil gun is triggered.
2.9.4.6.1 Oil gun purge conditions
2.9.4.6.1.1 Oil gun purge request, delay 2s.
2.9.4.6.1.2 Oil gun is impelled in place;
2.9.4.6.1.3 Oil gun angle valve is shut down;
2.9.4.6.1.4 Purge-steam pressure is normal.
2.9.4.6.2 Oil gun purge steps
After meeting the oil gun purge conditions, the oil gun purge will be started by the purge
command in the following steps:
2.9.4.6.2.1 Start the atomized valve while the igniter is impelled and ignited;
2.9.4.6.2.2 Open the purge valve;
2.9.4.6.2.3 The purge valve is closed after purging 60 seconds, while the atomized valve is closed
and the oil gun is withdrawn.
2.9.5. Inspection and maintenance in the operation of the oil gun
2.9.5.1 Check that the boiler-front oil pressure is normal.
2.9.5.2 Check that the oil and gas pipelines are not leaked.
2.9.5.3 Check the fire condition of the oil gun in the operation, and if the adverse fire is found, it is
withdrawn to remove the failure in time.
2.9.5.4 After the oil gun is shut down, the oil pipeline shall be immediately purged, and then the oil
gun is withdrawn.
2.9.5.5 In the normal operation of the boiler, should check that the oil gun is in a good standby
state. All the oil gun should be in the "remote control" position, the oil gun is prohibited to switch to
the "single-operation" position. (Single-operation position is only used in the maintenance or
testing of the oil gun)
2.9.5.6 Outage oil gun and igniter should be on the complete withdrawal position, or should
contact with the maintenance staff fro the processing.
2.9.5.7 The boiler–front oil system should be in good cycle standby state in the boiler running.
2.10 Coal mill, coal feeder and its system
2.10.1. Except for the implementation of the inspection prior to starting in line with the provisions of
general rule, the following examinations should be carried out:
2.10.1.1 Prior to starting, the baffle inspection and testing has been completed, the baffle positions
are correct. Check that the power supply has been supplied.
2.10.1.2 Inspect that the oil tank’s oil level and oil temperature of the coal mill oil station are normal,
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the electrical heating is put into operation at low temperature.
2.10.1.3 Electrical interlock, thermal power protection, automatic device and alarm system are
normally put into operation.
2.10.1.4 Inspect that the baffle positions of the coal mill are indicated correctly.
2.10.1.5 The sealed fan has been put into operation, the appropriate air pressure. Seal air and
primary air differential pressure are normal.
2.10.1.6 A primary air fan is at least put into operation, and the primary air header tube pressure is
more than 10kPa.
2.10.1.7 Check that the coal feeder and coal feeder’ sealing device are normal, the observation
window is clean and perspective.
2.10.1.8 Check that the boiler-front oil system, burner and oil gun are in line with the operation
conditions.
2.10.1.9 The slagging box’s dropping slag valve of the coal mill is opened, the slagging valve is
closed, the slagging box has been cleaned out.
2.10.1.10 Inspect that the filter screen differential pressure of the coal mill lubricant station is
normal, less than 2.5MPa, if the high filter screen differential pressure is found, it is switched to the
standby filter screen, and promptly notify for the maintenance and clean-up.
2.10.1.11 Check that the grinder roll spring loading system is normal, the separator’ s baffle is
correctly positioned.
2.10.1.12 Inspect that the vapor pressure of the coal mill is normal, the temperature is qualified.
Steam manual valve of the coal mill is opened, the electrically operated door is closed.
2.10.1.13 Inspect and open the sealed baffle of the coal feeder, the primary air fast turn-off baffle
of the coal mill.
2.10.1.14 The local control box signal of the coal mill is correct, it is controlled at the "remote"
location.
2.10.1.15 The lighting in the coal mill is in good condition, there are not the accumulated coals and
sundries in the machine body.
2.10.1.16 Check that the tension of the coal mill belt is suitable, there are not the damage and
deviation and so on phenomenon.
2.10.1.17 Check that the sag of the purge conveying chain is appropriate.
2.10.1.18 Contact the fuel to confirm the adequate coal quantity in the run coal bin.
2.10.2 Coal mill oil station operation
2.10.2.1 Coal mill’s lubricant station operation
2.10.2.1.1 Check that there is no oil-leakage phenomenon in the lubricant station, the oil level is
more than 2/3, the oil temperature is more than 25℃.
2.10.2.1.2 Start the lubricant pump, check the inlet lubricant oil pressure of the gear reducer is
more than or equal to 0.10MPa.
2.10.2.1.3 In case the oil return temperature of the gear reducer is less than or equal to 40℃, the
disk heat belt is automatically turned on and heating is started;
2.10.2.1.4 In case the oil tank’s oil temperature of the lubricant station is less than or equal to 35℃,
the electrical heating device is automatically put into operation; in case of more than 40℃, the
electric heating device is automatically cut-off.
2.10.3 Allowable furnace ignition condition
2.10.3.1 No MFT condition;
2.10.3.2 Flame check cooling air pressure is normal;
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2.10.3.3 Suitable air volume
2.10.3.4 Furnace purge completion;
2.10.3.5 Fuel leak trial completion .
2.10.4 Allowable coal-fired ignition condition
2.10.4.1 No MFT signal;
2.10.4.2 Any one of PAF runs with air preheater outlet hot primary air pressure ＞63.5mbar；
2.10.4.3 Air preheater outlet hot air temperature ＞177℃
2.10.5. Allowable coal mill ignition condition
2.10.5.1 Three from four, oil guns in layer AB are in running;
2.10.5.2 Coal mill B running and coal feeding amount ＞50t/h, and unit load ＞264MW (note: for
coal mill B, this phrase shall be changed to be: coal mill A or C running and coal feeding amount
＞50t/h，and unit load ＞264MW);
2.10.5.3 Unit Load ＞396MW
2.10.6. Coal feeder start conditions
2.10.6.1 Coal feeder has been activated;
2.10.6.2 Seal air baffle of coal feeder is opened;
2.10.6.3 Outlet baffle of coal feeder is opened;
2.10.6.4 All outlet baffles of coal mill are opened;
2.10.7. Coal mill start condition
2.10.7.1 No MFT signal;
2.10.7.2 Any one of PAF runs with air preheater A/B outlet hot primary air pressure＞63.5mbar；
2.10.7.3 Air preheater A/B outlet hog secondary air temperature ＞177℃；
2.10.7.4 Three from four, oil guns in layer AB are in running;
2.10.7.5 Coal mill B running and coal feeding amount ＞50t/h, and unit load ＞264MW (note: for
coal mill B, this phrase shall be changed to be: coal mill A or C running and coal feeding amount
＞50t/h，and unit load ＞264MW);
2.10.7.6 Unit load ＞396MW；
2.10.7.7 All fire inspections of corresponding layers in which the coal mills are located are free of
faults;
2.10.7.8 No signal to stop coal mill protection;
2.10.7.9 Seal air & bowl bottom differential pressure ＞ 20mbar, seal baffle of coal mill opened,
seal air exhaust baffle of coal mill opened;
2.10.7.10 Any one of lubricating oil pumps runs with oil pressure ＞0.09MPa, lasting for 3min.;
2.10.7.11 Coal mill motor bearing temp. ＜ 75℃, motor stator temp. ＜ 110℃, speed reducer
bearing temp. ＜60℃ and bearing temp. ＜70℃；
2.10.7.12 Coal mill 3/4 outlet baffle is opened;
2.10.7.13 Lubricating oil temperature ＞30℃；
2.10.7.14 Lubricating oil flow ＞220L/min；
2.10.7.15 Lubricating oil outlet filter differential pressure ＜25bar；
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2.10.7.16 Coal mill has outlet temperature at 65~82℃;
2.10.7.17 Coal mill inlet valve is opened and outlet valve closed;
2.10.8 Sequence start coal mill steps
2.10.8.1 Coal mill lubricating oil tank heater is automatically opened or closed, and the oil
temperature ＞35℃；
2.10.8.2 Start lubricating oil pump A or B (if one oil pump does not start and last for 5s, the other
one shall be started);
2.10.8.3 Open all outlet baffles of coal mill;
2.10.8.4 Open seal air baffle of coal mill;
2.10.8.5 Set the coal primary air control valve to be 30%;
2.10.8.6 Set the hot primary air control valve to be 30%;
2.10.8.7 Open coal mill inlet cold primary air isolating valve;
2.10.8.8 Open coal mill inlet hog primary air isolating valve;
2.10.8.9 Switch of coal mill inlet/outlet flow control circuit is in automatic mode;
2.10.8.10 When the coal mill outlet temperature ＞65℃, open the seal air baffle of coal feeder;
2.10.8.11 Open coal feeder outlet baffle and set the coal feeding amount as 22t/h;
2.10.8.12 Start coal mill;
2.10.8.13 After the coal mill has run for 60s, start the coal feeder;
2.10.8.14 After the coal feeder has started for 20s, open the inlet baffle of coal feeder;
2.10.9 Manually start the coal mill
2.10.9.1 Inspect and confirm that the start conditions of the coal feeder and coal mill are met.
2.10.9.2 Open all outlet baffles of coal mill;
2.10.9.3 Open seal air baffle of coal mill;
2.10.9.4 Adjust the primary air quantity, outlet temperature of the coal mill, grinding warm for 15
minutes.
2.10.9.5 Open the coal feeder seal air baffle, and the open the inlet baffle;
2.10.9.6 Start coal mill, and regulate the mill air volume and temperature;
2.10.9.7 Start coal feeder, and check the cleaning motor which shall also be started with interlock;
2.10.9.8 The coal feeder output is gradually increased to 22t/h or more.
2.10.9. 9 Check if the coal mill outlet temperature, bowl differential pressure, electric current,
vibration, primary air volume and coal feeder output are normal;
2.10.9.10 After the primary air quantity, air temperature, secondary air quantity control are
automatically put into operation and normal, the coal feeder output is gradually increased or coal
feeder is automatically put into operation.
2.10.9.11 Confirm that the burning of pulverized coal burner is stable and the flame check
signal is normal.
2.10.10 Operation and maintenance of coal feeder
2.10.10.1 Check that the belt running is normal, there are no the belt deviation, tear and
damage phenomenon, the weighting indication is normal. Clean-up chain operation is normal,
there are no the stalling and blockage phenomenon.
2.10.10.2 Observation window of the coal feeder is clean and perspective, good internal
lighting.
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2.10.10.3 Weighting roller rotation is normal, there is the accumulated coal on the roller.
2.10.10.4 There are no the sundries or lump coal blockage in the coal feeder.
2.10.10.5 The local control panel display is normal, non-alarm signal, the cumulative work is
normal in the coal amount indication.
2.10.10.6 It is prohibited for the operating personnel to adjust the mechanical equipment and
control system of the coal feeder, if the abnormal condition is found, should contact with the
maintenance staff for the handling.
2.10.10.7 Inspect that the drive motor, speed reducer of the coal feeder are normally operating,
there are no the abnormal phenomena such as heating and vibration and so on.
2.10.11 Coal mill operation and maintenance
2.10.11.1 Prior to starting the coal mill, and after shuting down the coal mill each time, must
inspect and clean-up the slagging box. In case of normal operation, should be regularly (1 to 2
hours) check the slagging box to prevent the slagging box from coal accumulation and
spontaneous combustion. When slagging with the slagging box, should first close the slag
dropping valve, and then open the slagging valve for the slagging; the slagging valve can be
opened only after the slagging is completed and slagging valve is closed.
2.10.11.2 Check that the coal mill’s vibration and noise are in line with the requirements , the
seal air device should be tight, non-air leakage, the bolts on the various positions are fastened.
The motor is clean, no vibration.
2.10.11.3 In case the coal mill is in manual control, it should be noted that the air quantity can
meet the air speed requirements. The outlet temperature of the coal mill is controlled at 66℃.
2.10.11.4 Inspect that the seal air and primary air differential pressure are normal, more than
2.0kPa.
2.10.11.5 Check that the inlet lubrication pressure of the reducer gearbox is more than or equal
to 0.10MPa.
2.10.11.6 Regularly check if the coal mill motor bearing temperature ＜ 75℃, motor stator
temperature ＜ 110℃ and speed reducer bearing temperature ＜ 60℃ and coal mill bearing
temperature ＜70℃;
2.10.11.7 Inspect that the filter screen differential pressure of lubricant station is less than 25bar. In
case the filter screen differential pressure of the lubricant station is high, it is switched to the
standby filter screen, should contact with the maintenance personnel for the clean up.
2.10.11.8 In the normal operation, should pay attention to monitor that the ventilation resistance
of the coal mill is normal so as to prevent the plugging wear.
2.10.11.9 In the normal operation of coal mill, when the thrust bearing temperature of the coal
mill rises abnormally, the feeding coal amount should be reduced to reduce the coal mill outlet
temperature operation; if the bearing temperature continues to rise to more than or the limited
values, the coal mill should be tripped, or it should be manually tripped .
2.10.11.10 Coal Mill System Alarm Parameters
1 Coal mill bowl differential pressure high ≥3.25kPa
2 Coal mill seal air & bowl bottom - differential pressure low ＜20mbar
3 Coal mill lubricating oil pressure low ＜0.9bar
4 Coal mill lubricating oil pressure low low ＜0.7bar
5 Coal mill lubricating oil flow low ＜220L/min
6 Coal mill oil station filter differential pressure high ≥2.5bar
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7 Coal mill return oil temperature high ＞49℃
8 Coal mill return oil temperature low ＜45℃
9 Coal mill oil tank – oil level low ＜200mm
2.10.12 Sequence outage coal mill steps
Press the "outage sequence control" button on the screen of the coal mill body system, then the
following steps should be implemented:
2.10.12.1 When coal mill outlet temperature ＜60℃, open the inlet cold primary air baffle;
2.10.12.2 Reduce the coal feeding amount to be zero;
2.10.12.3 Close the inlet hot primary air baffle;
2.10.12.4 Close the coal feeder inlet baffle;
2.10.12.5 Stop the coal feeder;
2.10.12.6 Stop the coal feeder and last for 60s, close the outlet baffle and seal air baffle;
2.10.12.7 Close the coal mill outlet baffle and last for 60s, and stop the mill motor;
2.10.12.8 Stop the coal mill and last for 60s, the seal air baffle shall be closed;
2.10.13 Normal outage of the coal mill
2.10.13.1 Gradually turn up the cold air adjustable baffle, close the hot-air adjustable baffle, and
gradually reduce the outlet temperature of the coal mill to 50℃ below.
2.10.13.2 Switch the coal feeder for the manual operation, gradually reduce the coal feeder output
to a minimum, and pay attention to monitor the vibration and current of the coal mill.
2.10.13.3 Close the inlet valve of the coal feeder, shut down the coal feeder, close the outlet valve
of the coal feeder. Confirm that the purge chain motor of the coal feeder is shut down.
2.10.13.4 Maintain that the primary air volume of the coal mill for the purge operation.
2.10.13.5 After purging, gradually shut down the cold air baffle of the coal mill.
2.10.13.6 Shut down the coal mill, close the outlet baffle of the coal mill.
2.10.13.7 Close the sealed baffle of the coal mill.
2.10.13.8 Open the slag discharge valve;
2.10.13.9 The sealed fan can be shut down only when the last one coal mill is shut down.
2.10.14. Coal Mill Emergency Stop
2.10.14.1 Emergency Stop Conditions
2.10.14.1.1 MFT
2.10.14.1.2 All PAF stop and last for 1s;
2.10.14.1.3 All primary lubricating oil pumps stop and last for 2s;
2.10.14.1.4 Lubricating oil pressure low low LL and last for 2s;
2.10.14.1.5 Coal mill motor temperature ＞95℃
2.10.14.1.6 Coal mill motor stator temperature ＞145℃
2.10.14.1.7 Coal mill bearing temperature ＞90℃
2.10.14.1.8 Coal mill speed reducer bearing temperature ＞80℃
2.10.14.1.9 Coal mill outlet baffle or exhaust baffle closed, two from four, lasting for 2s
2.10.14.1.10 All seal air fan stop and last for 10s;
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2.10.14.1.11 Seal air & bowl bottom differential pressure ＜20mbar, lasting for 10s;
2.10.14.1.12 Coal mill fuel loss (when the coal mill and coal feeder are in operation, open the
outlet baffle of coal feeder for 60s or 180s, with each vent valve opened, and no fire detector at
four corners 【three from four】), lasting for 10s;
2.10.14.1.13 Lubricating oil pump outlet oil temperature ＞65℃
2.10.14.1.14 Coal feeder runs and lasts for 10s, with coal mill inlet cold and hot primary air mixture
flow ＜90t/h;
2.10.14.1.15 Coal mill outlet temperature ＞93℃
2.10.14.2 Coal mill outage emergency steps
2.10.14.2.1 Close the hot air and cold air baffle. Close the outlet baffle of the coal mill.
2.10.14.2.2 Shut down the coal feeder and coal mill.
2.10.14.2.3 Open the inert steam motor-operated valve of the coal mill.
2.10.14.2.4 In case the outlet temperature of the coal mill is reduced to 82℃ below, close the inert
steam motor-operated valve according to the normal stop grinding procedures, close the sealed
baffle.
2.10.14.3 Operation after tripping due to the coal mill fault
2.10.14.3.1 Close the primary air quick shutoff baffle.
2.10.14.3.2 Close the outlet baffle of the coal mill.
2.10.14.3.3 Coal mill has been filled with the inert gas.
2.10.14.3.4 After filling the inert gas, it is deslagged with the slagging box
2.10.14.3.5 The sealed air should be normally put into operation without failure.
2.10.14.3.6 There are too much accumulated coals in the coal mill, which is necessary for the
manpower to remove them.
2.11 Use and stop for the drum two-color water level gauge
2.11.1 Cold state operation steps of the two-color water level gauge
2.11.1.1 Confirm that the maintenance work of the water level gauge has been completed, good
lighting, check on site that the water level gauge is in good condition.
2.11.1.2 Full-open the primary and secondary valves of the steam side and water side of water
level gauge, close the water discharge primary and secondary valves.
2.11.1.3 In case the disengagement surface is not clear after the water level gauge is put into
operation, the water level gauge should be washed, in case it can not be returned to be normal by
washing, should contact the maintenance staff for the handling.
2.11.1.4 For the repaired water level gauge orifice cover plate screw, after the water level gauge is
used for 3 to 5 hours, when the drum pressure and water level are stable, shut down the water
level gauge and notify the maintenance staff for the hot tight screw, the water level gauge is put
into operation again after the hot tight is end.
2.11.2. Hot state operation steps for two-color water level gauge
2.11.2.1. Confirm that the maintenance work of the water level gauge has been completed, good
lighting, check on site that the water level gauge is in good condition.
2.11.2.2. Confirm that the water discharge primary door is in full-open position, slightly open the
water discharge secondary valve.
2.11.2.3. Open the steam side, water side primary valves.
2.11.2.4 The water level gauge is pre-heated by slightly opening the steam side secondary valve,
so that the surface temperature of the water level gauge reaches to more than 150℃.
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2.11.2.5 After the end of the pre-heating, slowly close the water discharge primary and secondary
valves.
2.11.2.6 Alternately and slowly turn up the steam side and water side secondary valves.
2.11.2.7 When the surface temperature of the water level gauge is close to the drum wall
temperature, full-open the steam side secondary valve; full-open the water side secondary valve
after 5 minutes.
2.11.2.8Check that there is the slight fluctuation of the water level in the water level gauge, clearly
visible, is consistent with the CRT display.
2.11.3 Operation and maintenance of two-color water level gauge
2.11.3.1 Under normal circumstances, the liquid level instruction of the local water level gauge is
within the range of ± 50mm, and there is a slight up and down fluctuations, the water level gauge
should be no leaked, the water level is clearly visible, good ambient lighting.
2.11.3.2 In case the local water level gauge is vague, it should be washed promptly. Washing
steps are as follows:
2.11.3.2.1 Close the steam side and water side secondary valves of the water level gauge.
2.11.3.2.2 Close the water side primary valve of the water level gauge.
2.11.3.2.3 Full open the water discharge primary valve, slightly open the water discharge
secondary valve.
2.11.3.2.4 Slightly open the steam side secondary valve, the water level gauge is washed 3 to 5
minutes, after the dirt is washed down, close the water discharge primary and secondary valves.
2.11.3.2.5 Open the water-side primary valve.
2.11.3.2.6 Alternately and slowly open the steam side and water side secondary valves.
2.11.3.2.7 Check that there is the slight fluctuation of the water level in the water level gauge,
clearly visible, is consistent with the CRT display.
2.11.4 Separation operation steps of two color water level gauge
2.11.4.1 Alternately and slowly close the steam side and water side secondary valves..
2.11.4.2 Close the steam side and water side primary valves,
2.11.4.3 Full open the water discharge primary and secondary valves.
2.11.4.4 After the water, steam and dirt in the water level gauge body and pipeline are emptied,
close the water discharge primary and secondary valves.
2.11.5 Notice on the two color water level gauge running
2.11.5.1 When checking the water level gauge in situ, should stand at the side of the water level
gauge, not face against it.
2.11.5.2 When the water level gauge is seriously leaked or burst, immediately turn off the steam
and water side electrically operated valves for the isolation. If the electrical operation is failed, it is
necessary to manually turn off the steam and water side electrically operated valves, should wear
the insulated clothing, wear the mask and insulated gloves in line with the saft regulation
requirements, and close to the isolation point by observing the working substance spray direction,
in case the working substance spray direction is not seen due to the diffusing steam fog, it is
strictly prohibited to carry out the isolating operation.
2.11.5.3 The water level gauge operation should be carried out slowly to avoid the excessive
thermal shock, can not operate against the water level gauge. After the water level gauge leakage
is isolated, should contact the repair department in time, a long outage can not be allowed.
2.11.5.4 When the water level transmitter and water level switch used for the control are required
to isolate in the running, the safety measures should be made to prevent the malfunction of
automatic control and protection, and then is implemented under the thermal control personnel
custody.
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2.12 Intermitten blowdown and continuous blowdown outage
2.12.1 Intermittent blowdown flash tank outage
2.12.1.1 Inspection preparation before the intermittent blowdown flash tank is put into operation
2.12.1.1.1 Inspect that the intermittent blowdown flash tank is complete and in a good condition.
12.12..1.2 Check that the water discharge valve of the intermittent blowdown flash tank is
closed.
2.12.1.1.3 Inspect that the pipeline valve of the boiler drain header tube is closed.
2.12.1.1.4 Check that the drain valve of the boiler water pump and water discharge valve of the
deaerator are closed.
2.12.1.1.5 Check that the air heater, secondary expansion, continuous blowdown, continuous
blowdown flash tank, front and rear of the low water drum are drained to the intermittent blowdown
flash tank valve and are closed.
2.12.1.2 Intermittent blowdown flash tank operation
2.12.1.2.1 Open the open-type water to the front and rear intercept valves of the desuperheater
water regulating valve of the intermittent blowdown flash tank, check and close its bypass door.
2.12.1.2.2 The intermittent blowdown flash tank is put into operation, the drainage temperature
is automatically adjusted.
2.12.1.2.3 In accordance with the operation requirements, open the continuous blowdown, the
front and rear of boiler’s low water drum, the water are discharged to the intermittent blowdown
flash tank.
2.12.1.2.4 In accordance with the boiler operation condition, the drain valve on the drain header
tube is opened (at start initial stage, closed after reaching to the required parameters).
2.12.1.2.5 In accordance with the operation requirements, open the other relevant drain valves
to the intermittent blowdown flash tank.
2.12.1.2.6 Comprehensive inspect that the intermittent blowdown flash tank is normally
operating.
2.12.1.3 Intermittent blowdown flash tank outage
2.12.1.3.1 Shut down from the boiler drain header tube to the drain valve of the intermittent
blowdown flash tank.
2.12.1.3.2 Close that the continuous blowdown, front and rear of boiler’s low water drum are
drained to the intermittent blowdown flash tank valve.
2.12.1.3.3 Shut down the other relevant drain valves to the intermittent blowdown flash tank.
2.12.1.3.4 Open the intermittent blowdown flash tank’s water discharge valve, control that the
water drainage temperature is less than 600C.
2.12.1.3.5 After the intermittent blowdown flash tank is drained off, close the intermittent
blowdown flash tank’s water discharge valve.
2.12.1.3.6 The drainage temperature automatic adjustment of the intermittent blowdown flash
tank is stopped. Close the open-type water to the front and rear intercept valves of the
desuperheater water regulating valve of the intermittent blowdown flash tank
2.12.2 Continuous blowdown flash tank outage
2.12.2.1 Inspection preparation before the continuous blowdown flash tank is put into operation
2.12.2.1.1 Inspect that the continuous blowdown flash tank is complete and in a good condition.
2.12.2.1.2 Check that the pressure gauge of the continuous blowdown flash tank is put into
operation.
2.12.2.1.3 Inspect that the continuous blowdown flash tank has been put into operation.
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2.12.2.1.4 Close that the bypass valve of the level regulating valve of the continuous blowdown
flash tank is closed.
2.12.2.1.5 Open the steam and water side primary valves of the water level gauge of the
continuous blowdown flash tank, the water level gauge of the continuous blowdown flash tank is
put into operation.
2.12.2.1.6 Inspect that the safety valve of the continuous blowdown flash tank is complete and
in a good condition, the fixed value has been calibrated and qualified.
2.12.2.1.7 Close from the continuous blowdown flash tank to the steam supply valve of the
deaerator.
2.12.2.2 Continuous blowdown flash tank operation
2.12.2.2.1 Check if the safety valve, pressure gauge and water level gauge of continuous
blowdown flash tank are in normal operation;
2.12.2.2.2 Open the manual valve from continuous blowdown flash tank to regular blowdown flash
tank;
2.12.2.2.3 Open the manual valve before electric regulating valve of continuous blowdown flash
tank;
2.12.2.2.4 Open the manual valve of continuous blowdown flash tank;
2.12.2.2.5 Open the manual valves before and after the drainage regulating valve of continuous
blowdown flash tank;
2.12.2.2.6 Slightly open the drainage bypass manual valve from continuous blowdown flash tank
to regular blowdown flash tank;
2.12.2.2.7 Slightly open the electric regulating valve of continuous blowdown flash tank, warm up
the flash tank, pay attention to changes of water level, temperature and pressure of the flash tank,
after that, close the drainage bypass valve.
2.12.2.2.8 After fully warm up the continuous blowdown flash tank, gradually enlarge the opening
of electric regulating valve, after the water level of the flash tank increase, use drainage regulating
valve to control the water level;
2.12.2.2.9 Gradually open the manual connection valve from continuous blowdown flash tank to
deaerator;
2.12.2.2.10 After the water level of continuous blowdown flash tank is consistent with the setting
value, switch the drainage regulating valve of the flash tank to “automatic” operation;
2.12.2.2.11 According to chemical requirements, adjust the opening of electric regulating valve of
continuous blowdown flash to be the required, and close the manual valve from continuous
blowdown flash tank to the regular blowdown flash tank;
2.12.2.3 Continuous blowdown flash tank outage
2.12.2.3.1 Automatically switch off the drainage regulating valve of continuous blowdown flash
tank;
2.12.2.3.2 Close from the continuous blowdown flash tank to the motor-operated valve of the
deaerator.
2.12.2.3.3 In accordance with the requirements, close from the drum to the main manually
operated valve of the continuous blowdown flash tank, front manual operated valve of the
pressure regulation motor-operated valve of the continuous blowdown flash tank.
2.12.2.3.4After the continuous blowdown flash tank is emptied, close the front and rear manually
operated valves of the water level regulating valve of the continuous blowdown flash tank.
2.13 Boiler soot-blowing system
2.13.1 Sootblower system operation
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2.13.1.1 Inspection prior to put into operation
2.13.1.1.1 The maintenance of the sootblower system has been completed, the work sheet end
procedure has been handled.
2.13.1.1.2 For the repaired sootblower, should implement the manual preliminary operation in-situ
to confirm its working correctly.
2.13.1.1.3 The sootblower control system is in a good condition, the thermal fixed values and
mechanical fixed values are correct.
2.13.1.1.4 Confirm that the sootblowing steam pipeline and hanger and support are in the good
condition, good safety valve appearance.
2.13.1.1.5 Completion of the inspection and operation before starting the sootblowing steam
system.
2.13.1.1.6 Furnace sootblower inspection
2.13.1.1.6.1 The control box of the sootblower is in a good condition, the gear mesh and gap are
normal.
2.13.1.1.6.2 Sootblower’s inlet steam pipe flange connection is fixed and sealed well.
2.13.1.1.6.3 Sootblower’s motor shell grounding line is in a good condition.
2.13.1.1.6.4 Sootblower’s threaded tube appearance is in a good condition, no rust, the threaded
tube is located the withdrawal position.
2.13.1.1.6.5 Sootblower’s drive pinion shaft, pinion gear meshing with the large gear and
lubrication are well.
2.13.1.1.6.6 The oil level in the sootblower’s deceleration box is normal.
2.13.1.1.7 Long expansion sootblower inspection
2.13.1.1.7.1 Check that the sootblower is in the correct installation position.
2.13.1.1.7.2 After the sootblower’s front hanging fixed point is placed on the boiler, the
sootblowers should be able to move together with the furnace wall. The axis offset of the
sootblower due to the level thermal expansion of the furnace wall is supported by the sootblower’s
rear support.
2.13.1.1.7.3 In case of the cold state boiler, the sootblowing tube should be in the inclined state,
and in case of the hot state boiler, the sootblowing tube should be in the level state.
2.13.1.1.7.4 Sootblower’s forward and back limit switch is in the correct position.
2.13.1.1.7.5 The oil level of the sootblower’s gearbox is normal.
2.13.1.1.7.6 Sootblower’s motor shell grounding line is intact, drive gear and rack mating and
lubrication are intact, the guide roller can freely slide on the guide rod.
2.13.1.2 Soot-blowing and steam supply system operation
2.13.1.2.1 Inspection operation before the system is put into operation in line with the operation
checking card of the system.
2.13.1.2.2 Confirm that the power supply of the sootblowing program control operating panel has
been supplied, the system is shown normal.
2.13.1.2.3 Connect to the thermal power, the auxiliary steam is transmitted to the power supply of
the air preheater sootblowing motor operated valve.
2.13.1.2.4 Confirm that the drain valve of the sootblowing system and inlet steam manually
operated valve of the sootblower are turned on.
2.13.1.2.5 Confirm that the front isolation valve of the body (air preheater) sootblowing steam
pressure regulating valve has been opened. If the pipeline occurs the water impact, should shut
down the front isolation valve of the body (air preheater) sootblowing steam pressure regulating
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valve in time.
2.13.1.2.6 When unit load ＜30%MCR, the air preheater sootblowing steam shall use the steam
from auxiliary steam header, and confirm the auxiliary steam pressure is larger than 1.1MPa and
temperature higher than 280℃, otherwise sootblowing is not allowed; when the unit load ＞
30%MCR, sootblowing steam shall switch to steam supply from panel reheater inlet header;
2.13.1.2.7 The normal body sootblowing steam source pressure is 1.5MPa. It should be also
adjusted in the running course according to the actual situation.
2.13.1.3. Sootblower Operation Program
2.13.1.3.1 START PERMIT
1、NO ANY SOOTBLOWER OPERATING
2、SOOTBLOWER CABINET POWER OK
3、NO-MFT-SIGNAL
4、SOOTB SYSTEM IN AUTO
5、ALL SB SYSTEM VLVAUTO
6、SB POWR CABINET IN REMOTE POS
7、LOAD＞330MW（SB PERMISSIVE）
2.13.1.3.2 First out
1、SOOLB STM PT＜1MPa
2、MFT TO SOOTB
3、SOOTB STEAM FLL
4、SOOTB STM V1 NOT OPD
5、SOOTB STM V2 NOT OPD
6、ANY SOOTB OVERLOAD
7、SOOTBLOWER CABINET POWER LOSS
2.13.1.3.3 operation procedure
1、Put SOOTB STM V 1、2 and all drain valves to auto
2、Open sootblower steam regulating valve a little,warm up the sootblower steam pipes and
set the sootblower pressure is 16bar,at the same time put it into auto.
MAIN CTRL PANEL

3、 Push down enter main control drawing
GROUP SEQ SEL

4、Push down select sootblower grroup
AUTO CONTNCE STAR ENABLE

5、Push down → → T → start sootblower
6、When the sootblowing is finished,auto close the sootblowing steam valve,open the drain
valves.
Priority mode selecting:
1、Put the sootblower steam valve 1、2 and all drain valves into auto.
2、Open sootblower steam regulating valve a little,warm up the sootblower steam pipes and
set the sootblower pressure is 16bar,at the same time put it into auto.
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PRIORITY MODE
3、Push down select priority mode
MEIN CTRL PANEL

4 、 Push down enter main control drawing,at the left
PRIORITY SELEG
side Select the priority sootblower group.
PRIORITY MODE RESET

5、Push down reposite priority mode
SOOTB REMDTE CTRL

push down select soot blower local/remote position.
2.13.1.3.4 AH sootblower
AH SOOTB SEQ CTRL

1 、 Push down select steam source RH SOOTBLOWor AUX
SOOTBLOW
2、After selecting the steam source,put the valve into auto and hold the sootblower pressure
8bar.
READY AUTO NO CYCLE CYCLE

3 、 Push down → → or enter sootblower
porcedure.
4、When the sootblowing is finished,auto close the sootblowing steam valve,open the drain
valves.
2.13.1.3.5 In automatic mode, the sequential control of air preheater sootblower is:
Step NO Description
ⅠAuxiliary steam mode: open auxiliary sootblowing steam isolating valve
Step 1 (90HCB20AA001)
ⅡReheat steam mode: open sootblowing steam isolating valve 1 & 2
(90HCB10AA001、90HCB10AA002)
ⅠAuxiliary steam mode: open AH sootblowing pipe drain valve
ⅡReheat steam mode: open LE、RI、LE FR、RI RE sootblowing pipe drain valve
(90HCB11AA401、90HCB12AA401、90HCB13AA401、90HCB14AA401、) and
AH sootblowing pipe drain valve (90HCB15AA401)
ⅠAuxiliary steam mode: close AH sootblowing pipe drain valve
(90HCB15AA401)
Step 3 ⅡReheat steam mode: close LE、RI、LE FR、RI RE sootblowing pipe drain valve
Step 4 Start AT1、AT2 sootblower (90HCB15AT001、90HCB15AT001)
ⅠAuxiliary steam mode: close auxiliary sootblowing steam isolating valve
ⅡReheat steam mode: close sootblowing steam isolating valve 1 & 2
(90HCB10AA001、90HCB10AA002)
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ⅠAuxiliary steam mode: open AH sootblowing pipe drain valve
(90HCB15AA401)
Step 6 ⅡReheat steam mode: open LE、RI、LE FR、RI RE sootblowing pipe drain valve
2.13.1.3.6 In automatic mode, the sequential control of boiler proper sootblower is:
Step NO Description
Open sootblowing steam isolating valve 1 & 2 (90HCB10AA001 、
Step 1 90HCB10AA002)
Open LE、RI、LE FR、RI RE sootblowing pipe drain valve (90HCB11AA401、

Step 2 90HCB12AA401、90HCB13AA401、90HCB14AA401、) and AH sootblowing
pipe drain valve (90HCB15AA401)
sootblowing pipe warm done: valve 90HCB10AA001 & 90HCB10AA002
opened and sootblowing pre. 90HCB10CP001 no low, delay 300s,and temp.
Step 3
90HCB11CT601,90HCB12CT601,90HCB13CT601,90HCB14CT601＞180℃.
Close LE、RI、LE FR、RI RE sootblowing pipe drain valve (90HCB11AA401、
Step 5 Start sootblower in sequence.
Step 6 Close sootblowing steam isolating valve 1 & 2 (90HCB10AA001 、
90HCB10AA002) and sootblowing steam PCV (90HCB10AA101)
Open LE、RI、LE FR、RI RE sootblowing pipe drain valve (90HCB11AA401、
2.13.2 Steam sootblower operation and maintenance
2.13.2.1 Operation principle of sootblower
During the boiler startup, the sootblowers installed in the furnace and convection pass part can
be not put into operation, but the preheater sootblower must be put into operation in case the load
is less than 10% MCR, to prevent the excessive sediment from plugging the air preheater,
resulting in the difficulties for the boiler start-up and afterward purge during the start up, and
maintaining that there are no flammable and oily sediment on the heating surface. If the oily
sediment are not timely removed, when the load increases and the temperature increases, the oil
may volatile and on fire, causing the accident.
When the boiler is ignited, the pre-heater sootblowing is required the auxiliary steam source.
When the load is lower than 30% MCR, the air preheater sootblower carry out the continuous
sootblowing by the auxiliary steam source, when the load exceeds 30% MCR, it is switched to the
main steam source for the sootblowing.
The boiler furnace sootblowing and convection pass part sootblowing should be carried out in
case the boiler load is greater than 60%. When soot-blowing, it is necessary to appropriately raise
the furnace draft (10mmH2O column greater than normal condition).
When soot-blowing, it is generally carried out according to the flow direction of flue gas, the
furnace is first blown, and then superheater, reheater, economizer etc, are blown. When the coal
with larger ash is burned, the sootblowers at the tail flue and preheater as well as above
sootblower should be alternatively started, in order to ensure unobstructed pass. Otherwise, a
large number of blown ash are plugged in the economizer and preheater region, resulting in the
difficulties of the subsequent sootblowing.
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Sootblowing cycle should be determined based on the accumulated ash of the heating surface,
the coal-fired boiler is generally sootblowed once on shift. If the bootblowing time interval is too
long, it can impact on the soot-blowing effects, reduce the boiler efficiency. To obtain the best
sootblowing effect, a number of sootblowers should be selected to implement the supplementary
sootblowing with hand remote -operation based on the most vulnerable pollution region in the
furnace, it can reduce the number of procedure soot-blowing, saving the sootblowing medium.
When the boiler is shutdown each time, should inspect the sootblowing effects and heating
surface wear condition, adjust the sootblowing pressure in time. When the coal changes, should
pay more attention to this point.
2.13.2.2 Operation and maintenance of sootblower
2.13.2.2.1 After the sootblower is put into operation, the local patrol personnel should check the
working condition of the sootblower, if the sootblower’s failure is found, should immediately notify
the main personnel on duty to stop the sootblower. Contact the maintenance staff to hand-shake
out the failure sootblower (after the sootblower is stuck, it is strictly prohibited to stop the steam, so
as to prevent that the sootblower is bent due to the burning, the expanded failure can not be
removed).
2.13.2.2.2 The person on duty should regularly inspect the program implementation of the
sootblower, in case the program implementation error is found or sootblowing implementation is
stopped, should contact the thermal control personnel in time for processing.
2.13.2.2.3 After the sootblower is put into operation, the running personnel should strengthen the
boiler combustion adjustment, maintain a high furnace draft to prevent the furnace from rising the
positive pressure.
2.13.2.2.4 When sootblowing the boiler, strengthen the inspection of the cold ash hopper, if the big
coke is found to influence the submerged slag conveyor running, should contact main person on
duty in time to stop the boiler sootblowing, carry out the sootblowing after the failure is handled.
2.13.2.2.5 When sootblowing the boiler, check the wire drawing cable security of the sootblower, if
it is found that the wire drawing cable movement is blocked, should stop the operation of the
sootblower in time, contact the thermal person for the processing in time.
2.13.2.2.6 Regularly carry out the oiling maintenance of the sootblower gear and rack to prevent
the gear and rack from damaging.
2.13.2.2.7 Regularly replace the seal packing, to avoid that the packing is not tight to occur the
sootblower’s air leakage and damage the wire drawing cable and result in the person injury
accident.
2.13.2.2.8 If the leakage are found in the drain valve and total valve, shoul handle it in time (if it
can not be handled in the unit operation, the processing preparation must be ready, handle it in
time by making use of the shutdown opportunity ).
2.13.2.2.9 Periodic inspect the electrical control circuit, if the problem is found, should deal with it
in time.
2.13.2.2.10 Regularly inspect whether the sootblowing angle of the sootblower is normal, so as
avoid to damage the heating surface due to the non-conformity sootblowing angle, .
2.13.2.2.11 By making use of the shutdown opportunity, inspect whether there is any injury site on
the heating surface appearance of the sootblower’s sootblowing region, if the problem is found,
should organize the relevant technical staff to analyze and find out the reasons, take the
corresponding countermeasure in time.
2.14 Air compressor start and stop
2.14.1 Inspection preparation prior to starting the air compressor-
2.14.1.1 Check and make sure that all the pipeline are not leaked, the electrical system wiring is in
a good condition, the motor’s insulation is qualified and the power has been supplied, various
nuts and bolts are fastened tightly and reliable;
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2.14.1.2 Open the bottom blowdown valves of the front filter, gas-liquid separator, refrigerated
dryer, ultrafilter, oil removing filter, high efficiency ultrafilter, close them after emptying the
condensate water.
2.14.1.3 Fill the cooling water in the air compressor’ parts, check that the cooling water are normal;
2.14.1.4 The air compressor oil system is put into operation, the oil pressure and oil level are
normal, the oil is qualified;
2.14.1.5 Confirm that the gauges of the air compressor are normal;
2.14.1.6 Confirm that the alarms and trip protection of air compressor have been put into
operation;
2.14.1.7 Inspect that the hand-operated valve of the oil, water, gas system of the air compressor
body are opened, the outlet pipeline of the air compressor is smooth;
2.14.1.8 Check that all the setting values of the compressor control panel are correct.
2.14.2 Air compressor start
2.14.2.1 Air compressor local start
2.14.2.1.1 Turn on the control power switch of the air compressor.
2.14.2.1.2 CHECKING MACHINE (checking machine) is shown on the display screen of the
control panel of air compressor. Whether all the inspection parameters are normal, READY TO
START (ready to start) is shown on the display screen.
2.14.2.1.3 The air compressor start-up mode switch is switched to "LOC" position inside the local
control panel valve of the air compressor.
2.14.2.1.4 After READY TO START (ready to start) is shown on the display screen of air
compressor, press [I] (start) button on the air compressor control panel, start the air compressor. If
it is required for the sufficient gas (air main pressure below the minimum set value ), it is loaded
automatically after starting the air compressor.
2.14.2.2 Remote start of the air compressor
2.14.2.2.1 Turn on the control power switch of the air compressor..
2.14.2.2.2 CHECKING MACHINE (checking machine) is shown on the display screen of the
control panel of air compressor. Whether all the inspection parameters are normal, READY TO
START (ready to start) is shown on the display screen.
2.14.2.2.3The air compressor start-up mode switch is switched to "REM" position inside the local
2.14.2.2.4 Air Compressor will be controlled by the remote DCS.
2.14.3 Air compressor loading/ unloading
2.14.3.1 If the air compressor is already running and DISCHARGE PRESSURE (discharge
pressure) is less than ONELINE PRESSURE (oneline pressure), the air compressor will be loaded
by pressing the loading button on the air compressor control panel.
2.14.3.2 If the compressor is already running, the air compressor will be unloaded and maintained
the unloaded state by pressing the unloading button on the air compressor control panel.
RUNNING UNLOADED (running unloaded) and MODE: UNLOAD (mode: unload) are shown on
the display screen.
2.14.4 Normal operation and maintenance of air compressor
2.14.4.1 No abnormal noises when the air compressor is running.
2.14.4.2 Oil leakage-free, water leakage-free of the air compressor system,.
2.14.4.3 The air compressor oil system is normally running, the oil return temperature of the
lubricating oil temperature does not exceed 70℃.
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2.14.4.4 Fill the cooling water of the air compressor, the inlet pressure of the cooling water is 0.4 to
0.6MPa, the inlet cooling water temperature of the cooler does not exceed 40℃, the outlet cooling
water temperature does not exceed 48℃.
2.14.4.5 The inlet air temperature of the air compressor does not exceed 40℃.
2.14.4.6 The discharge pressure of the air compressor is not less than 0.8MPa, the discharge
temperature does not exceed 45℃.
2.14.4.7 The air flow rate of the inlet air filter of the air compressor is not more than 1.0 to 1.3m/s,
the pressure loss is 0.1 to 0.25MPa.
2.14.4.8 The status display of the air compressor control panel is correct, the alarm indicator light
is off.
2.14.4.9 During the normal operation of air compressor, the "remote control" way should be used,
the "local control" mode is adopted in case of the initial startup only after installing or repairing.
2.14.4.10 Parameter control of the normal operation of air compressor
2.14.4.10.1 Discharge temperature is no less than 45℃;
2.14.4.10.2 Discharge pressure is 0.8MPa;
2.14.4.10.3 Motor winding temperature is no more than 120℃;
2.14.4.10.4 Motor bearing temperature is no more than 80℃;
2.14.4.10.5 The motor current of the instrument service air compressor is no more than 246A, the
motor current of the plant service air compressor is no more than 177A.
2.14.5 Air compressor outage
2.14.5.1 Air compressor local outage
2.14.5.1.1 The air compressor start-up mode switch is switched to "LOC" position inside the local
2.14.5.1.2 Press [O] (outage) button on the control panel, if the air compressor is loading, then it is
unloaded 10 to 30 seconds, and then shut down; if the air compressor has been unloaded for the
operation, it is shut down immediately.
2.14.5.1.3 Open the air discharge valve, close the outlet valve, close the cooling water valve.
2.14.5.2 Air compressor remote outage
2.14.5.2.1 The air compressor start-up mode switch is switched to "REM" position inside the local
2.14.5.2.2 Air compressor will accept the remote DCS outage command.
2.14.5.3 Air compressor emergency outage
2.14.5.3.1 Under the emergency condition, press the EMERGENCY STOP (emergency stop)
switch on the control panel, the air compressor is shut down immediately.
2.14.5.3.2 The compressor can be restarted only after this emergency stop switch is manually
reset. By clockwise rotation, the emergency stop switch is reset.
2.14.5.4 Air compressor emergency outage condition
2.14.5.4.1 When the motor current is over the rated value.
2.14.5.4.2 When the motor smokes and on fire, and personal accident occurs.
2.14.5.4.3 Discharge pressure suddenly increases and more than the rated value, the piping and
cylinder generate the serious impact sound.
2.14.5.4.4 Any part temperature of the air compressor exceeds the allowable value.
2.14.5.4.5 The cooling water is interrupted.
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2.14.5.4.6 Lubricant system occurs the failure.
2.14.5.4.7 There is the abnormal sound in the air compressor and motor, the body are strongly
vibrated.
2.14.6. Refrigerated Compressed Air Dryer
2.14.1. Inspection before Startup of Refrigerated Compressed Air Dryer
2.14.1.1 Check the cooling system: observe the readings of refrigerant high & low pressure gauge
on the equipment instrument panel, which shall achieve a balance under certain pressure, and
such balanced pressure will fluctuate as ambient temperature fluctuating, generally at 0.5MPa ~
1.2MPa; if the reading of refrigerant low pressure gauge is zero, it indicates the refrigerant has
been leaked;
2.14.1.2 Check if the power supply is connected and voltage is normal;
2.14.1.3 Check if air pipeline is normal, inlet air pressure not over 0.8MPa and temperature ≤45℃;
2.14.1.4 Indications of Control Instrument Panel
Refrigerant low pressure gauge (pressure dew point gauge): Indicating refrigerant saturation
pressure in evaporator;
Refrigerant high pressure gauge: Indicating refrigerant condensing pressure;
Air outlet pressure gauge: Indicating compressed air pressure at dryer outlet;
Switcher (black knob): Switching of local/remote control;
Start ready light (green): the light is on after start button pressed and is black out after 5min when
compressor starts;
Start button (green): Button pressed to make dryer connect power supply and start working;
Stop button (red): button pressed to stop dryer operation;
Power light (red): The light is on after power supply connected and air switch is on;
Running light (green): The light is on when the dryer is in running state;
Refrigerant high/low pressure fault light (yellow): The light is on in case of dryer high/low pressure
protection switch tripping, and it needs to stop the equipment for inspection;
Motor overload fault light (yellow): The light is on in case of compressor working current overload
and overload relay tripping, and it needs to stop the equipment for inspection;
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2.14.2. Startup of Refrigerated Compressed Air Dryer
2.14.2.1 Connect power supply, turn on air switch, then the power light (red) on the equipment
instrument panel is on;
2.14.2.2 Press the start button (green), contactor pulling in, the start ready light (green) being on,
which is off after 5min, then the compressor starts running and the running light (green) is on;
2.14.2.3 Check if compressor is in normal operation, if there is abnormal noise, if the refrigerant
low pressure gauge pointer is in normal range of 0.3～0.5MPa (R22 refrigerant);
2.14.2.4 If everything is normal, start air compressor and open air inlet/outlet stop valve to supply
air to dryer, and meanwhile close the air bypass valve, at this time the air pressure gauge will give
the reading of air outlet pressure;
2.14.2.5 After observation for 5-10min, the air going through dryer processing can reach design
pressure dew point 2 ～ 10℃, at this time, the refrigerant high/low pressure gauge’s normal
indication range is:
Refrigerant lower pressure: 0.3～0.5MPa
Refrigerant high pressure: 1.2～1.6MPa
2.14.2.6 Slowly open the copper ball valve on the automatic drainer, and let the condensate in the
air flow into the drainer and discharged outwards;
2.14.3. Stopping of Refrigerated Compressed Air Dryer
2.14.3.1 Open bypass valve and allow the compressed air flowing to the downstream pipeline, and
then close dryer outlet valve;
2.14.3.2 Close dryer inlet stop valve, and unload the pressure;
2.14.3.3 Press the stop button (red) to stop the dryer, disconnect the power supply, and open the
manual drain valve to discharge the residual condensate;
Notes for dryer operation:
1. Avoid dryer from running in unload state for a long time as much as possible;
2. Prohibit frequent dryer starting/stopping in a short time, and starting interval shall be
10min at least, so as to prevent compressor damage;
2.14.4. Maintenance of Refrigerated Compressed Air Dryer
2.14.4.1 In equipment operation, check if the reading of refrigerant low pressure gauge is in
normal range, for overlow refrigerant pressure will result in frost or ice, enlarge pressure loss, and
may cause compressor damage, while overhigh pressure will result in reduction of system cooling
capacity;
2.14.4.2 Check the drainage of automatic drainer every day, clean the drainer filter regularly, so as
not to impair the drainage function due to clogging;
2.14.4.3 Whenever check the compressed air system, press the manual test button (TEST) on the
timer incidentally to check if the electric drainer is in normal work, which shall be closed tightly
after drainage;
2.14.4.4 At full-load condition, check if the pressure loss of air flow going through the dryer ＜
0.035MPa, otherwise, isolate the dryer from the system, contact relevant staff for cleaning;
2.14.4.5 Regularly check the appearance intactness of dryer and accessories, and not leakage of
pipeline, flanges and valves;
2.15 Furnace Flue Gas Temperature Probe Start/Stop
2.15.1 Inspection before Startup
2.15.1.1 Check if the appearance straight line of flue gas temperature probe is curved, twisted or
deformed;
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2.15.1.2 Cable, wire rope and rubber tube on respective pulley shall have at least 80mm pendant
but over the beam bottom;
2.15.1.3 Check if all terminal wirings of thermal couple are secure;
2.15.1.4 Check if all power and control circuit wiring are secure;
2.15.1.5 Check if the travel switch plug is in correct position;
2.15.2. Manual Operation
2.15.2.1 Manual operation can apply ratchet spanner to turn the square shank at the rear of trolley,
and it can also use special electric spanner of IK sootblower;
2.15.2.2 Prior to manual operation, check if the trolley, pulley holder, supportive roller and probe
gun are in normal operation or in jamming, and if the pulley holder’s wire, cable and rubber tube
need adjustment;
2.15.3. Putting Flue Gas Temperature Probe into Service
2.15.3.1 Put flue gas temperature probe into service before boiler startup, monitor the travel and
temperature change, in case of any abnormalities, check and eliminate in time;
2.15.3.2 After putting the flue gas probe into service, manually push forward and pull backward the
probe in a certain interval, take boiler temperature distribution under control, and locate the probe
in the point of maximum temperature to prevent local overtemperature;
2.15.3.3 In the process of boiler pressure increase, pay close attention to the test temperature of
flue gas probe which shall not exceed 538℃, enhance the combustion adjustment if there is rapid
upward trend;
2.15.3.4 If the tested temperature reaches the alarm value and return value, system shall alarm in
time and the probe shall return automatically in time, otherwise the probe shall be pulled out by
hand;
2.15.3.5 After the tested temperature of flue gas probe reaches 538℃, manual pull it out if it does
not automatically withdraw;
2.15.3.6 Check if the probe is normal afar it is withdrawn;
2.15.4. Notes
2.15.4.1 Conduct commissioning and test before the first official operation of the probe, ensure
correct electric wiring and thermal couple wiring;
2.15.4.2 Conduct necessary inspection and maintenance before putting the probe into operation,
eliminate in time the existed problem, test it and carry out commissioning, ensure reliable
mechanical operating system and location display system. Prohibit operation without prior
inspection and maintenance above said;
2.15.4.3 After the probe is put into the boiler, the power supply of control box, temperature
measuring device as well as control system shall not be switched off, for fear that the probe can
not be returned automatically in reaching the limit temperature and therefore be burned off.
2.15.4.4 After the probe is put into the boiler, pay close attention to the tested temperature, if the
probe can not be automatically returned when it reaches the temperature for withdrawal, pull it out
by hand in time;
3 Unit start and stop

3.1 Boiler cold start
Boiler start-up is divided into the cold start and hot start. While the former refers to the start-up
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under the non-pressure and room temperature condition after the boiler is repaired or a longer
time of reserve; the latter refers to the start-up under a certain pressure and temperature
circumstances after the boiler is shut down a shorter time. In fact, the latter is taken a certain stage
in the process of the former start as a starting point.
The aim to start the boiler is to supply the steam for the steam turbine. In the unit plant, the
boiler and steam turbine’s start is to carry out together, which is composed by a few of processes.,
such as filling , purge, ignition and heating tube, impulse starting and warm up, speed up and
paralleling in, increasing load and so on.
During startup, the internal working medium flow of the economizer, superheater and reheater
are not normal, there is the rare working medium flow in some pipeline, it does not flow even in a
short period time, the heating surfaces can not be cooled normally by the working medium. For
this reason, during startup, the combustion rate control is very important.
When the cold boiler starts the ignition, the furnace temperature is very low, in a certain period
of time after igniting, in order to control the heating processes of the various components and
prevent the over temperature of some heating surfaces, low fuel input, the furnace temperature is
not high. At this time, if the fuel can be not rightly controlled, it is easy to extinct and then
deflagrate, resulting in the equipment damage.
During startup, for the fuel used in the boiler, a part is used to heat the working medium and
boiler components, a part is used to discharge the steam and water, some working medium and
heat are lost. In addition, larger combustion loss when the boiler is burning at the low load, the loss
size is related to the start-up mode, operation way and duration and so on.
Therefore, it exits the security and economic aspect problem in the process of boiler start-up. In
principle, the boiler start-up, is to ensure that the equipment is in safe condition, can either meets
the requirements of the entire unit, or save the working medium and fuel as far as possible so that
the unit can connect in power network in the shortest time. For newly installed boiler, as can not
fully grasp the performance and the lack of operational experience, should be very cautious when
startup.
3.1.1 Inspection and testing before starting up the boiler
3.1.1.1 General inspection prior to starting the boiler
3.1.1.1.1 All the maintenance affecting the unit startup have ended, the work sheet has been
completed in accordance with the relevant provisions. The security measures are removed, the
operational staff have made clear the maintenance and understood the equipment improvement
situation.
3.1.1.1.2 Check that it should be clean and no sundries around all the equipments, smooth roads,
good lighting;
3.1.1.1.3 Check that the drum bovine eye water level gauge lighting is in a good condition, there
should be normal, high and low water mark lines on the water level gauge, the water level
surveillance television work is normal;
3.1.1.1.4 Inspect that the furnace sealing and boiler casing are in the good condition, the platform,
ladder and railing are complete, no scaffolding, no sundry and garbage;
3.1.1.1.5 Inspect that the sootblower and its pipeline are complete, the furnace, superheater and
preheater’s sootblowers should be on the withdraw position;
3.1.1.1.6 Check that the pipeline’s hanger and support are complete and firm, the fixed pin of the
spring hanger should be removed;
3.1.1.1.7 Check that the furnace flue gas temperature probe should be flexible;
3.1.1.1.8 Check whether the expansion indicators of the boiler are in the zero position, and record
their initial values;
3.1.1.1.9 Check that the work such as superheater, economizer, reheater and air preheater etc are
completed, no person and no sundry in the flue, clean heating surface;
3.1.1.1.10 Inspect that the inspection holes and manhole doors of the boiler are tightly closed;
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3.1.1.1.11 Inspect that the insulation of the boiler body and ancillary pipeline are in the good
condition, the protection casing is in a good condition;
3.1.1.1.12 Inspect that the pendulous device of the burner is flexible and reliable;
3.1.1.1.13 Inspect that the wind and smoke system baffle and baffle’s transmission device are in
good condition, flexible on-off;
3.1.1.1.14 Check that the heating surface in the combustion chamber is clean, coke and slag-free,
no sundry;
3.1.1.1.15 Inspect no internal coke button from the cold ash hopper ;
3.1.1.1.16 Inspect that the baffles temporarily installed on the relevant pipelines have already
been removed;
3.1.1.1.17 Confirm that the other safety measures erected for the maintenance such as grounding
line, short-circuit wire, work sign board and scaffolding etc have been removed, the permanent
fence and warning board have been restored;
3.1.1.1.18 Inspect that the start tool, equipment, all kinds of records, fire-fighting work are ready;
3.1.1.1.19 Confirm that the auxiliary system control power supply and signal power of the unit
have been supplied, and no abnormal;
3.1.1.1.20 Confirm that the signaling system is normal, the indication gauges and recording
instruments are in good condition;
3.1.1.1.21 Confirm that the ash hopper and electric precipitation internal work have been
completed, the system has been restored, and with start conditions;
3.1.1.1.22 Confirm that the DCS and DEH working are normal, CRT display is in line with the
actual state meter display of equipment.
3.1.1.2 Test before starting the boiler
3.1.1.2.1 Test general rule
3.1.1.2.1.1 The protection and interlocking test for main and auxiliary equipments shall be taken
first after the unit overhaul and minor repair, and the device is allowed to take test run and put into
operation only after the test is passed.
3.1.1.2.1.2 During each test, implement strictly in accordance with the requirements of test
measure.
3.1.1.2.1.3 Carry our relevant tests after qualified in temporary failure maintenance, maintenance
of protection and interlocking components and loop maintenance; shut down the boiler for
maintenance of other protection and interlocking.
3.1.1.2.1.4Test all local and remote electric valves, pneumatic valve, servo, remote and close
control system, and record the opening and closing time. Don’t test the operating system and
pressure-bearing electric valves and regulating valves.
3.1.1.2.1.5 Test methods are divided into static state and dynamic state method: during static test,
only provide test power supply for auxiliaries above 6kV, operation power supply for some
low-voltage power of 400V; during dynamic test, provide both of test power supply and operation
power supply. Carry out the dynamic test after passing static test.
3.1.1.2.1.6 Before unit and equipment interlocking protection test, thermal personnel shall meet
relevant conditions. Before equipment interlocking test, carry out manual startup and shutdown
test in situ and central control room, and make sure that it's eligible.
3.1.1.2.1.7 Make sure that each interlock, protection test operation and audible and visual alarms
are normal, each light indication and graphic displays are correct.
3.1.1.2.1.8 During normal unit operation, carry out periodic test after stability of unit operation and
follow strictly operation orders. Take the isolating measure for testing the equipment in operation,
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and do not affect the safety of operating devices. Foresee the possible results of accident during
the test.
3.1.1.2.1.9 Resume mandatory condition after the test, and put reliably relevant protection
interlocking, do not change randomly without stated approval process.
3.1.1.2.1.10 After the test, do the recovery work of systems and equipments; check the protection
values, analyze test results and prepare the detailed record.
3.1.1.2.1.11 After the test, shut down the power supply to each device. Take the maloperation
protection measure if the power supply is not off; switch the switches of the startup equipments to
RMT mode.
3.1.1.2.1.12 The equipment test is coordinated by the shift foreman (unit foreman) or unit section
foreman, is participated by the maintenance personnel, operated by the operating personnel, the
relevant personnel are at the scene.
3.1.1.2.2 Test provisions before start
3.1.1.2.2.1 Equipment test and preliminary operation must be applied in writing by the
maintenance staff, it can be executed only after it is agreed and the test command is issued by the
shift foreman.
3.1.1.2.2.2 Equipment test is coordinated by the person in charge of maintenance and operated by
operation personnel, the persons concerned are on site.
3.1.1.2.2.3 Test method of the equipment is divided into the static state and dynamic state; in case
of the static test, the power of more than 6kV is only supplied the test power, 400V low-voltage
power supply can be supplied the dynamical power; in case of the dynamic testing, the operation
and dynamical power are supplied.
3.1.1.2.2.4 The above tests are carried out after the overhaul and minor repair of the unit. Some
tests may also be implemented alone after maintenance in line with the needs. The dynamic test
must be carried out after passing the static test.
3.1.1.2.2.5 The pumps, smoke and wind baffle location etc should meet the program controlled
requirements. Prior to the protection and interlock test, the thermal power personnel should carry
out the test only after forcibly meeting the relevant conditions.
3.1.1.2.2.6 The test actions of the interlock, protection and accident buttons should be accurate
and reliable, the sound and light alarm, CRT screen state display are normal.
3.1.1.2.2.7 The tests of the motor-operated valve, adjusting valve and baffle are qualified.
3.1.1.2.2.8 Test requirements:
A) The system that has been put into operation as well as motor-operated valve and adjusting
valve under the pressure can not be tested.
B) For the servo mechanism with the local control and remote control, the local control and
remote control tests should be executed, and special person records on-off time and test
condition.
3.1.1.2.2.9 Test method:
A) Based on the test card, all the motor-operated valves and baffles should be carried out the
remote control and local control’s full open and full-close tests, the opening indications and local
indications should be consistent, the motor-operated valves and air baffles with middle stop should
be tested to be normal middle stop.
B) The pneumatic regulation unit should be flexible movement without leakage and abnormal
phenomenon.
3.1.1.2.2.10 Turn off –on and accident button test (static state)
A) Respectively start the auxiliaries, the turn off –on test are confirmed in the good condition,
resuming the closing position.
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B) Respectively shut down the auxiliaries in site with the accident button, the corresponding
auxiliaries should be tripped, the sound and light signal alarm are normal.
3.1.1.2.3 Test item prior to start
3.1.1.2.3.1 Transmission test of the motor-operated valve (baffle) and air-operated valve (baffle).
In case of test, confirm that the rotating direction of the motor-operated valve is correct, the on-off
of the air-operated valve is correct, the light signal state indication is correct. Record the on-off
time, action dead area condition of the valves.
Test methods:
a. Based on the valve test card, all the motor-operated valves and air baffles should be carried out
the remote control and local control’s full open and full-close tests, the opening indications and
local indications should be consistent, the motor-operated valves and baffles with middle stop
should be tested to be normal middle stop.
b. The pneumatic regulation unit should be flexible movement without leakage and abnormal
phenomenon.
3.1.1.2.3.2 The rotating equipment’s turn on -off and accident button test (stationary state).
a. Respectively start the force fan, suction fan, primary fan, coal mill, coal feeder, air preheater,
flame check fan for the remote turn on -off testing, inspect that the power equipments’ turn on–off
circuit are in good condition.
b. Stop the above power equipments by respectively pressing the accident button, at this time the
power equipments should be tripped, the accident alarm bell rings, the alarm window alarms, the
red light is off, the green light is on.
3.1.1.2.3.3 Unit interlock protection test
After meeting the test conditions (it is enforced by the thermal power personnel in case the
conditions are not met), the various linkages, tripping conditions of the equipment and system
interlock protection test should be simulated by the thermal power personnel, in order to observe if
the action and alarm situation are normal. Including: the interlock protection tests of the rotating
equipments, boiler’s MFT and IFT test, steam turbine, motor and boiler interlock and linkage tests
etc.
3.1.1.2.3.4 Boiler hydraulic test
a. Scope of the boiler hydraulic test
Economizer, water wall and superheater systems: self-feed water pump outlet to the main steam
valve of the steam turbine.
Reheater system: from the inlet hydraulic baffle of the primary reheater to the hydraulic baffle on
the outlet reheat steam pipeline of the final reheater.
Pipeline auxiliaries of the boiler body part.
Drum bovine eye water level gauge is used in the working pressure’s hydraulic test, not in the
ultra-pressure test.
b. Hydraulic test sequence: first low-pressure and then high-pressure, namely: first reheater
system hydraulic test, and then economizer, water wall and superheater system hydraulic test.
c. Boiler hydraulic test is divided into the working pressure test and ultra-pressure test. Boiler
body’s working pressure test refers to that the boiler pressure part is taken the drum working
pressure as test pressure, ultra-pressure test refers to that the boiler pressure part is taken the
drum working pressure of 1.25 times (unit: MPa) as test pressure.
3.1.1.3 The boiler start-up should has the conditions
Before starting–up the boiler, the maintenance of the equipment should be completed, the thermo
motor and electrical work sheet have been completed, the check and acceptance of the boiler
equipments are qualified, the rotating machines’ test run are normal. Before starting up the boiler,
the following calibration and test work are completed and in accordance with the requirements:
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1) Boiler hydraulic test;
2) Fan dynamic balancing test;
3) Furnace aerodynamic characteristic test;
Newly installed boiler (may be determined based on the condition after overhaul) should be carried
out the aerodynamic characteristics test, and boiler and auxiliary equipment can be
comprehensively inspected by testing, to understand their good condition and regulation institution,
automatic device and control instrument situation. Test results are provided the technical data for
the cold start and hot start, commissioning and operation. Main test contents:
a. Flow rate (flow) uniform regulation in the primary air tube. Through the test, the deviation of the
difference between the flow rate (flow) in the primary air tube and average valve of the layer as
well as the deviation of the ratio of the flow rate (flow) to the average valve of the layer should be
less than ± 5%.
b. Secondary air and perimeter air baffle characteristic test. Through the test, the relation curve
between the baffle opening and secondary wind speed under different wind pressure is obtained.
c. Aerodynamic field determination in the boiler.
4) Preheater’s cold state air leakage test;
5) Electric field no-load boost pressure test of the electrostatic precipitator;
6) Boiler’s auxiliary electric linkage and thermo motor protection verification.
The following equipments of the boiler are supplied the power supply: boiler auxiliaries and
accessory equipments; all the instruments, instrument panels, motor-operated valves, baffles,
baffles; automatic devices, program-controlled devices and boiler protection, alarm system and
lighting.
check that the valves of the boiler steam and water system, desuperheater water system, water
drain system, steam turbine bypass system etc are in line with the pre-start state.
Boiler cooling water system, fuel atomization steam system, compressed air system have been
put into operation; the electric precipitation ash hopper heating system, fan heater system have
been in hot standby state; the circulation of the boiler-front fuel cycle system has been established,
the winter fuel heating system has been put into operation, oil temperature and oil pressure are in
line with the requirements; coal pulverizing system, wind and smoke system, ash and slag removal
system have the operation conditions.
Boiler linkage and protection devices are in line with the pre-start requirements, the computer
system has the operation condition; the corresponding turbine and generator have the start
conditions; related system and equipment (fuel and chemical etc) have met the start requirements
of the boiler.
3.1.2 No start condition
3.1.2.1. Unit’s main linkage protection function test is unqualified.
3.1.2.2. DEH, FSSS, DCS control devices are not working correctly, to influence the startup or
normal operation of the unit;
3.1.2.3. The regulating device is failed, to influence the startup or normal operation of the unit.
3.1.2.4. The monitoring function of the unit’s main detecting instrument is lost, to influence the
startup or normal operation of the unit; or the main monitoring parameters of the unit are more
than the limit values.
3.1.2.5. The failures occur at both sides of the boiler drum local water level gauge, which can not
be put into operation.
3.1.2.6. The drum’s water level protection can not be put into operation.
3.1.2.7. Air preheater sootblowing can not be put into operation normally.
3.1.2.8. Control air source and programmable power supply of auxiliary equipments are abnormal;
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3.1.2.9. Boiler electromagnetic relief valve, safety valve and fuel speed off valve are tested to be
abnormal;
3.1.2.10. Boiler newly installed or after overhaul does not have hydraulic test or is unqualified in
test;
3.1.3 When starting up the unit, the following parameters should be monitored and adjusted:
3.1.3.1 Drum pressure, temperature, water level; main and reheating steam temperature, steam
pressure; wall temperature of the superheater and reheater,;
3.1.3.2 Furnace draft, furnace air volume, oxygen; furnace outlet flue temperature;
3.1.3.3 Suction fan stationary blade opening; force fan, primary fan moving blade opening; fan
current and bear temperature.
3.1.3.4 Exhaust gas temperature; heat primary air and secondary air temperature;
3.1.3.5 In oil system operation, regularly check the oil guns’ firing condition, fuel pressure and
temperature, as well as atomized steam pressure and temperature, and check the coal mill outlet
temperature and primary air flow.
3.1.3.6 Boiler water circulation pump current, inlet and outlet differential pressure, motor chamber
temperature, motor shell temperature, etc;
3.1.4 Operation prior to the cold start and impulse starting
Boiler water Start-up
LFO supply ID/FD PA fan boiler out
pump in service pump
in service in service of service
in serviece
Air preheater
in service Auxiliary
BFP Start-up boiler Boiler Sealing fan steam source
in service in service purge in service changed
Flame check
Electrical cooling fan
in service
Power
Available Turbine
Boiler water Boiler Coal pulverizing Oil gun out
ignition rolling system in service Full load
filling of service
Cooling water
in service Fan’s lubricating
oil station
in service
Air preheater put LFO supply

ACP system Coal bunker into continuous Bypass system EP out of
Coal mill’s pump out of
in service coal loading sootblowing in service service
lubricating service
oil station
Flow diagram of boiler start-up

3.1.4.1 System operation
In accordance with the relevant contents of section, "unit auxiliary equipment’s start and stop",
based on the check card, the following systems are put into operation step by step and their
normal operation are checked. When the system is put into operation, the equilibrium of the
section load distribution should be considered.
1 Closed Cycle Cooling Water System;
2 Plant service compressed air system;
3 Boiler slag hopper sealing water system;
4 Boiler water pump’s wash water system;
5 Auxiliaries’ lubricating oil systems;
5 Boiler-front fuel system.
6 Service water system;
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7 Fire water system;
8 Startup boiler system continuous steam supply to auxiliary header
3.1.4.2 Boiler water filling
3.1.4.2.1 Contact with the steam turbine professional personnel, the deaerator water tank is
supplemented to the normal water level, the auxiliary steam of the deaerator is put into operation
for the heating, so that the deaerator temperature slowly rises, as much as possible closing to the
drum wall temperature, the dissolved oxygen is qualified.
3.1.4.2.2 Prior to boiler water filling, put boiler pump into operation, for continuous water filling and
air exhausting, as well as low pressure cooling water system; put drum water level gauges into
service; put the industrial TV monitoring water level into operation;
3.1.4.2.3. Prior to boiler water filling, open all primary & secondary vent valves of the drum, vent
valve of economizer outlet pipeline, for easy air venting. Close boiler front manual & electric drain
valves at the bottom header, close boiler rear primary & secondary electric drain valves and
economizer drain valve at the bottom header, comprehensively check each drain valve of
feedwater system to see if they are closed;
3.1.4.2.4 If there is the water in the boiler, should report to the shift foreman based on the chemical
test result, so as to determine whether to discharge the water.
3.1.4.2.5 In case of the boiler filling, confirm that the boiler water pump has been used in the
continuous water filling. The filling temperature is strictly controlled at 40 to 60℃.
3.1.4.2.6 Start electric pump after deaerator water temperature meets requirements, check
economizer recirculating valve closed position, fill water to the boiler;
3.1.4.2.7 In case of the boiler filling, should strictly control the water intake speed. The water filling
time is no less than 2 hours.
3.1.4.2.8 In case of the boiler filling, should carry out the water filling and air discharge by high
pressure heating system. During the boiler filling, pay attention to the temperature difference
between the wall temperature in the drum and drum wall as well as boiler expansion.
3.1.4.2.9 When the drum is filled to the high water level (+200 mm), shut down the main feedwater
bypass valve, stop the drum filling, and open the economizer recirculation valve. Contact with the
thermal power personnel for the actual transmission test of the drum water level protection.
3.1.4.3 Boiler water pump start up
3.1.4.3.1 Boiler water pump is inched to discharge three times
3.1.4.3.2 Check that the drum water level is at +200mm, start B boiler water pump (intermediate
boiler water pump), when the drum water level decreases to the lowest visible level, shut down B
boiler water pump, it is re-filled to +200mm.
3.1.4.3.3 Start B boiler water pump. After the water level is stabilized, start the A and C boiler water
pumps.
3.1.4.3.4 In case two boiler water pumps are operated prior to ignition, the third boiler water pump
is started when the drum pressure rises to 0.689MPa.
3.1.4.3.5 Open the inlet header dosing valve of the boiler water pump, open the sampling valve of
the steam and water system and notify the chemical department.
3.1.4.4 Wind and smoke system operation of the boiler
3.1.4.4.1 Inspect and confirm that the boiler body, air and flue manhole door, observation door are
closed tightly, the sealing water of the boiler bottom slag hopper is put into operation normally.
3.1.4.4.2 Start A, B air preheaters, confirm that the outlet primary air and secondary air baffles,
inlet flue gas baffle of the air preheater are opened.
3.1.4.4.3 Start the suction fan at the one side, check that it is normal. Slightly open the stationary
blade to adjust the furnace draft to about -100 to -150Pa, the static blade is put into operation
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automatically.。
3.1.4.4.4 Start the force fan at the same side, check that it is normal.
3.1.4.4.5 Start the suction fan at the another side, check that it is normal.. Adjust the furnace draft
to around -100 to -150Pa, the static blade is put into operation automatically.
3.1.4.4.6 Start the force fan at the another side, check that it is normal.
3.1.4.4.7 Through adjusting the fan and auxiliary wind baffle opening of the secondary air box, the
furnace draft is stabilized at -30Pa, the total air volume is more than or equal to 30% MCR.
3.1.4.4.8 Regulate the auxiliary wind baffle, so that the differential pressure between the
secondary air box and furnace is about 380Pa.
3.1.4.4.9 Start an AC flame check fan, the standby fan is used in the reserve application.
3.1.4.4.10 Check that the furnace flame television camera lens is in good condition, inject the
cooling air.
3.1.4.4.11 Oil gun atomization, heating tube and water discharge of the purge steam system, they
are put into operation after heating the tube.
3.1.4.4.12 Heating tube and water discharge of the air preheater’s sootblowing auxiliary steam
system, it is put into operation after heating the tube.
3.1.4.5 Boiler purge
3.1.4.5.1 Boiler purge condition
Before the boiler is ignited, the continuous purge must be carried out 5min. When purging, the
following conditions must be met.
First class condition
1 No any MFT conditions;
2 One suction fan runs at least;
3 One FDF runs at least;
4 Two sets of air preheater run;
5 Air – flue passage is smooth;
6 One boiler circulating pump runs at least;
7 All fuel angle valves are closed;
8 All steam purging angle valves and steam valves are closed;
9 Two PAF stop;
10 All coal feeders stop;
11 All coal mills stop;
12 Outlet burner baffles of all coal mills are closed;
13 No flame and burner operation;
Second class condition
1 No any one of initial purging conditions disappears;
2 Total air flow ＞35% (larger than 910t/h, for reference only)
3 All secondary air baffles are in purging position;
4 Any one of fire detection cooling air fans runs and no pressure alarm;
5 Fuel leakage test is normal;
6 Drum water level higher than﹣100mm, and lower than﹢100mm;
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7 Furnace pressure higher than﹣996Pa, but lower than﹢996Pa;
3.1.4.5.2 Boiler purge operation
3.1.4.5.2.1 When the first class conditions for the above boiler purge are entirely met, the logic will
automatically carry out: place the auxiliary wind baffle on the purge position, close the OFA
auxiliary wind baffle, place the oscillating nozzle on the horizontal position.
3.1.4.5.2.2 When the first class and second class conditions for the boiler purge are entirely met,
the "allow purge" indicator light is on. Click the "start purge", the purge timer of 5 minutes starts the
countdown, "purge is carrying out” indicator light on the FSSS purge logic screen is on
3.1.4.5.2.3 All purge conditions must be maintained within 5 minutes purge cycle, if any condition
is not met, the purge operation will be terminated by the logic while "purge interruption" indicator
light is on, purge is carrying out “indicator light is off, the purge timer of 5 minutes resets. To
re-start the purge, the missing condition must first be restored, and then click "start purge" again,
carry out the re-purge and timing.
3.1.4.5.2.4 After the completion of the boiler purge five minutes, the "purge complete" indicator
light on the FSSS purge logic screen is on while manually reset MFT relay, start the ignition delay
timer of 20 minutes.
3.1.4.6 Fuel leakage test
3.1.4.6.1 Before the ignition of the boiler, must successfully carry out the fuel leakage test.
3.1.4.6.2 Confirm that the fuel system is in a boiler-front oil circulation state, the fuel feed pump
operating is normal, the header tube pressure in front the fuel trip valve is normal.
3.1.4.6.3 Fuel leakage test conditions:
3.1.4.6.3.1 MFT (main fuel trip);
3.1.4.6.3.2 Initial purging conditions OK；
3.1.4.6.3.3 OFT (oil trip);
3.1.4.6.3.4 All oil valves are closed;
3.1.4.6.3.5 Fuel pressure ≥0.8MPa
3.1.4.6.4 After meeting all the conditions, confirm that the MFT relay has been reset; click the
"reset" button on the OFT first logic screen and reset the OFT relay.
3.1.4.6.5 Confirm that after MFT relay and OFT relay have been reset, click "start test" button on
the fuel leakage test screen, then "in the test" indicator light is on, the logic automatically carry out
the following test procedures:
3.1.4.6.5.1 Allowable test conditions OK, fuel return valve closed;
3.1.4.6.5.2 Fuel pressure higher than 3MPa, close OFT valve;
3.1.4.6.5.3 If the fuel pressure drop is less than 0.1MPa (in 9s), fuel return valve and oil angle
valve leakage test OK;
3.1.4.6.5.4 Lasting for 6s, and open the fuel return valve;
3.1.4.6.5.5 Fuel pressure ＜2.9MPa, close oil return valve;
3.1.4.6.5.6 Lasting for 90s, if fuel pressure increase＜0.1 MPa, OFT valve leakage test OK;
3.1.4.6.5.7 If the fuel leak test is failed, shall notify the thermal and overhaul maintenance
personnel to check and handle, should carry out the furnace purge and leak test again.
3.1.4.6.6 Fuel trip reset;
3.1.4.6.6.1 No any of OFT conditions;
3.1.4.6.6.2 All oil valves are closed;
3.1.4.6.6.3 OFT has a delay for 20s;
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3.1.4.6.6.4 OFT valve is closed;
3.1.4.6.6.5 Fuel leakage test OK;
3.1.4.6.6.6 Operator resets in manual;
3.1.4.7 Boiler ignition
Before the boiler is ignited, the main protection of the boiler must be put into operation in
accordance with the provisions.
3.1.4.7.1 Fuel pre-ignition
3.1.4.7.1.1 Confirm that after the OFT relay and MFT relay reset, open the fuel trip valve and oil
return trip valve on the ignition condition screen, then the following allowable oil gun ignition
conditions are checked by the logic:
a)MFT rest
b) OFT reset
c) Fire detection cooling air fan is normal (any air fan runs without pressure alarm) ＞6.5kPa;
d) Atomized steam pressure ＞0.8MPa
e) Fuel supply pressure ≥1.5 MPa, and low fuel pressure switch does not act (＜0.6 MPa);
f) Fuel trip valve is opened;
g) Purging air flow is normal ＞35% (910t/h)
f) All burner are in horizontal positions (40~60%);
3.1.4.7.1.2 When all allowable conditions are satisfied, start the oil guns at four corners of the layer
in sequence;
3.1.4.7.2 Boiler ignition
3.1.4.7.2.1 Prior to the ignition, confirm that the vacuum of the condenser has been established;
Auxiliary steam header is in normal pressure and temperature; open the inlet header of the roof
tube and discharge valve of the wall enclosed superheater; open the economizer’s recirculation
valve; use the furnace flue gas temperature probe; adjust that the pressure difference between the
secondary air and furnace is remained at 0.36 to 0.38kPa.
3.1.4.7.2.2 Start the ignition procedure of the bottom layer (AB layer) oil gun, first use # 1 angle oil
gun, start the # 1 angle igniter, the pressure difference between the secondary air and furnace is
remained normally in case of the ignition, the pressure difference can be regulated through the
secondary baffle.
3.1.4.7.2.3 After the # 1 angle light oil gun is successfully put into operation, followed by using # 3,
# 2, # 4 angle light oil guns every 15 seconds. (Angle is numbered, starting from the boiler-front left
angle against the boiler, 1,2,3,4 respectively according to the clockwise direction). After the
second oil gun is ignited successfully, close the recirculation valve.
3.1.4.7.2.4 The oil gun should be put into operation to the various layers from bottom to top, first is
used to the opposite angle and then is used for the whole layer angle; when it is used for AB layer,
if the ignition is not successful, may try two times, if three times are not successful, should contact
with the maintenance staff for the processing. In case the ignition is failed, must re-purge the
furnace, and then carry out the ignition.
3.1.4.7.2.5 After the ignition each time, should observe the firing situation on site, confirm that the
oil gun atomization is good, applicable air distribution. Whether an oil gun is not fired, should
immediately shut down the oil supply solenoid valve of the oil gun, withdraw it from the operation
position. It can be put into operation only after purging it. Poor combustion is usually shown as:
instable ignition; smoke tail on the flame; not bright flame; the spark formed by the unburned
carbon; irregular flame.
3.1.4.7.2.6 After igniting the boiler, the air preheater is put into operation for the continuous
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sootblowing; confirm that the drain valves of the main and reheat steam pipeline, in front of main
steam valve and combined intermediate valve are opened, the drain valves of the top and bottom
valve seat of the main steam valve and combined intermediate valve are opened, the cylinder
body’s drain valve is opened, the drain valves of the high-duct and high-low bypass are opened.
3.1.4.7.3 Can choose the fuel layer program-start, diagonal angle program-start and single angle
program-start ignition modes on the fuel layer control screen.
3.1.4.7.4 After the oil gun is put into operation, observe whether the furnace flame surveillance
television and flame check indication are normal.
3.1.4.7.5 If there is no ignition or oil gun ignition is unsuccessful within 20 minutes after the MFT
trip relay reset, should protect the action by delaying the ignition, trigger MFT to request for the
furnace purge.
3.1.4.7.6 After the boiler is ignited, the furnace flue gas temperature probe is put into operation,
closely monitor that the furnace outlet temperature can not be greater than 540℃. PCV valve is
set up the "AUTO". Confirm that the economizer recirculation valve is opened. The air preheater is
put into operation for the continuous sootblowing. Should inform the person on shift to use the
electric precipitation vibration device.
3.1.4.7.7 Inspect and confirm that the following drain valves and release valves are opened:
3.1.4.7.7.1 In case of 5% MCR, start the bypass drain valve, roof tube’s inlet header drain
valve;
3.1.4.7.7.2 Reheater system’s drain valve;
3.1.4.7.7.3 Boiler body’s release valve;
3.1.4.8 Boiler’s temperature rise and boost pressure
3.1.4.8.1 After the boiler is ignited, gradually increase the oil gun’s temperature rise and boost
pressure. According to the boiler’s start curve (see attached diagram), strictly control the heating
up and boost pressure rate:
No. Phase Temperature rise rate Boost pressure rate
From the ignition start to

1 ＜0.35℃/min
30 minutes
From 30 minutes to the
2 2.2～2.5℃/min 0.03MPa/min
start pressure 1MPa
3 More than 1MPa 2.2～2.5℃/min ＜0.06MPa/min
3.1.4.8.2 In case an oil gun is used each time, should actually observe the fire situation in situ.
Should periodic inspect the boiler-front fuel system to prevent the oil leakage from generating the
fire accident.
3.1.4.8.3 When the drum pressure rises to 0.1MPa, should carry out the washing of the drum
water level gauge and check that the water level gauge indication are accurate.
3.1.4.8.4 When the drum pressure rises to 0.2Mpa, close all the air valves:
3.1.4.8.4.1 Drum’s air valve
3.1.4.8.4.2 Partition panel’s inlet air valve;
3.1.4.8.4.3 Partition panel’s out air valve;
3.1.4.8.4.4 Final superheater’s inlet air valve;
3.1.4.8.4.5 Final superheater’s out air valve.
* Before the steam turbine is vacuumized, close the reheater outlet air valve, plate reheater air
valve and rear wall enclosure reheater air valve.
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3.1.4.8.5 When the drum pressure rises to 0.5MPa, close the drain motor-operated valve of the
roof tube inlet header. And notify the maintenance personnel and thermal power personnel to carry
out the hot tight screw and wash the instrumentation pipeline.
3.1.4.8.6 When the hot primary air temperature reaches to 150℃, the first set of milling system is
put into operation.
3.1.4.8.6.1 Start A, B primary air fans, gradually increases the primary air pressure to the header
tube pressure of more than 10kPa, the primary air pressure is put into operation automatically.
3.1.4.8.6.2 After the normal operation of the primary air fan, start a sealing fan for the operation,
after the sealing air pressure is normally adjusted, another sealed fan is put into operation for the
back-up.
3.1.4.8.6.3 Start A coal mill, after it is normally operated, start A coal feeder. Gradually increase the
coal capacity, the boiler continues the temperature rise and boost pressure.
3.1.4.8.7 Bypass system operation
3.1.4.8.7.1 When the drum pressure is about 0.5MPa, contact with the steam turbine professional,
prepare to use the bypass system.
3.1.4.8.7.2 When the drum pressure is about 1.0MPa, contact with the turbine professional to set
up the high-and low-bypass pressure regulating valves for the manual mode, manually open the
high-bypass pressure regulating valve to 5% opening, slightly open the low bypass to carry out the
bypass pipeline heating.
3.1.4.8.7.3 In accordance with the main reheat-steam pressure and temperature condition, the
turbine professional is required to gradually open up the high-and low-bypass pressure regulating
valves.
3.1.4.8.7.4 When the bypass flow is up to 10% MCR working condition, withdraw the furnace gas
temperature probe (In case flue gas temperature is more than 540℃, it should be automatically
withdrawn), close the economizer recirculation valve and discharge valve.
3.1.4.8.8 When the drum pressure increases to 2.07MPa, stop the boiler water pump continuous
filling.
3.1.4.8.9 When the drum pressure increases to 2.7MPa, if the main steam temperature reaches to
278℃, the bypass valve of 5% MCR is fully opened.
3.1.4.8.10 When the main steam pressure is up to 4.0MPa, should applicable reduce the fuel
amount to maintain the stability of steam pressure. When the main steam temperature is up to
350℃, the parameters are controlled by the boiler in accordance with the steam turbine
requirements, the steam turbine is ready to conduct the impulse starting.
3.1.4.9 Steam turbine impulse starting
3.1.4.9.1 Steam turbine impulse starting and boiler operation during the warm-up
(1) The drum is maintained a low water level to prevent the drum water level from rising too much
after impulse starting.
(2) Adjust the fuel volume to stabilize the main steam temperature at about 350℃.
(3) Regulate 5% bypass water drain to stabilize the main steam temperature at about 4.6MPa.
(4) The outlet electrical discharge valve (PCV valve) of the overheater is set up for "automatic".
(5) When the initial load is maintained, should stabilize the steam temperature and steam
pressure as far as possible.
3.1.4.9.2 Confirm that the main steam parameters at the steam turbine side has reached the
impulse starting conditions
Main steam pressure: 5.9MPa Main steam temperature: 350℃ Reheater temperature:
340℃
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3.1.4.9.3 In accordance with the steam turbine professional requirements, adjust the combustion,
stabilize main steam pressure, main reheat steam temperature, the steam turbine begins the
impulse starting.
3.1.4.10 Boiler operation when the generators are paralleled with the load.
The unit is parallel in the power grid
(1) When the steam turbine rotating speed is up to 3000r/min, the unit begins to parallel in the
power grid.
(2) Applicably increase the fuel amount, the boiler is boosted at the boost pressure rate of
0.1MPa/min.
(3) 5% bypass is turned off automatically.
When the steam turbine rotating speed is up to 3000r/min, inspect that the boiler should has the
following conditions:
(1) Boiler parameters (main steam and reheat steam parameters) are stable, are in line with the
generator grid-connection requirements, the drum water level is normal.
(2) Stable combustion boiler.
Report to the shift foreman. The generator grid-connection operation is implemented by the
electrical professional.
3.1.4.11 Unit load rises to the normal operation
3.1.4.11.1 In accordance with the requirements of the steam turbine, increase the boiler load, the
main parameter change rate of the boiler should be controlled: load change rate of 3MW/min, the
steam pressure change rate is less than or equal to 0.10MPa/min, the regulating temperature rise
rate of the load increase is less than 1.8℃/min. The initial load of the generator is 30MW,
maintaining 25min for the warm-up operation.
3.1.4.11.2 In case of about 100MW load, the second set of coal pulverizing system is put into
operation.
3.1.4.11.3 When the hot primary air temperature reaches above 177℃, and the following coal
pre-ignition conditions are met:
a) Applicable secondary air temperature;
b) Normal primary air pressure;
c) Normal flame check air pressure;
d) Suitable air volume;
B coal mill is started and put into operation.
The coal pulverizing system operation should be based on the principles of the first bottom layer,
and then top layer and centralized combustion.
3.1.4.11.4 When the boiler load is more than 25% MCR, after the drum water level is stabilized,
according to the steam feed pump operation, the drum water level is put into operation
automatically .
3.1.4.11.5 In case of 200MW load, the third set of coal pulverizing system is put into operation. The
second steam pump is heated and put into operation.
3.1.4.11.6 When the boiler main steam pressure is up to 10MPa, turn up the continuous blowdown
to wash the silicon, according to chemical analysis, can continue to boost only when the boiler
water silicon content reaches to the allowable silicon content of the next class pressure. The
silicon content limit values of the boiler water under the different pressures are as follows:
Drum pressure (MPa) 9.8 11.8 14.7 16.7 17.7
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Limit valve of silicon
2.8 1.5 0.4 0.3 0.2
content (ppm)
3.1.4.11.7 Unit load: 300MW, stop all the oil guns, but must ensure the stable boiler combustion.
Stop the whole oil guns of the boiler, comprehensive inspect and close the drain valve of the unit
boiler side. Air preheater sootblowing is changed for the program-controlled sootblowing, inform
the gray water operator on duty to use the electrostatic precipitator, contact the thermal power
personnel to use the seal gap automatic adjustment device of the air preheater.
3.1.4.11.8 In case of 360MW load, the reheat steam temperature is up to 538℃, the swing control
of the burner is set up for automatic, the spray desuperheating control of the reheater is set up for
automatic.
3.1.4.11.9 In case of 360MW load, the fourth set of coal pulverizing system is put into operation by
the boiler.
3.1.4.11.10 In case of 450MW load, carry out the following operation inspection:
a. Start the fifth set of coal pulverizing system, the boiler body is fully blown by the sootblower after
stable combustion.
b. Comprehensive inspect the boiler leakage. Confirm that all systems are operating normally,
contact with the thermal power personnel to use all the automatic control.
c. Switch over the steam sources of auxiliary steam header, start the boiler and stop steam supply,
as per conditions;
3.1.4.11.11 Gradually equipped with full load, comprehensive inspect, adjust that the equipments,
systems of the unit are at their best operating state. Carry out the unit defect statistics.
3.1.5 Note in the start process
3.1.5.1. In the boiler startup process, closely monitor the operation of the boiler water pump:
a) Inlet and outlet differential pressure of the boiler water pump is more than 60kPa;
b) Normal boiler water pump’s motor current;
c) Motor chamber temperature of the boiler water pump is less than 60℃.
3.1.5.2. In case of oil filling, the special person should check it, should contact the relevant
personnel to deal with in time if the oil leak and bad combustion phenomenon etc are found.
3.1.5.3. In the course of oil filling, shall regularly check that the boiler-front oil fuel system is normal,
and maintain the continuous sootblowing of the air preheater.
3.1.5.4. In the process of Boiler boost and temperature rise, control the rate of the boost and
temperature rise in strict accordance with the boost and temperature rise curve, it is prohibited to
over-pressure and over-temperature. Pay attention to monitor the temperature difference between
the inner and outer walls of the drum.
3.1.5.5. In case the boiler load is less than 10% MCR, it is prohibited to use the superheater,
reheater desuperheater water.
3.1.5.6. In the boiler boost process, can carry out the low water drum waterdrainage of the
water-wall so that the boiler parts are uniform thermal expansion in accordance with the conditions,
in case of the waterdrainage, strictly control that the drum water level is normal; when the boiler is
abnormally expanded, should stop to boost, find the reasons, continue to boost after the
expansion is normal.
3.1.5.7. In the boiler start process, before the generators are paralleled, the furnace outlet flue gas
temperature should not exceed 538℃.
3.1.5.8. In case of the drum filling at the initial stage of the boiler start –up, close the economizer
recirculation valve, open the economizer recirculation valve after filling.
3.1.5.9. When the water flow or steam flow is more than or equal to 10% MCR, close the
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economizer recirculation valve, withdraw the furnace gas temperature probe.
3.1.5.10. In case the impulse starting of the steam turbine, adjust the 5% MCR bypass to stabilize
the steam pressure at 4.0MPa. After the steam turbine start-up, it is necessary to prevent the
fluctuations of the main steam, reheat steam temperature and pressure, prevent the steam with
water.
3.1.5.11. After the generators are paralleled, close 5% MCR, start the bypass valve.
3.1.5.12. In the whole boost process, when the SiO2 content is over the limit, should stop the
boost pressure, and turn up the continuous blowdown to wash the silicon.
3.1.5.13. When in adding the pulverized coal, pay attention to combustion adjustment, if the coal
does not fire after being added into the furnace, close immediately corresponding coal mill, identify
the cause and eliminate it, and then the second coal adding can be conducted. If the coal adding
fails for two times, stop the coal mill immediately and analyze the cause.
3.1.5.14. In case the burner is put into operation, should consider the adjacent layer running. In
case the burners of three-layers or below are operating, the adjacent layers are required to run; it
is prohibited to run in A, C, E or B, D, F burner so as to meet the CBF control requirements (except
in the case of accidents).
3.1.5.15. In the boiler startup process, should pay attention to monitor the parameter changes of
the air preheater, so as to prevent the occurrence of secondary combustion. When the outlet flue
temperature is found to increase abnormally, the air preheater is put into operation for the
continuous sootblowing and the necessary treatment is carried out.
3.1.5.16. The fuel amount should be uniformly adjusted in order to prevent too large fluctuations of
the drum water level, main and reheat steam temperatures, furnace draft.
3.1.5.17. Pay attention to monitor the automatic control working condition, such as furnace draft,
feeding air volume, coal feeder etc, should deal with in time if the abnormal condition is found.
3.1.5.18. Pay attention to monitor the combustion condition, adjust the combustion in time,
stabilized the combustion, especially when shutting down the oil gun, starting and stopping the
coal mill.
3.1.5.19. In the boiler startup and running, should pay attention to monitor the wall temperature of
the superheater and reheater so as to prevent the tube explosion due to the over-temperature.
3.1.5.20 After all oil guns are stopped, the fuel system should be in the standby cycle state, inspect
in situ that all oil guns have been withdrawn from the furnace.
3.1.5.21 In the boiler cold start, there are the maximum temperature difference between the
components, should inspect and record the boiler’s expansion indicator in case of various working
conditions, such as prior to filling the water, after filling the water, pressure of 0.3 to 0.5MPa,
pressure of 1.0 to 1.5MPa, 50% MCR load and full load condition and so on.
3.1.6 Combustion in the start process
3.1.6.1 In the startup process, combustion process is: ventilate and purge the furnace before
ignition, ignition, oil- coal multifuel combustion, coal-oil switch, full pulverized coal combustion.
Main questions of the combustion in the startup process are:
a. The combustion working condition should meet the startup process requirements of the unit;
b. Ensure the combustion stability and prevent the furnace explosion;
c. Improve the combustion efficiency and reduce the losses;
d. Save the fuel, switch to the pulverized coal combustion as soon as possible.
3.1.6.2 Purge the furnace by the boiler ventilation
Before the ignition of the boiler, should ventilate and purge the furnace to remove the residual
combustible and combustible gases in the furnace, prevent the furnace explosion in case of
ignition. The purge furnace methods have been described above.
3.1.6.3 Initial fuel quantity
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After the purge and ventilation of the furnace, the oil filling and ignition can be implemented. In a
comparatively short period of time after the ignition, the fuel quantity (fuel) is required to increase
to a required value, and remaining unchanged in a phase, the volume of the fuel is referred to as
the initial fuel volume. The size of initial fuel amount should be based on specific circumstances, it
is subject to the restrictions on the rate of temperature rise and boost pressure rate. At the same
time it should also be considered: stable combustion in case of the cold start, uniform
requirements of the furnace heat load; can meet the requirements of the steam turbine’s impulse
starting, speed up, parallel with the initial load etc.
3.1.6.4 Filling the pulverized coal for the combustion
At the initial phase of the start up, the boiler uses the fuel. In case it increases to a certain load, it is
required to start the milling system and fill the pulverized coal for the combustion, so as to carry
out the coal-oil co-combustion, and then oil is stopped to carry out the full pulverized coal
combustion. When to fill the pulverized coal; when to stop the oil, are mainly based on the stable
combustion, which are related to the coal, burner, and furnace structure. The initial coal filling
conditions are as follows:
(1) Furnace outlet gas temperature (usually about 280℃) – when the heat load in the furnace
reaches to a certain value.
(2) When the hot air temperature reaches to a certain value.
(3) Extent, which the furnace is full of the flame.
For the 600MW boiler, in case the steam turbine load rises to 10 to 20% or hot air temperature is
more than or equal to 150℃, can start the first set of pulverized coal system, and fill the pulverized
coal for the combustion.
3.1.6.5 Full stop oil combustion
Full stop oil should be determined depends on the fuel coal, in general, 50 to 60% MCR, in case of
the stable combustion, can stop to use all the oil guns to carry out the full coal combustion.
3.1.7 Heating surface protection in the start process
3.1.7.1 Superheater and reheater safety
Superheater or reheater is one of the main components in the boiler, and its working substance
temperature and tube wall metal temperature are the highest in the boiler. In the startup process,
the superheater and reheater safety are the very importance, which should meet two
requirements: first, the superheated steam temperature, reheat steam temperature should be
consistent with the requirements, such as steam turbine’s impulse starting, speed up, parallel in
and load up and so on; second, the tube wall of the superheater and reheater are no more than
the allowable temperature of the used materials, their headers and tubes etc, do not produce the
excess cyclical thermal stress in order to increase their service life.
(1) Superheater protection
In the start process, 600MW boiler carry out the superheater cooling by its own steam, but the
over-temperature of the superheater tube is often caused by too large heat deviation. The thermal
deviation of the superheater is generated in the start process due to:
1 Some tubes are plugged with the water due to the accumulated water of the vertical
superheater
Prior to start up, the accumulated water in the vertical superheater is unable to discharge. Start the
superheater after the hydraulic test, the water is filled with it. Start-up after operation and
shutdown, some water can be also accumulated in the vertical superheater due to the
condensation. After the ignition of the boiler, the water can be also condensed in case the steam
passes through the cold tube such as superheater, etc. The accumulated water in the serpentine
pipe can also result in the water plugging, impede the smooth steam flow, the accumulated water
in the column of the parallel pipe is often uneven, under the low steam pressure, some pipes with
less accumulated water are dredged, and some pipes with more accumulated water are still in the
water plugging state. The dredge pipe’s inlet and outlet differential pressures must be greater than
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the weight resistance of the water plugging pipe, in order to dredge the water plugging pipe.
Therefore, should limit the heat load, the water plugging pipe is handled by self-evaporation in
order to cool the pipe before the dredge flow is not reached.
In addition, for the wall overheater, such as coated tube, etc., the accumulated water can be
dredged by the drain valve on the bottom header. Ring-shape header drain valve, drain valve of
the horizontal flue coated lower header, inlet drain valve of the wall-type reheater are 100%
discharged to facilitate the water drainage. When the ring-shape header drain valve, horizontal
flue coated drain valve are boosted to 0.5MPa, it shall be turned down, it shall be turned down to
0% in case of the impulse starting of the steam turbine. The inlet drain valve of the wall-type
reheater is also closed when the pressure rises to 0.1MPa.
In order to heat up and dredge the superheater, at the start beginning, the outlet steam header
drain valve of the superheater is opened by 30%, the high-pressure bypass is opened by 20%.
When the pressure rises to 0.8MPa, the main steam valve is opened for the water drainage, the
water drainage of the steam outlet header of the superheater is closed, so as to carry out the
heating pipe for the main steam pipe.
② Reduce the heat transfer deviation
The combustion working condition in the boiler must be arranged to ensure that the furnace outlet
flue gas temperature is uniformly distributed. It is specified in 300MW boiler that the left and right
deviation of the furnace outlet are not more than about 30℃ in the start process, the maximum
deviation does not exceed 50℃. 600MW unit boiler ‘s furnace volume is large, and sectional area
of the furnace is also large, the large residual torgue is generated at the furnace outlet by the flue
gas, that is, the large left and right deviation are also generated at the horizontal flue inlet, which
would result in the left and right thermal deviation increase of the superheater and reheater.
(2) Reheater protection
When the boiler with the reheater is startup, the reheater security is mainly related to the bypass
system type, flue gas temperature, start-up mode of the reheater heating surface (mainly refers
to the steam parameters of the steam turbine impulse starting), as well as the steel performance
used in the reheater.
For the reheat unit of the secondary bypass system with the tandem arrangement, in the startup
period, the steam flows into the reheater through the high-pressure bypass, and then flows into the
condenser through low- pressure bypass, so that the reheater is made a certain cooling .
Reheater safety is also closely related to the impulse starting parameter, if the impulse starting
parameter is low, then the flue gas temperature of the reheater is low prior to the impulse starting,
which is beneficial to the reheater security. If the impulse starting parameter is high, the flue gas
temperature of the reheater is high prior to the impulse starting, which is adverse to the reheater
security.
For the unit with high and low levels of bypass system, the high-pressure bypass is opened in the
beginning of the start up, the reheater is cooled by the boiler own steam. When the pressure
increases to 0.8MPa, the low- pressure bypass is put into operation. However, the small steam
flow at the start-up initial phase is considered, poor cooling pipe wall capacity. In addition, the
reheater of the control circulation boiler (600MW unit) adopts the high temperature arrangement
(arranged at the furnace outlet), it is strongly heated. Therefore, at the ignition and boost pressure
initial phase, it is still used to control that the furnace outlet flue gas temperature is not more than
538℃, until the turbo-generator is parallel, through the flow increase of the reheater, the furnace
outlet gas temperature meter can be considered to withdraw. If in this startup process, the furnace
outlet flue gas temperature is more than 538℃, the boiler is suspended the continuous boost by
the computer control system (DCS), it is made the further boost after the flue gas temperature is
reduced to the specified value.
3.1.7.2 Economizer protection
The vast majority of the drum boiler adopt the recirculation pipe connecting between the drum and
economizer inlet header, so as to form a natural cycle circuit through the economizer, which plays
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a role to continuously supply the water flow for the economizer when the water in the serpentine
pipe on the upper part of the economizer is generated the bubble due to the evaporation, the
economizer is protected through the recirculation tube during the ignition. However, when the
boiler is flooded, the water temperature fluctuation in the economizer is large, particularly to the
later phase of the ignition, as the boiler water temperature is much higher than the feed water
temperature, and thus the fluctuation is greater. Such fluctuation will result in the alternating
temperature stress in the economizer tube wall, occur harmful effects on the weld seam of the
economizer. At the same time, the running personnel operation become more trouble. The
recirculation valve should be carried out the switching operation by whether the boiler is flooded,
that is, when the boiler is flooded, the recirculation valve should be closed, otherwise, the feeding
water will be flowed into the drum through the recirculation tube short circuit, the economizer is not
cooled due to the non-water flow. After filling, the feeding valve should be closed while the
recirculation valve should be opened.
During the ignition and boost pressure of the control circulation boiler, the economizer is carried
out the forced cycle by the boiler water circulation pump, large circulation water quantity, good
reliability of the economizer protection, the recirculation valve should be not carried out the
frequent switching operation. The water temperature fluctuation in the economizer is smaller due
to the large circulation water volume, reducing the possibility of the economizer damage.
Recirculation valve is opened in case of startup, it is closed in case of the economizer continuous
feeding.
3.1.8 Washing silicon
3.1.8.1 Principle of washing silicon
With the increase of the boiler working pressure, the steam density increases continuously, the
steam nature is closer to the nature of water, the ability to dissolve the salt will be stronger. The
design / working pressure of 600MW boiler drum in this project is 19.79/18.84MPa, with a larger
steam soluble salt capacity.
Steam soluble salt has the following characteristics:
(1) Saturated steam and superheated steam can dissolve the salts, the salts can be dissolved in
the saturated steam, it can be also dissolved in the superheated steam.
(2) The steam soluble salt capacity, as the pressure increases, the solubility increases; as the
pressure drops, the dissolved salt capacity of the steam declines.
(3) Higher the salt content in the boiler water, then higher the salt content dissolved in the steam.
(4) Steam has the dissolution selectivity to the salt, a variety of salts in the boiler water can be
divided into three classes:
First class salt: silicate (H2SiO3), maximum solubility in the steam;
Second class salt: Na (OH), NaCl, CaCl2, etc., the solubility of the such substance in the steam is
much lower than the first class;
Third class salt: Na2SO4, Na2SiO2, Na3PO4, CaSO4, MgSO4 and so on, very low solubility in the
steam, even when the vapor pressure is at 20MPa, its dissolution question is not considered.
Therefore, for the sub-critical pressure boiler, the most importance is that the silicic acid is
dissolved in the steam. The silicic acid dissolved in the steam will has a very bad consequence,
the silicic acid enters the steam turbine with the steam, the steam can do work while expanding in
the steam turbine, the pressure drops, the silicic acid is precipitated from the steam in a solid form
to deposit at the low pressure part of the steam turbine, serious impact on the security economic
operation of the steam turbine.
Therefore, during the startup of 600MW unit boiler, the silicic acid quantity of the boiler water is
strictly controlled, to discharge the boiler water with high concentrations of silicic acid, to ensure
that the steam silicon volume is within 200μg/l, this process is known as wash silicon. The actual
washing silicon operation is to carry out the continuous blowdown to the boiler water, discharge
the boiler water with high concentrations of silicic acid so as to ensure the quality of the steam.
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3.1.8.2 Wash silicon control
When the drum boiler is boosted to 10MPa, start the wash silicon, that is, the subsequent boost
must be subject to the silicon content in the boiler water. Sampling according to chemical analysis,
after the silicon content in the boiler water reaches to the next level pressure allowable contents, it
can be boosted to the corresponding value, and is continued to implement the wash silicon.
Allowable silicon content in the boiler water under the different pressure are as follows:
Pressure (MPa) 9.8 11.8 14.7 16.7 17.7
SiO2 content in boiler water (μg / L) 3300 1280 500 300 200
3.2 Other state start
3.2.1. Hot start (without the bypass system)
3.2.1.1 The start-up mode is used only for the start, with the boiler steam pressure of 7MPa, and
steam turbine at hot state.
3.2.1.2 Preparation prior to start should be implemented in line with the relevant chapters of the
cold start.
3.2.1.3 Impulse starting conditions
3.2.1.3.1 Inspect the preparatory work prior to the impulse starting of the cold start, confirm that
the system is normally operating.
3.2.1.3.2 Steam temperature, steam pressure meet the impulse starting parameters and are
stable.
3.2.1.3.3 The first-class steam temperature and first-class metal temperature should be good
matched, the first-class steam temperature is determined by the impulse starting parameters
according to appendix 3 "hot start recommended value - impulse starting and with minimum load"
curve. In any case, the first class steam temperature does not allow 110℃ more than first-class
metal temperature or 56℃ lower than first-class metal temperature.
3.2.1.3.4 Recommended impulse starting parameters
Main steam pressure 7MPa Main steam temperature 450℃ Reheat steam temperature
425℃
3.2.1.3.5 In accordance with the impulse starting parameters, use the curve in the appendix D,
determine the speed rise rate.
3.2.1.4 Speed up
3.2.1.5 Parallel in the power grid with load
3.2.1.5.1 After the warm-up end of 5% load unit, the load rises at 1.5% loading rate.
3.2.1.5.2 After the unit load rises to 30% MCR, the load rises to the rated load, at 0.30MPa/min
boost pressure rate and at 2% loading rate.
3.3 Outage and maintenance of boiler
Boiler shutdown is caused by a variety of reasons, which it is preplanned to shut down, it is also
shut down due to the unit defects and accident. There are two general situations about shutdown
way, normal shutdown and accident shutdown. Normal shutdown can be divided into two,
shutdown to cold standby (or maintenance) and shutdown to hot standby. As matter of fact, there
are three shutdown modes.
Shutdown to cold standby, refer to that after the boiler is shut down, it has been cooled to the room
temperature for back-up or repair, so-called normal shutdown. This way generally uses the sliding
pressure shutdown, the boiler’s fuel is gradually lowered along with the unit load reduction, to
ensure that the steam temperature, pressure and flow adapt to the requirements of turbine until
the boiler is shutdown and extinguished.
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Shutdown to hot standby, referring to that after the boiler is shut down, the heat loss is prevented
as far as possible, as so to restart in a relatively short time, this way generally uses the constant
pressure shutdown. The unit plant is more than 80% load, the steam turbine gradually turn down
the governing valve, to reduce the load. The steam turbine automatically maintains the main
steam pressure along with the gradual reduction of the boiler combustion, to constant reduce the
load, the main steam superheat temperature is more than or equal to 100℃. Otherwise, the
setting value of main steam pressure should be appropriately reduced.
Accident shutdown refers to the shutdown in accordance with the accident requirements, such as
damage to body heating surface, major accident of the auxiliary system or failure and defect of the
turbine side, the fuel must be cut off under the working load, so as to rapidly cool the boiler.
3.3.1 Shutdown characteristics of the control circulation boiler
3.3.1.1 The shutdown is a cooling process, the unit is slowly cooled in the shutdown process to
prevent the boiler component from generating too much thermal stress and even damage to
components due to the excessive cooling. For the drum boiler, the drum thermal stress is still the
core issue to limit the shutdown, cooling and depressurization speed. In the shutdown process,
the drum lower wall contacts with the boiler water, its internal wall temperature is equal to the
saturation temperature under the current pressure. Outer wall temperature is higher than the inner
wall temperature, the drum lower wall contacts with the steam, the drum inner wall discharges the
heat to the steam due to the pressure drop, there is a layer steam with the superheat degree
closing to the wall surface, the result is that the wall temperature of the upper part of the boiler is
higher than the lower part, the outer wall is higher than the inner wall, so that the upper part of the
boiler is pressurized, the lower part is pulled, therefore the depressurization cooling speed is
subject to temperature difference between the lower and upper walls of the drum and temperature
difference between inside and outside the walls.
For the control circulation boiler, because there are the circular clapboard in the drum, coupled
with the forced circulation flow of the boiler water pump, the entire drum inner wall contacts with a
mixture of steam and water, there is no temperature difference between the upper and lower wall,
and the depressurization speed is subject to the temperature difference between inside and
outside the walls of the drum, so the depressurization speed can be faster.
3.3.1.2 In general, it can be ventilated and cooled 4 to 6 hours after the boiler is shutdown. It can
be accelerated and cooled after the control circulation boiler is shutdown cooling, so as to carry
out the forced ventilation. But it shall also strengthen the surveillance on the variations of the drum
upper–lower and inner-outer wall temperature differences;
3.3.1.3 Application of slip parameter outage, during the entire shutdown process, the decrease of
the boiler load and parameters is carried out in line with the requirements of the steam turbine.
The combustion is gradually weakened, the temperature is reduced and the pressure is lowered.
The steam turbine is shut down and the boiler is shut down after the steam turbine load reduction
is completed, .
3.3.2 Shutdown steps
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LFO supply pump Flame check
ID out of
out of service service cooling fan out
of service
Air preheater put LFO supply pump Bypass system Start-up boiler FD out of Air preheater
into continuous operation nomal in service
sootblowing out of service service out of service
Cuting down Stop upper Oil gun Stop under Turbine Fire Boiler water Boiler Aux.
Boiler Boiler water
load/dropping Coal Coal extinguishing pump equipment
press.&temp. in service manual trip purge power off discharge
Mill(D/E/F) Mill(A/B/C) out of serviece
Start-up Auxiliary Sealing fan PA fan out Air preheater out

boiler in steam system out of of sootblowing
in service of service
service service
Flow diagram of Boiler shutdown

3.3.2.1Normal shutdown
The boiler can be stopped under the normal work condition as a hot standby or cold standby, or for
scheduled maintenance, which is known as the normal shutdown. In general, the shutdown
process includes a few steps, such as preparation prior to shutdown, decreasing load and
stopping combustion, boiler cooling.
3.3.2.1.1 Principle of normal shutdown
(1) Before the boiler is shutdown, conduct a comprehensive boiler inspection, defect statistics in
order to eliminate it after the shutdown.
(2) When the load is reduced, should fill the oil and stabilize the combustion in time in accordance
with the combustion condition in the boiler. For the disabled burner, it should be injected a small
amount of cooling wind.
(3)When the load reaches to zero, the fuel is fully stopped, the boiler is turned off. 30 to 40% of
the air volume is still maintained for the ventilation 5 minutes after extinguishing, to purge the boiler,
remove the possible residue combustible in the furnace and flue; while the stokehole oil should be
completely split, and then suction fan and force fan operation can be stopped.
(4) After extinguishing, the preheater continues to run, the preheater running can be stopped only
after the preheater’s inlet flue gas temperature is more than 120℃, and there is maintenance
work.
3.3.2.1.2. Preparation prior to the outage
3.3.2.1.2.1 Respectively start to test run the host AC and DC pumps, jacking oil pump, check the
normal rotation, normal turning motor idling test.
3.3.2.1.2.2 Make the preparation of the auxiliary steam, shaft seal and deaerator steam source
switch.
3.3.2.1.2.3 Inform the person on post to conduct a comprehensive inspection for the equipment
system, make the defect statistics, make the preparation before the shutdown. Inform the
chemical, fuel, ash and water person on the external post to conduct the preparatory work before
the shutdown.
3.3.2.1.2.4 Conduct a comprehensive boiler-front fuel system inspection, confirm that the system
back-up is in good condition. Oil guns are qualified in firing test, and be ready for operation at any
time;
3.3.2.1.2.5 If the shutdown is within five days, the coal feeder belt should be dry running,
according to the arrangements of the shift foreman, decide whether the coal bunker is vacant
burned. In case the shutdown is more than 15 days, the coal bunker should be vacant burned.
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3.3.2.1.2.6 Calibrate the upper and lower water level gauges of the drum once.
3.3.2.1.2.7 Conduct a comprehensive sootblowing to the boiler heating surfaces.
3.3.2.1.2.8 Remove the ash and slag in the slag hopper.
3.3.2.2 Unit sliding stop
3.3.2.2.1 After receiving the sliding stop command from the shift foreman, the boiler starts to
reduce the heat load, progressively shut down the coal pulverizing system, the order is from top to
bottom. In accordance with the slip stop curve requirements of the steam turbine, the temperature
is started to reduce, the pressure is reduced. In case of unit slip stop, the first level cylinder
temperature of steam turbine’s high and medium pressure must not be less than 400℃, unless
required to report to the chief engineer for approval.
3.3.2.2.2 The boiler is reduced the load at the load change rate of less than 3MW/min, main steam
pressure change rate of less than of 0.15MPa/min. In case of the load drop, the feeding coal rate
of the coal mills should be equally reduced until the rotating speed of the coal feeder is reduced to
40%, the coal mills are shut down from top to bottom (coal feeder belt should be idling).
3.3.2.2.3 Load: 300MW, main steam pressure: 10MPa, main steam temperature: 520℃, reheat
steam temperature: 500℃.
Three coal mills are retained for the stable operation 30 minutes. Air preheater is sootblowed
once.
3.3.2.2.4 The load is continued to reduce at the load change rate of less than 3MW/min, and the
main steam pressure is reduced at the change rate of less than 0.10MPa/min.
3.3.2.2.5 Load 240MW, start the pump, and after the pump is operating normally, an outage
steam-drive feed water pump is withdrawn from the operation or shut down.
3.3.2.2.6 When the rotating speed of the coal feeders of three coal mills are lowered to 40%, A
layer of oil gun is put into operation, the upper coal mill is shut down. Air preheater is put into
operation for the continuous sootblowing, the seal gap automatic adjusting device of the air
preheater device is lifted to the maximum position. The gray water is informed to withdraw from the
electric precipitation.
3.3.2.2.7 In case of the load 150MW, the water supply control is switched to the single impulse.
The high pressure heater operation is withdrawn. Pay attention to the feedwater temperature
change, adjust the steam temperature.
3.3.2.2.8 When the rotating speed of a coal feeder in the remaining two running coal mills is lower
than 50%, the oil gun can be added according to the combustion stability condition, the rotating
speed of the coal feeder is reduced with the load reduction.
3.3.2.2.9 In case of the load 120MW, release the superheater and reheater water injection control
for the manual, release the burner swing angle control for the manual; switch the main water
supply pipe to the bypass running in accordance with the water supply flow.
3.3.2.2.10 In case of the load 100MW, maintain a coal mill running.
3.3.2.2.11 When the water supply flow is less than or equal to 10%, open the economizer
recirculation valve.
3.3.2.2.12 In case of the load 60MW, set up the burner swing angle at the horizontal position. Shut
down the coal feeder, purge the last coal mill, fast reduce the active power to zero, reduce the
reactive power near to zero, the generator and system are splitted, check that the generator stator
voltage and three-phase current are returned to zero. Start the host AC lubricating oil pump and
seal oil back-up pump, manually open the steam turbine valve, close the high and medium
pressure main steam valves and regulating valves, the rotating speed begins to drop.
3.3.2.2.13 Shut down the last coal mill, shut down the primary air fan and sealed fan.
3.3.2.2.14 Shut down all oil guns, confirm that the MFT alarm window is on, the furnace is off.
3.3.2.3 Work after the boiler is shutdown
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3.3.2.3.1 After the boiler is extinguished, the force fan and suction fan continue to run and maintain
the 30% MCR ventilation quantity to purge 5 minutes, after re-reset, purge the non-purged oil gun.
3.3.2.3.2 Completely split the boiler-front fuel system, turn off the oil supply hand-operated valves
of the angle oil guns, to confirm that the fuel recirculation valve is opened.
3.3.2.3.3 According to actual conditions, decide whether to adopt forced ventilation to cool furnace,
or stop FDF & IDF and close all air valves & baffles to make a stuff furnace;
3.3.2.3.4 The drum is filled to high level +200mm, shut down the feed water pump, open the
economizer recirculation valve.
3.3.2.3.5 Shut down two boiler water pumps, retain a boiler water pump for the operation, can shut
down the third boiler water pump only when the boiler water temperature is below 150℃.
3.3.2.3.6 In case of the drum pressure of 2.0MPa, fill the condensated water to the boiler water
pump for the continuous water injection.
3.3.2.3.7 The air preheater can be shut down only when the inlet flue gas temperature of the air
preheater is below 150℃.
3.3.2.3.8 The flame check fan can be shut down only when the furnace outlet temperature is below
80℃.
3.3.2.3.9 When the drum pressure decreases to 0.17MPa, open the release valves of the boiler
top.
3.3.2.3.10 When the boiler water temperature is less than 93℃, the boiler water pump is turned off,
open the water wall low water drum water discharge valve, intermittent blowdown valve,
economizer water discharge valve, water discharge valves of the steam system, so as to empty
the boiler water.
3.3.2.3.11 If it is required for the water discharge under the pressure and waste heat drying, when
the drum pressure decreases to 0.8 to 0.5MPa, shut down the boiler water pump and the power is
off, open the water wall low water drum water discharge valve, intermittent blowdown valve,
economizer water discharge valve for the rapid thermal water discharge. When the drum pressure
decreases to 0.2 to 0.15MPa, open the water discharge valve of the steam system, water
discharge valve of the desuperheater, the steam release valves of the boiler top for the water
discharge.
3.3.2.3.12 After the water discharge of the boiler water pump is completed, stop the continuous
water injection of the boiler water pump. The water discharge of the boiler water pump’s motor
chamber is carried out according to the conditions.
3.3.2.3.13 Confirm that the greywater can be informed and deslagging system is shut down when
there is not the ash residue in the boiler bottom slag system.
3.3.2.3.14 The vibration of the electrostatic precipitator and ash handling system have been kept
running until it is confirmed that the ash-free is dropped out in the ash hopper.
3.3.3 Cooling before the boiler is extinguished
3.3.3.1. Normal cooling
(1) 6 hours after the boiler is extinguished, open the suction fan and force fan outlets as well as
air baffle and baffle, so that the boiler is naturally ventilated and cooled.
(2) 18 hours after the boiler is extinguished, start the suction fan and force fan, maintain the air
volume of 30% MCR, to implement the mandatory ventilation cooling of the boiler.
(3) Control the depressurization speed by making use of the drain valve of the superheater.
When the outlet steam pressure of the superheater and drum wall temperature drop to the
specified value, open the drum air valve, discharge valve of the water wall and discharge valves of
the economizer, conduct a comprehensive water discharge of the boiler.
3.3.3.2. Forced cooling
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When there is repair work on the boiler heating surface or the boiler is rapidly cooled and
depressurized due to the other reasons, the cooling methods can be used in the following:
(1)Shut down all the suction fans and force fans after the boiler is extinguished, close the baffle
cold stoking of the flue gas system. After 4 hours, open the baffle of the flue gas system to
establish the natural ventilation; six hours after it is extinguished, start the suction fan and force fan,
maintain the air volume of 30% MCR, to implement the mandatory ventilation cooling.
(2)If the boiler heating surface is blasting, serious leakage, after the boiler is extinguished and
purged, shut down a group of suction fan and force fan, maintain the air volume of 30% MCR for
the forced cooling.
(3) After the boiler is extinguished and purged, if it is necessary to conduct the forced ventilation
cooling immediately, it should be approved by the chief engineer.
(4) The drum water level should be maintained at a high level as far as possible until the water
discharge.
(5) Control the depressurization speed by making use of superheater water drainage. When the
superheater outlet steam pressure and drum wall temperature decrease to the specified value,
open the drum air valves, discharge valves of the water wall and discharge valves of the
economizer, so as to empty the boiler water. If it is required to dry the thermal water drain, when
the drum pressure drops to 0.5MPa below, should conduct the rapid thermal water drain, notify the
sewage station.
Note: in the fast-cooling process, when the drum wall temperature is more than or equal to 50℃,
should stop the forced cooling.
a) In the fast-cooling process after the boiler is extinguished, the drum should be always
maintained at a high level.
b) 12h after the boiler is extinguished, can open the induced draft fan baffle to conduct the natural
ventilation cooling.
c) If there is the repair work after the boiler is shut down due to the fault, can conduct the forced
cooling of the boiler. 8 to 10h after the boiler is extinguished, open the induced draft fan baffle;; 18h
after the boiler is extinguished, start an induced draft fan and force fan for the ventilation cooling,
maintain the furnace draft at -100Pa to -200Pa.
d) After meeting the maintenance conditions, stop the induced draft fan and force fan operation.
3.3.3.3. Accident (failure) shutdown
(1) The load is reduced in accordance with the general normal shutdown, if it is required to
increase the reduction load force, it should be carefully considered.
(2) In the depressurization process, must pay great attention to any possible occurrence of air
cavitation in the boiler water pump, in the absence of cavitation occurrence, the drum water level
should be maintained within the normal range. When the force fan and suction fan are stopped, in
case the boiler water temperature is below 150℃, stop the operation of the boiler water pump. If
the air cavitation occurs (the differential pressure is reduced), stop the operation of the boiler water
pump immediately.
(3)After the boiler is extinguished, should maintain the rated air volume of 30%, and purge the
furnace. After the purge is end, cool the boiler at smaller air volume. When the inlet flue gas
temperature of the preheater is less than 204℃, stop the operation of the force fan and suction fan,
close all the wind and smoke baffles, conduct the cold stoking of the boiler.
(4)In case the boiler is shut down due to the heating surface leakage, after the end of the furnace
purge, retain a suction fan to maintain the normal furnace draft. After the steam is disappeared,
stop the suction fan to maintain the natural ventilation cooling.
3.3.4 Note on the shutdown
3.3.4.1 Carry out the full sootblowing before the boiler is shutdown, the full sootblowing is
completed before splitting.
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3.3.4.2 The pre-heater should be completely sootblowed before the boiler is shutdown, to prevent
that the ash is fastened on the heat accumulation components and it is difficult to eliminate after
the temperature decreases.
3.3.4.3 In the sliding stop course, the steam turbine and boiler should be co-ordinated, there
should be no rebound phenomenon in case of the temperature reduction and depressurization.
When the coal mill is shut down, should pay close attention to the changes of the main steam
pressure, temperature, furnace pressure and drum water level. Steam temperature decline speed
is in strict line with the requirements of sliding stop curve.
3.3.4.4 When the boiler load is reduced, the burner outage order is from top to bottom, all the coal
feeder are evenly reduced the coal supply rate until the coal feeder speed decreases to 40%. And
then set by set shut down corresponding coal mills from the top layer. When the coal feeder is
stopped, the coal drop pipe and belt should be idling. After the coal feeder is shut down, the coal
mill continues to run in order to pump the pulverized coal.
3.3.4.5 Pay attention to the burning condition when the load is reduced, may fill the oil to stabilize
the combustion in time. When the boiler is extinguished, confirm that the outage oil gun has been
purged and completed, all the oil gun hand-operated valves have been closed.
3.3.4.6 In the load down process due to the boiler fault shutdown, should closely pay attention to
monitor whether there is the occurrence possibility of the air cavitation in the boiler water pump, in
the event of the occurrence, should shut down immediately the failure boiler water pump, if
necessary, carry out an emergency shutdown.
3.3.4.7 In case the feed water flow is less than 25%, the economizer recirculation valve should be
automatically opened.
3.3.4.8 In the shutdown process or after the shutdown, should pay attention to the drum water
level and check whether the desuperheater water valve is leaked, to prevent the steam turbine
from water penetration. In case the boiler is not required to fill the water, should turn off the electric
pump.
3.3.4.9 If the boiler is used for the hot standby, should completely split the boiler-front fuel system
after purge, shut down the suction fan and force fan, close all the baffle cold stoking.
3.3.4.10 After the boiler is extinguished, the special person should monitor and control the drum
water level and drum wall temperature difference. Closely monitor the inlet and outlet flue gas
temperature of the air preheater. When the secondary combustion phenomenon is found such as
abnormal increase in flue gas temperature and abnormal furnace pressure fluctuation and so on,
should take the fire-fighting measures immediately.
3.3.4.11 After the boiler is extinguished, prior to shutting down the suction fan and force fan,
should make the start and stop interlock switch test of the fans’ oil station pump, and make the
records.
3.3.4.12 In the depressurization process, the boiler water temperature change should be not more
than 166℃/h. After the boiler is extinguished, should maintain at least a boiler water pump for the
running, should maintain the high drum water level running before shutting down the boiler water
pump. After the boiler water pump is shut down, should continue to fill the low pressure cooling
water, so as to prevent the temperature rise of the boiler water pump motor, closely monitor the
temperature of the boiler water pump motor.
3.3.4.13 According to the chief engineer order, in case of the boiler drum pressure of 0.5MPa,
should take the conservation methods such as hot water discharge conservation, or rechargeable
pressure and heating method, dry maintenance method, nitrogen charge conservation, wet
conservation method and so on.
3.3.4.14 In the depressurization process of the boiler, should record various part expansion at full
load and 50%, 30%, 20% load and after the extinguishing.
3.3.5 Boiler maintenance
After shut down, in case of the back-up or overhaul, the boiler is required to conduct the
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maintenance so as prevent the corrosion of heating surfaces.
3.3.5.1 Water drainage with pressure, waste heat drying method (applicable to the boiler overhaul
and minor repair, or standby of more than 10 days)
Boiler is cooled in accordance with the normal cooling method, when the drum pressure
decreases to 0.8 to 0.5MPa, shut down the boiler water pump and power is off, open the water
wall’s low water drum drain valve, intermittent blowdown valve, water drain valve of the
economizer for the quick hot discharge. When the drum pressure decreases to 0.2 to 0.15MPa,
open the water drain valve of steam system, water drain valve of the desuperheater, release
valves of the boiler top to dry the heating surface. After drying in the boiler, place the moisture
absorption agent in the drum or header, etc. Regularly inspect, add or replace the moisture
absorption agent during the maintenance,.
3.3.5.2 Short-term shutdown (within 4 days)
1) Maintain the same concentration of ammonia and hydrazine as in the normal operation.
2) Fill the nitrogen in the superheater and drum, and maintain the gauge pressure of 0.0343MPa.
3) Fill the nitrogen to the shell side of the feed water heater.
4) If the boiler is shutdown and is implemented the partial maintenance:
a) Drain and vent of the required maintenance part.
b) The rest parts of the boiler will be isolated as far as possible under the nitrogen pressure (gauge
pressure of 0.0343MPa).
c) If the superheater and reheater can not be filled the nitrogen for the protection, they should be
filled with the boiler water for the protection.
d) In case of the shutdown maintenance, when the boiler can not use wet or dry filling nitrogen for
the protection, the protective film can be formed at the tube wall to protect the boiler tubes prior to
the shutdown, in NH3-N2H4 passive way.
3.3.5.3 Protection of the long-term shutdown (more than 4 days)
Long-term shutdown can adopted the dry protection, the wet protection can also be used.
3.3.5.3.1 Wet protection
1) Protection of the boiler water side
With the boiler shutdown and cooling, fill the drum water level to the high water level, close the
drain valve and sampling valve. When the boiler water temperature decreases to below 150℃,
inject N2H4 and NH3 through the dosing pump. At this time, the boiler circulating pump should run,
so that the liquid medicine is uniformly mixed with the boiler water. The boiler water should include
10ppm ammonia and 200ppm hydrazine, pH value of the boiler water should be close to 10. When
the drum pressure decreases to 0.172MPa, open the drum nitrogen charge valve, the nitrogen
pressure in the drum is maintained at 0.0343MPa.
2) Superheater and reheater protection
When the drum pressure decreases to 0.172MPa, open the filling valves of the superheater and
reheater, the superheater and reheater is filled with the demineralized water or condensed water
containing 10ppm ammonia and 200ppm hydrazine, the pH value of these solution should be
close to 10. The water is filled to the outlet that can not be drained. After the water overflows from
the air valve, close the air valve, stop the filling. Afterwards, open the nitrogen charge valve,
charge the nitrogen to the superheater and reheater, and maintain the nitrogen pressure at the
gauge pressure of 0.0343MPa.
3.3.5.3.2 Dry protection
1) Dry protection, that is, the nitrogen is charged to protect the water side and steam side heating
surfaces. The methods are as follows:
a) When the drum pressure decreases to 0.172MPa, open the nitrogen charge valve, maintain
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the nitrogen pressure of 0.3MPa, open the drum and superheater nitrogen charge valve, charge
the nitrogen to the drum and superheater for the water drain.
b) Open the water wall lower header’s drain valve and sewage valve, drain valve of the
economizer for the water drain, the water drain valve should be controlled, pay attention to that the
boiler pressure is not less than 0.1MPa. When there is no water in the drum, open the nitrogen
charge valve of the economizer.
c) After the water of the water wall and economizer are emptied, the nitrogen pressure in the
drum, economizer and superheater are maintained at the guage pressure of 0.0343MPa.
d) When the reheater pressure decreases to 0.172MPa, open the nitrogen charge valve of the
reheater, charge the nitrogen to the reheater; when the reheater temperature is less than 100℃,
the nitrogen pressure in the superheater is maintained at the guage pressure of 0.0343MPa.
e) Regularly test the nitrogen purity, pay attention to the nitrogen pressure, so as to ensure that the
nitrogen pressures of the nitrogen systems are maintained at the gauge pressure of 0.0343 MPa.
Protection during boiler repair
3.3.5.3.3 It may be protected according to the same methods of the short-term shutdown
maintenance, that is, the dry and wet protection are used for the part that the dry and wet
protection can be carried out. In case the dry and wet protection can be not used, the protective
film can be formed at the tube wall in the NH3-N2H4 passivation method prior to shut down, so as to
reduce the corrosion during the maintenance period.
3.3.5.4 Management during the boiler protection
3.3.5.4.1 Check the nitrogen pressure in the system once on each shift, to maintain the pressure
at the gauge pressure of 0.0343MPa.
3.3.5.4.2 Regularly inspect the nitrogen purity.
3.3.5.4.3 In case of the long-term protection, sample from the protection system once a week,
analyze the content of NH3-N2H4.
3.3.5.4.4 If it is not immediately started after the repair, the part should be injected with the
demineralized water containing 10ppm ammonia and 200ppm hydrazine, and charged with the
nitrogen to the nitrogen pressure at the gauge pressure of 0.0343MPa.
3.3.5.4.5 In case of the wet protection, check if there is any abnormal condition about the valve
switch position of the protection system once on each shift.
4 Operation and maintenance of the unit
4.1.. Overview
4.1
With the increase of the steam parameters and increase of the unit capacity, the entire unit
structure has become even more complex. From the security and economic point of view, the
regulating requirements in the unit operation has also become higher and higher. Power plant load
is based on the user needs, the change load at any time will affect the stability operation of the unit,
the interference from the outside condition is known as "outside interference." In the entire power
system, even if some units can run with a certain load within a period of time, but their working
condition are impossible without any change, and any changes in working conditions would lead to
changes in a certain operating parameters. The task of the unit adjustment is to adjust its
operating conditions in time, enable them to adapt to the external load needs as soon as possible,
while all operating parameters of the unit do not exceed their allowable change scope, that is, it is
required to ensure that the unit can safely and economically run under a variety of disturbance
conditions.
The quality of steam is measured based on its quality (impurity level is less than the requested
value) and parameters (pressure and temperature). For the boiler with the constant pressure
operation, it is usually required to supply the steam with a certain parameters; when using the
variable pressure (sliding pressure) operation mode, the steam pressure is required to change
with the unit load. Obviously, the regulation methods required by the different operation methods
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are different.
The boiler evaporation capacity is based on the burning thermal discharge and heat transfer
capacity of the heating surface, the pressure as one of the outlet steam parameters is based on
the balance between the boiler evaporation capacity and steam demand capacity of the steam
turbine; the boiler oulet steam temperature is based on the balance between the heat transfer
capacity of the overheater and reheater heating surfaces and heat absorption capacity through
steam; the steam quality is determined by the salinity of the boiler water, the salinity of the boiler
water is determined by the feed water quality and sewage discharge capacity. Boiler heating
surfaces are under the pressure, and also work under the allowable temperature with the
corresponding materials, must have the sufficient steam and water flow in order to maintain that
the metal is not over-temperature. The operation characteristics of the boiler, or ability to meet the
requirements of turbine-generator, as well as boiler operation reliability, security and frequentative,
to a large extent, are based on the design and manufacture of the boiler. And also to a certain
extent, it is determined by the operation regulation.
Modern large-scale unit adopts the distributed control system to implement the monitoring,
inspection and regulation task, its automatic control device must also be applicable to the
operational characteristics and requirements of the unit. Therefore, regardless of hand regulation
or automatic adjustment, must rightly understand the operating characteristics of the unit as base,
the operating characteristics include the static characteristics and dynamic characteristics, two
aspects. When some disturbance occur in the unit running, which aspects will be affected and
what parameters will change, as well as how their change direction and final change magnitude
are, such problems are determined by the static characteristics of the unit. As for the change
speed and fluctuation margin of the parameter in the transition process of the change, that is,
relationship between the parametric variation and time, refers to the problem of the dynamic
characteristic study. For the static characteristics and dynamic characteristics of the unit, the
operating personnel must understand. In the automatic adjustment technology, it is required to
have the quantitative numeral description of the unit characteristics, that is, establish the
mathematical model of the unit.
Boiler drum has a certain of water storage, some differences between the feed water capacity and
evaporation capacity can be allowed in a short period of time. However, the greater the capacity of
the boiler, less the water storage of the drum is relatively. So it is necessary to regulate the feed
water capacity in accordance with the evaporation capacity, so as to prevent the drum water level
from excessive changes. Too low water level will affect the safety of water wall; too high water
level will make the steam with water, thus affecting the quality of steam and enabling the
superheated steam temperature to decline. For the control circulation boiler, too low water level
will damage the normal working of the boiler circulation pump, leading to the same consequences.
Therefore, the boiler drum should have the task of the water level regulation.
The steam produced by the boiler is required a certain of heat, when the heat quantity generated
by fuel combustion is balanced with the heat quantity, which is required to maintain a certain
evaporation capacity, the stable steam pressure can be maintained. When the external load
changes, it is necessary to change the fuel quantity and feed air volume according to the
proportion, the aspirating capacity should be also adjusted correspondingly in order to maintain a
certain vapor pressure and furnace draft. This is the boiler load or steam pressure control, which is
the burning rate adjustment. For the pulverized coal-fired boiler, it is also the regulation issue of
coal pulverizing system.
In the running process of the power generation unit, the steam turbine, boiler and motor are
closely interrelated, the entire unit has become a more independent and organic overall operation.
Therefore, in the control mode, the steam turbine, boiler and motor must be conducted the
surveillance and operation as a whole. The boiler and steam turbine are applicable to the network
load requirements, co-ensure the stability of the relevant operating parameters. However, the
production procedures of the boiler and steam turbine have the different characteristics, and their
dynamic characteristics are very different. The boiler is a controlled plant with a larger thermal
inertia, compared with the steam turbine, its adjustment process is quite slow. And the boiler is
applicable to the load regulation while it is also necessary to ensure that the parameters meet the
requirements, such as main steam temperature, pressure, feed water flow and furnace draft.
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Similarly, the steam turbine is applicable to the load regulation while some parameters of its own
should also meet the requirements. From this, two relatively independent objects exist in the unit,
they are either interrelated each other, or independent each other. Therefore, the steam turbine
and boiler must adopt the cooperative control mode.
4.2.. Purpose and task of boiler operation adjustment
4.2
4.2.1 Ensure that the main parameters are operated in the normal range, find and handle the
defect of the equipment in time, make full use of the computer’s monitoring function so that the unit
can operate safely, economically and efficiently.
4.2.2 Adjust the boiler filling and combustion, ensure that the boiler steam temperature, steam
pressure and evaporation capacity can meet the external load requirements.
4.2.3 Maintain the ignition stability in the boiler, appropriate burning center, uniform distribution
furnace heat load, reduce the thermal deviation, keep the clean heating surface, prevent the
coking heating surface; reduce the flue gas temperature, reduce the heat loss and improve the
boiler efficiency.
4.2.4 Maintain the normal steam temperature, steam pressure and drum water level.
4.2.5 Maintain the qualified steam and water quality through the boiler continuous blowdown and
intermittent blowdown.
4.2.6 Reasonable arrange the operating modes of the equipment and system, in order to run in the
best working conditions, improve the unit economical efficiency.
4.3 Operation and maintenance contents
4.3.1 The operating staff on various posts should regularly and correctly record the meter
according to the run log requirements, and completely record the abnormal and operation
conditions occurred in the unit on duty and record in the duty record.
4.3.2 During the unit operation or back-up, should conduct the regular and specified line tour
inspection of the equipment. Focus on the oil system, prevent the oil leak fire accidents. If the
problem is found, should report in time and contact with the relevant departments for the
elimination, make the accident anticipation against the equipment defect. When making the
quarantine measure, should pay attention not to affect the thermal sampling, when necessary, the
possible maloperation protection is confirmed and removed by the thermal power.
4.3.3 Regularly check the unit operation and monitor the meter instruction. When the difference
between the meter instruction and normal value is found, should identify the reasons. In case of
the equipment failure, should contact and report in time, and take necessary measures. The
current, sound, temperature, vibration, bearing oil level and so on of the operation equipments
should be normal.
4.3.4 The standby equipment should be in a good standby, the interlock is in the input position,
good bearing oil quality, normal oil level.
4.3.5 Should pay particular attention to the operation conditions of the unit in the following
circumstances:
4.3.5.1 Rapid load change;
4.3.5.2 Steam parameters or vacuum rapid change;
4.3.5.3 Abnormal voices in the steam turbine;
4.3.5.4 System failure;
4.3.5.5 The automatic mode can be not put into operation.
4.3.6 Reasonably and timely adjust the operating mode, analyze and handle the abnormal
equipment, ensure the safe and economic operation.
4.3.7 In accordance with the load changes, monitor, adjust the shaft seal steam pressure of the
steam turbine, the air does not leak in the steam turbine, the steam does not leak out.
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4.3.8 The operating personnel on duty should make the regular test and switch work of the
equipments according to the provisions, and has the right to supervise the relevant staff to do the
preventive maintenance of the equipment, such as regular refueling of the equipment, media
testing, periodic tight screw, washing meter tube, etc.
4.3.9 Should closely monitor the operating parameters and operating status in the equipment
operation, with the exception of the accident handling, the equipment is prohibited to run in excess
of its output.
4.3.10 The equipment to be put into operation or equipment run with the failure should be
enhanced the inspection and surveillance.
4.3.11 In case the suction fan and force fan of the boiler are operating parallel, after the parallel
fans are started, gradually increase the opening of their stationary and moving blades, while
turning down the stationary and moving blades of the running fans until the output of two fans are
the same.
4.3.12 In case it is required to stop one side for the maintenance due to some reasons in the
boiler’s suction fan, force fan and primary air fan parallel operation, should first gradually decrease
the boiler heat load to 300MW, and then gradually transfer the load of the outage fan to the
running fan, decide whether to stop the coal mill run according to the load situation. After the
operating parameters are stable adjusted, stop the fan to be shut down. After the unilateral fan
operation is normal and stabilized, decide whether to increase and reduce the electrical load in
accordance with the fan and coal mill output situation.
4.3.13 In the start and stop the course of the boiler as well as normal operation, the total air
volume must be controlled in strict accordance with the total air volume of more than 30% MCR.
4.3.14 Should set up the control equipments for the automatic mode in the operation of the unit,
monitor the reliability of automatic devices. When the automatic device happens the failure,
remove the automatic for the manual operation, maintain the operating parameters within the
allowable range.
4.3.15 In case the personnel on duty is encountered the abnormal conditions or significant change
of the unit operating condition, must remove the relevant automatic adjustment depending on the
circumstances, carry out the manual adjustment, so that the operating parameters of the unit are
stabilized. In case removing the manual adjustment and carrying out the automatic operation,
must be careful. When adjusting the coal mill load, adjusting the fan output, as well as adjusting
the main, reheat steam temperature desuperheater water, should pay attention not to
over-adjustment, and should contact with each other, make the co-ordination, and avoid
large-scale fluctuations of the operating parameters, so as to avoid the abnormal unit or accident
expansion.
4.3.16 The coal mill occurs the tripping in the normal operation, should immediately inspect that
the outlet baffle of the coal mill and cold wind baffle have been closed, the coal mill has been
tripped, or should manually shut down or stop immediately, and contact the thermal staff to inspect
and deal with.
4.3.17 In case one coal mill or more coal mills occur the tripping in the operation, should fill the oil
for combustion-supporting in a timely manner based on the load condition, adjust the output of the
running coal mill in time, so as to stabilize the parameters of the unit as much as possible (confirm
the boiler fire is not extinguished before adding fuel).
4.4 The Operation Adjustment
4.4.1 The Steam Temperature Adjustment
4.4.1.1 When the load of boiler is greater than 50%MCR, the temperature of superheated steam
shall be controlled within a rated value of 541±5℃ and the temperature of reheated steam shall be
controlled within a rated value of 541±105℃, while the temperature difference at two sides outlets
of superheated steam is less than 5℃ and the temperature difference at two sides outlets of
reheated steam is less than 10℃; When the load is less than 50%MCR, the temperature of
superheated steam and reheated steam shall be controlled in accordance with the temperature
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curve of starting-up of turbine.
4.4.1.2 When the boiler is running, the factors that affect the changes of steam temperature shall
be lessened to the greatest extent. Much attention must be paid to the monitoring for the
temperature changes on the walls of superheater and reheater. And the temperature changes
need to be adjusted in time to prevent the temperature on the walls of reheater and superheater
increasing the limit value.
4.4.1.3 It needs to be understood very well about how the load change impacts the steam
temperature. It shall be learned to use he stage one, stage two desuperheat water and the swing
angle of burner nozzle for adjusting the steam pressure
4.4.1.4 A spray-type desuperheater with two stage nozzles is mainly adopted in the temperature
adjustment of superheated steam. Stage one desuperheater controls the temperature of the inlet
of dividing plate inlet. Stage two desuperheater controls the temperature of outlet of the outlet of
final-stage superheater. In stable boiler running, put automation on first and second stage of water
spraying. When the temperature fluctuates violently, it could be regulated manually. In addition, the
temperature of superheat steam can be adjusted by using up-down moving of burner nozzle. The
following measures can be adopted when the temperature of superheat steam:
4.4.1.4.1 Slowly reduce the amount of desuperheat water, monitoring the steam temperature
changes on the back of desuperheater. A sudden decrease or increase is forbidden to apply to the
amount of desuperheat water.
4.4.1.4.2 Lower the swing angle of burner nozzle appropriately or keep it in upper space of burner,
put on the burner sets of lower space to lower the combustion center.
4.4.1.4.3 Strengthen the sootblowing on boiler furnace and economizer.
4.4.1.4.4 Under the precondition of the completeness of combustion, try to decrease the air
blowing rate or strengthen the secondary air in upper space, and weaken it in the lower pace in
condition that total volume of air is not changed.
4.4.1.4.5 Reduce the heating load of boiler and decrease the feeding quantity of the coal. The oil
can be used for supporting the combustion when it is not stable.
4.41..5. The following measures are basically adopted when the temperature of superheated
steam is low:
4.4.1.5.1 Slowly reduce the amount of desuperheat water, monitoring the steam temperature
changes on the back of desuperheater. A sudden decrease or increase is forbidden to apply to the
amount of desuperheated water.
4.4.1.5.2 Raise the swing angle of burner nozzle appropriately or keep it in upper space of burner,
put on the burner sets of lower space to raise the combustion center.
4.4.1.5.3 Strengthen the sootblowing work on convention heating surface.
4.4.5.4 Strengthen the combustion or add the air amount appropriately.
4.4.1.6 The temperature adjustment of reheat steam mainly adopts swing angle of burner nozzle
to change the height of combustion center in furnace, accordingly change the temperature of gas
outlet of furnace. In addition, spray attemperator for reheater accidents is set to use in accident
condition.
4.4.1.7 Under the condition of high temperature of reheat steam, if there is no temperature
decreasing by changing the swing angle of burner nozzle and the coefficient of excessive air, the
spray attemperator for reheater accidents shall be put into use.
4.4.1.8 Fully analyze the reasons that caused the steam temperature changing, make a
comprehensive adjustment to it. It is unilateral to rely on adjusting the temperature with water
spray and swing angle of burner nozzle.
4.4.1.9 In the unit running, if coal pulverizing machine tripped or load throw-off happened, break
the interlock automation of desuperheat water off in time and then adjust it manually to avoid a
delay adjustment of automation, leading to an over-high temperature, and a high-width fluctuation
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of reheat steam temperature.
4.4.2 The Steam Pressure Adjustment
Main steam pressure is the important value for steam quality, and is the important parameter for
stability of running unit. Main steam pressure is the balance for both steam quantity which the
boiler generated and the turbine needed. A wide-range fluctuation of steam pressure will directly
have an affect on the safety and economical operation for boiler and turbine.
The decreasing of the steam pressure will reduce the enthalpy drop of expansion work for steam
in the turbine, increasing the steam consumption. For example: the steam pressure reducing to
5% of the rated value, and the consumption of steam increasing 1%. A lower steam pressure is not
able to support the full output capacity. If the full output capacity is still maintained, it certainly will
make the steam flow increased. This will give rise to an increase in the flexural stress to the last
stage blades and the axial thrust to the rotors, impacting the safeties and economies of running
unit.
If the steam pressure is higher, the steam consumption can be reduced (at present boiler has 5%
over-pressed capacity). But if the steam pressure is too high, it will be very dangerous to the safety
of boiler, turbine and pipelines, especially to the regulating stage blades if they are over loaded.
Because the flexural stress that the moving blades afforded is directly proportional to the product
of steam flow and enthalpy drop of regulating stage. Even if the unit is not overloaded, the flow is
lower than rated value, and the regulating dome pressure decreases while the unit is in the
working condition with a fully opening of No.1 governing valve and a fully close of No.2 governing
valve, the flow which passes the No. 1 governing valve will also exceed its rated value, causing
the regulating blades overloaded and with the highest flexural stress. A too high steam pressure
will also create a too high mechanical stress on the pressure-containing members of boiler and
fastening pieces. That will reduce the life circle and cause damage to the equipments.
Over-high steam pressure will lead to a safety valve popping and cause too much losses of
working medium and heat; frequent safety valve action will make the safety valve’s setback
un-tight or abrasive, and leaking.
Frequent fluctuation of steam pressure will also make the metal of pressure-containing members
in the condition of alternating stresses and cause an endurance failure on them.
Therefore, the range and rate of variation of main steam pressure must be strictly monitored and
controlled.
4.4.2.1 The Impacts of Change Rate of Steam Pressure
4.4.2.1.1 There are two main reasons that impact boiler safety for rate changing of steam
pressure.
(1) The sudden change of steam pressure, such as when steam pressure suddenly increasing
owning to the sudden increase in load, will possibly lead to the steam with a great amount of water,
thus making the steam quality worse off and superheat temperature increase (but when the steam
pressure decreases owning to the worsened combustion, the steam will not be generated with
water).
(2) During the running as the load of boiler fluctuates, if actions are not taken to regulate it
promptly and correctly, frequently fast changes resulted from the fluctuation would cause the metal
heating surface of boiler under the repeated or alternating stresses most of the time especially
with some other factors, such as the impact of thermal stresses. Finally, that will possibly leads to
the endurance failure on the metal heating surface.
4.4.2.2 The Factors Impacting the Variation of Steam Press
When the variation of load leads to the changes of steam pressure, the rate of steam pressure
changing explains the ability to keep or recover the rated steam pressure of boiler. The rate of
steam press basically has a connection with the rate of load changes, the heat storage capacity of
boiler and the thermal inertia of fuel-burning equipment. Moreover, if the operators can take action
in time to regulate the steam pressure changes, the steam pressure can be recovered to the rated
value.
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(1) The Rate of Load changes: The impact of the rate of load changes on the rate of steam
pressure is obvious. The faster the load changes, the faster the steam pressure changes. Or, the
slower the steam pressure changes.
(2) The Heat Storage Capacity of Boiler: The so-called Heat Storage Capacity means the amount
of heat which the boiler can absorb or store as the external load changes while the combustion
condition is unvaried.
When the external load varies, boiler’s internal working medium and the temperature and thermal
content of metal are all varying. For example, when the steam pressure decreases owning to the
load increase, the saturated temperature will decrease and the heat of liquid (the quantity of heat
which a kilogram of water needed when it is heated from 0℃ to the saturated temperature) in
boiler will correspondingly decrease. In this case, there is a surplus amount of heat containing in
boiler water (and metal of heating surface), and this surplus heat (because the boiler water can be
vaporized into steam with heating up to a lower saturated temperature) containing in boiler water
and in metal will make the boiler water itself vaporize into steam. This is called “additional
evaporation capacity”. It plays an important role in slowing down the steam pressure. But, due to
that the “additional evaporation capacity” is a limited amount, it is impossible for “additional
evaporation capacity” to totally prevent the steam pressure from decreasing. The bigger the
“additional evaporation capacity” is, means, the bigger the heat storage capacity is, and the slower
the rate of steam pressure decrease is; On the contrary, the faster the rate of steam pressure
decrease.
In the practical operation of boiler, when the external load increases, the evaporation capacity
(output) cannot meet the needs of the load due to the lagging characteristic (namely combustion
equipment has thermal inertia) of combustion regulating system. This will inevitably cause a steam
pressure decrease. In this case ( namely before the combustion condition is not able to change),
the boiler can only generate the additional evaporation capacity by means of the heat containing in
working medium and in metal to adapt the needs of external load. Therefore, the heat storage
capacity of boiler can be understood as: the ability for the boiler to keep the output itself within a
certain interval as the working condition varies.
It is learned from the above explanation that during the running, when there is no change in the
combustion condition, the variation of boiler pressure will cause the releasing or storing of heat for
working medium and metal. Under the condition of steam pressure increasing due to load
increasing, the working medium and metal will be storing the heat which they have absorbed due
to the increasing of saturated temperature; Under the condition of pressure decreasing due to the
load increasing, the working medium and metal will release the heat which they have stored, and
then create the “additional evaporation capacity”.
It can be learned from the knowledge of the pyrology that the higher the steam pressure is, the
smaller the variation of liquid heat is. That means under this condition of pressure variation, the
smaller the heat which the working medium and metal released is, therefore, the smaller the heat
storage capacity of subcritical pressure boiler is. So in terms of heat storage capacity, while under
the condition of load changing, the rate will be changing fast because the subcritical pressure
boiler is sensitive to the variation of steam pressure.
The heat storage capacity of boiler has a connection with the water volume in the boiler and
amount of metal of heating surface. For the subcritical pressure boiler, its water volume in the
boiler and metal consumption is relatively small, so its heat storage capacity is small and it is
sensitive to the variation of steam pressure. Because the boiler with steam drum has thick-wall
steam drum with a big volume, its heat storage capacity is comparatively big.
The impacts on boiler operation for heat storage capacity have good effects and also bad effects.
For example, the heat storage capacity of steam drum boiler is very big. When the external load
changing, the capacity of keeping output for boiler is accordingly big, and the rate of parameter
changing is accordingly slow. This is benefit to boiler operation; but on the other hand, when it is
needed to artificially change the boiler output, the big heat storage capacity will cause a slow
responding of the output and parameter.
(3) The inertia of combustion equipment: The inertia of combustion equipment refers to the
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interval of time from the starting of fuel’s amount changing to the establishment of new heat load in
furnace. Under the condition of load changing, the bigger the inertia of combustion equipment is,
the slower the rate of recovery steam pressure is. On the contrary, the rate of steam pressure
recovery will be faster.
The inertia of combustion equipment is connected with the fuel kinds and the type of pulverizing
system.
4.4.2.3 There are two main reasons that impact the main operation parameter for steam pressure
changing:
(1) The Impacts on Water Level
When the steam pressure decreases, the saturated temperature is reduced to make parts of boiler
water vaporize, causing the “expansion” on volume of boiler water, so the water level increases;
On the contrary, when the steam pressure increases, the saturated temperature is increased to
make parts of the vapor bubbles in boiler water condense, causing the “shrinkage” on the volume
of boiler water, so the water level decreases. If the variation of steam pressure is caused by load
changing, the change of water level in the explanation mentioned above is just a temporary
phenomenon (fake water level), after that it will be changing to the opposite direction.
(2) The Impact on Steam Temperature
As a general rule, the superheat steam temperature will goes up as a result of steam pressure
increasing. This is because the saturated temperature increasing follows steam pressure
increasing, and more amount of heat must be consumed for the process in which water is changed
into steam (the metal of water wall also needs to absorb additional amount of heat). Under the
condition that the amount of fuel is not changed, the amount of evaporation for boiler need to
instantaneously be reduced (because parts of vapor bubbles are condensed). That means the
amount of evaporation going through the superheater is reduced. So, the absorptive amount of
evaporation per kilogram on average is increased, leading to the increasing of superheat steam.
4.4.2.4 The Reasons for Steam Pressure Change
The variation of steam pressure actually reflects the balancing relation between the boiler
evaporation and the external load. But the balancing is relative, and the unbalancing is absolute.
The external change of load and the variation of boiler evaporation which caused by the
combustion and working conditions in the furnace usually break the balancing mentioned above.
Therefore, the change of steam pressure is a necessity.
The cause which leads to the variation of boiler steam pressure can be classified under the two
following aspects: one is the external factor of boiler which is called “external disturbance. The
other one is the internal factor of boiler which is called “internal disturbance”.
(1) The External Disturbance
The external disturbance refers to the natural decrease and increase of external load, and the load
throw-off in the accident. It specially reflects in the variation of evaporation which the turbine
needed.
When the external load changes such as the load is increasing, the amount of evaporation from
boiler to turbine will be increased and the steam pressure is inevitably caused to decrease. At this
moment, the steam pressure can be quickly recovered to a normal value if the evaporation
generated from boiler just meets the amount of evaporation which the turbine needs with adjusting
the calcinating condition in the boiler and increasing the amount of fuel and air flow appropriately.
It is learned from the above explanation that in the sight of material balance, the stability of steam
pressure depends upon whether the boiler evaporation and the external load are in a balance
condition. When the boiler evaporation just meets the amount of evaporation which the turbine
needs, the stream pressure will be normal and stable. When the boiler evaporation is higher or
lower than the amount of evaporation which the turbine needs, the steam pressure will increase or
decrease. So, the variation of steam pressure and the external load are correlated closely.
(2) The Internal Disturbance
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That means the variation of steam pressure is caused by its own factors of the boiler and the
turbine. It basically refers to the change of combustion condition in the furnace (such as instability
or abnormality of combustion) and the abnormal working condition in the furnace.
When the external load is in a stable condition, the stability of steam pressure mainly depends
upon the stability of combustion condition in the furnace. When the combustion condition is normal,
the steam pressure changes slightly. When the combustion is unstable or abnormal, there will be a
change of furnace hot intensity which causes the changes of heat absorption capacity on the
heating surface and then causes the increasing or decreasing of steam quantity produced from
the water wall. This will cause big inevitable changes in the steam pressure.
There are many factors that affect the unstable combustion and abnormal combustion. For
example, the variation of coal quality, the quantity of coal powder sent to the furnace, the variation
of coal fineness, the inappropriate coordination of air and coal powder, the improper matching of
air velocity and air quantity, the clinkering in the furnace, and some other consequences resulted
from the trouble of coal pulverizing system etc.
Besides, the variation of boiler heat exchange can also affect the stability of steam pressure. The
process of combustion and the process of heat transmission are synchronous in the boiler furnace.
The heat given off from the combustion of fuel is mainly transmitted to the heating surface of water
wall through a way of heat radiation, and change the water evaporation into steam. Therefore, if
the heat exchange condition changes and the working medium on the heating surface are not able
to get enough heat which it needs or too much heat is transmitted to the working medium, the
generated steam quantity must be affected and the steam pressure will be changed unavoidable.
Due to that the coefficient of heat conductivity for clogging and fouling is very low, the condition of
heat exchange on the heating surface of water wall will be worsened when there is some clogging
or fouling created on the water wall or inside tubes. Therefore, in order to ensure the normal
condition for heat exchange, the combustion shall be correctly regulated according to the
operation condition including sootblowing or blow down etc. to keep the cleanliness on the heating
surface.
4.4.2.5 The Steam Pressure Adjustment
The change of steam pressure reflects the balancing relation between the boiler evaporation and
the external load.
The variation of external load exists objectively. But the amount of boiler evaporation can be
achieved through the way of adjusting the combustion capacity to the boiler by the operators. For
example, during the load increasing, the steam pressure can be kept within a normal range if the
amount of fuel is added timely and the combustion is adjusted correctly with a matching increase
in the boiler evaporation; On the contrary, the steam pressure would be unstable and decrease if
the amount of fuel isn’t added timely and the combustion isn’t adjusted correctly with the result that
the evaporation is not able to support the load consumption. Therefore, the control and adjustment
to the steam pressure is the matter of how to regulate the amount of fuel and boiler combustion
correctly to control boiler evaporation well and make it adapt to the requirement for external load.
During the process of steam pressure adjustment, it shall be noticed to decrease the amount of
coal when the steam pressure is increasing. When the steam pressure tends to be stable, more
coals are added appropriately to keep the steam pressure stable and let it not to decrease. The
theory is the same when the method of reducing coal quantity is adopted for decreasing the
pressure.
When the steam pressure is very high and needed to reduce a big quantity of coals, it shall be
noticed to decrease the air flow. If this coordination is not done very well, it will cause an
instantaneous increase in the steam pressure instead.
When the load needs to be increased, the boiler steam pressure shall be reduced. At this moment,
it needs to add the amount of coal and strengthen the combustion while the air flow needs to be
increased (and it also needs to add the amount of feed water and change the amount of
desuperheat water). For the operation sequence of increasing the amount of fuel and air flow, as a
general rule, it’s better to increase amount of air flow first and then increase the amount of fuel in
rapid sequence. If the amount of fuel is increased before increase the air flow with a delay, the
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lacking of air flow for combustion will cause a loss of incomplete combustion. Because there is a
certain amount of excess air in the furnace, in some practical operations when the load is
increased greatly and quickly, it needs to increase the amount of fuel first and then increase
amount of air flow in rapid sequence in order to keep a stable steam pressure not letting it
decrease so sharply. In the low-load condition, there are relative much excess air in the furnace,
so the amount of fuel can be increased before increasing the air flow when the load is increased.
When the air flow is increased, the first thing needs to be done is to open the inlet baffle of induced
draft fan, and then adjust the blades with a bigger angle in the forced draft fan. If the forced draft
fan is opened firstly, it will cause a positive pressure in the furnace and the flames and gases might
be possibly breaking-out and hurt people. The way of increasing the amount of fuel is to increase
the amount of coal powder of each muffle burner simultaneously or individually (to increase the
speed of coal feeder, the speed of each coal feeder normally can be changed synchronously—the
coal feeding quantity), or to increase the number or set of burners---increasing the running number
of coal grinding mill. Within the normal range of load adjustment, the speed of coal feeder is used
for synchronously regulating each coal feeder. Otherwise, spare coal grinding mill and relevant
burner must be put into use. In addition, fewer burners shall be put into use when the load is low
and coal feeder’s high speed shall be adopted to keep a higher density of coal powder in the outlet
side of burners. That will be propitious to the burning of coal powder when the load is low. When
the load is high, many burners shall be put into use for balancing the heating load in the furnace.
That can make it burning in a stability condition.
In the adjustment of steam pressure, if the steam pressure drop is caused by some internal
disturbance reasons such as excessive decreasing of coal power or unstable combustion,
measures for stable combustion shall be adopted in time for recovering the steam pressure, and
enhancing the monitoring for the changes of steam pressure and steam temperature, and
controlling the pressure of turbine monitoring section within the rated value. The measure of
decreasing load can be taken for recovering the steam pressure if it is necessary. When the high
pressure is caused by internal disturbance, the fuel shall be reduced promptly. If the unit capacity
is not full of charge, the load and steam admission can be increased temporarily, and then the
normal running mode shall be adopted after the steam pressure is recover.
In the unit running, a coordinated control is adopted for boiler-turbine to meet the requirement that
can quickly adapt to the external load. And the main steam pressure also needs to be reached to a
stable state to meet the requirement for the unit running.
4.4.3The Adjustment of Combustion
The stability for burning process in furnace is importantly correlated with the reliability for the
whole running unit. For example, the instability of burning process causes a fluctuation to steam
parameter. It will not only affects the stability of the load, but also brings an impact on boiler, steam
pipeline and turbine; A flameout in furnace will bring a more severe consequence; If the heating
surfaces of water wall and furnace outlet are slagged due to over-high temperature of furnace or
flame bending, it might possibly raise the temperature discrepancy of gases on the two sides of
heating surface in flue and leads to a heat discrepancy, causing parts of the pipeline burst for the
excess temperature on pipe wall.
Combustion Adjustment
4.4.3.1 In boiler operation, pay attention to monitor the furnace flame and exhausted gas from the
stack. Maintain combustion in stable and good condition; check the furnace combustion condition,
observe the coal firing distance, observe the fire flame which shall be in bright golden yellow color
and not deflected and adhered to the wall, maintain a proper flame filling in the furnace, otherwise
adjust in time the opening of relevant auxiliary air baffle and make correction. The flue gas
temperature at both sides of heating surface shall be close, and inlet flue gases of air preheaters
at both sides have differential temperature smaller than 15℃. The furnace outlet flue gas
temperature difference shall not be larger than 50°C. Regularly check if there is coking in boiler,
adjust the combustion and switch on the sootblowing of boiler proper if there is; if the coking is
serious and treatment is invalid, report to relevant director and contact boiler maintenance staff to
handle.
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4.4.3.2 In boiler oil fuel firing, the flame shows in bright white color; in coal fuel firing, the flame
shows in bright golden yellow color. When switching on the oil fuel firing operation, contact in time
the director in duty to change the ESP operation mode;
4.4.3.3 In normal boiler operation, switch the furnace negative pressure and air flow, as well as
oxygen amount to automatic control mode. The furnace negative pressure shall be controlled as
about -50Pa. Pay attention to furnace leakage, and maintain the furnace tightness.
4.4.3.4 Check timely the speed of coal feeder in automatic control mode, in accordance with
change of main steam pressure and load, and switch the “automatic” mode to “manual” mode or
start/stop coal pulverizing system when necessary. Pay attention to furnace combustion in
adjustment;
4.4.3.5 In boiler operation, pay attention to monitor the automatic control of furnace negative
pressure and air flow, and put those automatic controls of coal pulverizing system into operation.
The perimeter air baffle and secondary air baffle shall be in automatic position. Make treatment
and adjustment in time in case of any abnormalities.
4.4.3.6 In boiler operation, pay attention to check the working state of flame monitor, flame
strength signal and coal mill. Maintain the fineness of pulverized coal in qualified state. Regularly
check the combustor, secondary air box and air valve, contact for treatment in time in case of any
problems found.
4.4.3.7 In boiler operation, the boiler front fuel oil system shall be in good standby condition;
4.4.3.8 In normal boiler operation, maintain the boiler exhaust gas temperature and oxygen in the
flue gas be in specified range;
4.4.3.9 Opening of perimeter air baffle and secondary air baffle of standby mill burner shall be in
automatic control mode. Regularly check if there is coking or spontaneous burning of
accumulated pulverized coal inside the burner;
4.4.3.10 Maintain the opposite firing in the coal mill, and maintain the coal mill current within
specified range. In operation, put corresponding oil gun into operation timely when the burner fire
detection is found unstable in operation.
4.4.3.11 Maintain normal air pressure of primary air header to ensure the primary air flow, without
too large fluctuation, especially in starting/stopping the coal mill, special attention shall be paid.
The differential pressure of seal air and primary air shall be in specified range.
4.4.3.12 Primary air burner tilt angle is in “automatic” position, which shall be reduced as much as
possible in allowable conditions of steam temperature.
4.4.3.13 In normal boiler operation, adjustment baffle of over fire air shall be in “automatic” position,
and the tilt angle adjustment of three-layer over fire air shall also be in “automatic” position;
4.4.3.14 When in low load, switch on fewer burners, adopt higher coal feeder speed and maintain
relatively high concentration of pulverized coal in burner outlet. But the higher coal feeder speed
will increase the coal mill output and increase the coal particle size, and will result in coal mill full
load when severely. Therefore, the coal feeder speed shall ensure the mill output is under the
maximum and the pulverized coal fineness is in specified range.
The Analysis and Observation on Coal Powder’s flaming (only for reference)
Phenomenon Analysis of Cause Measures and Adjustment
Bight and stable Suitable air distribution

flame, in the color of Even and suitable coal
bright golden yellow fineness
Big air-coal ratio, big A. Pay attention to air-coal ratio, avoid the
Brightening and steam output flameout
dazzling flame
Furnace slagging B. Timely adjustment,
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Appropriately reduce the air volume
Yellow and flashing Excessive air volume
flame Pay attention to the output of coal
Large ash content in coals
pulverizer
Air volume might be justo
minor
Red and flashing Appropriately adjust the air volume
Inappropriate matching of
flame Reduce the fineness of coal powder
air and coal
Rough coal powder
Excessive air volume
A. Appropriately adjust the air volume
Rough coal powder
B. Reduce the fineness of coal powder
Over-low furnace
Darkened red and C. Keep the water seal of cold ash hopper
temperature
unstable
D. Put oil gun into operation in time to
Big air leakage quantity on
support combustion
cold ash hopper
For the tangential corner firing, an over large tangential circle or a more percentage of course coal
powder is more likely to cause the rough size coals crash on the wall surface and create clogging.
According to what CE recommended, the percentages of coals which are more than a weight of
200μm are not allowed to exceed 2%. When the air flow from four corners outlet of the burners on
the same layer is not uniform, the flaming center will be forced to move towards one side that the
momentum is small, and cause some clogging on that side. The operational layer for burners, fuel
amount allocation, and swing angle of burner will also have an affect on the temperature
distribution in the furnace, and the position of flaming center are more likely to be shifted. When
more burners of the bottom layer have been put into operation with a bigger depression angle, the
slags are more likely to appear in the area of cold ash hopper. The area of slagging is correlated
with the geometric shape of boiler furnace. Generally speaking, for the pyknic-type boiler, the
slags are more likely to be formed on top of boiler furnace; for the tall-slim type boiler, the slags are
more likely to appear on the burning area. The sootblowers work in a relatively tough environment
that will easily cause troubles to them, so the problem of sootblowers needs to be solved in time. If
the heating surface didn’t get cleaned because of sootblower fault, the slagging condition will be
turned badly and cause a big bulk of slags falling leading to a block in the slag notch. Therefore,
under this condition, sootblowing operation should be paid more attention to the blowing
sequences between each sootblower and also the condition of slags releasing at the slag
releasing gate. The slagging condition is related with the flue gas content in this area. The
formation of reducing atmosphere should be avoid because the reducing atmosphere will make
the ash melting pointing to reduce at large degree.
The burning quantity need to be regulated by changing coal feeding quantity and air volume. In
large capacity unit, this process will be completed with the actions in concert with: the layers of
operations of coal feeder, coal mill and burners, the opening degree of each air-gas baffle and the
regulating and coordinating of forced-induced draft fans. Under the condition of low load, it also
needs to be coordinated with the oil gun for keeping stable combustion. The outlet temperature of
superheater and reheater should also be taken into account for the configuration mode of burners
that are put into operation. In the air volume for entering into furnace, the rational proportioning
among the first, second air and the over-fired air shall also be taken into account, and this will
affect the mixtures after the firing; the above is especially important to the swirling burner. Because
its flames, unlike tangential combustion in which there are the effect of mutual induced ignition and
mixture between that of burner jet outlets, are set in group of burners. The process of burning
quantity regulating is the relatively unstable process for coal pulverizing system and combustion of
furnace in which the mixture concentration for the air in the outlet of coal mill and the temperature
of air flow are more likely to fluctuate. It needs to be timely regulated to the temperature and
quantity of first air to ensure the coal mill’s output and coal mill’s outlet temperature. The variation
of first air also has an affect on coal fineness of the outlet of coal mill. When the amplitude of
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regulation is larger, the angle of deflector baffle of the separator shall be accordingly adjusted
(medium speed mill) to maintain an appropriate coal fineness. Regulations for burning quantity are
also affecting the following conditions: stability of firing in the outlet of burner, the furnace burning
condition, furnace outlet gas temperature and clogging and fouling.
For the stability of combustion, coal powder quantity and air quantity of outlet of the burners are
required to be changed simultaneously for ensuring the stability of firing and burning condition as a
result of stabilizing the air-coal ratio. An over-large time interval and change amplitude are more
easily to cause an over large change amplitude associated with the firing and burning condition,
and lead to instability of firing and burning condition. The most severe subsequence might be the
flameout. Therefore, it is important to know very well it from the starting regulation for coal feeding
quantity to the time delay of the coal quantity changing; it is also important to master it from the
starting of air quantity of the forced draft fan to the time delay of air quantity changing of the
burners. So, for the synchronous changes of air-coal quantity of burner’s outlet, it can be solved by
operations according to the above time delay. Under normal condition, the time delay of coal
pulverizing system is always larger than that of the air system, so it needs a quick reaction of coal
pulverizing system. On the other hand, since the system has a certain responded speed to the
load, the over large adjustment that exceeds this speed is feasible. And some regulations shall be
made for it in the normal operation of boiler.
Air quantity regulation, as one part of burning regulation, is for the air-coal ratio during the process
of burning that are maintained by feeding air volume and feeding coal quantity. The former one
affects or determines the oxygen concentration condition and temperature condition where the
burning process is continuing in furnace, and determines the excessive air coefficient and
temperature of furnace outlet; the most possible burning quantity relies on the latter one. The
raising up of temperature and oxygen concentration is all propitious for the processing of burning
and the promotion of burning-out degree. Both are contradictory. Due to the reason of thermal
capacity, the raising of excessive air signifies the decreasing of temperature level of theoretical
burning temperature in furnace and actual temperature in furnace. A good burning condition in
furnace depends on the reasonable application between temperature factors and concentration
factors, that means air-coal ratio or feeding quantity of air and coal is appropriate, and the
coefficient of excessive air of furnace outlet is appropriate. Although from some reference
materials that recommend the coefficient of excessive air of furnace outlet, owning to the complex
concentration of temperature distributed in furnace, with a different design for furnace and burners,
the optimum value for the coefficient of excessive air of furnace outlet is various and needed to be
probed in practical operation. The feeding air volume or the coefficient of excessive air, except the
affects on burning condition, q2、q3、q4 and boiler efficiency, will have an effect on the operation of
superheater, reheater and outlet steam temperature. The reasons for variation of outlet steam
temperature is mainly because of the variation of gas-air flow rate, and also come down to the
affect on variation of steam temperature for the variation of outlet gas temperature on each
heating surface.
The air regulation, as one important item during the boiler operation, is one of the most important
factors for stable and complete combustion. When the load of boiler changes as the burning
quantity changing, it needs to adjust the air supply quantity. Normal and stable combustion
demonstrates that the air-coal ratio is reasonable, and then in the center of furnace is shown a
golden brown flame equally full of the furnace without touching all around water wall. And with
stable color, there will be no obvious sparks (sparks emerge possibly because of coal powder
separation phenomenon, moreover low temperature or coarse coals can also cause the
appearance of sparks), and the gas exhaust from chimney will be appeared as light grey, the color
will be more light if the ESP functions efficiently.
The excessive air coefficient of furnace outlet the air volume organized to send to the furnace will
be decided by the excessive air coefficient from furnace outlet. The air volume entering into the
furnace generally based on the concentration of O2 and adjusts the regulation of excessive air
coefficient that is:
α＝21／ (21-O2)
In 600MW unit, the regulations of air distribution adopts the way of changing the erection angle for
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blades of the axial flow forced draft fan to adjust the air distribution quantity in the furnace. No
matter the boiler load decrease or increases, if the operating point for air fan is within stable range
under the condition of tolerant output, the air distribution quantity is usually adopted by adjusting
the erection angle for blades of forced draft fan. But it is forbidden for air fan to be operated in
surge area. In the operation for adjusting the blades of forced draft fan, in order to judge if it has
accomplished aims for adjustment, the following things should be noticed: the regulation range of
moving blades, observe the variation of indication for motor voltage meter, draft meter, furnace
chamber negative pressure control meter and oxygen meter.
660MW boiler adopts the balanced ventilation method, and the furnace chamber and air flue duct
are under the negative pressure condition. The negative pressure of furnace chamber shall be
maintained in the precondition that flue gases is not overflow, more small its value is the more it is
better, generally maintaining at － 100 ～ ±50Pa. In the process of flue gases generation and its
exhaust, if the flue gases quantity exhausts out of furnace chamber is equal to the gases quantity
from combustion, the out and in substances will be in balance, then the air pressure of furnace
chamber remains relatively unchanged. If one of the values mentioned above is changed, the
balance will be disturbed, with the changes of furnace air pressure. Even though the induced air or
forced air is not changed (in balance) in the operation, the furnace chamber draft will be changed
because that combustion condition changes more or less.
The negative pressure is different on different height of the furnace. This is because the
temperature or unit weight is different both outside and inside of the furnace, the furnace negative
pressure will be decreased as the enlarging of furnace chamber height (or say the up-flow force
inside furnace is self-generated ventilation force of air flow). In order to avoid gas-dust leakage on
top of furnace, there should be large negative pressure at the bottom of furnace chamber. It can be
seen that the higher the negative pressure detecting position for furnace chamber is, the small the
negative pressure should be. The negative pressure detecting point for large capacity boiler
furnace shall be set at the bottom of the rear panel superheater (furnace chamber outlet).
The furnace chamber negative pressure shall be regulated by adjusting the guide blade opening in
the outlet of induced draft fan. When the feeding air-coal quantity changes as a result of the
decreasing or increasing of boiler load, if the induced air quantity is not able to follow up, the
furnace negative pressure will be changed. Therefore, the regulation of furnace chamber negative
pressure is actually the adjustment for induced air quantity. In order to avoid positive pressure
inside furnace, forced and induced air quantities shall be synchronously adjusted. When the load
increases, the regulation for induced air quantity shall be a little more advanced; when the load
decreases, the regulation lags behind. In the regulation for furnace chamber negative pressure,
the pressure differential value between boiler furnace and wind-box will be affecting the air volume
(auxiliary air baffle is controlled by the pressure differential between furnace chamber and
wind-box), outlet air-coal ratio of the burner and the stability of burning. Therefore, there is
limitation for regulating speed which cannot be acted with undue haste.
4.4.3.2 Some issues which should be noticed in the process of combustion adjustment:
4.4.3.2.1The Control Parameter for Combustion Regulation
a. The control value of each parameter for combustion regulation shall be confirmed after the
boiler combustion test. The control parameter for combustion regulation will be obtained according
to designed coals class and checked coal class.
b. The control value of each air ratio confirmed with the coal class includes the first air ratio and
the first air speed; Fuel flow ratio and fuel flow speed, auxiliary wind ratio and wind speed etc. are
used for controlling and adjusting various air pressures to meet the air distribution requirement.
Attentions need to be paid to flux ratio of two sides, and if the ratio is deviated, it should be
adjusted in time.
c. Check the burning condition inside furnace, the length of coal firing. Check it whether the light of
flame is golden brown, not deflected and has a flame of fine fullness. Or regulations should be
done timely to the opening degree of auxiliary air baffle for a calibration.
d. In normal operation, keep the flue gas oxygen content of economizer outlet at 4％～5％ (equal
to the excessive air coefficient 1.24 ～ 1.31) to maintain the excessive air coefficient of furnace
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chamber outlet. The maximum air volume≮25％ of rated air volume.
e. Maintain the furnace chamber negative pressure.
f. Pay attention to air leakage condition for furnace chamber; keep the leakage proofness of
furnace chamber.
g. Maintain qualified coal fineness.
4.4.3.2.2 The Combustion Adjustment for Load Changing
To adapt the variation of load, adjustment needs to be done to the fuel quantity. For the direct
blowing pulverizing system, synchronous changing the speed of coal feeder is adopted to coal
powder quantity inside burners when the load of boiler changes widely. When there are no big
changes for the load of boiler, the way can be used by starting and stopping the coal mill, or say, to
changing the fuel quantity by changing the shutting mode of burner layers.
When boiler load changes, while adjusting the fuel quantity, forced and induced air quantity shall
also be adjusted for keeping the stability of steam temperature and steam pressure. To increase
the load, the first thing needs to be done is to enhance the forced air volume and then increase the
coal feeding quantity; To reduce the load, firstly things should be done is to reduce the coal
feeding quantity, and then decrease the forced air volume and induced air volume for keeping the
furnace chamber negative pressure. The forced air volume shall be adjusted timely in accordance
with the decreasing and increasing of load for keeping a reasonable excessive air volume inside
furnace ( the oxygen value of flue gas at the outlet of economizer is prescribed value), and finally
accomplish the economical combustion. To keep the furnace chamber negative pressure for
controlling the working condition of induced draft fan, the setting for negative pressure can be
operated manually on the keyboard.
4.4.3.2.3 The Running Mode for Burners
The working condition of burner is not only affected by air distribution condition but is also related
with the load of furnace chamber and the distribution of fuels inside the furnace, or related with the
running mode for burners (the allocation for burner load, shutting mode).
In order to keep a correct center position for flames and avoid the phenomenon such as the flames
deflecting, more efforts should be made to ensure that the load is symmetrically and even
distributed to each burner---an even coal powder distribution on four corners for the burner with an
appropriate allocation for airs and coals. For the direct blowing pulverizing system, the method for
coal powder regulation at four corners is basically depended on the throttle orifice embedded on
first air pipe of pulverizer outlet. Due to that the throttle orifice are more likely to be abrasive after it
has been running for a long time. The result causes that the characteristic of throttle orifice will be
changed, then the resistant characteristic of pipelines will be changed leading to an unevenness of
four corners distribution of coals powder and air powder. This shall be specially noticed. If the four
corners leveling are affected by throttle orifice, then it shall be moved and changed with a new one
in order to prevent it from affecting the normal burning condition.
For the four corners arranged direct flow burner, changing the auxiliary air volume and the upper
and lower array of nozzles of the burners is also the one of the measures for the adjustment of
flame center and the improvement and enhancement for the air powder mixtures and combustion
efficiency. Of course, it’s better to make full advantage of the characteristic of the adjustable
declined angle of coal powder burner. In the condition of ensuring normal temperature, the
declined angle of burner can be kept a little declined in order to reduce the temperature of furnace
outlet, avoid the clogging on the furnace outlet and improve the combustion economical efficiency.
But it should be noticed to avoid the clogging on cold ash hopper.
Fewer burners should be put into operation during the low load condition. And high speed coal
feeder should be adopted to keep a high coal powder concentration at the outlet of burner.
Because the heat load in the furnace chamber will be low for the low load condition in which the
fire are easily tend to be out, the first thing should be considered is the stability and then the
economical efficiency. In order to avoid the fire-out, besides keeping a relatively high concentration
of coal powder in the burner outlet, it is also important to relatively reduce the negative pressure
and appropriately adjust the air-coal ratio of burner to avoid over-large fluctuation on air flow rate.
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If necessary, put the oil guns for supporting combustion to keep a stable flaming.
The following principles can be taken as references for burner operation:
a. The burners are only forced to stop under the condition for stabilizing the combustion and
adapting the boiler load and ensuring the parameter of boiler. At this moment, economical
efficiency is considered as the secondary importance.
b. Stopping the upper burner and starting the lower burner can reduce the flaming center and is
propitious for complete combustion. But that will make the steam temperature decreasing
(compared with stopping the lower burners and starting upper burners)
c. When the burners need to be switched to others, the first thing should be done is to put spare
burners into operation and stop them till normal condition to avoid discontinued combustion or
weak combustion.
d. When the burners are switched or stopped or started, the effects such as combustion, steam
temperature should be taken into consideration. It’s forbidden to operate arbitrarily.
In the process of starting, stopping the burners or changing the burner load (changing of coal
powder quantity), attention should be paid to the coordination between air volume and coal
quantity. For the stopped burnings in the operation, less volume of airs should be used for cooling
down the burners in order to ensure that the nozzles will not be easily broken.
4.4.4 Control and regulation of drum water level
4.4.4.1 The task of drum water level regulation is to make the water supply amount meet the
evaporation of the unit and maintain the drum water level in the normal range. ±50mm, and reduce
the water level fluctuation as much as possible. The feedwater shall flow into the drum
continuously and evenly.
4.4.4.2 In operation, it shall maintain intactness of water level gauges of two drums at any time,
with correct and clear indication, as well as sufficient lighting;
4.4.4.3 In operation, regularly check the working condition of boiler pump, and prevent large
fluctuation of water level caused by pump malfunction;
4.4.4.4 When the boiler load is ≤ 10% MCR, the water supply regulation and control adopts a
single impulse drum water level control, the water flows into the drum through the water bypass;
when the boiler load is > 10% MCR, the water supply regulation and control adopts three impulse
control of drum water level, superheated steam flow, water supply flow, the water flows into the
drum through the main water supply electric valve.
4.4.4.5 When the changes of operating condition causes the fluctuation of drum water level, water
level shall be closely monitored, if necessary, manual control shall be switched.
4.4.4.6 When the drum water level rises due to improper water level regulation, the continuous
electric valve must be openly widely to reduce drum water level; when the drum water level
appears to be very low and needs large amount of water supply, the attention shall be paid to
high-and low pressure heater operation to prevent the cutoff due to the poor heater overload drain.
4.4.4.7 The indication of drum water level gauge must be accurate, drum water level measurement
adopts the reading of differential pressure-type water level gauge during the operation, the staff of
every shift shall check in-situ water level gauge and remote water level gauge, if any deviation is
found, he or she shall promptly notify for the maintenance.
4.4.4.8 When regular sewage is taken due to bad water quality in the boiler, water level shall be
monitored and regulated.
4.4.4.9 During normal operation of the units, the control of the drum, deaerator, condenser water
level shall be put in automatic mode to maintain the continuous, uniform water supplement for the
drum, deaerator and condenser, if any automatic control abnormalities and abnormal water levels
are found, automatic regulation should be switched immediately to manual regulation mode and
the thermal staff shall be notified for maintenance.
4.4.4.10 When the unit load increases or decreases too rapidly, changes of main steam pressure
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is too larger, or the safety valve is started, the attention shall be paid to drum water level changes,
and the impact of false water level shall be considered carefully and three water levels shall be
coordinated and controlled.
4.4.4.11 In the occasions of water supply pump startup and shutdown, automatic failure of makeup
water system, the leakage of the boiler heating surface, high pressure heater emergency drain,
the water level shall be monitored and regulated.
4.4.4.12 Water level change is easily caused in the following circumstances during boiler
operation:
a)Large load increase or decrease;
b)Safety valve action;
c) Rapid change in fuel amount;
d) When a water pump starts or stops;
e) Automatic water supply fails;
f) Pressure parks leak;
g) When turbine regulating valve, bypass valve, superheater drain valves and main steam
pipeline are opened or closed;
h) Boiler pump starts or stops or trips in operation;
Pay attention to avoid the circumstances above said in boiler operation, when they occur,
enhance monitoring and adjustment of water level.
4.5 Precaution of operation regulation
4.5.1 During normal operation, the unit is in coordinated control, the unit and the boiler as a whole
jointly control the unit load and main steam pressure, the setting value of main steam pressure is
regulated automatically along with unit load curve.
4.5.2 Under steam turbine TFB operation mode, the steam turbine controls the main steam
pressure by changing the opening of CV control valve.
4.5.3 Under boiler BFT operation mode, the boiler controls the main steam pressure by changing
the combustion control.
4.5.4 When manual mode and automatic mode switch each other, it is necessary to monitor and
keep actual value of steam pressure consistent with the setting value, and then switch. Under
manual control of main steam pressure, substantial changes are banned, the rate of change shall
be controlled not more than 0.1MPa/min.
4.5.5 Main steam pressure during normal operation is set at 16.7MPa, the pressure shall be
regulated within the specified scope.
4.5.6 In accordance with the requirements of unit load, constant pressure operating conditions
shall be kept in 50%~100% B-MCR range, the superheat steam and reheat steam shall be kept at
the rated steam temperature; the sliding pressure operation condition shall be kept in 45%~100%
B-MCR range, the superheat steam and steam reheated steam shall be kept in its rating
temperature, the deviations are allowed within ± 5 ℃.
4.5.7 When the main steam pressure changes, the causes are timely analyzed to regulate the
combustion; the combustion condition changes as a result of coal quality change or abnormal
operation of milling system, the corresponding measures shall be taken for different situations and
the combustion shall be regulated to manual mode if necessary.
4.5.8 When the units is in the coordination and control method, the attention for change of primary
air and secondary air pressure on impact of combustion should be paid when the wind mill starts
and stops to prevent the significant change of steam pressure due to combustion mutations.
4.5.9 When valve failure of the turbine causes the change of main steam pressure, the combustion
rate should be adjusted immediately; if main steam pressure significantly increases, main steam
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PCV valve shall be open to release the pressure.
4.5.10. During normal operation, the combustion shall be regulated in accordance with the load,
fuel property, operating mode of milling system, fineness of pulverized coal, flue gas temperature,
air flow, oxygen, burning condition of pulverized coal, flue gas temperature on both sides of
furnace outlet.
4.5.11 During normal operation of the boiler, the furnace negative pressure should be monitored to
maintain the furnace pressure at -50Pa; At the same time, the attention shall be paid to monitor the
automation control of primary air pressure, second air pressure and the rotation speed of coal
feeder, if any abnormal incidents are found, manual control shall be switched and the reasons
shall be investigated to ensure stable combustion. When the combustion is unstable, the fuel oil
shall be timely added to make the combustion stable.
4.5.12 According to the nature of coal quality, determine the suitable ratio of primary air, secondary
air and the perimeter air, horizontal swing angle of OFA secondary air and timely elimination of air
flow deviation at left and right side shall be carried out and flue gas temperature at both sides of
furnace outlet shall be ≯ 50 ℃.
4.5.13 During normal operation of the boiler, check the coking at the water wall, screen, and
burner outlet, appropriately regulate the ratio of air and pulverized coal, maintain optimal
combustion conditions, control the oxygen at required range. If any coking is found, timely adjust
the combustion; if the coking is serious, strengthen the sootblowing to reduce the boiler load; if the
steps don’t work, report to the leadership, and contact for maintenance.
4.5.14 During boiler operation, keep the primary air regulation at the speed ≥ 25m / s, ensure the
pulverized coal is not deposited in the pulverized coal pipeline. Regulation of secondary air shall
meet the distribution of the oxygen at the outlet of the economizer, auxiliary air, perimeter air and
combustion air.
4.5.15. During boiler operation, ensure symmetric operation of corner burner on every layer,
prevent the operation of missing corner; keep the normal swing of burner nozzle in automatic
control; if it is manual position, in order to ensure normal work of swing mechanism, the burner
nozzle is not allowed to stay a long time in same position, carry out manual swing two times at
least in every shift.
4.5.16. In order to maintain a reasonable fineness of pulverized coal, pulverized coal fineness in
the design is R90 = 22%. According to chemical analysis and timely regulation of baffle opening of
mill separator, during low-load operation, appropriately reduce the fineness of pulverized coal in
order to facilitate the combustion.
4.5.17. During boiler low-load operation, use the burner in the adjacent layer, maintain the higher
concentration of coal in order to facilitate the ignition and combustion of pulverized coal. During
boiler high-load operation, use the burner, so that the furnace heat load is uniform, and the
combustion is stable.
4.5.18. During boiler high-load operation, under the condition of compliance with the requirements
of steam temperature, keep the upward angle of the burner not too large to prevent the flame
center move too much which may make too high temperature at furnace outlet and result the
coking.
4.5.19. Measures of boiler low-load stable combustion
4.5.19.1 Pay attention to changes of coal quality, think ahead to the accidents of combustion
instability.
4.5.19.2 The strengthening of the furnace flame, negative pressure, steam temperature, steam
pressure and power of the surveillance, expected to do a good job accidents, prevent the flameout
due to low furnace heat load. When in load adjustment, control the load shedding rate smaller than
5MW/min
4.5.19.3 Fuel system shall be ready for operation at any time. Open drain valve of fuel steam
atomization main pipe, and ensure that the atomized steam pressure not less than 0.9Mpa and
temperature not lower than 200°C; in case of automatically adjusted oil pressure being unstable,
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switch timely to manual adjustment; ensure the oil pressure normal and ensure the boiler front oil
pressure 1.3-1.5Mpa, and ensure the oil guns are ready for operation at any time.
4.5.19.4 In case of combustion instability, add the oil timely, pay attention to mill operation mode
before adding oil, and confirm the boiler fire is not extinguished. If it can not confirm if the boiler fire
is extinguished, handle as per fire extinguishing procedures; at this time, prohibit adding any fuel
to the boiler;
4.5.19.5 Keep the oxygen around 5.0%; in case of abnormal automatic regulation of primary air
baffle in the mill, switch to manual regulation.
4.5.19.6 In accordance with the load, determine the operating sets of the mill, during boiler low
load operation, avoid the compartment operation of the mill as far as possible. Stabilize the
combustion by putting oil gun into operation when it is necessary that the coal mills in alternative
layers can operate. Coal mill start/stop must be in the principle that the one starts first shall stop
later. Enhance the inspection on coal mill, make adjustment in time if any abnormalities are found,
prevent mill vibration;
4.5.19.7 Check and close the man hole and observation hole on the furnace; check the slag
discharge valve at the furnace bottom, maintain waterseal water level, and reduce the furnace air
leakage; During load shedding, control the load shedding rate at less than 5MW/min.
4.5.19.8 During low load operation, turn the second air throttle, perimeter air throttle of the burner
of the shutdown mill in upper layer small. Burner tilt angle shall be as small as possible in
allowable conditions of steam temperature.
4.5.19.9 Master the change rule of combustion intensity, if any combustion instability is found , add
the oil first and then regulate to prevent the boiler blameoff. In case of boiler flameoff, handle it in
accordance with MFT principle.
4.6 Steam quality control
The superheated steam in the operation of boiler unit shall be consistent with the steam quality
standard regulation of GB/T12145-1999 thermal power generating units and steam power
equipment.
The superheated steam quality assurance value at the outlet of the boiler: Sodium ≦ 10 µg/kg;
silicon dioxide <20 µg/kg; copper: <5 µg/kg; iron ≦ 20 µg/kg.
4.6.1 To ensure that water supply, boiler water quality.
4.6.2 To avoid the sudden increase of unit load and sudden drop of steam pressure.
4.6.3 To control drum water level in the range of ± 50mm.
4.6.4 To control the continuous emission and constant, ensure the salinity of boiler water is less
than its critical salinity under the steam parameters.
4.6.5 The size of emissions depends on the salinity of boiler water and steam; during the normal
sewage, use the continuous blowdown flash tank, and recover steam after steam quality is
qualified and send it to the deaerator, sent the drain to blowdown flash tank; only if continuous
blowdown flash tank is abnormal in operation, drain directly the sewage into to blowdown flash
tank. Regular drain shall be conduct on the chemical requirements, heat the pipe to prevent water
clash before the drain.
4.6.6 Regular drainage shall be carried out under the relatively low load, when the pressure of
steam drum is high, it may damage the blowdown pipe, valves and continuous blowdown flash
tank, but also may disrupt the water circulation; during the drainage, slowly open the regulation
valve after the electric drainage valve opens, pay attention to the changes of water level, and the
drain time shall not be more than 30 seconds.
4.6.7 During the drainage, it is important to ensure the water level within the normal range; in case
of abnormal change in water level, close immediately the electric drainage valve and regulating
valve. During the drainage, prevent overpressure of blowdown flash tank. After the drainage,
check the drainage valve whether it is tightly closed.
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4.6.8 The drain pipe of lower drum behind the water wall can be used for regular drainage and also
for boiler water drain; The drain pipe of lower drum in front of water wall is only used for boiler
water drainage after the boiler shutdown, it cannot be used for emergency water drainage during
normal operation and also not for sewage.
4.7 Boiler sootblowing
4.7.1 The purpose of boiler sootblowing is to maintain a clean heating surface, to improve heat
transfer efficiency, to prevent heating surface from coking, to maintain flue free-flowing, to reduce
flue resistance, to reduce power consumption of the blower.
4.7.2 Check before sootblowing
4.7.2.1 All sootblowers are at exit position; Electric motor is in good electrical connection, its
mechanical part is in integrity, and its transmission gear is in normal order;
4.7.2.2 The piping, valves, flanges for sootblowers system are in good condition with no leakage;
the supports and hangers are complete and fast;
4.7.2.3 The local pressure meters are complete with good indication;
4.7.2.4 The sootblowing control device is in good condition; the plug-in units in the cabinet are in
reliable connection; the power supplies for sootblowing are in normal condition.
4.7.3 The sootblowing should be done when the load is higher than 70%MCR and the flame is
stabile.
4.7.4 Increase properly furnace negative pressure and keep stable while sootblowing, strengthen
the monitoring of furnace negative pressure and suction fan control, and, if necessary, keep the
fixed blades running of suction fan at manual mode. At the same time, strengthen the monitoring
and adjusting to the temperature of the main steam and reheat steam.
4.7.5 Soot-blow in the order of flow direction of flue gas, and symmetrically soot-blow at the same
time.
4.7.6 Soot-blow the air preheater once per shift in principle, and partly or wholly soot-blow other
heating surfaces according to the cleanliness. Soot-blow the air preheater once whenever starts
sootblowing of the boiler body and after sootblowing. During the main body sootblowing, enhance
the monitoring of pressure difference of flue gas at the inlet and outlet of air preheater, so as to
soot-blow the air preheater in time.
4.7.7 Strengthen on-site inspection while boiler sootblowing. If the sootblower is found stuck or
failed to return in place, contact the maintainer immediately to handle. Do not soot-blow the
heating surface at fixed-point, and keep the steam source freely flow while sootblowing.
4.7.8 If the sootblower gets stuck in the furnace and could not take out, when it is confirmed to be
burnt bent or could not take out after 2 hours, close the steam source manual valve of the
sootblower to prevent damage of the heating surface, and then leave it to the maintainers for
further treatment.
4.7.9 Do not allow to open the inspection hole near the sootblower to observe the flame during
sootblowing. Stop the sootblowing immediately when the boiler combustion is not stable or MFT
and RB occurs.
4.7.10 After sootblowing，check the automatic shutdown of steam source valve and drain valve
and then restore the normal furnace negative pressure. Check all sootblowers on the scene to
make sure they are returned back and if internal leak of the sootblowing is found, close the manual
valve of steam incoming of the sootblower, and contact maintainers for treatment. Check the
stopped sootblower once per shift, contact maintainers in time if any defect is found.
4.7.11 Strictly prohibit to put the sootblower into furnace without steam flowing. While the
sootblower putting into the furnace or taking out from the furnace, keep the steam source valve
open to prevent the sootblower from burning out.
4.7.12 Keep the slag dredger of the boiler continuous running while sootblowing; check slag
dredger regularly if it works normally.
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4.7.13 Monitor the overflow water of furnace hopper, make sure it works normally and there is ash
deposits and coke blocking.
4.7.14 Make sure the turning machine and chains of slag dredger s operate normally.
4.8 Furnace slagging
The pre-condition of slagging is the collision of coal soot particles and the wall. The coal soot
particles move with airflow in pulverized coal furnace; Furthermore, coal soot particles in larger
size are easy to be separated from turning airflow and makes collision with wall surface, so the
sharp turning of airflow and the fineness of coarse pulverized coal make it easy for slagging. Both
low soot particle melting temperature and high wall temperature will make it easy to show molten
state while collision of soot particle and wall surface; The coarse soot particles will show molten
state for high separating speed, short separation time before collision with wall surface, and hard
cooling; unclean cooling wall, weak heat absorption capacity，high regional temperature and weak
cooling capacity for soot particles make soot particles easy to show the molten state while collision.
The characteristic temperature of fusion of the soot is relative with its environmental atmosphere,
the melting temperature will be high at oxidizing atmosphere, and it will be low at reducing
atmosphere, so the excess air coefficient will also affect slagging in furnace. That’s why slagging
is not only determined by soot feature; it also has close relationship with wide range of factors.
4.8.1 Soot meltbility at high temperatures
(1) Soot meltbility and measurement of three characteristic temperatures of soot
Coal will leave ash after combustion, but the soot is not a single substance, so it has no fixed
melting point(MP)，namely, there is no concurrent margin temperature for its solid and liquid state.
There is no obvious margin temperature when it gradually transfers from solid to liquid state while
heating, this transfer feature is called meltbility. The indication method of soot meltbility is, under
serious test conditions, to make soot to a certain shape and observe the relationship of its state
change and the temperature.
China adopts the pyramid method extensively used in the world to measure the soot meltbility, that
is to make soot to a equilateral triangle pyramid of 20mm high, 7mm long of hemlines, put the
pyramid into a soot melting point meter which could adjust temperature, and heat up in a stated
speed. After heating to a certain extent, the soot pyramid will deform under the weight of itself,
then get soft and change to liquid state. Pyramid method is, according to the shape changing
observed through eyeballing, to indicate the soot meltbility with the characteristic temperatures
corresponding to the following figure:
Deformation of soot pyramid and three characteristic temperature of indicating meltbility

DT-deformation temperature; ST-softening temperature; FT-molten (Flow)temperature
(a) Deformation temperature DT ： The corresponding temperature during the top of the soot
pyramid is getting roundish or bending.
(b) Softening temperature ST: The corresponding temperature when the soot pyramid touches the
base plate from the main body to the top, or when it changes to a ball, or a semi-sphere with the
height equal to or less than length of hemline.
(c) Fusion temperature FT：The corresponding temperature when the pyramid melts to liquid state,
or spread to lamina which the thickness is less than 1.5mm, or the pyramid is getting smaller up to
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nearly disappearance.
Because the soot contains many ingredients, it has no definite melting point and its shape is
changed gradually. DT, ST, FT are three temperatures in liquid and solid phase, not the
temperature from liquid phase to solid phase, are just mean temperature interval during the shape
changing. The temperature interval of DT, ST and FT affect the boiler operation very much. The
large temperature interval means that the coexistence of solid-phase and liquid phase over a wide
temperature range, the viscosity of soot changing slowly with the temperature, this kind of slag is
called long slag which can keep long time of viscosity during cooling procedure, that's why it's
easy for slagging in furnace; small temperature interval will cause soot's viscosity rapidly change
with temperature change, this kind of slag is called short slag which will have very short period of
time for slagging during cooling process. It is generally agreed that：if D-value of DT, ST is at 200
~ 400℃, it will generates long slag，short slag at 100 ~ 200℃.
(2) Factor analysis of soot meltbility
Main factors impacting soot meltbility are soot chemical compositions and the characters of
environmental medium (atmosphere) of high temperature around the soot; the former is internal
cause and the latter is external cause, and two of them interact.
① Chemical compositions of soot: The chemical composition of soot can be divided into acid
oxide mainly composed of SiO2, Al2O3, TiO3 and basic oxide mainly composed of Fe2O3, CaO,
MgO, Na2O, and K2O etc. The ash fusion points of these oxides are very high in pure state and the
phase transition temperature is constant. A12O3 in soot could increase ash fusion point; and basic
oxide in soot could reduce ash fusion point.
Melting temperature of hackneyed pure oxide
Melting Temperature Melting Temperature
Oxide Name Oxide Name
(℃) (℃)
SiO2 1716 Fe2O3 1566
A12O3 2043 K2O 800～1000
CaO 2521 TiO3 1837
MgO 2799 FeO 1377
However, the soot generated by coal combustion is usually eutectic combined with many
ingredients. The melting temperature of these complex eutectics is much lower than the melting
temperature of pure oxide, and there is no definite and fixed phase transition temperature from
solid phase to liquid phase. And the eutectic with low melting point has also the characteristic to
melt other mineral substance which is still in solid phase, making some elements of soot be melted
at the temperature which is much lower than its melting-point temperature, causing the melting
temperature of soot components lower than temperature listed in the table below.
Melting temperature of some complex compounds in soot
Name of complex Melting temperature Name of Complex Melting temperature
compound (℃) compound (℃)
Na2 SiO2 877 CaO·FeO·SiO2 1100
A12O3·Na2O 6 SiO2 1099 2FeO·SiO2 1065
CaO·Fe2O3 1249 CaO· A12O3·SiO2 1170
Ca·MgO 2 SiO2 1391 Ca·SiO2 1540
② The character of hot environment medium (atmosphere)around the soot. In the boiler furnace,
there are two hot environmental mediums around soot, the first is oxidized medium which contains
oxygen and results of complete combustion, and mainly generated at the part near the outlet of
the burner, as well as the outlet of the furnace; The second is weak reduced medium which
contains little amount of oxygen and composed of the result of complete combustion and imperfect
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combustion，and this kind of weak reduced medium is mainly generated at part section in front of
pulverized fuel fired boiler.
The medium character around the soot is different and the iron in soot has different state. For
instance, the iron in oxidized medium shows ferric oxide (Fe2O3)state with higher {*>melting
point(MP); Iron in reduced medium shows metallic iron Fe state with higher melting point(MP); but
the iron shows FeO state in reduced medium with melting point of 1377℃, but FeO is easy to
created FeOSiO2 with SiO2 in soot which has very low melting point of 1065℃.
If combustion process is not arranged well in boiler furnace, the result of imperfect combustion will
appear and the medium will be weak reduced medium, causing ash fusion point decrease and
result the slagging.
4.8.2 Slagging on heating surface
The slagging on heating surface could generate on the cooling wall, as well as screen superheater
near the area of furnace's outlet. The slagging on cooling wall surface reduces heat absorption
capacity of cooling wall and evaporative capacity, and increases the gas temperature and results
in overrate of superheat steam temperature and reheat steam temperature. The slagging on the
heating surface of furnace outlet reduces heat absorption capacity of these heating surfaces,
blocks flowing of flue gas at the same time，which results flow resistance and increasing refracted
deviation between paralleling tube and the heating surface.
As the slagging on the heating surface occurs in the state of collision between soot particle and
the wall, it adheres on the wall, so the firs condition of slagging is the collision between both of
them so that the soot particle in molten state has adhesive ability. It has been mentioned before,
that the particles composing the soot have different components and melting temperature. There
is certain temperature distribution inside the furnace. Generally, the gas temperature in the central
part of the flame in pulverized fuel fired boiler is very high, and a considerable portion of soot
particle is in molten or semi-molten state; the gas temperature near the furnace wall is lower. Soot
particles in furnace will move with the air flow, or be separated from the airflow, and in this
separation process, the temperature of soot particles will change with the velocity of movement, it
moves from high-temperature section to the wall, and the condition of environmental temperature.
If there is a sufficient cooling condition, the original particle in molten state will be the solid again
lose its adhesive capacity and lose the slagging conditions; on the contrary, the extent of
generating slagging will be large, that's the basic causes of slagging on the heating surface. It is
closely related with soot characteristics, velocity field in the furnace, temperature field, the particle
size of soot and so on, as well as the above-mentioned, the slagging in pulverized fuel fired boiler
is unavoidable, the question is just the extent or if it's increasing rapidly.
(1) Fundamental factors affecting slagging on heating surface
It is observed from fundamental causes of slagging, there are three fundamental factors which
affects the slagging: ①The aerodynamic field in the furnace, the particle size and weight density of
the soot, which influence on the flowing of flue gas and soot particles in the furnace. ② the
separation of soot particles from flue gas and the collision with the wall are relative with fineness of
pulverized coal and selective deposition of the soot. ③ The combustion characteristics of coal, the
temperature field in the furnace composed of boiler load and furnace aerodynamic field as well as
molten characteristics of the soot, all these will affect that the soot particles in molten state have
coking ability, and they have relationship with the heat load of the heating surface, cleanliness
extent of the heating surface as well.
The airflow keeping close and rushing to the wall in the furnace will affect the combustion process,
and promote collision between particles and the wall as well. The sudden change of airspeed and
flow direction promotes the particles separated from the airflow and increases the chance of
collision with the wall. In the same state of flow, the larger and heavier particles will be easier to be
separated and get more chances to make collision with the wall. Therefore, aerodynamic field test
is required for all pulverized fuel fired boilers to assure that the airflow will not close and rush to the
wall by adjusting air speed and air input from each nozzle; The velocity gradient is small near the
wall region, which also limits coarse particles in pulverized coal (such as the particles larger than
297μm not bigger than 2% recommended by CE).Aerodynamic field in the furnace and the
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combustion characteristics of pulverized coal determine the release of heat distribution; The
aerodynamic field and the heat-absorbing capacity of heating surface determine the distribution of
the heating surface, and sequentially determine the temperature field of the furnace. If the
resultant temperature field makes a certain distance between the flame center and the furnace
wall, and the place near furnace wall is an area with lower temperature, then the soot particles
separated from the high temperature region gains a chance to be cooled into solid, and there will
be less possibility to generate the slagging. Of course, this is also related to the time that the
particles experienced in the region, namely movement velocity, the molten characteristics of the
soot and the particle size. Larger particles have large thermal capacity and small coefficient of
heat transfer which make it difficult to be cooled into solid. The overall temperature inside the
furnace will increase with the increase of heat load of the boiler and the released heat from inside
the furnace, at the same time, the net heat flux density (heat load/per unit of heating surface) will
increase, wall temperature will increase accordingly, the temperature near the wall section will
increase because of overall temperature level inside the furnace and also the wall temperature,
and then the cooling capacity for nearby soot particles will be weak accordingly which will result in
slagging on the heating surface. Lower cleanliness of heating surface will increase wall
temperature which has similar situation. It is seen that impacting factors are complicated, and the
molten characteristic of soot is the main reason but not the only one.
(2) Boiler design operation and slagging
After discussing the fundamental impacting factors, in accordance with design and operation,
control the extent of slagging inside the furnace through the following factors.
① Flue gas temperature at furnace outlet. The flue gas temperature at furnace outlet shows the
temperature Level inside the furnace, condition of soot particles' state, the coking tendency of
heating surface at furnace outlet in great extent. Therefore, for the boiler which combusts the coal
with low melting point, its furnace outlet temperature is always designed to very low level. For the
boiler which the reheat steam temperature is adjusted through the angle of swing burner, the
maximal angle of upwards swinging is limited by coking of heating surface at the furnace outlet
(upward swing makes flue gas temperature of furnace outlet increase).
② Boiler load. The boiler load will be increased by increasing the fuel amount and the net heat
flow of the heating surface, as mentioned above, the former, fuel amount, shows overall furnace
temperature level, and the latter means the outer wall temperature of the heating surface.
Therefore, the increase of boiler load means that the possibility of slagging inside the furnace
increases. One of the principal handing measure is to reduce boiler load.
③ Furnace height of the upper part of burner. From the pulverized coal combustion process, a
certain height is required to meet the need of combustion process or the flame length. The
temperature distribution inside the furnace is closely related to the height. The temperature gets
down rapidly and soot particles get the possibility to be cooled into solid. If the height from the
upper part (the tiptop of primary air nozzle) to the bottom of screen superheater is too small, the
slagging possibility increases for screen superheater, or it results severe slagging. The height in
boiler design is corresponding to combustion characteristics of burnt coal types and molten
characteristics of soot.
④ Heat load of furnace wall and burner section. Heat load of furnace wall is the ratio of the furnace
heat and the projected area of furnace wall, it shows the absorbency of water wall to the furnace
heat, and that is the temperature level inside the furnace, especially near furnace wall section, or
the cooling capacity to soot particles close to the wall surface. Heat load of burner section shows
the relative centralization and decentralization of the arrangement of burners. Burner section is the
section of most drastic speed and temperature change, maximal gradient, most intense
combustion, highest section temperature level and easiest generation of the slagging. Therefore,
the heat load value of burner region adopts low limit for the boiler with the coal type of high
slagging orientation.
⑤ Air quantity of combustion and mixed ratio of air and pulverized coal. The lack of air inside the
furnace will easily generate monoxide resulting in decreasing largely of ash fusion point which will
cause slagging inside the furnace. This will be much easier to happen while using volatile coal. If
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the mixture of fuel and air is not complete or the mixed ratio of air and pulverized coal is not very
well, it will result in more air at one location while less at other location, even if sufficient air is
supplied; some corners have more pulverized coal but less air while others have more air but less
pulverized coal, in this way, the areas with more air will create (weak)reducing gas which will lower
the soot fusion point lower and cause local slagging.
⑥ Flame deflection and pulverized coal flow close to wall. The defects of the burner or abnormal
operating conditions of aerodynamic force inside the furnace will cause flame deflection or
pulverized coal flow close to wall. Flame deflection causes highest temperature area of flame zone
moving to furnace wall which results sever slagging on water wall.
⑦ Fineness of pulverized coal. The coarse particles of pulverized coal is easily separated from
airflow to make collision with wall surface, it needs longer combustion time and flame length as
well, and furthermore, it’s not easy to be cooled into solid for large heat capacity and small
coefficient of heat transfer. Therefore, when the coal types with low characteristic value of melting
temperature are used, the fineness of pulverized coal is required to control well.
⑧ Sootblowing for heating surface. The slagging is unavoidable in pulverized coal fired boiler，the
question is the slagging degree. Once the heating surface get slagged, the surface temperature
will go up, the cooling capacity to soot particles near heating surface will weaken which will result
in vicious circle (the slagging will become severe). Heating surface of the boiler is kept clean or
kept away from serious staining through sootblowing. Once the slagging gets severe, the cleaning
ability of the sootblower will be reduced. Therefore, the layout and operation of the sootblower
must be corresponding to the slagging trend of applied coal types to clean the deposited scoot in
time.
4.8.3. Slagging prevention
The slagging prevention shall mainly begin from the preventing of too high furnace temperature,
flame clash to the wall and ash fusion point decrease.
(1) Prevent too high temperature of heating surface wall
Keep the balance of corner air and pulverized coal, and keep the balance of corner effusion
momentum as possible, and try to minimize effusion deflection degree. Keep flame center as close
as possible to combustor center, keep the appropriate diameter of contact circle to prevent air
from scouring furnace wall which may result the slagging.
(2) Prevention of too much reduced gas (medium) generated inside the furnace.
First of all, Maintain the suitable operating condition of aerodynamic force inside the furnace, and
keep the balance of air and pulverized coal, or some nozzles of primary air is in oxygen deficiency
due to too high density of pulverized coal, and reducing atmosphere appear. In this atmosphere,
the reducing gas reduces Fe2O3 in the soot to FeO and reduces the ash fusion point. And FeO and
SiO2 form eutectic whose melting point is much lower up to 150 - 200℃, and this may cause
severe slagging.
(3) Good fuel management and suitable fineness of pulverized coal
Fix the fuel types and remove the stones as far as possible to reduce the slagging possibility.
Maintain the suitable fineness of pulverized coal; don't make pulverized coal too coarse to avoid
the flame center too high resulting slagging on heating surface of burner outlet, or prevent the
pulverized coal from into the cool furnace hopper resulting slagging and so on.
(4) Good operation supervision
It is required that the operators shall concentrate, pay close attention to the operating condition of
combustion inside the furnace, inspect the slagging condition in site especially at the time of
severe slagging. Use program-controlled device to take sootblowing regularly and prevent worse
slagging condition.
(5) Mixed combustion of different coal types
The method of the mixed combustion of different coal types is good to prevent or ease the
slagging. For the coal types with severe slagging property, the slagging will be effectively
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controlled by mixed combustion of the crystallized type coal with high melting point. However,
master the ash characteristics before and after mixing and select the suitable coal types or
additives while adopting the method of mixed combustion of different coal types.
4.9 Unit operation method
4.9.1 Unit control
4.9.1.1 The unit load can operate in the range of 40% to 100% with the method of coordinated
control. As long as there is no fault in the system, it can operate with the method of coordinated
control. During the process of the unit startup, when three sets of the coal mill are in automatic
operation, it should carry out gradually into a coordinated manner. During normal operation,
according to the current situation of primary and secondary equipments, select the unit control
mode, take the abnormal lateral as tracked target. When one of the following circumstances occur,
promptly shut the coordinated control, switch to manual regulation so as to avoid the accidents.
4.9.1.1.1 The RB working condition appears, but RB function is not automatically achieved;
4.9.1.1.2 When the condition feature deteriorates, main unit parameters deviate from normal
control range, and don’t return for a long time;
4.9.1.1.3 During the unit high-load operation, main steam pressure continued to rise while main
steam temperature drops drastically.
4.9.1.2 Unit control method
① BASE
When the boiler main control and turbine main control are in manual mode, the control method is
BASE.
② BFT
Under the method of BFT, put the boiler main control in automatic method, control pressure,
manual control of turbine main control power. When MFT occurs, it automatically switches to
TFB.When the power measurement error is big, it will automatically switches to TFB.This method
is a common method. Switch the method with screen switch button.
③ TFB
Under TFB, put the turbine main control into automatic method, control pressure. Boiler main
control manual control power.
④ Boiler CCS
Under the operation of CCS, put turbine main control into automatic method, and the unit enters
into CBF method. This method is common coordinated method.
When RB occurs at the boiler side, it will automatically switch to TFB.
When the boiler main control is in manual control, it will automatically switch to TFB.
⑤ Turbine CCS
During the TFB operation, it puts the boiler main control into automatic mode, the unit enters into
CTF. When RB at steam turbine side occurs, it will automatically switch to TFB.
When steam turbine is in manual control, it will automatically switch to TFB.
⑥ Remote ADS
The unit in CBF or CTF mode can enter into ADS mode. In this control mode, it allows medium
regulation and control the unit load through ADS.
ADS mode may appear in CBF and CTF modes, the operation mode can be switched between
these models. ADS mode can be automatically switched to original control mode in the following
cases: locking load increasing, locking load decreasing, remote scheduling failure, load rejection.
The maximum and minimum Unit load limits are still effective under ADS mode.
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4.9.2 RB (Run back)
Under CCS of the operating unit, the load rejection will appear when one of the following cases
occurs:
4.9.2.1 One draught fan tripping;
4.9.2.2 One suction fan tripping;
4.9.2.3 One primary fan tripping;
4.9.2.4 One steam pump tripping;
4.9.2.5 One air preheator tripping.
4.9.2.6 Boiler pump trips and only one operates;
In the case of load rejection, if the control mode is ADS, it will force to shut down and make the
minimum unit setting rate non-functional.
4.9.3 RUN DOWN
When one of the following cases occurs, the function is to reduce forcefully the load:
4.9.3.1 The coal controller is in maximum power, but the fuel quantity is far less than the directive
requirements;
4.9.3.2 Fraught fan is in maximum output, but the air is far less than the directive requirements;
4.9.3.3 Water supply in maximum, but water supply amount is far less than the instructive
requirements;
4.9.3.4 The suction fan is in maximum output, but furnace negative pressure is far less than the
directive requirements;
4.9.3.5 The primary fan is in maximum output, but primary air pressure is far less than the directive
requirements.
4.9.4 BLOCK load change
4.9.4.1 When any of the following cases occurs, the block load decreases:
a) Water flow is larger than instructive requirement, or water supply amount is in minimum amount;
b) Air volume is larger than instructive requirement, or the draught fan is in minimum amount;
c) Coal quantity is greater than instructive requirement, or the coal controller is in minimum output;
d) The negative pressure is greater than instructive requirement, or the suction fan is in minimum
output;
e) Primary air is greater than the instructive requirement, or the primary fan is in minimum output.
4.9.4.2 When any of the following cases occurs, the block load increases:
a) The coal controller is in maximum output, or the fuel is less than the directive requirement;
b) The draught fan is in maximum output, or the air volume is less than the instructive requirement;
c) The water supply is in maximum, or water supply volume is less than the instructive
requirement;
d) The suction fan is in maximum output, or the furnace pressure is less than the instructive
requirement;
e) The Primary fan is in maximum output, or the air pressure is less than the instructive
requirement.
4.9.5 Unit protection interlocking operation mode
All operations, standby equipment protection, interlocking must be put. If any failure causes to
withdraw from the operation, the regulated approval procedure must be provided. If any parameter
abnormality is found during operation, if it is confirmed to be the measurement loop or
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measurement component failure, contact the thermal staff to cut down the protection which may
cause maloperation in order to prevent misuse of the protection. After power equipment tripping,
check if electrical protection is in operation, and then verify thermal protection; if the tripping
reason is unclear, don’t put the equipment in operation, (except to accident handling). After the
standby equipments interact, thoroughly investigate the reason of interacting; if original equipment
failures, stop the unit and maintain.
4.9.6 Pulverizing system operation mode
4.9.6.1 If the unit load is in 360 ~ 500MW, keep 4 coal mills in operation, otherwise put or stop one
coal mill.
4.9.6.2 During normal operation, keep the coal mill operation in rated conditions as far as possible.
During the process of unit load decrease, the output of all coal mills is less than 50%, stop one
coal mill. During the process of load increase, the outputs of all coal mills are close to the
maximum, but still unable to meet the need, start one standby coal mill, and balance the output of
each coal mill.
4.9.6.3 If coal pulverizing system starts and stops in the coordination method, slowly carry out or
suspend the load increase or decrease of the coal mill to prevent load increase or decrease
generating the disturbance during the process of startup and shutdown; during coal pulverizing or
sootblowing process, slowly air volume to avoid the air volume mutation of other coal mills.
4.9.6.4 Under normal conditions, switch the standby mill at evening shift. During load valley in the
evening, stop one coal mill; during load increase to the peak in the morning, start another coal mill
stopped for longer period of time. If no emergency, the Continuous standby time of one coal mill
shall not be more than 7 days. Before starting the coal mill, clean the slagging tank and ensure
that the slag falling door is open and the slag tapping door is closed.
4.9.6.5 In low load operation, if the spray requires adjacent layer operation, prohibit A, C and E
coal mill operation mode.
4.9.6.6 During coal mill normal outage, purge and clean the coal mill. After emergency outage,
carry out the inert gas recharging in accordance with the requirement. If any leakage in Inert
recharging door, close inert recharging steam valve of coal mill, open it while inert recharging and
close it after completion
4.9.6.7 When the temperature is low, maintain the oil system of stopped coal mill in operation, and
put electric heating to prevent extremely low oil temperature.
4.9.7 Boiler pump operation mode
4.9.7.1 Boiler pump water supplement
① When purge water and supplement water source is the condensate water, after boiler ignition
and 2.07MPa of drum pressure, stop the continuous water supplement of boiler pump.
② Another source of supply water as standby
4.9.7.2 Boiler pump low pressure cooling water
① In normal operation, use the cooling water booster pump of boiler pump for the supply of boiler
pump low pressure cooling water.
② If any failure of the cooling water booster pumps of boiler pump or outage of closed water
system, immediately start the emergency cooling water pump of boiler pump for water supply.
4.9.7.3 Set three boiler pumps for each boiler, keep three sets in normal operation; two for full load
operation, one for 60% BMCR load operation.
4.9.8 Air compressor operation mode
4.9.8.1 The Project is provided with total three sets of instrument air compressor and three sets of
plant air compressor. In the process of normal unit operation, it shall maintain respective two sets
of instrument compressor and of plant compressor in operation. Maintain air supply pressure in
0.8MPa and the maximum temp. ＜50℃;
123
4.9.8.2 Under normal mode, close the contact valve of main air tube for instrumentation and plant
service. If deficient air for instrumentation or no interact of tripping standby of air compressor for
instrumentation, immediately open the contact valve of main air tube for instrumentation air supply,
increase the output of air compressor for plant service at the same time or open another air
compressor for plant service to ensure adequate air supply for instrumentation.
4.9.8.3 In any circumstances, do not open the contact valve of main air tube for instrumentation
and plant service for plant air supply.
4.9.8.4 After the maintenance of air compressor, slowly add the cooling water to prevent the
impact on safety operation of air compressor due to sudden pressure decrease in cooling water
main tube.
4.9.9 Motor operation mode
4.9.9.1 There shall be the nameplate of the manufacturer on the shell of each motor. If the
nameplate is missing, add new one in accordance with original factory data or test results.
4.9.9.2 There shall be clearly marked arrows on the motor and auxiliary equipments to indicate the
direction of rotation; there shall be clear IDs on the shells to show their affiliation. There shall mark
“Startup”, “Operation” and “Stop” signs on the device
4.9.9.3 As for motor switches, contactors, operating handle and emergency button, there shall be
clear marks to indicate which motor they belong. There shall be one shield for emergency button.
4.9.9.4 There shall be solid shields of the motor and the clutch for mechanically connection, the
shell and startup device shall have good grounding.
4.9.9.5 Regularly inspect and test the standby motor to ensure it can start at any time, and
regularly shift for operation.
4.9.10 Normal operation parameter monitoring
4.9.10.1 Main parameter limit of boiler normal operation
SN Parameter Unit Normal High limit Low limit Tripping
1 Drum water level mm ±50 127 -178 254/-381
2 Drum pressure MPa 19.9
3 Main steam flow t/h 2187.13
4 Main steam pressure MPa 17.5
5 Main steam temperature ℃ 541 546 536
Reheat steam
6 ℃ 541 546 531
temperature
Furnace negative
7 Pa -37 980 -980 3300/-2450
pressure
8 Flue gas temperature ℃ 135
Pressure differential at
9 inlet and outlet of boiler kPa 294 110.32 60
pump
Motor chamber
10 temperature of boiler ℃ 4～60 60 4 60
pump
Superheat temperature
11 ℃ 5
differential at both sides
12 Reheat temperature ℃ 10
124
differential at both sides

Temperature at tube wall
13 of low superheat vertical ℃ 463
section
14 ℃ 490
of screen superheat
15 of back screen ℃ 568
superheat
16 ℃ 582
of end screen superheat
17 ℃ 566
of screen reheat
18 ℃ 580
of end reheat
Oxygen content in flue
19 % 3～8
gas
20 Pressure of fuel header MPa 2.5～2.7 0.5 0.5
Atomizing steam
21 MPa 0.6～0.8 1.1 0.5 0.5
pressure
22 Primary air pressure kPa 8～12
Flame detection cooling
23 kPa 7 5.6
air pressure
4.9.10.2 Operating parameter limit of main and auxiliary equipments of the boiler
4.9.10.2.1 Fan operating parameter limit
Motor lubricant
1 MPa 0.4 0.1
pressure
Motor lubricant
2 ℃ 20～50 55 20
temperature
Oil screen
3 MPa 0.01
4 Bearing vibration mm/s ≤4.6 5.5
Fan bearing
5 ℃ 80 90
temperature
Motor bearing
6 ℃ ＜80 80 90
temperature
7 Fan surge kPa 5
Motor winding
8 ℃ ＜100 100 130
temperature
4.9.10.2.2 Blower operating parameter limit
125
1 Lubricant pressure MPa 0.3～0.35
2 Lubricant flow L/min 25 3
Lubricant
3 ℃ 35 45 25
temperature
Controlling oil
4 MPa 2.5 3.53 0.8
pressure
Oil screen
5 MPa 0.35
6 Bearing vibration mm/s ≤4.6 11
Fan bearing
7 ℃ 75 100
temperature
Motor bearing
8 ℃ 80 95
temperature
A 2.43
9 Fan surge kPa
B 2.29
Motor winding
10 ℃ 100 100 130
temperature
4.9.10.2.3 Operation parameter limit of Primary fan
1 Lubricant pressure MPa 0.3～0.35
Controlling oil
2 MPa 2.5 3.5 0.8
pressure
3 Lubricant flow L/min 25 3
Lubricant
4 ℃ 35 45 25
temperature
Oil screen
5 MPa 3.5bar
6 Bearing vibration mm/s ≤4.6 8.0
Fan bearing
7 ℃ 80 90
temperature
Motor bearing
8 ℃ 70 95
temperature
Motor winding
9 ℃ 100 100 130
temperature
Motor lubricant
10 MPa 0.4 0.1 0.05
pressure
Motor lubricant
11 ℃ 55 20
temperature
4.9.10.2.4 Coal mill operation parameter limit
126
Air and pulverized
1 coal temperature at ℃ 65 82 55 93
the coal mill outlet
Reducer thrust
2 bearing ℃ ≤50 60 80
temperature
3 Lubricant pressure MPa 0.5 0.47
Lubricant screen
4 differential MPa 0.1
pressure
Oil tank
5 ℃ 30～40 40 35
temperature
Oil temperature in
6 ℃ 45 49 65
the system
Safety valve
7 MPa 0.63
operating pressure
Motor winding
℃ ＜110 110 145
temperature
Motor bearing
℃ ＜75 75 95
temperature
seal air differential
mbar 20mbar
pressure
Inert steam
MPa 0.4～0.6
pressure
Lubricant oil
temperature of ℃ 90 100
grinder roll
4.9.10.2.5 Boiler pump operation parameter limit
Differential pressure of
1 kPa ＞60KPa ＜60KPa ＜60
pump outlet and inlet
2 HP cooling water flow m³/h ＞10 8.6 ＜7
3 LP cooling water pressure kPa 0.4 0.2
Screen differential
4 pressure of water injection MPa ＜0.025 0.145
cooler
Water injection screen
5 differential pressure of MPa ＜0.172 0.655
single pump
LP cooling water
6 ℃ 30 ≤37.8
temperature at the inlet
LP cooling water
7 ℃ ≤44.5
temperature at the outlet
127
Motor chamber
8 ℃ 4～60 60 65
temperature
4.9.10.3 Steam and water quality standards
Title Item Unit Setting value
hardness umol/L ≤1.0
pH 8.8～9.5
Oxygen content μg/L ≤6.3
Conductivity μs/cm ≤10

Water supply
Fe ug/L ≤50
Cu ug/L ≤10
SiO2 μg/kg ≤100
Na+ μg/kg ≤100
PH 9.0～10.5
PO43- mg/L 1～3

Boiler water
SiO2 μg/kg ≤3
Conductivity μs/cm ≤60
Na+ μg/kg ≤10
SiO2 μg/kg ≤20

Saturated,
Conductivity (25℃) μs/cm ≤0.3
superheat steam
Fe μg/L ≤20
Cu μg/L ≤5
4.9.11 Equipment periodic working

4.9.11.1 Periodic working of normal operation
Operating
SN Item date Shift supervisor requirement
staff
At the
Once at Vice duty Normal lighting and
1 Thermal signal test shift --
each shift staff sounds.
handover
At 600MW working
condition or the
corresponding
At the working condition
Drum water level Once at Vice duty
2 shift Inspector required at main
gauge correction each shift staff
handover steam pressure
13.0MPa, water
level gauge
deviation is less
128
Operating
staff
than 30mm.
In accordance with
At the device indication,
Four tube leakage Once at Vice duty
3 shift Inspector record the “Norma”,
device inspection each shift staff
handover “Over limit” or
“Warning” .
In-Process check if
Burner, OFA cyclone the swing is normal,
Once at Vice duty
4 elimination swing Duty staff and the DCS
each shift staff
angle test indication is
corresponding.
In
accordance
Boiler periodic Vice duty Ensure boiler water
5 with Duty staff
drainage staff quality qualified.
chemical
requirement
The operating staff
Once long contacts with the
Morning Vice duty
sootblowing Duty staff manufacture timely,
shift staff
every day enhances the
monitoring.
Night shift
Three times
6 Boiler sootblowing Afternoon The operating staff
short Vice duty
shift Duty staff enhances the
sootblowing staff
monitoring.
every day Evening
shift
Random The operating staff
Air reheator Vice duty
at every Duty staff enhances the
sootblowing staff
shift monitoring.
Once Morning Vice duty In-process
7 AB、CD oil gun purge duty staff
everyday shift staff inspection
Drum water level
Each Vice duty
8 gauge in-site flush at Night shift Inspector Clean flush
Sunday staff
A,B side
Over-high or Contact the thermal
On 13th,
over-low level Morning staff, cut down
9 28th of each duty staff Duty chief
warning test of shift drum water level
month
drum water level automatic method.
Standby oil pump
Afternoon Vice duty The inspector
10 startup test of A, B Each Friday duty staff
shift staff checks in site.
Primary fan
Tightness test of fuel On 10th of
Morning The inspector
11 oil supply and return each duty staff Boiler chief
shift checks in site.
tripping valve month
Electrical loop test of On 10th of Morning Close the manual
12 duty staff Boiler chief
PCV valve each month shift gate of PCV valve
129
Operating
staff
and ensure the

normal operation of
manual switch of
PCV solenoid valve
DC flame detection On 6th of Afternoon Vice duty The inspector
13 duty staff
fan switch each month shift staff checks in site.
On 7th and
A, B draught fan air Afternoon Vice duty The inspector
14 22th of duty staff
cooler switch shift staff checks in site.
each month
On 8th of
Afternoon Vice duty The inspector
15 Seal fan switch every duty staff
shift staff checks in site.
month
Stop one
at the
valley,
Pulverizing system Once every Vice duty Operate 10h at
16 start duty staff
switch week staff least
another
one at the
peak,
Standby oil pump
startup test of A Each Vice duty The inspector
17 Night shift duty staff
draught fan and A Monday staff checks in site.
suction fan
Standby oil pump
startup test of B Each Vice duty The inspector
18 Night shift duty staff
draught fan and B Wednesday staff checks in site.
suction fan
Take the sampling
Fly ash and slag Once Morning Vice duty at morning shift and
19 Inspector
sampling everyday shift staff send to chemical
laboratory.
When the boiler
can’t properly put
Furnace coal, the oil for stable
Every duty Vice duty
20 pulverizing coal Inspector combustion or is
shift staff
sampling forced to reduce the
output due to poor
coal quality
Before the Ignite the boiler
Leakage test of fuel
21 boiler duty staff Boiler chief after it passes the
oil system
ignition test.
The production
Safety valve test of technology
boiler drum, Once every department
22
superheator, year arranges the plan
reheator and the operating
staffs cooperate.
23 Oil filter switch Morning Vice duty duty staff Oil filter front and
130
Operating
staff
shift staff back differential

pressure ≥0.05MPa
On 9th and
Air compressor Evening Vice duty The inspector
switch shift staff checks in site.
each month
On 9th and
Air compressor drier Evening Vice duty The inspector
switch shift staff checks in site.
each month
Water drainage of Once at
26 Inspector —— Drain cleanly.
gas tank every shift
Water drainage of
the aftercooler, oil
Once at
and dust removal
27 every 2 Inspector —— Drain cleanly.
filter, gas-liquid
hours
separator and main
tube
Once at
Water drainage of
28 every 2 Inspector —— Drain cleanly.
the drier
hours
Complete inspection
Once at
29 of air compressor Inspector —— Carefully inspect
every hour
system equipment
Night shift：02:00---08:00
Morning shift：08:00---14:00
Afternoon shift：14:00---20:00
Evening shift：20:00---02:00
4.9.11.2 Works before and after equipment maintenance
No. Title Requirement
Full sootblowing of boiler proper and
1 Taking place before unit outage
preheater
2 Water flushing of preheater Taking place after unit outage
Main protection test of the unit, boiler and Carry out after the unit overhaul and current
3
power supply maintenance
Interlock and protection test of all auxiliary Carry out after the unit overhaul and current
4
equipments maintenance
Carry out after the unit overhaul and current
5 Electrical door and pneumatic door test
maintenance
6
7
Safety valve correction of boiler steam and Carry out after the unit overhaul or safety valve
8
water system regulation
9 Once at every six years
131
Carry out after the unit overhaul or the
10
adjustment of speed governing system
11 Unit thermal test Before and after the unit overhaul
12 Boiler efficiency test Before and after the unit overhaul
At every three months and after unit overhaul
13 Air leakage test of the air preheator
and current maintenance
Actual drive test of drum water level Carry out after the boiler overhaul and current
14
protection maintenance and before the startup.
After the boiler overhaul and current
15 Boiler water pressure test maintenance or leakage repair of the heating
surface
16 Boiler safety valve correction test After the boiler overhaul
5 Interlocking protection and test

5.1 Boiler interlocking protection
5.1.1 Boiler MFT main protection
Boiler Main Fuel Trip
MFT Test (soft circuit
circuit))
Interlock Conditions Execution Action Results
MFT soft trip button
All FDF stop, lasting for 1s
All IDF stop, lasting for 1s
All PAF stop, and at lest one coal mill in operation
All air preheaters stop, lasting for 10s
All boiler circulating pumps fail (stop or inlet/outlet
differential pressure ＜68.6kPa), lasting for 5s
Drum water level (intermediate value of three
points)HHH＞254mm
points)LLL＜﹣381mm
Two selected from three furnace pressures HH
（﹢3300Pa）
Two selected from three furnace pressures LL（﹣
2450Pa）
All fire detection cooling fans stop or Two
selected from three outlet pressures LLL (＜ MFT action and interlock
3.23kPa)，lasting for 10s or other equipments
Total air amount ＜30%MCR (780t/h), lasting for
3s
Turbine tripping and unit load ＞66MW
All fuel oil fire detection lost (two selected from
four corners in one layer have no fire detection)
and all coal layers have no fire detection, (one
132
layer has no fire detection, i.e. two selected from
four corners have no fire detection), and boiler
fire extinguishing successfully memorized (i.e.
two selected from four corners in any fuel oil layer
have fire detection);
All oil fuel loss, (all oil angle valves closed or OFT
closed) and all coal fuels lost, (coal fuel in one
layer lost, i.e. coal mill stops or the outlet valves
at four corners closed), and boiler fire
extinguishing successfully memorized;
After initial boiler fire extinguished, ignition fails
for three times
Circuit))
MFT Test (Relay Circuit
MFT soft trip button pressed
All FDF stop, lasting for 1s
All IDF stop, lasting for 1s
All PAF stop, and at least one coal mill in
operation
All air preheaters stop, lasting for 5s
All boiler circulating pumps fail (stop or inlet/outlet
differential pressure＜68.6KPa), lasting for 5s
points)HHH＞254mm
points)LLL＜﹣381mm
Two selected from three furnace pressures HH
（﹢3300Pa）
Two selected from three furnace pressures LL（﹣
2450Pa） Mount two MFT sensors in
All fire detection cooling fans stop or Two MFT relay circuit, trip the
selected from three outlet pressures LLL (＜ MFT relay circuit, trip coal
mill, stop coal feeder,
3.23kPa), lasting for 10s
close OFT valve, close
Total air amount ＜30%MCR, lasting for 3s superheater and
or reheaeter water spray
Turbine tripping and unit load＞60MW electric valve, stop ESP
All fuel oil fire detection lost (three selected from and sootblowing system;
four corners in one layer have no fire detection)
and all coal layers have no fire detection, (one
layer has no fire detection, i.e. three selected
from four corners have no fire detection), and
boiler fire extinguishing successfully memorized
(i.e. three selected from four corners in any fuel
oil layer have fire detection);
133
All oil fuel loss, (all oil angle valves closed or OFT
closed) and all coal fuels lost, (coal fuel in one
layer lost, i.e. coal mill stops or the outlet valves
at four corners closed), and boiler fire
After initial boiler fire extinguished, ignition fails

for three times
Operator Station Manual Button
MFT Reset State (soft circuit and relay circuit)

No any one of MFT conditions
MFT circuit reset and MFT
Furnace purging completed
and relay circuit reset
MFT reset button pressed
(Soft Circuit) MFT Test Action
After MFT action Results
Tripping of coal mill A, B, C, D, E, F
Close fuel trip valve
Close all fuel angle valves
Close primary attemperating water valve of superheater on the side A &B
Close secondary attemperating water valve of superheater on the side A &B
Close attemperating water valve of reheater
Tripping of PAF A&B
Tripping of ESP A&B
Tripping of coal feeder A, B, C, D, E, F
Open fuel return valve
Stop sootblowing system
Tripping of seal air fan A & B
(Hard Circuit) MFT Test Action
After MFT action Results
1)Tripping of coal mill A, B, C, D, E, F
2)Close fuel trip valve
134
3)MFT trip ETS1 passage
4)MFT trip ETS2 passage
5)Close primary attemperating water valve of superheater on the side A &B
6)Close secondary attemperating water valve of superheater on the side A &B
7)Open the reheater attemperating water valve
8)Tripping of PAF A & B
9)Tripping of ESP A & B
10)MFT to FSSS#1
11)MFT to MCS#1
12)MFT to sootblowing steam
13)MFT to turbine bypass system
14)Tripping of coal feeder A, B, C, D, E, F
5.1.2 Boiler Ignition System Trip (OFT) Protection
Oil Fuel Trip (OFT) Test
Oil Fuel Trip and Reset Conditions
Oil Fuel Trip Conditions
Execution
Interlock Conditions Results
Action
MFT
Manual trip Close OFT
OFT valve is closed and not all oil valves are valve, open fuel
closed return valve,
close all oil
OFT valve is not closed, and not all oil valves angle valves,
are closed, Two selected from three fuel close all steam
pressure transfer switch actions ＜0.5 MPa or angle valves,
close all steam
OFT valve is not closed, and not all valves are purging valves
closed, atomized steam pressure ＜0.5 MPa,
lasting for 5s
Oil Fuel Trip Reset
No any OFT conditions
All oil valves are closed;
OFT exists, lasting for 20s;
Oil fuel trip valve is closed;
and Test circuit reset
Oil fuel leakage test OK
Operator manual reset
5.1.3 Coal Mill Interlock Protection

Allowable Starting of Coal Feeder
Interlock Conditions Execution Results
135
Action
Coal mill is running;
Seal air baffle of coal feeder is opened; Allow coal
Outlet baffle of coal feeder is opened; and feeder starting
All outlet baffles of coal mill are opened;

Stopping of Coal Feeder Protection
Execution
Action
Coal feeder is running and the discharge is
blocked, lasting for 30s;
Coal feeder is running, and the belt motor is in
fault, lasting for 10s;
Coal mill stops, lasting for 1s;
Stop coal
MFT or feeder
Outlet baffle of coal feeder is closed, lasting for protection
3s;
All outlet baffles of coal mill are closed;
Allowable Starting of Coal Mill
Execution
Action
No MFT signal;
Any one of PAF in running and and
number of coal mill in running is less (allo
than 3) or all PAF in running w
and coal
Preheater A/B outlet hot primary air
pressure ＞63.5mbar igniti
on)
Preheater A/B outlet hot secondary air
pressure＞177℃
Three of four, oil gun in layer AB is put into
or
operation
Mill B is in operation and coal feeding amount
(Coal
＞50t/h and unit load ＞264MW (note: for mill mill
B, this phrase shall be changed to be Mill A or igniti
Mill C is in running and coal feedin g
feeding on
amount ＞50t/h50t/h and unit load ＞264MW
264MW
264MW) ener
Unit load ＞396MW gy)
Allow
No failure of all fire detector in the corresponding layer an
startup of
of coal mill d
coal mill
No signal indicating coal mill protection stop
Coal mill seal air and bowl bottom, differential pressure
＞20mbar, coal mill seal air baffle opened, and the
mill seal air exhaust baffle opened
Any one of lubricating oil pumps running and oil
136
pressure＞0.09MPa, lasting for 3min
Coal mill motor bearing temp. ＜75℃,motor stator
temp. ＜110℃, decelerator bearing temp. ＜60℃,
bearing temp. ＜70℃
Coal mill 3/4 outlet baffle opened
Lubricating oil temp. ＞30℃
And
Lubricating oil flow ＞220L/min
(lubricating
Lubricating oil outlet filter differential oil OK)
pressure ＜25bar
Coal mill outlet temperature at 65~82℃
Coal mill inlet valve opened and outlet valve closed
Stopping of Coal Mill Protection
MFT
All PAF stop, lasting for 1s;
All lubricating oil pumps stop, or
lasting for 2s; (lubricating
Lubricating oil pressure is low oil system
LL, lasting for 2s; is in fault)
Coal mill motor temperature ＞95℃

Coal mill motor stator temperature ＞145℃
Coal mill bearing temperature ＞90℃
Coal mill decelerator bearing temperature ＞
80℃
Coal mill #1 outlet baffle or
exhaust baffle is closed
Coal mill #2 outlet baffle or Any two
exhaust baffle is closed of the Stop coal mill
four protection,
Coal mill #3 outlet baffle or close mill outlet
items,
exhaust baffle is closed and inlet baffle,
lasting for
2s or open steam fire
Coal mill #4 outlet baffle or
valve of the mill
exhaust baffle is closed
All seal air fans stop, lasting for 10s;
Seal air and bowl bottom differential pressure
＜20mbar, lasting for 10s
Coal mill fuel loss (when the coal mill and coal
feeder are in operation, open the outlet baffle
of coal feeder for 60s or 180s, with each vent
valve opened, and no fire detector at four
corners 【three from four】), lasting for 10s
Lubricating oil pump outlet oil temperature ＞
65℃
137
Coal feeder is running, lasting for 10s，and coal
mill inlet cold & hot primary air mixture flow ＜
90t/h
Coal mill outlet temperature ＞93℃
Coal Mill Lubricating Oil Station
Execution
Action
Coal mill lubricating oil tank oil level ＞200mm Allow
and lubricating oil
Coal mill lubricating oil tank oil temperature ＞ pump A or B
25℃ starting
Coal mill lubricating oil pump interlock
is input;
and
Coal mill is in running, and lubricating
oil pump stops;
Coal mill lubricating oil pump interlock
is input;
and or Automatically
Lubricating oil pump running for 25s,
start the
in oil pressure ＜0.09MPa
standby
Coal mill lubricating oil pump interlock lubricating oil
is input; pump
and
Lubricating oil pump running for 25s,
in oil flow ＜0.22m³/min
Coal mill lubricating oil tank heater interlock is
input;
Automatically
Coal mill lubricating oil tank oil level ＞200mm start the
and
Coal mill lubricating oil tank oil temperature ＜ lubricating oil
35℃ tank heater
Coal mill lubricating oil tank interlock is Automatically

switched on; stop the
and
lubricating oil
Coal mill lubricating oil tank oil temp. ＞40℃ tank heater
Execution
Action
Automatically
close the inlet
baffle of coal
feeder and the
Coal feeder stops, lasting for 1s;
coal feeding
amount is
indicated as
11t/h;
Automatically
Coal mill stops, lasting for 1s; stop the coal
feeder
138
5.1.4. IDF Interlocked Protection
IDF trips in case of any one of the following conditions:
No. Description Remark
1 MFT and 2/3 furnace pressure ＜﹣2540Pa Lasting for 3s
2 All air preheaters stop; Lasting for 5s
3 IDF is running for 20s with flue gas inlet baffle not opened;
4 IDF is running for 10s with flue gas outlet baffle closed;
5 IDF bearing temp. ＞90℃
6 IDF motor bearing temp. ＞90℃
7 IDF motor stator coil temp.＞130℃
8 All IDF lubricating oil pumps stop; Lasting for 3s
9 Vibration value HH ＞7.1m/s
10 All cooling air fans stop; Lasting for 10s
IDF alarms in case of any one of the following conditions:

1 IDF vibration ≥5KPa
2 IDF motor lubricating oil station filter differential pressure ≥100KP
3 IDF motor lubricating oil system has major fault;
4 IDF motor lubricating oil system is normal;
5 IDF lubricating oil system outlet pressure is low L; ＜1bar
6 IDF lubricating oil system temperature is high H; 45℃
7 IDF motor lubricating oil system oil tank oil level is low L;
8 IDF motor lubricating oil system initializes alarm;
5.1.5. FDF Interlocked Protection

FDF trips in case of any one of the following conditions:
1 MFT and 2/3 furnace pressure ＞﹢3300Pa Lasting for 3s
2 All air preheaters stop; Lasting for 10s
3 All IDF motors stop; Lasting for 1s
4 IDF on one side tripping and IDF on the other side running; Lasting for 5s
5 FDF is running for 20s, with outlet baffle not opened;
6 FDF bearing temp. ＞100℃
7 FDF motor bearing temp. ＞95℃
8 FDF motor stator coil temp.＞130℃
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9 All FDF lubricating oil pumps stop; Lasting for 3s
10 FDF vibration HH exist (higher than 11mm/s)
FDF alarms in case of any one of the following conditions:

FDF hydraulic oil pump outlet/inlet filter differential pressure
1 ≥3.5bar
is high
2 FDF hydraulic oil pressure OK ≥25bar
3 FDF hydraulic oil pressure is low L ＜25bar
4 FDF hydraulic oil pressure is low low LL ＜8bar
5 FDF lubricating oil amount is low L ＜3L/MIN
6 FDF surge sensor differential pressure ＞2KPa
7 FDF hydraulic oil tank oil temperature is normal ＞35℃
8 FDF hydraulic oil tank oil temperature is low L ＜25℃
9 FDF hydraulic oil tank oil level is low L ＜243mm
5.1.6. PAF Interlocked Protection

PAF trips in case of any one of the following conditions:
1 MFT
2 All FDF stop; Lasting for 1s
3 All IDF stop; Lasting for 1s
4 PAF is running for 20s with outlet baffle unopened
5 PAF bearing temp. ＞90℃
6 PAF motor bearing temp. ＞95℃
7 PAF motor stator temp. ＞130℃
All PAF lubricating oil pumps stop, or oil pressure/oil flow is
8 Lasting for 3s
low;
9 All PAF hydraulic oil pumps stop; Lasting for 3s
10 PAF vibration HH exists ( higher than 11mm/s)
PAF alarms in case of any one of the following conditions

PAF hydraulic oil pump outlet/inlet filter differential pressure
1 ＞3.5bar
is high;
2 PAF hydraulic oil pressure is normal; ＞25bar
3 PAF hydraulic oil pressure is low L;
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4 PAF hydraulic oil pressure is low low LL; ＜8bar
5 PAF lubricating oil flow is low L ＜3L/min
6 PAF hydraulic oil tank oil temperature is normal; ＞35℃
7 PAF hydraulic oil tank oil temperature is low L; ＜25℃
8 PAF hydraulic oil tank oil level is low low LL ＜243mm
9 PAF surge sensor differential pressure ＞2kPa
10 PAF lubricating oil station is normal;
11 PAF lubricating oil station has major fault;
12 PAF lubricating oil station has minor fault;
13 PAF lubricating oil station - pressure is normal; ＞0.2MPa
14 PAF lubricating oil station - differential pressure is high;
15 PAF lubricating oil station - oil flow is low;
16 PAF lubricating oil station - outlet oil temperature is high;
17 PAF lubricating oil station - pressure is low;
18 PAF lubricating oil station - oil level is high;
19 PAF lubricating oil station - oil level is low;
5.1.7. Air Preheater Interlock Protection

Allowable Startup Conditions of Air Preheater Main Motor
Air preheater is in remote control mode;
Auxiliary motor of air preheater stops;
No signal indicating main motor sensor Allow main motor
and
error starting
Air preheater has no fire alarm;
Allowable Stopping Conditions of Air Preheater Main Motor
Air preheater inlet flue gas temperature
lower than 150℃
Auxiliary motor is in interlocked status
and in remote control mode, and no Allow main motor
or
signal indicating sensor error stopping
All IDF stop;

Air Preheater Main Motor Stand-up for Service
Main motor speed
Main motor interlock button is pressed; sensor tracks the
auxiliary motor speed
and
Auxiliary motor must be in running
(disconnected, lasting for 5s)
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Automatic Starting of Air Preheater Main Motor
Main motor interlock button is pressed Allow automatic
and
Auxiliary motor stops, lasting for 1s; starting of main motor
Allowable Starting of Air Preheater Auxiliary Motor

Air preheater is in remote control mode;
Air preheater main motor stops;
No any signal indicating auxiliary motor Allow starting of
and
sensor error; auxiliary motor
Air preheater has no fire alarm;
Allowable Stopping of Air Preheater Auxiliary Motor
Air preheater inlet flue gas temperature
under 150℃
Main motor is in interlocked status and
in remote control mode, and no signal Allow auxiliary motor
or
indicating sensor error; stopping
All IDF stop;

Air Preheater Auxiliary Motor Stand-up for Service
Auxiliary motor interlock button is
pressed; Auxiliary motor speed
sensor tracks the
Main motor must be in running and main motor speed
(disconnected, lasting for 5s)
Automatic Starting of Air Preheater Auxiliary Motor
Interlocking is input; Allow automatic
and starting of auxiliary
Main motor stops, lasting for 1s; motor
Interlocking of Air Preheater Baffle
Automatically open the air
preheater flue gas inlet
baffle, secondary air outlet
Air preheater running; baffle and primary air outlet
baffle
5.1.8 Superheator, reheator tube wall temperature protection

No Protection content Remark
Low superheater vertical section tube wall temperature up to
1 Alarm
442℃
2 Partition screen tube wall temperature up to 542℃ Alarm
3 Back-screen superheator tube wall temperature up to 575℃ Alarm
142
4 End-class superheator tube wall temperature up to 582℃ Alarm
5 End-class reheator tube wall temperature up to 634℃ Alarm
5.1.9 Relevant protection on sootblowing system
SN Protection content Remark
1 Sootblowing steam main tube low to1.5MPa Alarm
2 Sootblowing steam main tube up to 3.5MPa Alarm
Rated value of body sootblowing and water draining
3
temperature 235℃
Rated value of air preheator sootblowing and water draining
4
temperature280℃
5.1.10 Boiler pump interlocking protection
When any following case occurs, the boiler pump trips:
1 Motor chamber temperature≥60℃
All cooling water pumps stopping and emergency pump
2
stopping, lasting for 10s
Boiler pump casing and inlet pipeline differential metal
3
temperature＞50℃, lasting for 5s;
All cooling water pumps stopping and emergency cooling
4
water pump stopping, lasting for 10s
5 Emergency button pressed
When any following case occurs, the boiler pump alarms:
1 Motor chamber temperature≥60℃ Alarm
2 LP cooling water halting or lower than 70% of rated water flow Alarm
cooling water flow in boiler pump motor chamber＜70%
3 Alarm
(7.7m³/h)
4 Inlet and outlet differential pressure of any pump＜70kPa Alarm
Inlet and outlet differential pressure of less than two pumps to Reducing the load to
5
more than 112.5kg/cm2 60% of BMCR
Furnace Booster Pump Interlocked Protection

Linked to opening of
1 Emergency furnace booster pump operating
outlet valve
Linked to closing of outlet
2 Emergency furnace booster pump stopping or tripping
valve
Linked to starting of
3 Running cooling water booster pump tripping
standby pump
143
Two sets of booster pump tripping or two sets of running Linked to starting of
4
cooling water pump being of low pressure emergency booster pump
Linked to tripping of
5 All closed water pump tripping cooling water booster
pump
5.1.11. Seal Air Fan Interlocked Protection

Seal air fan tripping in one of the following conditions:
No. Protection Content Remark
1 MFT
2 All PAF stop Lasting for 3s
3 Seal air fan operates and outlet baffle closed lasting for 20s
Seal air fan alarming in one of the following conditions:

1 Seal air main pipe pressure is lower to 12kPa Linked to standby air fan
2 Seal air fan tripping Linked to standby air fan
Seal air fan inlet filter front & rear differential pressure ＞
3
1.2kPa
5.1.12. Air Compressor Interlocked Protection

Instrument compressor A - interlock startup
Execution
Interlock Startup Conditions Results
Action
Instrument compressor B -
tripping
or
Instrument compressor C -
tripping Linked to
and startup of
Instrument compressor outlet main pipe pressure or instrument
＜7bar compressor
A
Instrument compressor B or C operates
Instrument compressor outlet main pipe pressure and
＜6.2bar
Instrument compressor B – interlock startup conditions
Execution
Action
Instrument compressor A -
Linked to
tripping
startup of
Instrument compressor C - or and instrument
tripping or compressor
144
Instrument compressor outlet main pipe pressure
B
＜7bar
Instrument compressor A or C operates
＜6.2bar
Instrument compressor C– interlock startup conditions
Execution
Action
Instrument compressor B –
tripping
Instrument compressor A - or
tripping Linked to
and startup of
Instrument compressor outlet main pipe pressure or instrument
＜7bar compressor
C
Instrument compressor B or A operates
＜6.2bar
Opening of Contact Valve for Instrument/Maintenance Air Compressor
Execution
Action
All instrument compressor stop, lasting for 5s
Any one maintenance compressor operates Linked to

Maintenance compressor outlet main pipe opening of
pressure＞Instrument compressor outlet main pipe contact
pressure, i.e. ＞7bar valve
and
Instrument compressor outlet main pipe pressure
＜6.2bar
Maintenance Air Compressor
Maintenance Air Compressor A – interlock startup conditions
Execution
Action
Maintenance air compressor Linked to
B - tripping startup of
or compressor
Maintenance service air A
compressor C- tripping
Maintenance Air Compressor B – interlock startup conditions

Execution
Action
A - tripping or startup of
Maintenance air compressor compressor
145
C - tripping B
Maintenance Air Compressor C – interlock startup conditions
Execution
Action
A - tripping startup of
or
Maintenance air compressor compressor
B - tripping C
5.1.13.. Boiler Main Interlock

Coal Mill Tripping Interlock Test
Execution
Action
Linked to stop
Coal mill tripping, lasting for 1s; of
corresponding
coal feeder
Seal Air Fan Tripping Interlock Test
Execution
Action
Seal air fan A - tripping Lasting for 10s,
linked to
and shutdown of all
Seal air fan B - tripping coal mills and
coal feeders
PAF Tripping Interlock Test
Execution
Action
Two PAF operate, disconnection lasting for 2s; In RB mode,
and stop mill F, E, D
One PAF tripping in sequence
PAF A - tripping Lasting for 1s,
linked to stop of
all coal mills,
PAF B - tripping and coal feeders
and seal air
fans
FD
FDFF Tripping Interlock Test
Execution
Action
All FDF operate, disconnection lasting for 2s; In RB mode,
and stop mill F, E, D
One FDF tripping in sequence
FDF A - tripping Lasting for 1s,
146
and linked to
shutdown of all
FDF B - tripping PAF, coal mills,
coal feeders
and seal air
fans
IDF Tripping Interlock Test
Execution
Action
Two IDF operate, disconnection lasting for 2s; Lasting for 1s,
linked to
shutdown of
corresponding
and
One IDF tripping FDF; in RB
mode, stop mill
F, E, D in
sequence
IDF A - tripping Lasting for 1s,
linked to stop of
all FDF, PAF,
IDF B - tripping and coal mills, coal
feeders and
seal air fans
Air Preheater Tripping Interlock Test
Execution
Action
Air preheater A & B operate, disconnection Linked to stop
lasting for 15s; of
and corresponding
One air preheater main & auxiliary motor IDF, FDF and
tripping, lasting for 10s; PAF
Air preheaer A – main & auxiliary motor stop at Lasting for 10s,
the same time linked to stop of
all FDF, IDF,
PAF, coal mills,
Air preheaer B – main & auxiliary motor stop and coal feeders
at the same time and seal air
fans
5.1.14. Fire Detection Cooling Air Fan Interlock Test
Fire Detection Cooling Air Fan Test
Equipment checked: AB fire detection cooling air fan
Execution
Allowable Stop Conditions Results
Action
Main fuel trip (MFT), lasting for 60min Fire detection
cooling air fan A
Fire detection cooling air fan A or B operation or or B stops
Execution
Action
147
Fire detection cooling air fan A or B is in
interlock status
Fire detection cooling air fan A or B Inked to start
stops fire detection
and
Fire detection cooling air fan A or B cooling air fan A
or or B
operates, and cooling air main pipe
pressure low L ＜5.6kPa
Fire Detection Cooling Air Fan Alarming
Resul
NO. Description Values
ts
Fire detection cooling air fan A – inlet/outlet differential
1 ＞3.7kPa
pressure high
Fire detection cooling air fan B inlet/outlet differential
2 ＞3.7kPa
pressure high
3 Fire detection cooling air fan outlet main pipe pressure LL1 ＜3.23 kPa
6 Fire detection cooling air fan outlet main pipe pressure L ＜6 kPa
5.2 Unit test

5.2.1. Acceptance check after maintenance
5.2.1.1 There shall be abnormal moving report for alteration of equipment system after overhaul
and regular repair.
5.2.1.2 The operating staffs shall join in the work of acceptance check during each system and
equipment trial operation, and during trial operation, detailed review about the devices shall be
taken and the work-sheet procedure could be done and they should be done well only after the
acceptance check is completed.
5.2.1.3 If any equipment defect is found during the acceptance inspection, which cannot ensure
the safe operation of the units, report to the maintenance staffs. Eliminate the equipment defects
before putting into operation and input the defects into the management computer for the archives.
5.2.1.4 Remove the temporary facilities for maintenance and restore original facilities. Keep the
site clean, all channels clear, railings complete, lighting good, heat insulation complete, the
supports and hangers integrated and fast.
5.2.1.5 The units, each auxiliary system and equipments are complete, and there is no debris
inside the equipments.
5.2.1.6 The connection of pipeline valves is in good condition; the valves are flexibly opened and
closed; hand wheels are integrated and the nameplates are complete with paint color and signs for
flow direction in line with Technical Management Code for Electric Power Industry.
5.2.1.7 Check if the opening and closing of each fire observing hole, man hole and inspection hole
are flexible and the tightness is good after closing.
5.2.1.8 Control panel in central control room, in-site control panel and cabinet and so on shall be
complete and integrated; the indication of each indicator is correct and can be used; sound and
light alarm device is in good condition. Each meter, keyboard, operating handle, push button and
so on are integrated and in good condition; CRT display is clear and there are reliable indoor
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emergency lighting.
5.2.2 General test rules
5.2.2.1 The protection and interlocking test for main and auxiliary equipments shall be taken first
after the unit overhaul and minor repair, and the device is allowed to take test run and put into
operation only after the test is passed.
5.2.2.2 During each test, implement strictly in accordance with the requirements of test measure.
5.2.2.3 Carry our relevant tests after qualified in temporary failure maintenance, maintenance of
protection and interlocking components and loop maintenance; shut down the boiler for
maintenance of other protection and interlocking.
5.2.2.4 Test all local and remote electric valves, pneumatic valve, servo, remote and close control
system, and record the opening and closing time. Don’t test the operating system and
pressure-bearing electric valves and regulating valves.
5.2.2.5 Test methods are divided into static state and dynamic state method: during static test,
only provide test power supply for auxiliaries above 6kV, operation power supply for some
low-voltage power of 400V; during dynamic test, provide both of test power supply and operation
power supply. Carry out the dynamic test after passing static test.
5.2.2.6 Before unit and equipment interlocking protection test, thermal personnel shall meet
relevant conditions. Before equipment interlocking test, carry out manual startup and shutdown
test in situ and central control room, and make sure that it's eligible.
5.2.2.7 Make sure that each interlock, protection test operation and audible and visual alarms are
normal, each light indication and graphic displays are correct.
5.2.2.8 During normal unit operation, carry out periodic test after stability of unit operation and
follow strictly operation orders. Take the isolating measure for testing the equipment in operation,
and do not affect the safety of operating devices. Foresee the possible results of accident during
the test.
5.2.2.9 Resume mandatory condition after the test, and put reliably relevant protection interlocking,
do not change randomly without stated approval process.
5.2.2.10 After the test, do the recovery work of systems and equipments; check the protection
values, analyze test results and prepare the detailed record.
5.2.2.11 After the test, shut down the power supply to each device. Take the maloperation
protection measure if the power supply is not off; switch the switches of the startup equipments to
RMT mode.
5.2.3 Unit test
5.2.3.1 Unit interlocking protection test
Carry out the interlock protection test of devices and system after meeting all test conditions
(thermal staff mandatorily implement if not), thermal staffs simulate different kinds of interlocks,
operating condition of tripping to observe the operation and alarm.
5.2.3.2 Electric door (baffle plate) and pneumatic door (baffle plate) test
Confirm the correct turning of electrical door (baffle plate), correct opening/closing of pneumatic
door (baffle plate) and correct indication of light signal. Write down the opening/closing time of
each door (baffle plate) and dead area of the action.
5.2.3.3 Trial operation of rotational machine
5.2.3.3.1 Procedure for trial operation of rotational machine:
1) Confirm the correct rotation direction;
2) As for the newly installed rotational machines, continuously operate not less than 8 hours after
the startup; operate not less than 2 hours of trial operation after overhaul and minor repair.
3) During the trial operation, the operating staffs are responsible for the operation, and the
149
maintenance staffs are responsible for inspecting and observing trial operation of rotational
machines. Immediately shut down the machines if abnormal.
4) After the startup of rotational equipments, step up the load to the rated value, and keep the
current of electric motor not exceed the rated value;
5) Hand over the equipments for operation after qualification of trial operation; record the
handover.
5.2.4 Boiler hydraulic test
5.2.4.1 Purpose of boiler hydraulic test
The purpose of hydraulic test is to check the tightness of boiler pressure-containing components
and find if there is any deformation and damage, and ensure safe, stable and reliable operation of
the boiler.
5.2.4.2 Hydraulic test condition
5.2.4.2.1 Carry out hydraulic test for rated operating pressure after boiler overhaul and minor
repair or leakage maintenance of heating surface;
5.2.4.2.2 Carry out super hydrostatic test if the boiler shows one of the following cases:
A) Carry out super hydrostatic test one at every 6 years after boiler putting into operation (after
overhaul);
B) New installation or remove of the boiler;
C) Boiler shutdown for one year before putting into operation;
D) More than 50%of total replacement numbers of water wall tube and boiler tube;
E) After larger area welding maintenance of boiler pressure-bearing components outside heating
surface tube (if super hydrostatic test is separately taken for the pressure-bearing component, the
hydraulic test is not required);
F) After replacement of all superheated tubes or economizer tubes;
G) After replacement of steam drum, superheater header or water wall header (if one separate
hydraulic test is taken for the component before installing on the boiler, then the super hydrostatic
test for the boiler is not needed);
H) After the finishing of uneven area of main parts of the boiler (such as steam drum, superheater
header, water wall header and others).
5.2.3.4.3 Pressure provision for hydraulic boiler test (unit: MPa)
The pressure of super hydrostatic test for water wall and superheater is 1.25 times of steam drum
working pressure; the pressure of super hydrostatic test for reheaher is 1.5 times of the pressure
at the inlet of the reheater.
Super hydrostatic
System Design pressure Hydraulic test pressure
test pressure
Superheated steam and
19.9 19.9 29.45
water system
Reheating steam
4.6 4.6 6.9
system
5.2.4.4 Water cubage for each pressure-bearing component of the boilers (unit: m3)
Steam Water wall and
Item Economizer Superheater Reheater Total
drum connector
Water
80 66 176 240 238 800
space
150
5.2.4.5 Scope of hydraulic boiler test
5.2.4.5.1 System of economizer, steam drum, water wall, water pump of the boiler and
superheater system: from the outlet of self-feeding pump to the closure plate for hydraulic test of
steam piping at the outlet of superheater or to the front of main steam valve of steam turbine .
5.2.4.5.2 Reheater system: from the back of baffle for hydraulic test of steam piping at the inlet of
cold section of the reheater to the section in front of baffle for hydraulic test of steam piping at the
outlet of cold section of the reheater.
5.2.4.5.3 The evacuation tube attached to pressure-bear components of boiler body, drain tube
and relevant secondary valve.
5.2.4.5.4 Other attached pipeline of the boiler: from sootblowing, sampling, draining, chemical
dosing, desuperheating water pipeline to relevant primary valves.
5.2.4.5.5 Only working pressure hydraulic test for drum local water level gauge and no super
hydrostatic test.
5.2.4.6 Inspection and preparation before hydraulic boiler test
5.2.4.6.1 Check and make sure that maintenance work of boiler steam and water system related
to hydraulic boiler test has been finished and operation order has ended.
5.2.4.6.2 Make sure that local pressure meter with 0.5 precision has been installed at the outlets of
steam drum and reheater, and outlet pressure indication has already corrected.
5.2.4.6.3 Make sure that required means of communication are ready.
5.2.4.6.4 Take the measures to prevent popping when the pressure of boiler safety valve reaches
to 85% of rated pressure; keep the control switch of electric relief valve at “OFF” position to
prevent it from opening during hydraulic test.
5.2.4.6.5 Check and make sure that boiler steam water and system has been isolated from steam
turbine; open drain valves behind main steam valve of steam turbine, drain valves before and
behind no-return check valve and drain valves above and downward intermediate pressure main
stop valve.
5.2.4.6.6 Keep generally the environmental temperature above 5℃ during hydraulic test.
5.2.4.6.7 Adopt the de-mineralized water or condensate water after ammoniating and hydrazine
water in hydraulic test, and the water quality requirement is as follows:
Ammonia Hydrazine Visible solid
Item Chloride ion Iron chloride Ph value
concentration concentration matters
Standard 10 ppm 200 ppm 25 ppm 100 ppb About 10 < 1 ppm
5.2.4.6.8 Keep the temperature of boiler feed water not below 21℃ and not too high as well,
prevent the vaporizing and oversized temperature stress, and control the wall temperature of
steam drum at less than 50℃.
5.2.4.6.9 Before the entry of boiler feed water, check and make sure the valves of boiler steam
water system in good condition according to valve check cards.
5.2.4.7 Qualification standard for hydraulic boiler test
5.2.4.7.1 Make sure there is trace of no water and water mist on metal wall and welding line of
components for hydraulic test.
5.2.4.7.2 Make sure no obvious residual deformation of pressure parts after macro-inspection.
5.2.4.7.3 Keep the pressure drop of economizer, water wall and superheater system not bigger
than 0.5MPa / 5min, and the pressure drop of reheater system not bigger than 0.25MPa / 5min.
5.2.4.8 Operation procedure for reheater hydraulic test and super hydrostatic test
5.2.4.8.1 Inform thermal staffs to put outlet and inlet pressure meters, and open the primary valve
151
of each pressure meter.
5.2.4.8.2 Add the baffle at the inlet and outlet tube of the reheater, close medium pressure main
stop valve, no-return check valve and high and low-pressure bypass valve.
5.2.4.8.3 Check and make sure all valves of reheater system at hydraulic test position.
5.2.4.8.4 Switch on electric valve of water desuperheating of the reheater, start up electric pump
and open water valve of center tap at the middle of electric pump to feed water, control water
feeding speed through desuperheating water regulation valve of the reheater, shut off after
continuous water flowing from air valve.
5.2.4.8.5 Increase the pressure by rotation number of electric pump and desuperheating water
electric valve of the reheater, and keep the pressure increasing rate not exceeding 0.3mpa / min.
5.2.4.8.6 Stop the pressure increasing while the inlet pressure of the reheater reaching to 4.6MPa,
shut down desuperheating water electric valve of the reheater and the regulating valve of
desuperheating water, keep it for 5 minutes and record the pressure dropping value and take
complete inspection.
5.2.4.8.7 If super hydrostatic test, continue to increase pressure after locking tightly the outlet and
inlet safety valve of the reheater with holding apparatus, keep the pressure speed not exceeding
0.1MPa / min, increase pressure to 6.9MPa and hold on for 20min and then drop it down to
working pressure of 4.6mpa, then check.
5.2.4.8.8 After qualification of hydraulic test, open drain valve in front of the desuperheater of the
reheater for decompression, and keep the decompression speed not exceeding 0.5MPa / min.
5.2.4.8.9 When the pressure drops to zero, open air valve and drain valve to drain water
completely.
5.2.4.9 Operation procedure of hydraulic test and super hydrostatic test for the economizer, water
wall and superheater system
5.2.4.9.1 Inform thermal staff to put each water gauge and pressure gauge and open the primary
door of each pressure gauge.
5.2.4.9.2 Add the baffle at outlet tube of the superheater, shut down high-pressure main steam
valve and high & low pressure bypass valves.
5.2.4.9.3 Fasten safety valve at the outlet of the superheater with holding apparatus, check and
make sure all valves of boiler steam and water system at hydraulic test position.
5.2.4.9.4 Start up electric pump to feed water for the boiler, control water-feeding speed with
adjusting valve of Fw bypass and shut out after water coming out continuously from air valve.
5.2.4.9.5 Boost the pressure with the rotation number of electric pump and adjusting valve of Fw
bypass, control the rate of pressure rising at the speed of less than 0.3MPa / min while the
pressure is under 10.0MPa and keep the speed of 0.2MPa / min while the pressure is above
10.0MPa.
5.2.4.9.6 When the pressure rises to working pressure, stop the pressure boosting and take
preliminary examination, continue the pressure boosting while leak is not detected.
5.2.4.9.7 When the pressure rises to 85% of working pressure, stop pressure boosting and take
complete inspection, continue pressure boosting while leak is not detected.
5.2.4.9.8 Stop the pressure boosting while the inlet pressure of reheater reaches to 19.9MPa, shut
down electric valve, adjusting valve of Fw bypass, hold it on for 5 minutes and record the pressure
dropping value and take complete inspection.
5.2.4.9.9 if super hydrostatic test, split water level in-situ gauge, fasten tightly each safety valve
with holding apparatus, continue pressure boosting with the speed of less than 0.1MPa /.
5.2.4.9.10 While the pressure reaches 29.45MPa, stop the pressure boosting, shut down feed
water valve, stop electric pump, keep on for 20min, then drop to working pressure of 19.9mpa, and
then take the inspection.
152
5.2.4.9.11 After the qualification of hydraulic test, open drain valve for decompression with the
speed at less than 0.5MPa / min; while the pressure drops to zero, open each air valve and drain
valve for dewatering. If the boiler is ready for operation and the water quality is eligible, drain the
water to reach normal water level of steam drum, and drain completely the accumulated water in
the superheater and reheater.
5.2.4.9.12 If the boiler will not be put into operation in short time, while the pressure steps down to
0.5MPa, shut each air valve and drain valve to stop pressure relief, and then take nitrogen-filling
protection, or take other maintenance measure of boiler shutdown.
5.2.4.10 Precaution for hydraulic boiler test
5.2.4.10.1 Unify the command during hydraulic test.
5.2.4.10.2 Implement the hydraulic test in the sequence of low-pressure first and then high
pressure, firstly carry out the hydraulic test for the reheater system and then the hydraulic test for
coal economizer, water wall and superheater system.
5.2.4.10.3 Before water feeding, make sure the valve from tested steam drum to bypass is in good
condition.
5.2.4.10.4 Assign specific staffs to take charge of pressure boosting and take strict precautions
against overpressure. Take the indication of local pressure gauge of steam drum as required
pressure, assign the specific staffs in the control room to observe CRT pressure. Frequently
communicate with each other; while the deviation of pressure indication is large, ask for the
thermal staffs to confirm and correct.
5.2.4.10.5 Keep even and steady of pressure change, strictly control the speed of pressure rising
and avoid it exceeding rated pressure. Regulate the water intake flow slowly and evenly, and
prevent water clash.
5.2.4.10.6 Do not purge manometer tube and sampling tube during pressure boosting.
5.2.4.10.7 During the hydraulic test of economizer, water wall and superheater, monitor closely the
reheater pressure, prevent the reheater from pressure rising or overpressure, and strengthen
monitoring of cylinder temperature of steam turbine.
5.2.4.10.8 Before boiler water filling, put boiler pump to feed water continuously.
5.2.4.10.9 During boiler super hydrostatic test, isolate the heat control gauge, transmitter, local
water level gauges and others, and keep any person away from the boiler body.
5.2.4.10.10 After the completion of boiler water filling, drain out the water in steam tube completely,
dismantle the baffle and restore the system state before the boiler shutdown;
5.2.5 Boiler drum water level protection actual transmitting test.
5.2.5.1 Test conditions and requirements
5.2.5.1.1 After boiler overhaul and repair and before boiler startup, carry out boiler drum water
level protection actual transmitting test.
5.2.5.1.2 After the completion of all boiler maintenance, make sure the boiler is ready for startup.
5.2.5.1.3 Check FSSS loop and make sure it is complete and in good condition.
5.2.5.1.4 After the completion of relevant boiler interlocking protection test, make sure it can be
normally operated.
5.2.5.1.5 Put the drum water level protection in operation.
5.2.5.1.6 Fill water into the boiler to normal water level, inform thermal staffs to implement boiler
drum water level protection actual transmitting test.
5.2.5.2 Test procedure
5.2.5.2.1 Split the MFT protection of high drum water level and split MFT protection of low drum
water level.
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5.2.5.2.2 The operating staffs shall take local water gauge (or electrical probe water level gauge)
as second maximum water level of boiler water filling and drum water level gauge, then control the
water flow and speed of boiler water filling, inform thermal staffs at the same time to prepare for
verifying full water of balance vessel at the side of steam turbine.
5.2.5.2.3 The thermal staffs judge full water of balance vessel with the method of dewater from
side relief pipeline of balance vessel at the transmitter. While the water discharging continuously
from the transmitter, the thermal staffs shall inform the operating staffs in time to stop boiler water
filling.
5.2.5.2.4 The operating staffs reduce the drum water level to normal water level with continuing
continuous drainage or large discharging, and the thermal staffs correct and confirm the indicating
value of differential-pressure water level gauge.
5.2.5.2.5 Put MFT protection of high drum water level.
5.2.5.2.6 According to the requirements of thermal personnel, the operating staffs fill water into the
boiler slowly and implement high boiler drum water level protection actual transmitting test.
5.2.5.2.7 Adjust the boiler feed water, boost slowly the drum water level to ＋127mm according to
drum water level indicated on CRT, alarm window alarms for high drum water level; feed the water
into the boiler continuously and boost slowly the drum water level to ＋254mm, and alarm window
alarms for too high drum water level, and then the boiler MFT starts.
5.2.5.2.8 Check MFT and make sure it works normally, and confirm that the first cause of MFT is
the action of high drum water level protection.
5.2.5.2.9 During the test, while the drum water level exceeds ＋ 254mm, and MFT protection of
high drum water level does not work, stop the boiler water filling and contact the thermal staffs in
time to inspect.
5.2.5.2.10 after the completion of high boiler drum water level protection actual transmitting test,
lower the drum water level to normal water level with continuous drainage or large water
discharging; then implement the low boiler drum water level protection actual transmitting test.
5.2.5.2.11 Put MFT protection of low drum water level into the operation.
5.2.5.2.12 According to requirements of thermal staffs, the operating staffs lower slowly the drum
water level to -178mm, and then alarm window alarms for low drum water level; continue to lower
the drum water level to -381mm, then alarm window alarms for too low drum water level, and then
the boiler MFT starts.
5.2.5.2.13 Check MFT and make sure it works normally, and confirm that the first cause of MFT is
the action of low drum water level protection.
5.2.5.2.14 During the test, while the drum water level is lower than ＋381mm, and MFT protection
of low drum water level does not work, stop the boiler water filling and contact the thermal
personnel in time to inspect.
5.2.6 Boiler safety valve verification
5.2.6.1 Principle of safety valve verification
5.2.6.1.1 Verify relevant value of safety valve after the unit overhaul or maintenance of safety
valve.
5.2.6.1.2 Assign the boiler maintenance chief to host safety valve verification, ask the
maintenance staff for verification and ask for the operating staffs for the operation.
5.2.6.1.3 Make sure that perfect technology and organization measures are available for safety
valve verification.
5.2.6.1.4 The sequence for safety valve verification is that first high pressure valve to low pressure
valve. Verify the drum safety valve, safety valve at the outlet of superheater, safety valves at the
inlet and outlet of the reheater one by one.
5.2.6.2 Prerequisite of safety valve verification
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5.2.6.2.1 After the completion of boiler maintenance, inspect boiler body and auxiliaries before the
startup; make sure to meet the startup requirements.
5.2.6.2.2 Install the communication tools between verification site and central control room.
5.2.6.2.3 Put the bypass system and vacuum system of steam turbine into normal operation, and
keep the vacuum of the condenser in normal.
5.2.6.3 Specification of Safety valves
Set press. Blowdown Capacity

No. Location
MPa.g % t/h
1 Drum No.1 19.95 4 279.846
2 Drum No.2 20.15 5 284.081
3 Drum No.3 20.35 6 288.400
4 Drum No.4 20.55 7 292.807
5 Drum No.5 20.55 7 292.807
6 Drum No.6 20.55 7 520.661
7 SH outlet No.1 18.31 4 178.887
8 SH outlet No.2 18.49 4 180.783
Boiler SH steam maximum evaporation: 2187 t/h

Relieving capacity through drum safety valves: 1958.602 t/h ( 89.56% )
Relieving capacity through SH outlet safety valves: 359.670 t/h ( 16.45% )
Relieving capacity through SHO & drum safety valves: 2318.272 t/h ( 106.00% )
9 RH inlet No.1 4.60 4 208.451
10 RH inlet No.2 4.64 4 210.458
11 RH inlet No.3 4.69 4 212.679
12 RH inlet No.4 4.73 4 214.692
13 RH inlet No.5 4.73 4 214.692
14 RH inlet No.6 4.73 4 214.692
15 RH inlet No.7 4.73 4 258.838
16 RH outlet No.1 4.30 4 162.581
17 RH outlet No.2 4.40 4 164.278
Boiler RH steam capacity: 1839.8 t/h

Relieving capacity through RHO safety valves: 326.859 t/h ( 17.77% )
Relieving capacity through RHI safety valves: 1534.502 t/h ( 83.41% )
Relieving capacity through RHO & RHI safety valves: 1861.361 t/h ( 101.17% )
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5.2.6.4 Verification of safety valve with hydraulic verification device
5.2.6.4.1 Boost drum pressure to 80% of minimum setting pressure of safety valve according to
curve of temperature rising and pressure rising, stabilize unit load and take calibration. Switch the
control switch of electric relief valve to “Off” position.
5.2.6.4.2 After the verification of outlet safety valve of the superheater, switch the control switch of
electric relief valve to “Automatic” position and verify electric relief valve.
5.2.6.4.3 Adopt hydraulic verification device to verify safety valve of the reheater. When the
pressure reaches to 4.0MPa, keep it and verify safety valve.
5.2.6.5 Precaution for verification of boiler safety valve
5.2.6.5.1 While verifying safety valve, strengthen to monitor steam temperature, steam pressure
and water level.
5.2.6.5.2 After the verification of safety valve, record its popping pressure and setback pressure in
detail.
5.2.6.5.3 During the boiler operation, do not increase the popping pressure of safety valve or
fasten tightly with holding apparatus.
5.2.6.5.4 Stop the verification immediately if abnormal during safety valve verification.
6 Accident Treatment
6.
6.11 Accident Treatment principle
6.1.1 If accident occurs, the treatment shall be carried out in the principle of secure person, secure
grid and secure equipment. The duty staff shall lead the unit personnel to treat the accident under
the leadership of duty chief in accordance with the provisions. All orders of duty chief except those
could hurt directly to the people body and equipment shall be implemented immediately, otherwise
the reason of order refusal shall be declared. When the duty chief insists the wrong orders, the
duty staff shall report to the top leadership.
6.1.2 If the accident occurs, the operating staff shall find out promptly main cause of the accident
and eliminate the threat against the safety of persons and equipments, and ensure the normal
operation of equipments with no failure. During the accident treatment, the impact of each step to
relative systems shall be considered carefully to avoid the enlargement of the accident. If
emergency stopping, the service power shall not be lost.
6.1.3 If the unit fails, the operating personnel shall treat the accident in accordance with the
following steps.
6.1.3.1 Make certain the unit failure has occurred in accordance with the parameter changes, CRT
display, equipment interacting, screen alarm, alarm window, failure printing and unit external
phenomena：
6.1.3.1.1 Eliminate promptly the threats against the safety of person body and equipment, split
immediately down the failed equipment if necessary;
6.1.3.1.2 Find promptly out the failure feature, position and scope, and then treat and report;
6.1.3.1.3 Keep the normal operation of the equipment with no failure;
6.1.3.1.4 Report to the duty chief as possible in each stage of accident treatment so as to report to
main control room in time and take correct countermeasure to prevent the accident overspread.
6.1.3.2 After identifying the system and other equipment failure, take measures to maintain unit
operation, resume the normal operation of entire unit as soon as possible.
6.1.3.3 While dealing with the accident, all posts should be information-sharing, under the unified
command of duty chief, close coordinate and promptly deal with the failure in accordance with
regulated procedure and try to prevent the accident enlargement.
6.1.3.4 Deal with the accident quickly and accurately. Repeat the order once after receiving;
promptly report the implementation to the commander after the implementation.
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6.1.4 If the accident or failure is out of this provision, the duty staffs shall make correct judgment
on the basis of their experiences, take actively the countermeasures and deal quickly with. If the
time permits, ask for the duty chief, and deal with the accident under the guidance of duty chief.
6.1.5 During dealing with the accident, in case that it reaches the condition of emergency boiler
shutdown, unit shutdown, but no protect operation responds, immediately adopt manual MFT or
manual tripping; in case the auxiliary equipment reaches the emergency outage condition but no
protection operation responds, immediately stop the operation of auxiliary equipment.
6.1.6 If a sudden unit tripping occurs, resumed the unit operation as soon as possible after the
handle of accident is completed and the cause of the accident is identified.
6.1.7 During the unit failure and the troubleshooting of accidents, the operating personnel are not
allowed to leave their posts. If the accident troubleshooting occurs in handover time, the shift shall
be extended. Before the handover, the shift personnel shall continue to work till the completion or
the interval of accident troubleshooting. The successive shift shall actively to assist the accident
troubleshooting.
6.1.8 During accident handling process, the outsiders are prohibited to surround the control room
or stay in the failure position
6.1.9 After the accident troubleshooting, the duty personnel shall immediately report to the higher
leadership about the accident and handle, record the accident time, accident phenomenon,
accident development, Troubleshooting process and accident analysis in detail. After the shift,
organize the duty staffs to carry out the accident analysis and prepare the report.
6.2 Boiler shutdown due to Failure
6.2.1 Emergency boiler shutdown
Emergency boiler shutdown by hand operation in case of one of following conditions:
1. MFT shall act but not act;
2. All drum water level gauges are damaged;
3. Normal drum water level can not be maintained in case of boiler blasting;
4. Boiler steam-water tube blasting threats the equipment and personal safety;
5. Fire alarm in boiler plant, directly influencing safe boiler operation;
6. Boiler steam pressure increases to safety valve operating pressure, and all safety valves fail to
operate and PVC valve can not be opened;
7. Blasting inside furnace or flue, making main equipment damaged or second combustion in tail
flue;
8. Interruption of reheat steam;
9. Boiler safety valve is unable to get back to the seat after operation, steam pressure decreasing
and steam temperature varying to be such that the turbine does not allow;
10. Abnormal DCS system can not be monitored;
Troubleshooting of emergency boiler shutdown
1. In case of emergency boiler shutdown, press manual MFT button at same time; if MFT
responds, it will automatically carry out emergency boiler shutdown.
2. Check the following interlocking operations if they are normal, otherwise carry out immediately
manual operation:
2.1 All coal mills, coal feeders, primary fans tripping.
2.2 Fuel tripping valves closing, all oil incoming valves of oil guns close and all purge of oil guns
clock.
2.3 Heat, cool air baffle and regulating baffle, outlet baffle of coal mill close.
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2.4 Electric valves of primary, secondary spraying of the superheater and the reheater accident
spraying close.
2.5 Locking sootblowers. If MFT occurs during boiler sootblowing, the sootblowing suspends.
Confirm the sootblowers splitting.
2.6 Steam turbine tripping.
2.7 Water supply pump tripping.
2.8 Mandatory boiler purge and ventilation for five minutes. If suction fans and draught fans all
tripping, mandatorily ventilate 15 minutes (except the case of second combustion in the tail), and
start the fan to purge the boiler before ignition.
3 Control the superheater pressure in permitted limit.
4 Control and keep drum water level normal, when water supply stops, open the recirculation
valve of coal economizer (except for the economizer and water wall leakage).
5. Air preheater shall maintain continuous operation;
6. Carry out other operations in accordance with normal boiler shutdown and related provisions of
accident troubleshooting.
6.2.2 Application for boiler shutdown due to failure
If any of the following case occurs, ask for the instruction of duty chief to shut down the boiler:
1. Serious deterioration of boiler feed water, steam quality, and not improved after many
treatments;
2 Leakage of boiler pressure components (decide whether to apply for shutdown depending on
specific circumstances, specific parts).
3 No possibility of normal operation after maintenance many times due to serious coking in the
boiler.
4 No possibility of maintaining normal furnace negative pressure after countermeasures due to
serious fouling in boiler flue.
5 Severe over-temperature of boiler steam and moderate heating surface wall which could not be
reduced after many times of adjustment
6 No guarantee of normal operation of two types of water level gauges
7 Loss of control gas source which could not be restored in short period of time
8 No normal operation due to boiler safety valve failure.
Troubleshooting of boiler shutdown application
1. Implement after the application shutdown command, carry out the boiler shutdown procedure
with normal sliding shutdown.
2. Inspect & repair after the boiler shutdown, and do maintenance work.
3. Maintain one suction fan operating after boiler shutdown, due to leakage of furnace pressure
parts, stop the suction fan after furnace steam disappears.
4. Do not open the recirculation of coal economizer after boiler shutdown due to economizer
leak.
6.2.3 MFT
1 Main phenomena
1.1 The Acousto-optic alarm is sent, window icons alarm, CRT display alarms and the recall print
starts.
1.2 Emergency shutdown button indicator lights.
1.3 MFT operation cause firstly display.
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1.4 Cut off all fuel and furnace flame.
2. Causes for MFT Action
2.1 Manual MFT button pressed;
2.2 All FDF stop, lasting for 1s;
2.3 All IDF stop, lasting for 1s;
2.4 All PAF stop and at least one coal mill in running;
2.5 All air preheaters stop, lasting for 10s;
2.6 All boiler circulating water pumps fail (stop or outlet/inlet differential pressure ＜ 68.6KPa),
lasting for 5s;
2.7 Drum water level (mean value of three points) HHH＞﹢254mm
2.8 Drum water level (mean value of three points) LLL＜﹣381mm
2.9 Two selected from three furnace pressures HH (﹢3300Pa)
2.10 Two selected from three furnace pressures LL (﹣2450Pa)
2.11 All fire detection cooling air fans stop or two selected from three outlet pressure LLL ＜
3.23KPa, and lasting for 10s;
2.12 Total air volume ＜30%MCR (780t/h), lasting for 3s
2.13 Turbine trip and unit load ＞60MW
2.14 All fuel oil fire detection lost (two selected from four corners in one layer have no fire detection)
and all coal layers have no fire detection, (one layer has no fire detection, i.e. two selected from
four corners have no fire detection), and boiler fire extinguishing successfully memorized (i.e. two
selected from four corners in any fuel oil layer have fire detection);
2.15 All oil fuel loss, (all oil angle valves closed or OFT closed) and all coal fuels lost, (coal fuel in
one layer lost, i.e. coal mill stops or the outlet valves at four corners closed), and boiler fire
2.16 Ignition failure occurs 3 times after initial boiler fire extinguishing;
3. Manual (intervene) handling principle after MFT operation
3.1 After MFT action, it shall pay close attention to changes of drum water level, ensure electric
feedwater is put into operation and ensure the drum water level is normal;
3.2 Review and close tightly the spraying nozzles of the superheater and reheater to prevent
sudden drop of steam temperature.
3.3 Find out the reason of MFT operation and eliminate it, sootblow the furnace, reset MFT,
re-ignite and recover the unit operation.
3.4 During MFT operation, the oil gun is operating, and re-ignition, carry out the sootblowing.
3.5 For the coal pulverizing system stopping in MFT action, it shall purge primary air pipes one by
one with cold air after reigniting, adjust the air flow and cola mill outlet temperature, ventilate for
15min, and then the coal pulverizing system can be restarted, after which it shall pay attention to
monitor the furnace combustion and prevent deflagration from occurring.
3.6 When boiler MFT operates, the duty staff shall close promptly in situ the outlet contact door of
probe cooling fan and primary fan, check if another cooling fan interacts (otherwise manually
activate). After the unit recover the stability, the duty staff open contact door from the outlet of
primary fan to flame detection cooling fan, stop one flame detection cooling fan and maintain the
outlet pressure of flame detection cooling fan > 16 inches water column.
3.6 If the cause of MFT action has not been identified, or defects can not be eliminated in a short
time, the furnace shall be ventilated for 5-10min, and then close IDF and FDF inlet/outlet baffle,
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stop FDF and IDF, and process as per hot standby boiler shutdown.
6.2.4 Instrumentation air losing
1. Phenomena
1.1 Alarm due to two instrumentation air pressure
1.2 Regulation failure of pneumatic control valves, not automatically regulating relevant water level
and temperature
1.3 change of individual pneumatic control valve or full open or full close
2 Causes
2.1 All operating air compressor tripping, not putting standby air compressor or deficient load of air
compressor
2.2 Serious leakage of Instrumentation air pipes and not holding air pressure
2.3 Closing total air source valve by mistake
2.4 After the operation of compressed air system, not return of safety valve due to jam.
3 Troubleshooting
3.1 Immediately increase the output of operating air compressor, start up standby air compressor,
comprehensively inspect and regulate the compressed air systems.
3.2 Comprehensively inspect any serious leakage of the system, try to isolate if any.
3.3 Before air pressure restoration manually adjust in situ some important valve or manual bypass,
and ensure to keep important parameters of the deaerator, water level of the condenser, host
lubricant temperature normal.
3.4 As for some pneumatic valves, baffles, baffles and so on, manually regulate the corresponding
one which can be manually regulated.
3.5 Closely monitor units operating condition, urgently shut down the boilers and the units if the
units cannot maintain the operation.
3.6 After shutdown and outage, operate in situ the relevant pneumatic valves, baffles, baffles, to
prevent equipment damage.
6.2.5 Runback protection
1. Phenomena
1.1 Unit 50% R.B sound & light alarm;
1.2 Sound & light alarm of important auxiliary machine tripping occur, and control parameters of
tripping machine are fluctuated;
1.3 Unit load drops to 300MW automatically and rapidly, and then becomes stable;
1.4 Significantly dropping of main steam flow, feed water flow, steam pressure, relatively reducing
of steam temperature
1.5 CCS automatically switches the operation mode to “turbine follow” mode, and target load
instruction reduced to 300MW automatically;
1.6 Some coal pulverizing systems automatically trip, and only three equivalent systems in the
lower layer operate;
2. Causes:
2.1 Unit load greater than 360MW, two FDF in service, one of which tripping;
2.2 Unit load greater than360MW, two IDF in service, one of which tripping;
2.3 Unit load greater than360MW, two PAF in service, one of which tripping;
2.4 Unit load greater than360MW, two electric pumps in service, one of which tripping and the
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other not starting by interlock;
2.5 Unit load greater than360MW, two boiler pumps in service, one of which tripping and the other
not starting by interlock;
3. Treatment:
3.1 When the R.B automation is in good condition, the unit control mode will switch automatically
from CCS to “Unit Follow”, and set the strong load shedding to 330MW as per RB load shedding;
3.2 Identify the fault cause from the first picture pop up on the screen since the equipment tripping,
and eliminate the fault in time and restore to original operating status.
3.3 In R.B automation process, operator shall pay close attention to parameter changes. As long
as the automotive operation is normal, generally no interference is needed before the unit
operation becomes stable.
3.4 In case of air fan fault, check if the tripping fan outlet valve is closed, otherwise close it
manually. Pay attention to monitor the furnace combustion, and feed fuel in time if the combustion
is instable;
3.5 If one electric pump tripping and the other not starting by interlock, it shall manually start the
electric pump. Pay attention to monitor and adjust the drum water level, if the water level has large
automatic deviations, it shall immediately adjust it by hand.
3.6 Pay attention to regulation of main/reheat steam temperatures to prevent them from dropping
quickly.
3.7 In case of PAF tripping, pay attention to monitor the primary air pressure change, if operation
of three coal pulverizing systems can not be satisfied, it shall put the oil layer into operation in time,
and one or two systems can remain in running;
3.8 After eliminating the fault, restore the system after receiving instrumentation, and reload the
system;
3.9 In case of any abnormalities in R.B automation process, it shall immediately switch relevant
automatic mode to manual mode for treatment and adjustment;
3.10 In case of R.B automation failure, immediately and manually trip one an upper-layer coal mill,
put the oil gun of bottom-layer operating coal mill to support the combustion. According to the
specific circumstances, split relevant automatic operation, regulate drum water level, drum
pressure, furnace pressure, oxygen and other parameters in limit range. At the same time, turn
governing valve of steam turbine to reduce the electricity load, till it matching the heat load of the
boiler. If necessary, shut down the operation of some coal mill.
3.11 If R.B failure results in boiler fire extinguishing, it shall immediately purge the boiler and ignite
it asap in allowable conditions, and restore the unit to original operating status;
3.12 In the process of manual RB, while reducing quickly heat load of the boiler and selecting of
coal mill tripping, pay attention to the change of main steam temperature and reheater steam
temperature.
6.2.6 Overfeed of water into the drum
1 Phenomena
1.1 High water level in the indication of drum water level gauge and window alarm for high water
level.
1.2 Feed water flow abnormally larger than steam flow.
1.3 While serious overfeed of water, sharply dropping of main steam temperature, water clash in
steam pipes.
1.4 While too low of main steam temperature until protection value to start the protection operation,
steam turbine tripping.
1.5 Steam salinity increasing
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2 Causes
2.1 Failure of water supply automatic regulation, disorder of machine speed control, or regulation
failure of hydraulic coupling device pump coupled device at pump operation.
2.2 Incorrect indication of water level, improper manual or automatic regulation.
2.3 False drum water level, wrong judge and not regulating in time due to sudden changes of
operating conditions or safety-valve operation.
3 Troubleshooting
3.1 If high water level is found, compare water flow and steam flow, compare each water level
gauge and confirm the accuracy of their indications.
3.2 If water level indication rises over 127mm and continues to rise, immediately shut down the
automatic operation mode of water supply, manually reduce the rotation speed of 小机 or reduce
the output of electric pump till water level does not rise any longer and has the downward trend,
open the water drainage to larger level if necessary.
3.3 In case of the accident, use differential pressure water level gauge and manually regulate in
reference to two color water level gauge.
3.4 If water enters into the superheater, immediately open the drainage valves of the superheater
system and close them after steam temperature recovers to normal.
3.5 If drum water level rises to 254mm and the protection operation doesn’t work, manually
operate MFT.
3.6 Open all continuous drainage valves and split the desuperheater.
3.7 Report to duty chief and relevant leadership. When drum water level drops to normal level,
close continuous drainage valves, maintain the normal water level, open the drainage valve of the
superheater, ask duty chief for re-ignition of the furnace after the drainage.
6.2.7 Shortage of water into the drum
1 Phenomena
1.1 Low indication of each drum water level gauge, window alarm of low water level.
1.2 If leakage of boiler heating surface, water flow is abnormally larger than normal steam flow.
1.3 If water supply system failure, water flow is abnormally less than normal steam flow.
1.4 Main steam temperature rising due serious shortage of water.
2 Causes
2.1 Failure of automatic adjustment of water supply, control disorders of BFPT rotation speed or
disorder of adjustment of electric pump scoop.
2.2 Suddenly trippping of the operating small steam turbine, steam pump, not timely starting of
electric pump, or too high power load, deficient water supply.
2.3 Disrupting of water supply, or closing of electrical valve at the inlet of the coal economizer by
mistake due to procedure disorder of high pressure heater splitting.
2.4 Water supply pipe and boiler heating surface bursting.
2.5 False drum water level, wrong judge and improper operation due to mutation of operation
conditions.
2.6 Improper operation while boiler drainage.
3 Troubleshooting
3.1 If low water level is found, compare water flow and steam flow, compare each water level
gauge and confirm the accuracy of their indications.
3.2 If water level indication drops over -178 mm and continues to drip, immediately shut down the
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automatic operation mode of water supply, manually increase the rotation speed of small steam
turbine or increase the output of electric pump, increase the water feeding. Stop immediately the
sewage while boiler drainage.
3.3 In case of the accident, use differential pressure water level gauge and manually regulate in
reference to two color water level gauge. Check high pressure heater water system and begin
immediately in situ startup if CRT could be opened due to valve closed by mistake.
3.4 If the water supply flow is much larger than the flow of steam flow, drum water level still drops,
it is suspected that the boiler leaks, so carefully listen to the voice in situ to confirm. Shut down the
boiler for troubleshooting after the leakage is confirmed.
3.5 If drum water level drops to -330mm and the protection operation shall work, or else manually
MFT.
3.6 After the boiler drum water level drops or boiler MFT, if differential pressure and pump current
boiler pump are too low or abnormally swing with abnormal vibration and abnormal noise, shut
down the boiler pump immediately. Slowly supply the water in accordance with water shortage
situation, avoid thermal shock to the drum.
3.7 If the drum low water level gauge indicates the water level is below minimum water level, shut
down the valve of water supply, stop the water feeding, split the desuperheater and close the
continuous sewage and sampling valves.
3.8 Determine the water shortage degree after the shutdown of boiler; if water shortage degree
can be determined, enhance the water supply and re-ignite, otherwise do not feed the water, ask
chief engineer whether to start water feeding and boiler re-ignition.
6.2.8 Damage of water level gauge
1 Phenomena
1.1 Steam jetting, water jetting.
1.2 Greater noise.
2 Causes
2.1 Large changes of mica chip temperature of water level gauge.
2.2 Deficient thickness of mica chip of water level gauge with low pressure bearing capability.
2.3 Deficient strength or uneven surface of pressure bearing surface.
2.4 Improper operation of purging water level gauge.
3 Troubleshooting
3.1 If one set of drum local water level gauge is damaged, split it out and notify for maintenance
solution, use another water level gauge to compare and monitor the drum water level; recover it in
8h, if it cannot be repaired in 8h, extend the time limit but not exceeding 24h at best with approval
of chief engineer.
3.2 If all drum local water level gauges are damaged and there are two types of accurate and
reliable lower ground water level gauge with different principles, allow the boiler to continue 2h
operation, but maintain the stability of the boiler load, the balance between water flow and steam
flow, repair the drum water level gauges as soon as possible.
3.3 If all drum local water level gauges are damaged, low ground water level gauge is not reliable
or cannot refer, shut down the boiler immediately.
3.4 If all low ground water level gauges fail, immediately carry out the emergency boiler shutdown.
6.2.9 Boiler Air Fan Faults
1. Big vibration of air fan
1.1 Phenomenon:
1) Fan bearing vibration indication exceeds the normal, and fan vibration alarm triggered;
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2) Abnormal increase or violent swing of air fan electric current;
3) Abnormal noise of local fan;
4) Abnormal system operation parameters;
1.2 Causes:
1) Rotor center misaligned, and anchor bolt loosen;
2) Foreign objects entering fan or the blade felled, or stuck inside due to friction;
3) Fan bearing damaged;
4) Fan is in an unstable working area;
5) Serious fouling or wear of fan turning part, or receiving uneven load;
1.3Treatment:
1) Immediately switch off automatic adjustment, and adjust output manually;
2) Conduct comprehensive inspection on air fan, identify and eliminate the cause, and
restore the fan to normal operation;
3) In case of treatment invalid and vibration reaching tripping level with impossibility to
control the upward trend, it shall manually stop or trip the air fan;
2. High bearing temperature
2.1 Phenomenon:
a) Fan bearing temperature indicates increase;
b) Alarm of high bearing temperature;
c) Temperature increase of lubricating oil and cooling water;
2.2 Causes:
1) High oil temperature, low oil level;
2) Oil quality goes bad;
3) Bearing wear or damage;
4) High ambient temperature;
5) Low lubricating oil pressure, low cooling water pressure and flow;
6) Insufficient output of bearing cooling fan;
7) Bearing vibration;
2.3 Treatment:
1) Increase cooling water flow;
2) Feed oil or change oil;
3) Replace lubricating oil filter and raise the oil pressure if the filter differential pressure is
large;
4) Check the cooling fan and ensure normal output;
5) Other treatments can contact maintenance staff for handling;
3. Decrease of lubricating oil or hydraulic oil pressure
3.1 Phenomenon:
1) Oil pressure gauge locally indicates drop;
2) Bearing temperature increase;
3) Alarm of low oil pressure;
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4) Moveable blade can not be adjusted or it is slow;
5) Running oil pump tripping, and standby oil pump starting by interlock;
3.2 Causes:
1) Filter clogged with large differential pressure;
2) Oil system leakage;
3) Insufficient pump output;
4) Low oil level of oil tank;
3.3 Treatment:
1) Switch to standby filter, check and clear filter;
2) Check the tank oil level, and feed oil when low;
3) Check working condition of oil pump, switch to standby oil pump;
4) Identify cause and contact maintenance staff for treatment;
4. Abnormal sway of air fan adjustable blade
4.1 In case of shaking of adjustable fan blade for no reason, if the fan control is in “automatic”
mode, immediately switch it to “manual” mode; if the blade shaking continues and affects the air
pressure, immediately contact the thermal staff and go to the site to switch the local control
mechanism of adjustable fan blade to be in “manual” mode, or contact the main control center for
local adjustment;
5. PAF stall
5.1 Phenomenon:
1) ”PAF stall” alarm;
2) Large fluctuation of air fan outlet flow, primary air flow, primary air pressure and furnace
pressure;
3) Large PAF current change;
4) In case of serious stall, PAF casing and air duct vibrate and produce obvious abnormal
noise;
5.2 Causes:
1) Serious fouling of air preheater and air heater results in inconsistency of fan outlet flow and
opening of moving blade, and makes the fan enter stall area;
2) Misclosing of primary air system baffle and failure of blade adjustment make the fan be in
stall area;
3) Large adjustment of moving blade or misoperation in paralleling the fans makes the fan be
in stall area;
4) Load imbalance of two PAF;
5) Coal pulverizing system tripping in operation or unreasonable operation of coal pulverizing
system start/stop
6) Air heater leakage and icing, air duct blockage;
5.3 Treatment:
1) Immediately switch the PAF moving blade control mode from “automatic” to “manual”,
reduce the opening of moving blade, regulate the output and balance the load of two air fans,
maintain primary air pressure in normal, and meanwhile adjust the IDF stationary blade and
make the furnace pressure be in normal range, and adjust the boiler load until stable;
2) If the failure is caused by misclosing of primary air system baffle, immediately open the
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baffle and meanwhile adjust the opening of moving blade;
3) If the serious fouling of air preheater and air heater cause IDF stall, immediately carry out air
preheater sootblowing;
4) Clear air duct obstruction and make it smooth;
5) In case of coal pulverizing system tripping in operation, open the cold primary air baffle of
standby coal mill for ventilation, and the start/stop operation of coal pulverizing system shall
be slow and stable, so as to reduce a substantial change of primary air pressure;
6) If the stalling disappears after treatment, maintain the normal operation; if the treatment is
invalid or the stall has severely threatened the equipment safety, stop the fan immediately;
6.2.10 Air Preheater troubleshooting

1. Fault tripping of air preheater
1.1 Phenomenon:
1) Air preheater stops and alarms;
2) Air preheater outlet flue gas temperature increases abnormally;
3) Air preheater outlet primary/secondary air temperature drop abnormally;
4) Unit load dropping;
5) Air preheater outlet differential pressure increases;
6) Delayed startup by interlock trips FDF and IDF on corresponding side, and automatic
stopping trips inlet/outlet flue gas baffle of air preheater;
1.2 Causes:
1) Motor overload caused by mechanical failure, such as seal damage, over fouling, jamming
by foreign substance and drive failure, etc.;
2) Both main motor and auxiliary motor can not be started; motor frequency inverter has fault
in electric or control circuit;
3) Air preheater upper/lower bearing temp. ＞85℃。
4) Thrust bearing or guide bearing damaged;
1.3 Treatment:
1) After tripping of air preheater motor, the standby motor shall be started by interlock,
otherwise it shall be started manually. After startup of standby motor, check if it is in normal
operation. If the standby motor trips again, forced startup by hand is prohibited. In case of
signal air preheater failure, unit RB shall act, if not, manual action shall be done
immediately. Transfer the fan output immediately, reduce the boiler output, and make the
boiler fan on one side operate;
2) Properly control the boiler load, steam temperature and pressure, ensure stable boiler
combustion;
3) Tightly close the inlet/outlet baffle of tripping air preheater;
4) After boiler operation becomes stable after adjustment, monitor the flue gas and air
temperature of air preheater, and take preventive measures against fire accident of air
preheater;
5) Boiler MFT action shall start automatically in case both two air preheaters trip at the same
time, otherwise the MFT action shall be started manually.
6) When the air preheater restarts operation after maintenance, it shall closely monitor the
temperatures of flue gas, air, thrust bearing and guide bearing, as well as seal jamming.
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7) If it is found that the rotary air preheater stops, isolate it immediately, put turning into
operation; if the baffle isolation is untight or the rotor can not be turned, the boiler shall be
shut down immediately;
1.4 Note:
1) After air preheater stop, it must ensure the inlet flue gas temperature ≤150℃;
2) In the process of boiler operation, the air preheater stops for some reasons, when it restarts,
turning shall be put into operation. The rotor shall be put into continuous operation after it is
evenly expanded;
3) Start the motor for 5s, then stop it for 15s, and restart the motor, repeat such operation for
several minutes to make the rotor parts contact flue gas, and even the rotor expansion
before putting it into continuous operation;
4) If the operation above said fails, switch off motor power supply, and make manual turning
for two circles. After the rotor is evenly expanded, put it into continuous operation;
5) After the rotor is free to rotate, put the sootblower into operation;
2. Air preheater being on fire
2.1 Phenomenon:
1) Air preheater outlet flue gas temperature increases abnormally;
2) Air preheater outlet air temperature increases abnormally;
3) Air preheater outlet & inlet differential pressure increases abnormally;
4) Air preheater electric current increases or swings abnormally;
5) Air preheater fire alarm device is triggered;
2.2 Causes:
1) Overlow inlet temperature of air preheater makes the flue gas temperature lower than the
dew point temperature, and the condensation at the cold end results in sticking and accumulation
of combustible carbon particles;
2) Humid cold end of air preheater is easy to stick debris;
3) In boiler operation, overlarge or overlow combustion air volume provided, boiler startup
and shutdown frequent or low load kerosene co-combustion sustained for a long time;
4) In boiler operation, incomplete combustion deposition caused by large fluctuation of
combustion or furnace negative pressure;
5) Combustible deposition is on fire, caused by heating resulted from the flue gas and air
baffles are not tightly closed when the air prehater fails or fan one-side operation stops;
2.3 Treatment:
1) In case air preheater is on fire, immediately stop operation of FDF, IDF and PAF on
corresponding side;
2) Close the inlet/outlet flue gas baffle of air preheater;
3) Maintain operation of drive device of air prehater as much as possible;
4) Immediately put fire extinguisher into service;
5) Check if the rotor and seal are normal after fire extinguished;
6) If the air preheater is on fire in shutdown process, it shall start the drive device first before
putting out the fire;
7) Check if outlet flue gas baffle of air preheater is normal after fire extinguished; check if inlet
primary and secondary air baffle are normal; open the drain valves of PAF and FDF to drain
the water, and check if there is water or ash existed in the FDF or PAF, and if they can be
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launched;
8) Conduct drying treatment on air preheater after fire extinguished;
2.4 Preventive measures:
1) Pay attention to monitor the temperatures of the flue gas side and air side of air preheater;
2) Enhance the sootblowing of air preheater, in the period of boiler startup and shutdown,
and in the period of low load operation;
3) Check the interior of air preheater after boiler shutdown, identify sootblowing cycle
according to deposition;
4) Mandatory air preheater sootblowing before boiler shutdown;
5) Clean the thermal accumulator by water according to its pollution degree when in boiler
shutdown;
6) In order to guarantee the starting of air heater in winter, it shall process in time in case of
leakage, to ensure inlet air temperature of air preheater and prevent condensation;
7) In case of boiler shutdown more than 1 week, it must check the heating surface of rotary
air preheater and shall clean in time and ventilate for drying if there is oil dirt hanging or fouling
clog;
8) Enhance the monitoring of air preheater inlet/outlet temperature during operation,
immediately identify the cause in case of any abnormal temperature rise;
3. High bearing temperature of air preheater
3.1 Causes：
1) Emulsion of bearing lubricating oil and low oil level;
2) High temperature, interruption and deficiency of bearing cooling water;
3) Bearing damaged;
4) Water goes into oil, or oil quality goes bad;
5) Oil level is overhigh or oil viscosity is inappropriate;
3.2 Treatment:
1) Immediately conduct comprehensive inspection on the oil system of guide & thrust bearing,
identify the cause and eliminate it, restore the system to normal operation;
2) In case of treatment invalid or impossibility to handle in a short time, it can decrease the
boiler output and strive to slow the upward trend of bearing temperature rise;
3) In case of treatment invalid, the bearing temperature rise shall automatically stop when the
temperature reaches the tripping value, if the automation fails, it shall stop by hand operation;
4) Take unit load reduction measures after air preheater stopping;
4. Severe seal wear of air preheater
4.1 Phenomenon:
1) Air preheater air leakage rate increase;
2) Air preheater electric current increases or overcurrent;
3) Primary & secondary air temperature rises and flue gas outlet temperature drops;
4) FDF, PAF and IDF output increase;
4.2 Causes:
1) Overtemperature of flue gas into air preheater is greater than the set value;
2) Volume of air going though the air prehater decreases;
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3) In hot standby status, the air preheater has flue gas but no air going through;
4) Air preheater rotor speed is lower than the set value;
5) Air preheater is in running before isolation;
4.3 Treatment:
1) Reduce boiler output and maintain the electric current within the scope of rated values;
2) Speed up the air preheater rotor if the speed is too low;
3) In case of big leakage, shut down the boiler and notify the maintenance staff to replace the
seal of air preheater;
4.4 Measures:
1) Whenever there is flue gas flows through air preheater, there shall be air flowing through
the air preheater;
2) Only in emergency and maintenance condition can the slow gear of variable-frequency
converter be applied;
3) Isolate air preheater before operation;
6.2.11 High main steam pressure
1. Phenomena of high main steam pressure
1.1 Alarm for high main steam pressure
1.2 High indication of main steam pressure
1.3 When the pressure rises to the value of security valve operation, popping of security valve
1.4 After security valve operation, drum water level firstly rises and then drops.
1.5 Gas exhaust sound sent out from the top
2. Causes of high main steam pressure
2.1 Sudden dropping of electricity load
2.2 No response of security valve
2.3 Disorder of boiler feeding controller
2.4 Unsuccessfully putting high pressure and low pressure bypass
2.5 High pressure heater stopping or false trip;
2.6 Abnormal coal pulverizing system;
3. Troubleshooting of high main steam pressure
3.1 When increase of main steam pressure is detected, it shall find the cause asap to eliminate the
abnormality and restore normal pressure, and prohibit overload operation;
3.2 Automatically switch off the coal feeder, reduce coal feeding amount by hand operation
immediately, and stop part of coal mill operation when necessary, and feed oil to aid the
combustion as per conditions;
3.3 Manually open the electromagnetic relief valve
3.4 Contact to steam turbine, and then open high and low pressure bypass valves.
3.5 When main steam pressure exceeds the operation pressure of safety valve but the safety
valves do not responds, carry out emergency manual shutdown and take measures to reduce the
pressure at the same time.
3.6 After the boiler pressure recovers, close the electromagnetic relief valves and contact to steam
turbine and close the bypass valves.
3.7 When the steam pressure drops to the popping pressure of safety valve, manually shut down
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the security valve if the safety valve is still not reset to the popping. If the safety valve is still not
reset to the popping due to jamming, ask the duty chief for boiler shutdown and troubleshooting.
3.8 Closely monitor the boiler water level and steam temperature regulation, change to manual
regulation if necessary.
6.2.12 Water wall damage
1 Phenomena of water wall damage
1.1 Drum water level decreases, and sharply in sever case, and feedwater flow is abnormally
greater than steam flow;
1.2 Furnace negative pressure switches to be positive, and flue gas and steam emitted in the
untight positions of access hole, valve and furnace wall, with leakage sound being heard;
1.3 Steam flow and pressure decrease;
1.4 Combustion instable, the flame dark and the boiler fire put out in sever case;
1.5 Boiler pump has abnormal parameters when drum water level is overlow;
2 Causes of water wall damage
2.1 Unqualified feedwater and furnace water result in scaling and corrosion on the inner wall of
water tube;
2.2 Malfunction of boiler pump results in poor water circulation;
2.3 The water tube blocked with debris results in tube wall overheating;
2.4 Poor welding quality, and unqualified material;
2.5 Individual tube is worn down by pulverized coal, and the tube wall produces thermal fatigue or
becomes thin after clearing by sootblowing water;
2.6 Big slag falling off damages the tube wall of bottom ash hopper;
2.7 Improper processing in case of serious boiler water reduction, continuous water filling resulting
in sharp tube cooling or serious boiler water reduction resulting in boiler blasting due to
overheating;
2.8 Water wall expansion is blocked;
3 Troubleshooting of water wall damage
3.1 If the normal water level can be maintained in case water wall tube blasting is not so serious, it
can properly reduce the operation parameters, report to director in duty and ask for instruction of
furnace shutdown;
3.2 If the normal water level can not be maintained in case of water wall tube blasting, the furnace
shall be shut down immediately;
3.3 After furnace shutdown, enhance the water filling, but stop it if the water level does not
increase, and prohibit opening the economizer recirculating valve;
3.4 If water reduction is sharp in water wall tube blasting, water filling is prohibited;
3.5 After furnace shutdown, maintain IDF operation, and exhaust the flue and steam inside the
furnace before such shutdown;
6.2.13 Leakage of coal economizer
1 Phenomena of economizer leakage
1.1 Drum water level decreases and feedwater flow is abnormally greater than steam flow;
1.2 Sound is heard in the position of leak;
1.3 Big temperature difference of flue gas at the rear of economizer, and the flue gas temperature
decreases at leakage side;
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1.4 Alarming of four-tube leakage detection device;
1.5 Big temperature difference of flue gas at both sides of the inlet of air preheater;
2 Coal economizer leakage causes:
2.1 Scaling and corrosion in the tube due to unqualified water
2.2 Poor quality of manufacture, installation or maintenance welding, or tube quality defects
2.3 Fly ash wearing, foreign material jamming in the tube
2.4 Not open of recirculation valve of coal economizer after ignition and pressure rising or boiler
shutdown and water supply stopping.
2.5 So much change of feeding water temperature or water flow
2.6 Serious wearing and damage in sootblowing area due to sootblowing
3 Troubleshooting of coal economizer leakage
3.1 When the economizer leakage is such that the drum normal water level can be maintained, it
can keep the operation with reduced parameters in a short time, report to director in duty and ask
for instructions of boiler shutdown;
3.2 When the economizer tube blasting is such that the normal water level can not be maintained,
it shall immediately shut down the boiler;
3.3 Pay attention to monitor the working conditions of ash handling system and air preheater,
enhance the patrol inspection;
3.4 It shall continue water filling to the boiler after the boiler shutdown, which shall be stopped if
the water level can not be maintained. After water filling stop, the economizer recirculating valve is
not allowed to be opened;
6.2.14 Overheator tube leakage
1 Phenomena of superheater leakage
1.1 Sounds emission from the leakage position of the superheater
1.2 Furnace negative pressure swinging, suction fan current increasing (at automatic air suction
control) and flue gas emission to the air form unclosed position if serious.
1.3 Flue gas temperature deviation at both sides of superheater leakage, rear superheat steam
temperature and wall temperature rising, main steam temperature dropping if it is the final
superheater leakage.
1.4 The feeding water flow is abnormally greater than the corresponding electricity load.
1.5 Main steam pressure dropping and unit load dropping if serious.
2 Superheater leakage causes
2.1 Deterioration of heat transfer and tube over-temperature due to unqualified steam quality and
tube wall scaling
2.2 Poor quality of installation & maintenance and unqualified tubes
2.3 Over-temperature of the superheater for long time
2.4 Corrosion due to severe wear of fly ash and fouling of the superheater
2.5 Debris jamming in superheater tube
2.6 Water wall coking, furnace outlet temperature increasing
2.7 In low load, superheater damage duo to unstable temperature of the desuperheating water,
water entry into the superheater
2.8 In abnormal combustion, flame deflection, or flame center up-shift. Too much deviation of flue
gas heat or temperature increasing of superheating area
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2.9 Over-temperature of superheater wall due to incorrect startup and shutdown
2.10 Superheater damage due to wrong installation of the sootblower
3 Troubleshooting of superheater leakage
3.1 If any leakage is found, immediately report to the duty chief, contact relevant maintenance
personnel to identify the cause and apply for boiler shutdown and maintenance as soon as
possible.
3.2 Contact the duty chief, request to immediately lower the operating parameters, switch the
operation mode to boiler manual operation mode.
3.3 Reduce the load, pay attention to the stability of combustion.
3.4 If the leakage is serious, and steam temperature could not be controlled which may endanger
the safe operation of equipments, immediately shut down the boiler, and retain one suction fan in
operation in order to maintain boiler flue gas and steam emission by furnace negative pressure.
6.2.15 Reheater leakage
1. Phenomena of reheater leakage
1.1 Sounds near the reheater
1.2 Pressure dropping at the outlet of the reheater
1.3 Suction fan current increasing (at suction fan automatic control)
1.4 Too much reheat steam temperature deviation or abnormally increasing
1.5 Instability of furnace negative pressure, smoke emission from the leakage position if serious
leakage
1.6 Feeding water flow increasing under same unit load
2 Reheater leakage causes
2.1 Scaling or corrosion in the tube due to poor quality of steam quality for long time
2.2 Poor quality of tube installation and maintenance welding, poor material or manufacturing
defects
2.3 Fly ash wear or improper installation of the sootblowers
2.4 Often over-temperature during operation
2.5 Fatigue of the reheater tube caused by improper operation in startup and shutdown process
3 Reheater leakage troubleshooting
3.1 Immediately report to the duty chief, contact relevant maintenance personnel to identify the
cause and apply for boiler shutdown and maintenance as soon as possible.
3.2 If the leakage is serious, and it could maintain the normal operation, immediately shut down
the boiler, and retain one suction fan in operation.
6.2.16 Boiler coking
1 Phenomena of boiler coking
1.1 Flue gas temperature and exhaust gas temperature at each position increasing.
1.2 Boiler steam temperature rising and desuperheating water flow increasing.
1.3 Often falling of gray cinder in cold hopper
2 Boiler coking causes
2.1 Poor coal quality with low ash melting point
2.2 Over-combustion of oil and coal mixture
2.3 Deficient air volume, incomplete combustion, flame center up-shift and too thick partially
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reduced air
2.4 Too high furnace heat load and furnace temperature
2.5 Furnace flame deflection and uneven distribution of temperature field
2.6 Sootblowers failure or no sootblowing
2.7 Outage of high pressure heater
3 Boiler coking troubleshooting
3.1 Completely and comprehensively sootblow.
3.2 Regulate the combustion, reduce the flame center height and regulate flame center position,
and appropriately increase the volume of excess air.
3.3 Ask for the duty chief, appropriately reduce the load, combustion rate, and furnace
temperature, increase the furnace negative pressure and carry out the decoking work.
3.4 Apply for boiler shutdown if it cannot maintain normal main steam temperature or wall
temperature of superheater exceeds the allowable values after regulation.
6.2.17 Secondary combustion at the tail of boiler flue
1. Phenomena
1.1 The tail flue gas temperature increases abnormally;
1.2 Current swing increasing of air preheater, bearings and shell temperature increasing, jamming
if serious.
1.3 Primary air, secondary air temperature increasing
1.4 Furnace pressure fluctuations, automatic open of suction stationary vane, and suction fan
current rising.
1.5 Steam temperature rising at the inlet of isolation screen superheater, primary spraying water
volume increasing.
2 Causes
2.1 During boiler startup (outage) process, the mixture of coal and fuel oil is too long, so that the
fuel is deposited at the rear heating surface, waveform board of air preheater.
2.2 The combustible material depositing inside the flue tail due to the low load operation time of
the boiler is too long.
2.3 Not burnt pulverized coal into boiler tail flue due to too rough of pulverized coal or improper
combustion, so that did not burn the coal into the boiler flue.
2.4 Sootblower failure and abnormal long-term operation.
3 Troubleshooting
3.1 When the tail flue gas temperature increases abnormally, it shall check the cause at first,
regulate the burning device and input steam sootblowing to clear the heating surface;
3.2 If the secondary combustion is confirmed, it shall stop the boiler immediately;
3.3 Stop FDF and IDF, tightly close each air valve, baffle and flue holes, strictly forbid ventilation,
and start corresponding sootblowers to extinguish the fire;
3.4 Strengthen the water feeding and water drainage.
3.5 While serious combustion of air preheater, put water purge to put out the fire. During
fire-fighting, maintain the operation of air preheater, strictly prohibit to starting up the maintenance
hole of air preheater.
3.6 Confirm that the fire have been extinguished, after flue gas temperature distinctly dropping,
check the flame in each section of flue, eliminate the deposition of combustible material, start the
ventilation fan to ventilate for 10 ~ 20min, after comprehensive inspection, confirm no damage of
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equipment, report to duty chief and start re-ignition.
4 Prevention of secondary combustion at flue tail
4.1 Allow the boiler ignition only after the qualification of leakage test of main fuel oil tubes. If
leakage test of fuel oil main tube fails, investigate the cause and prohibit the boiler ignition before
defect elimination.
4.2 While putting oil gun in early ignition, observe oil gun flame through in-situ flame monitor and
flame monitor, if no fire of oil gun but display of oil gun fire signal, manually shut down the oil gun,
contact the maintenance personnel to identify the cause, prohibit re-ignition before identification of
the cause.
4.3 While bad atomizing of oil guns, timely contact for the maintenance and clean up the oil gun.
The operating personnel shall regulate the air volume to ensure the full combustion of fuel oil in
accordance with the situation of oil gun combustion.
4.4 While putting coal mill with low load operation, put all adjacent layer oil guns of selected mill
into operation. After the output of pulverized coal from the coal mill, ensure sufficient power of oil
gun to ignite. After three coal mill operation and stable combustion, stop the combustion support of
oil gun.
4.5 Sootblow with the sootblowers in accordance with the provisions. While putting oil gun or load
less than 25% of rated load, maintain continuous sootblowing with the air preheater, sootblow
once at every 8 hours after oil gun outage or load more than 25% of rated load.
4.6 Enhance the monitoring of flue gas temperature at the outlet of air preheater, especially the
monitoring during early ignition of the boiler, long time operation at low load, co-combustion of coal
and oil, and enhance the regulation of pulverized coal fineness and combustion and suitable coal
concentration to ensure complete combustion.
4.7 During the process of normal operation or operation of unilateral suction fan, control the
oxygen volume within the specified scope, add the load in accordance with oxygen volume, and
prohibit the combustion without oxygen.
4.8 If the outage of air preheater is found, separate it immediately and put fire-fighting steam and
jigger device. If the baffle is not tight or the rotor cannot move, shut down the boiler immediately.
6.2.18 Abnormal of milling system
6.2.18.1 Spontaneous combustion of coal mill
1 Phenomena
1.1 Window alarm lighting due to rapidly rising of the temperature at the outlet of coal mill.
1.2 Thermal radiation at external wall of coal mill increasing.
1.3 Thick smell of gas after opening the slag disposal gate.
1.4 The slag disposal box being burnt glow at serious degree.
2 Causes
2.1 During long outage of coal mill, spontaneous combustion due to not emptying of all deposited
pulverized coal.
2.2 Flammable and explosive materials in coal.
2.3 Not airtight of Hot air baffle.
2.4 External fire source.
2.5 Not filling inert steam after shutdown of coal mill
3 Troubleshooting
3.1 Quickly close all baffle baffle, cut off from the air if the fire is found in the outage of coal mill.
3.2 Fill inert steam immediately to put out the fire.
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3.3 Close the inert steam after the temperature at outlet of coal mill drops to normal.
3.4 Contact the maintenance staffs to handle after coal mill cooling.
6.2.18.2 Firing during the operation of coal mill
1 Phenomena
1.1 Window alarm lighting due to rapidly rising of the temperature at the outlet of coal mill
1.2 Thermal radiation at external wall of coal mill increasing.
1.3 The slag disposal box being burnt glow at serious degree.
2 Causes
2.1 Too high temperature at the outlet of coal mill due to failure of coal mill temperature regulation
or failure of coal mill cold air baffle.
2.2 Flammable and explosive materials in coal
2.3 Idle operation and external overheat due to improper operation regulation.
3 Troubleshooting
3.1 Keep coal mill in operation.
3.2 switch the coal feeder of coal mill to manual mode and increase coal feed volume.
3.3 Open widely cold air baffle, gradually close hot air baffle, and maintain the air volume.
3.4 The temperature at the outlet of coal mill shall drop after regulation. Shut down the coal mill if
not.
3.5 Close the outlet baffle, primary air baffle and secondary air baffle after the outage of coal mill.
3.6 Put inert steam into coal mill.
6.2.18. 3 No coal feed in coal mill
1 Phenomena
1.1 Significantly dropping of the current in coal mill.
1.2 Smaller opening of hot air regulating baffle and larger opening of cold air regulating baffle in
automatic mode of coal mill.
1.3 Short time dropping of unit load.
1.4 Temperature rising at the outlet of coal mill.
1.5 Large vibration of coal mill.
2 Causes
2.1 Coal jamming in coal feeder.
2.2 Coal depositing in raw coal bunker.
2.3 No coal feeding in coal feeder.
2.4 Coal blocking in coal drop pipe.
3 Troubleshooting
3.1 Inspect the operation coal feeder in situ, and confirm that not feeding coal of coal feeder
cannot be restored, shut down this milling system, start up the standby coal mill.
3.2 Regulate the output of other milling systems, and maintain the unit load.
6.2.18. 4 Coal mill vibration
1 Causes
1.1 No coal or less coal in mill.
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1.2 Coal jamming in coal mill.
1.3 Large quantity of iron pieces, stone and wood pieces.
1.4 Coal block formation due to too much moisture content.
1.5 Components loose in coal mill.
2 Troubleshooting
2.1 Increase the coal feed if less coal volume.
2.2 Reduce the coal feed volume and increase air volume if coal jamming in coal mill.
2.3 Strengthen the slagging disposal if too much iron pieces, stone and wood pieces in coal mill.
2.4 Strengthen the coal mixture if too much moisture content.
2.5 Shut down this milling system if severe vibration.
6.2.18. 5 larger slag discharge of coal mill
1 Causes
1.1 Startup of coal mill.
1.2 Emergency shutdown of coal mill.
1.3 Bad coal quality.
1.4 Serious wear of mill roller, liner and nozzle, or nozzle ring loss.
1.5 Too rapidly increasing of coal mill output during operation, less air volume.
2 Troubleshooting
2.1 Timely discharge the slag to eliminate it since too much discharging slag is normal during
startup and emergency shutdown.
2.2 Increase the air flow for coal mill.
2.3 Reduce the coal feeding if increasing air flow for coal mill doesn’t work.
2.4 Shut down this coal mill for maintenance if too much slag.
2.5 shut down the coal mill and contact for maintenance if Serious wear of mill roller, liner and
nozzle, or nozzle ring loss.
6.2.19 Boiler water pump failure
6.2.19.1 High temperature of motor chamber of boiler water pump
1 Causes
1.1 Deficiency or interruption of low pressure cooling water, steam resistance in the tubes or high
cooling water temperature.
1.2 Not completely discharging of the air in motor chamber.
1.3 Leakage of high pressure cooling water system in motor chamber.
1.4 Inadequate water filling pressure in motor chamber.
1.5 Jamming of High-pressure cooling water filter.
1.6 Motor wear or auxiliary impeller damage in motor chamber of boiler water pump.
1.7 Temperature sensor and alarm device failure of boiler water pump.
2 Troubleshooting
2.1 Check if any leakage of low-pressure cooling water system and regulate the low-pressure
cooling water pressure, flow and temperature to normal. Change to backup water source if
necessary.
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2.2 Reduce the low-pressure cooling water temperature and open the air valve to empty the air in
tubes.
2.3 Inspect if the valves of high-pressure cooling water system is in correct position, if any closed
valve leaks. Isolate it if any leakage of boiler water pump motor, high pressure water system or
system valve is found; increase the cooling water volume of insulation parts and motor cooler,
feed the high-pressure into the motor if it cannot be isolated and apply the boiler shutdown; keep
water temperature shall not exceed 50 ℃ while water feeding.
2.4 If plant service power shutdown causes the loss of low-pressure cooling water and failure
power protection switching is normal, immediately start the cooling and boosting pump for boiler
water pump emergency shutdown, ensure that cooling water flow of boiler water pump motor is ≥
7.7m3 / h. if failure power protection switching is not normal and it cannot timely feed the normal
cooling water, the motor temperature rises to 65 ℃, shut down the boiler water pump immediately
and take temporary measures to reduce motor temperature.
2.5 If the closed cooling water system failure makes the loss of low-pressure cooling water,
immediately start boiler water pump, and shut down cooling pump, ensure cooling water flow of
boiler water pump motor is ≥ 7.7m3 / h.
2.6 During boiler water pump operation, the temperature of motor chamber is high and
low-pressure cooling water is normal, high-pressure cooling water system has no leakage, it may
be the boiler water pump motor bearing wear, filter plugging, or high-pressure cooler leakage,
immediately shut down the boiler water pump.
2.7 If backup pump motor chamber temperature is high, start boiler water pump for high-pressure
water to continuously fill the water. Activate boiler water pump in operation to speed up the internal
high-pressure cooling water flow so as eliminate it. if temperature decline of motor chamber and
it can also maintain the operation, maintain and repair after shutdown.
2.8 No matter what kind of cause, shut down the boiler water pump if motor chamber temperature
reaches to 65 ℃.
6.2.19.2 Mechanical failure of boiler water pump
1 Phenomena
1.1 Obvious friction sounds or sounds of metal clash in the pump.
1.2 Pump body vibration.
1.3 Large current fluctuations in boiler water pump, and the current increasing.
1.4 Boiler water pump output dropping, inlet and outlet pressure dropping.
2 Causes
2.1 Mechanical wear.
2.2 Bearing damage.
3 Troubleshooting
3.1 Start up standby pump, and shut down the failed pump, handle it after boiler shutdown.
3.2 Reduce the unit load if necessary.
6.2.19.3 Output reduction of boiler water pump
1 Phenomena
1.1 Low differential pressure at the outlet of boiler water pump.
1.2 Small current of boiler water pump.
1.3 Abnormal sounds and vibration in boiler water pump.
2 Causes
2.1 Air remains in boiler water pump.
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2.2 Vaporization in boiler water pump.
2.3 Too low drum water level.
3 Troubleshooting
3.1 Exhaust the air in pump and tube at startup.
3.2 Maintain drum pressure so that it cannot dropped too rapidly during boiler operation.
3.3 Maintain and control drum water level during boiler operation.
3.4 Switch to standby pump for operation, and then put again after outage.
3.5 Contact for maintenance after mechanical failure and shutdown.
6.2.19.4 Other
6.2.19.4.1 Troubleshooting of high temperature alarm in motor chamber
A. Check if the low pressure cooling water system is normal;
B. Check if the motor is leaked or high pressure cooling water connection is leaked;
C. Check if the temperature sensor is normal;
D. Check if the bearing is damaged (hearing on site)
6.2.19.4.2 If the temperature exceeds 65 ℃, the pump shall stop immediately before filling of high
pressure water in the following sequence:
Open valve #14→ open valve #15→ open valve # 16 → (open valve # 9 → open valve
# 10 → open valve # 13) valve #9, #10 and #13 already in normal operation in opened
status
※If the motor chamber temperature increases rapidly after the filling of high pressure
water, it indicates that the water temperature is too high to satisfy the cooling
requirements, so it shall stop the filling immediately (no other choice for no standby
cooling water source available).
6.2.19.4.3 If the standby pump motor chamber temperature is high, the pump shall be started to
accelerate the inner high pressure cooling water flowing, and check the cause, if the
temperature reaches alarm value or tripping value, the measures above mentioned shall be
taken;
6.2.19.4.4 Troubleshooting of low pressure cooling water
If low flow alarm of low pressure cooling water is triggered, it shall check the cooling water system
in case of one boiler pump alarming, and adjust the cooling water flow of each pump, and it shall
start the standby cooling water booster pump in case of two sets or more than two sets of boiler
pump alarming, moreover, it shall start the emergency cooling water pump if the alarm can not be
canceled.
6.2.20 Sootblowing system failure
6.2.20.1 Low sootblowing main tube pressure
If the steam main tube pressure is lower than rated value, clock all sootblowers’ operation on this
main tube; inspect in situ and confirm all sootblowers are closed. If the steam pressure recovers to
normal, it automatically closes the alarm, and the interrupted program automatically operates from
the break point.
1 Causes
1.1 Low boiler steam pressure;
1.2 control valve failure or controller failure in boiler sootblowing and pressure reduction system;
1.3 Pressure switch failure of sootblowing main tube.
2 Troubleshooting
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2.1 Inspect in situ if the pressure gauge indication of boiler sootblowing and pressure reduction
system is normal, inspect if any leakage of steam pipes is found; if any steam valves don’t open
fully; if the spool is off. Increase the steam pressure.
2.2 Inspect in situ if the action of control valve of boiler sootblowing and pressure reduction system
is normal, contact the thermal staffs for maintenance if necessary.
2.3 Contact the thermal staffs to inspect the pressure switch if the pressure indication of main tube
pressure gauge is normal but it still alarms about Low boiler sootblowing main tube pressure.
6.2.20.2 Low sootblowing main tube temperature
1 Causes
1.1 Poor drainage of sootblowing main tube and low temperature in steam main tube;
1.2 Drainage valve failure of sootblowing main tube;
1.3 Temperature switch breakdown of sootblowing main tube.
2 Troubleshooting
2.1 Inspect if the drainage valve is open, and if the drainage time is enough.
2.2 Contact the maintenance staffs to inspect the drainage temperature switch.
6.2.20.3 Sootblower startup failure
The sootblower doesn’t move from original position after the startup signal of the sootblower is
sent 5 to 10 seconds, and the indicator of “Startup Failure” lights, and the alarm system alarms.
1 Causes
1.1 Sootblower’s motor failure;
1.2 Low sootblowers steam pressure;
1.3 Sootblowers steam switch failure
2 Troubleshooting
2.1 Trip the sootblowers, contact the maintenance staffs to check whether the motor supplies the
electricity, whether the motor is burnt and if there is a problem of control signal.
2.2 Contact the boiler maintenance staffs to regulate the lift valve opening of the sootblowers, and
further increase incoming steam pressure.
2.3 Contact thermal staffs to check the pressure switch.
6.2.20.4 Motor overload of the sootblower
1 Causes
1.1 Motor operation under phase-lacking condition;
1.2 Mechanical jam, failure or too large torque.
2 Troubleshooting
2.1 Contact thermal staffs to inspect the motor after the sootblower shutdown.
2.2 Contact the maintenance staff to inspect if the transmission parts are failed, regulate the
sootblower.
6.2.20.5 Sootblowing overtime
If the time of sootblower putting or shutting exceeds the protection setting value, the “Over-time”
indicator lights. If the sootblowing is in putting state, the sootblower immediately shut down; if the
sootblower is in overtime process state, the alarm system alarms.
1 Causes
1.1 Mechanical jam, failure or too large torque;
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1.2 Motor burnt damage;
1.3 signal not sending due to return stroke switch failure.
2 Troubleshooting
2.1 Immediately contact the maintenance staffs to Manually shut down the sootblowers and
prevent the sootblower from burnt damage.
2.2 If the sootblower returns in place after inspection, contact the maintenance staffs to replace
stroke switch, eliminate the alarm.
2.3 If the electric power/control power loses, the system sends the fault signal to DCS, and the
electric power indicator flashes. Quickly find out the equipment failure, immediately resolve the
failure and shut down the sootblowers manually if the sootblower is operation.
6.2.21 Air compressor and dehydrater failure
6.2.21.1 Urgent shutdown of air compressor in the following situations
1 The motor current exceeds the rated value.
2 The Motor is smoking or on fire.
3 The temperature at any part exceeds the accepted value of air compressor.
4 The accident occurs which may endanger the safety of persons and equipments.
5 Metallic friction noises of air compressor and electromotor come out and the main body strongly
vibrates.
6.2.21.2 Start up standby air compressor firstly, and then stop the failed air compressor under
following situations:
1 Abnormal aggrandizement of motor current, burning smell from insulating material or extreme
hot of motor enclosure
2 Strong vibration of the pipeline
3 Abnormal noises from air compressor and electromotor
4 Other conditions threatening safe operation of devices
6.2.21.3 Causes and troubleshooting of air compressor failure
1. Power-on lamp failure
Cause: Lack of control power
Troubleshooting:
1) Check fuse of the controller.
2) Check secondary side control voltage of the transformer.
2. Air compressor shutdown due to high temperature
Causes:
1) Poor coolant oil circulation
2) Poor electrical connection
3) Poor cooling effect
4) High environmental temperature
Troubleshooting
1) Check if the coolant oil level is normal, coolant oil is clean, coolant oil system is no leak and
temperature-sensing valve is normal.
2) Check if the thermister fails.
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3) Check if air screen, aftercooler, and exhaust outlet are jammed.
4) Improve draft condition of air compressor room.
3 Overload of motor
Cause: Relay protection action due to overcurrent.
Troubleshooting:
1) Check actual working pressure, Lower setting value if too high.
2) Shut down air compressor and switch off, check rotation flexibility.
3) Check pressure drop of separator core.
4) Check if the voltage of power is normal.
4. Too high of discharging pressure
Causes:
1) No load shedding of air compressor
2) Pressure sensor failure
3) Too high setting value of main pipe pressure
Troubleshooting:
1) Check and replace load shedding magnet valve or air control valve.
2) Check and replace pressure sensor.
3) Lower the setting value of main pipe of pressure.
5. Compressed air pressure cannot reach rated pressure
Causes:
1) Too larger of air volume
2) Low opening pressure of safety valve
Troubleshooting:
1) Check if the pipeline and valve have air leakage and check if there is the user of large air
consumption.
2) Check if setting value of safety valve is too low.
3) Check if the inlet valve is open.
4) Check if the motor works normally.
5) Check if opening/closing setting pressure of safety valve is proper.
6) Check if air suction filter of air compressor is jammed.
6. Handling of large consumption of coolant oil
1) Check if oil return tube is jammed, and clean the tube.
2) Check if the core of oil separator damages and replace if necessary.
7. Handling of non-loading of air compressor
Check if air valve of air compressor is open;; if it is not open, switch off all power supplies, then
check air valve again and make sure it can open freely. Otherwise, check if the motor works
normally.
8. Handling of safety valve opening under continuous loading of air compressor
Check if the opening or closing of minimum pressure valve is stuck,, safety valve fails and the
setting value of safety valve is correct.
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9 Alarm protection of air compressor and causes
9.1 CHANGE COOLANT FILTER: Alarm if differential pressure of 1DPS filter element is larger
than 0.14MPa, and that 2CTT oil injection temperature is higher than 49℃.
9.2. CHANGE INLET FILTER: Alarm when negative pressure sensor of air inlet 1AVPT is greater
than 0.5kPa and air inlet valve is completely open.
9.3. CHANGE SEPR ELEMENT: Alarm when oil separator pressure 3APT is larger 100kPa than
discharge pressure of 4APT unit and air inlet valve is completely open.
9.4. HIGH DISCHARGE PRESS: Alarm after three seconds time-delay when discharge pressure
of air compressor is greater than 0.88MPa,, air compressor will unload the load at this moment.
The air compressor loads again when discharge pressure of air compressor drops below to its
rated pressure.
9.5. SENSOR FAILURE 4ATT: Alarm if this sensor is uninstalled or ruptured.
9.6. CHECK INLET CONTROL: Alarm if air compressor is unloaded but the negative pressure is
less than 20kPa.
9.7. CHECK INLET CTRL SYS: Alarm if air inlet butterfly valve is in wrong position.
9.8. CHECK MOTOR ROTATION: Alarm if the rotation direction of air compressor is incorrect.
9.9. CONTROL POWERLOSS: Alarm when control voltage of air compressor is lost.
9.10. EMERGENCY STOP: Alarm if the emergency stop button is pressed. Reset this button, and
the alarm can close.
9.11. FAN MOTOR OVERLOAD
9.12. HIGH AIREND DISCH TEMP: Alarm if discharge temperature of air compressor is higher
than 109℃,, and then the air compressor trips.
9.13. LOW SUMP AIR PRESSURE: Alarm if air compressor is on full-load operation and the
SUMP air pressure drop to lower than 140kPa.
9.14 LOW UNLOAD SUMP PRESS: Alarm if air compressor is on unload operation and the SUMP
pressure drops lower than 100kPa and lasts more than 15 seconds.
9.15 MAIN MOTOR OVERLOAD.
9.16 MEMORY FAULT: Alarm if the controller judges any memory fault. Verify the sensor and
check all of setting values.
9.17. REMOTE START FAILURE: Alarm if the remote start button is pressed down or the button is
always on pressed state after air compressor operation.
9.18. REMOTE STOP FAILURE: Alarm if remote stop button is always on pressed state and the
start button is closed.
9.19. SENSOR FAILURE 1AVPT(or 3APT,4APT,2CCT,2ATT): Alarm if a sensor is absent or
ruptured.
9.20. STARTER FAULT: Alarm if the starter contact is open when air compressor is running or
starter contact cannot open while the stop instruction is given to air compressor.
9.21. STEPPER LIMIT SWITCH: Alarm if two limit switches are activated at the same time.
10. Reset for alarm status of air compressor
When the alarm is active, ALARM will flash on the window,, press down STATUS button status
window will appear on the video display unit, and ALARM button still on which means the alarm is
still on. Alarm status will list operating condition of air compressor while alarming. Read the titles
and values of each listed term beside the buttons by shifting the arrows.
While pressing ALARM button,, Video display unit will return to RESET button of ALARM window.
Alarm on ALARM window alarm will reset by pressing RESET button twice.
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6.2.21.4 Failures and Treatment of Refrigerated Compressed Air Dryer
The dryer failures mainly lie in two aspects: electrical system and cooling system, and the failures
will inevitably lead to compressor failure to start, reduced cooling capacity or equipment damaged.
Correct identification of failure causes and adoption of rational exclusion method involves not only
theoretical knowledge of electrical and cooling technique but also practical skills. Some failures
may have several causes, so it must conduct the comprehensive analysis of such failures at first in
order to find effective solutions. In addition, some failures may be caused by users’ incorrect
utilization and maintenance, which is called “false failure”, therefore, only practical operation can
identify the actual failures and find the correct solutions. Some common failures and exclusion
methods of the dryer are specially listed as follows:
Failures Analysis of Causes Solutions
1. Check power supply system;
1. No power supply;
A. Cold dryer 2. Replace with new fuse;
2.Blown fuse;
does not work
3. Check in accordance with circuit
3. Circuit breaking or loosen;
diagram;
1.Power supply lacking phase
or voltage out of allowable 1. Check power supply and make
range; the voltage within rated range;
2. Incorrect wiring; 2. Check in accordance with circuit
diagram;
3.Relay or contactor is not
pulled in; 3.Check the cause, replace or
B. Compressor repair;
does not work 4.If the compressor is
launched by capacitor, the 4. Replace the starting capacitor;
capacitor is damaged;
5.Adjust the pressure switch
5.Poor quality of high/low setting value, or replace pressure
voltage protection switch; protection switch;
6.Compressor mechanical 6. Replace compressor;
failure, like jamming;
1. Excessive heat load and 1. Reduce heat load and inlet air
overhigh inlet air temperature;
temperature;
2. Improve ventilation and reduce
2. Ambient temperature is too ambient temperature;
high;
3. Clean condenser or increase
C. The light 3.Condenser fouling or cooling water volume, and reduce
indicating lacking cooling water and inlet cooling water temperature;
refrigerant cooling water temperature
pressure fault 4. Find the cause and conduct
overhigh;
is on due to maintenance;
overhigh 4.Air mixing in cooling
5. Exchange any two of the three
refrigerant system;
phase lines or replace the fan;
pressure; 5. Fan rotation is incorrect or
6. Replace the expansion valve;
fan motor fails;
7. Replace the filter;
6. Abnormal expansion valve;
8. Discharge part of refrigerant
7. Dry filter clogging;
(conducted only after exclusion of
8. Too much refrigerant filling; above causes)
D. The light of 1. Detect leakage, re-vacuumize

1. Refrigerant insufficiency of
refrigerant and add refrigerant;
leakage;
pressure fault 2. Increase compressed air flow or
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is on due to load;
2. Air flow or load too small;
overlow 3. Adjust or replace hot gas bypass
refrigerant 3. Hot gas bypass valve not
valve;
pressure; opened or poor;
4. Reduce cooling water flow or
4. Ambient temperature too
close cooling water;
low;
1. Heat load too large and
1.Reduce heat load and inlet air
inlet air temperature too high;
temperature;
E. The light of 2. Ambient temperature too
2.Improve ventilation, reduce
thermal high;
ambient temperature;
overload fault 3. Heat degree too high due
is on due to 3. Add refrigerant;
to insufficient refrigerant;
overlarge 4.Reduce compressor startup
compressor 4. Compressor overload;
number;
running 5. Compressor lacks of oil or
current; 5. Check compressor oil level, add
oil level too low;
lubricating oil;
6. Compressor bearing wear
6.Replace compressor;
or jamming;
1. Air flow or load too small;
F. Water
1. Increase compressed air flow or
freezing in 2. Hot gas bypass valve not
load;
evaporator, opened or poor, and
presented as meanwhile the expansion 2. Adjust or replace hot gas bypass
water not valve opened too large; valve and expansion valve;
drained and ice
3.Evapovator drain outlet 3. Clear the drain outlet, and totally
particles blown
clogging due to excessive drain the condensate in
from drain
water accumulated that evaporator;
valve;
resulted in ice blockage;
1. Low inlet air pressure;
2. Pipeline valves not totally 1. Increase inlet air pressure;
opened;
2. Open all air pipeline valves;
3. Pipe diameter too small,
3. Improve air pipeline system;
elbow too much or pipeline
too long; 4. Refer to F1-3;
G. Equipment
running 4. Evaporator ice blockage; 5. Clean or replace filter;
normally with 5. Air compressor suction, 6. Check drainage system, repair
large pressure filter clogging; or replace;
drop
6. Excessive water in 7. Increase equipments or replace
equipment; with equipment mode of larger
processing capacity;
7.Processing capacity of
selected equipment mode is 8. Reverse cleaning with cleaning
too small; agents;
8.Air system fouling;
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1. Correct or replace;
1. Curved fan blade;
2. Replace the fan;
2. Fan motor bearing wear;
H. Overhigh 3.Check expansion valve, adjust or
level of 3. Refrigerant liquid returning; replace;
equipment
4.Compressor damage 4. Replace compressor;
running noise
(jamming, bearing wear)
5.Check the oil levee, add
5. Compressor lacks of oil; lubricating oil and check if the oil
heater is in normal operation;
I. Liquid 1.Clogging of valve on 1. Open the valve and remove the

pipeline high-pressure side; clogging;
frosting 2. Clogging of dry filter; 2.Replace the filter;
J. Suction 1. Abnormal expansion valve; 1. Replace expansion valve;

pipeline 2. Hot gas bypass valve not 2. Adjust or replace the hot gas
frosting opened or poor; bypass valve;
6.2.22 Abnormal steam parameters

1. Phenomena
1.1 Too high or too low of each main steam, reheat steam pressure and temperature
1.2 Alarm due to over-limit of parameters
1.3 Change of unit load
1.4 Change of axial displacements, differential expansion and others of the main equipment
2. Causes
2.1 Control system failure of pressure and temperature, or misalignment of desuperheating water
2.2 Sudden load rejection of unit
2.3 Sudden split of high-pressure header
2.4 Sudden open of safety valve of steam system
2.5 Sudden change of coal quality or out of order of milling system operation
3 Troubleshooting
3.1. Handle separately the control system failure according to failure degree, switch to manual
mode and adjust the pressure and temperature to normal if necessary, and adjust them through
adjusting combustion etc.
3.2 Regulate load change rate If it caused by sharp load fluctuation and handle according to
relevant regulations if the load change is caused by operating conditions of protection operation.
3.3 Regulate the unit load in time for the protection operation split of high-pressure header.
3.4 Regulate the milling system if the milling system operation is out of order which caused unrest
of boiler heat load, or stop if necessary.
3.5. When main steam temperature and reheat steam temperature are abnormal,, handle
according to the following provisions:
3.5.1 Allow the unit to take continuous operation when the main steam temperature and reheat
steam temperature are changing in the range of 537±8℃.
3.5.2 Do not allow the accumulated operating time between steam temperature of 545 ~ 551℃to
exceed 400 hours; do not allow the once-through operation to exceed 30 minute, otherwise, shut
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down the unit due to failure; if the operation time exceeds 400 hours, shut down the unit if the
temperature exceeds again.
3.5.3 If main steam temperature and reheat steam temperature are allowed to shift to extreme of
565℃, or to operate between 551 ~ 565 ℃, make sure the accumulated operation time shall be
less than 80 hours, or else carry out unit failure shutdown immediately. carry out unit failure
shutdown immediately if the steam temperature is more than 565℃. If main steam temperature
and reheat steam temperature are always too high, reduce appropriately the combustion of the
upper burner and take the sootblowing.
3.5.4. If main steam temperature and reheat steam temperature are abnormal, take the measures
promptly to recover steam temperature to normal,, and if main steam and reheat steam
temperature drop continuously and reach the level of lower 84℃ than rated value (454℃) or
steam temperature rapidly drops more than 50 ℃, carry out unit failure shutdown immediately.
3.5.5 If main steam temperature and reheat steam temperature are abnormal, take the measures
promptly to recover steam temperature to normal,, and if main steam and reheat steam
temperature drop continuously and reach the level of lower 84℃ than rated value (454℃) or
steam temperature rapidly drops more than 50 ℃, carry out unit failure shutdown immediately.
3.5.6 If steam pressure and steam temperature change abnormally, pay attention to turbine
expansion difference, axial shift, axial vibration, pressure of supervisory section and shift trend of
each control objective, carry out unit failure shutdown immediately if the limit is exceeded.
6.2.23 Unit load shift
1 Causes
1.1 System thrust, vibration or abnormal boiler operation
1.2 Out-of-step of generator
1.3 Abnormal of turbine control system or abnormal of steam governing valve operation
1.4 Maloperation of high and low press bypass or sudden stopping of heat returning and extraction
of steam
2 Troubleshooting
2.1. Release CCS coordination control and find out reasons rapidly according to CRT display,
relevant instrument reading and external indications.
2.2. Take relevant operations rapidly according to the order of duty chief if system vibration occurs.
2.3 Reduce the active power of generator and increase manually electric excitation if the
generator is out of step.
2.4 Control strictly unit output and do allow the operation with over-limit output if unit load suddenly
change due to grid cyclic wave change.
2.5 Switch immediately to manual control If it is caused by abnormality of control system, and carry
out emergency shutdown if the treatment cannot be taken during operation.
2.6 Regulate throttle flow of steam turbine and stabilize steam parameters if the abnormal
variation of boiler operation causes sudden load change.
2.7 Allow the throttle flow to work with load accordingly if the governing valve is broke and lost,,
and do not increase or reduce the load if the governing valve is stuck.
2.8. Check if thrust bearing, oil exhaust temperature of each bearing, axial shift, differential
expansion, vibration are normal..
2.9. Check if water levels of the desecrator, the condenser, the heater and the gland heater are
normal.
6.2.24 DCS failure
1. All DCS operator station failure
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1.1 Phenomena
1.1.1 Blank screen or deadlock for all of upper computers.
1.1.2 No response of graphic display of mouse or keyboard operation
1.1.3 No more change for each parameter and alarm display etc. on DCS graphic display.
1.2 Causes
1.2.1 DCS power failure
1.2.2 DCS signal interface break.
1.2.3 Software error DCS control
1.2.4 Hardware fault in DCS.
1.3 Troubleshooting
1.3.1 Handle it according to flame failure related rules if DCS failure and boiler flame failure.
1.3.2 Change to backup operation mode If the boiler flame is on and backup manual operation and
supervisory instruments are usable to support the unit normal operation temporarily; solve the
problems and recover the operating mode of operator station, otherwise, stop the unit and boiler.
Shut down the unit and boiler If no reliable monitoring measure of backup operation.
1.3.3 Monitor drum water level, furnace negative pressure, temperature, and pressure and boiler
combustion condition with local water level monitor, flame television, drum water level gauge,
furnace negative pressure, and main/ reheat pressure, temperature and other supervisory
instruments.
1.3.4 Keep unit load stability, take manual load regulation properly and keep normal pressure if
steam pressure is instable.
1.3.5 Contact thermal staffs immediately for inspection and handling.
1.3.6 Shut down the boiler immediately if the operating condition of boiler combustion cannot be
controlled, the parameter is abnormal and DCS failure cannot be removed.
1.3.7 Close locally each oil, air and flue gas valve or baffle with manual or electric method, stop the
rotating equipments after the boiler shutdown.
2 Some operator station failures
2.1 Apply those usable operator stations to monitor the operation of the unit continuously if some
operator stations failure.
2.2. Stop important operations.
2.3. Contact thermal staffs to deal with the faults rapidly.
2.4. Handle according to the operating conditions if the problem cannot be resolved.
3. Handling for the controller or corresponding power failure in the system:
3.1. Switch to backup manual mode of operation if auxiliary controller or corresponding power
failure, and deal with the system failure rapidly; make the auxiliary equipments out of service if the
condition is not allowed.
3.2 Switch automatic mode to manual mode for the operation if the regulating loop controller or
corresponding power failure, deal with system failure rapidly at the same time,, and take
corresponding measures according to actual condition.
3.3 Replace the controller modules or repair immediately if boiler protection controller failure; take
the forcible measures to supply the power and prevent the controller from initialization at that
moment if boiler protection power failure. If the recovery fails, carry out the boiler emergency
shutdown.
6.2.25 Common faults of fire detection probe cooling air fan
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1. Causes of large vibration
1.1 Mounting bolts, locating screws, bearing or coupling becomes flexible;
1.2 Coupling or bearing misaligned or excessively worn;
1.3 Motor is not appropriately aligned;
1.4 Shaft bending;
1.5 Debris accumulated in the impeller;
1.6 Excessive wear or erosion of the impeller;
1.7 System pressure is over large or it is off due to vibration damper, and air flow is blocked;
2. Causes of big noise
2.1 Fan stalling;
2.2 System vibrating;
2.3 Assistive devices or parts become flexible;
2.4 Bearing wear;
6.2.26 Auxiliary Power Interruption
1. Phenomenon:
1.1 Operating motor stops, and voltage and current indication is back to zero;
1.2 MFT action, boiler turned off;
1.3 Accident alarm;
2. Causes:
2.1 Auxiliary power supply in service is failed, and standby power supply has not been connected;
3. Treatment:
3.1 In case high-voltage auxiliary power interruption does not cause boiler fire extinguishing, it
shall rapidly adjust the combustion and control the parameters based on the loads that can be
maintained by FDF and IDF at one side;
3.2 In case of low-voltage auxiliary power interruption does not cause boiler fire extinguishing, it
shall properly adjust the combustion, control the parameters and restore power supply asap;
3.3 Ensure normal operation of equipments connected to boiler security power supply, i.e. FDF oil
pump, IDF oil pump, PAF oil pump, air preheater motor and coal mill oil pump, which shall have
been launched;
3.4 In case the boiler fire extinguishing is caused by auxiliary power supply interruption, the
processing shall be conducted as per handling of boiler fire extinguishing. After boiler shutdown, it
shall:
1) Reset the switch of tripping equipment;
2) Check the running status of air preheater, maintain continuous operation, otherwise put
the air preheater turning gear, and maintain it in running state;
3) Check the status of standby cooling water of boiler pump, pay attention to the chamber
temperature of pump motor;
4) Re-ignite the boiler after power supply is restored;
5) Ensure the closed cooling water has restored operation before startup of boiler pump;
6) Check if the fire detection cooling fan is in normal operation;
6.2.27 I&C and Instrument Power Supply Interruption
1. Phenomenon:
188
1.1 Electric actuator indicator light is off, opening indicator back to zero, and electric remote
operation of relevant equipments is out of control;
1.2 In the mode of automatic, the automatic operation does not work;
1.3 Abnormal instrument indication;
1.4 Boiler combustion may be instable and even fire is extinguished;
2. Treatment:
2.1 Switch automatic mode to manual mode, and adjust the drum water level as per local water
level gauge;
2.2 If the boiler fire has been off, processing as per boiler extinguish circumstance;
2.3 If the boiler fire has not been off, it shall maintain the unit load in stable as much as possible,
and monitor on site the local water level gauge and pressure meter of the drum, and carry out
comprehensive analysis by reference to relevant parameters of steam turbine. Prohibit blind
operation.
2.4 Report to director in duty, and notify thermal workers to restore the power supply rapidly;
2.5 In normal circumstance, the operation can sustain for 20min; in abnormal circumstance, ask
instruction from director in duty for boiler shutdown.
Appendix: Curve and Table
189
Appendix01: Cold Start Curve
190
←│power put in service
←│instrument put in service
←│start start-up of boiler
←| CWP(circulating water pump) washing and filling up
←|start BFP C
←|start CWP
←|start Flame check cooling fan
←|start Air preheater
←|start ID FAN
←|start FD FAN
←|fuel oil leak test is ok,purge 5 minutes
←|oil guns in layer AB in service
←| In case of 5% MCR, start the bypass drain valve,the BYPASS SYSTEM in service
←|the boiler drum pressure is 2.1MPa,stop CWP filling
←|oil guns of another layer in service
←|main steam pressure 5.9MPa,main steam temperature 350℃，reheater steam temperature 340℃,start turbine rolling
←|stop the bypass drain valve of 5% MCR and close the bypass ,system
←|start primary fan and sealing fan
←|the outlet hot air temperature of air preheater up to 177℃,start the 1st mill system
←|when the load is 25%MCR,start the fist BFPT
←|start the 2nd mill system
←|50%MCR load,start the 3rd mill system and stop the oil guns,in the same time the Electrostatic Precipitator in service
←|switching auxiliary steam to reheating cold section
←|stop the start-up boiler
←|according to the load,start the 4th mill system
←|CCS in service
←|start the 5th mill system,the load is 660MW
191
Appendix02: Warm Start Curve
192
←|start BFP C
←|start ID FAN
←|start FD FAN
←|CCS in service
193
Appendix03： Hot Start Curve
194
←|start BFP C
←|start ID FAN
←|start FD FAN
←|CCS in service
195
Appendix04：Very Hot Start Curve
196
←|start BFP C
←|start ID FAN
←|start FD FAN
←|CCS in service
197
Appendix05：Relationship (DP of Boiler furnature and load)
198
Appendix06：Relation of Superheater injection flow flow and Load
喷水量与负荷的关系曲线（滑压） The culve of injection flow and load(sliding pressure)
喷水量 injection flow
总喷水量 Total injection flow
一级喷水量 The first injection flow
二级喷水量 The second injection flow

负荷 load
199
Appendix07：the relation of reheat steam temperature rating and load
200
再热蒸汽温度与负荷的关系曲线（定压） the relation culve of reheat steam temperature
rating and load（fixed pressure）
再热蒸汽温度与负荷的关系曲线（滑压） the relation culve of reheat steam temperature
rating and load（sliding pressure）
再热蒸汽温度 Reheat steam temperature
负荷 load
201
Appendix08：过热蒸汽温度定值与负荷关系
the relation culve of superheat steam
过热蒸汽温度与负荷的关系曲线（定压）
temperature rating and load（fixed pressure）
the relation culve of superheat steam
过热蒸汽温度与负荷的关系曲线（滑压）
temperature rating and load（sliding pressure）
过热蒸汽温度 superheat steam temperature
负荷 load
202
Appendix 9: Control principle list of secondary air baffle
Mixed
Air Furnace Ignition and
combustion of Single pulverized
chamber Name single oil
sootblowing pulverized coal coal putting
No. putting
and oil
Swirl
Open at 50%MCR,
eliminating
OFA Close full open or manual
secondary
mode at 80%MCR
air
Swirl
eliminating Close while stopping F coal mill,
FF Set up △P control
secondary otherwise set up △P control
air
F Perimeter
F The openness is the function of F-tier coal mill output
air
Both of E coal
mill and F coal
If putting oil
mill stop, put this
gun, the
Swirl tier oil gun, the
openness is Close if E coal mill
eliminating openness is the
the function and F coal mill stop,
EF oil open function of oil
of oil otherwise set up
secondary pressure, close if
pressure, △P control
air not putting oil
otherwise
gun, otherwise
close
not set up △P
control.
E perimeter
E The openness is the function of E-tier coal mill output.
air
Deflecting
DE secondary Set up △P control
air
D perimeter
D The openness is the function of D-tier coal mill output.
air
Both of C coal
mill and D coal
If putting oil
mill stop, put
gun, the
this tier oil gun,
openness is Both of C coal mill
Deflecting Open the openness is
the function and D coal mill stop,
CD secondary the function of
of oil otherwise set up
air oil pressure;
pressure, △P control
close if not
otherwise
putting oil gun,
close
otherwise set up
△P control
C perimeter
C The openness is the function of C-tier coal mill output.
air
Forced
BC startup All open or manual
Set up △P control
secondary after oil stop
air
203
B perimeter
B The openness is the function of B-tier coal mill output.
air
Both of A coal mill

If putting oil and B coal mill
gun, the stop, put this tier
Deflecting openness is oil gun, the Both of A coal mill
oil the function openness is the and B coal mill stop,
AB Open
secondary of oil function of oil otherwise set up
air pressure, pressure; close if △P control
otherwise not putting oil
close gun, otherwise
set up △P control
A perimeter
A The openness is the function of A-tier coal mill output.
air
Direct
blowing All open if putting A coal mill, otherwise
AA Set up △P control
secondary set up △P control
air
Appendix 10 Saturated steam temperature comparison table under relative pressure
Pressure Temperature Pressure Temperature Pressure Temperature
MPa ℃ MPa ℃ MPa ℃
0.098 119.61 3.138 238.07 6.178 278.50
0.196 132.87 3.236 239.76 6.276 279.52
0.294 142.92 3.334 241.42 6.374 280.53
0.392 151.11 3.432 243.03 6.472 281.53
0.49 158.07 3.53 244.62 6.571 282.52
0.588 164.17 3.629 246.17 6.669 283.50
0.687 169.60 3.727 247.68 6.767 284.47
0.785 174.53 3.825 249.17 6.965 285.42
0.883 179.03 3.923 250.63 6.1063 286.37
0.981 183.20 4.021 252.07 7.061 287.31
1.079 187.08 4.119 253.48 7.159 288.23
1.177 190.71 4.217 254.86 7.257 289.15
1.275 194.13 4.315 256.22 7.355 290.06
1.373 197.36 4.413 257.56 7.453 290.96
1.471 200.43 4.511 258.87 7.551 291.85
1.569 203.35 4.609 260.16 7.649 292.73
204
1.667 206.14 4.707 261.44 7.747 293.60
1.765 208.82 4.805 262.69 7.845 294.47
1.863 211.39 4.903 263.92 7.934 295.32
1.961 213.85 5.001 265.14 8.042 296.17
2.059 216.23 5.1 266.34 8.14 297.01
2.158 218.53 5.198 267.52 8.238 297.85
2.256 220.75 5.296 268.68 8.336 298.67
2.354 222.90 5.394 269.83 8.434 299.49
2.452 224.99 5.492 270.96 8.532 300.30
2.55 227.01 5.59 272.08 8.63 301.11
2.648 228.98 5.688 273.19 8.728 301.90
2.746 230.89 5.786 274.27 8.826 302.69
2.844 232.76 5.884 275.35 8.924 3.3.48
2.942 234.57 5.982 276.41 9.022 304.26
3.04 236.34 6.08 277.46 9.12 305.03
9.218 305.79 12.356 327.502 15.495 345.232
9.316 306.55 12.454 328.105 15.593 345.75
9.414 307.35 12.553 328.71 15.691 346.242
9.513 308.05 12.651 329.31 15.789 346.734
9.611 308.79 12.749 329.889 15.887 347.225
9.709 309.52 12.847 330.468 15.985 347.717
9.807 310.25 12.945 331.047 16.083 348.209
9.905 310.98 13.043 331.628 16.181 348.701
10.002 311.70 13.141 332.206 16.28 349.193
10.1 212.41 13.239 332.785 16.377 349.684
10.199 313.12 13.337 333.364 16.475 350.176
10.297 313.822 13.435 333.943 16.573 350.668
10.395 314.517 13.533 334.523 16.671 351.136
10.493 315.212 13.631 335.101 16.769 351.604
10.591 315.897 13.729 335.648 16.967 352.072
205
10.689 316.582 13.827 336.195 16.1066 352.54
10.787 317.257 13.925 336.742 17.604 353.009
10.885 317.932 14.024 337.289 17.162 353.477
10.983 318.598 14.122 337.836 17.26 353.945
11.082 319.64 14.22 338.382 17.358 354.413
11.18 319.921 14.318 338.929 17.456 354.881
11.278 320.578 14.416 339.476 17.554 355.349
11.376 321.6 14.514 340.023 17.652 355.795
11.474 321.874 14.612 340.57 17.75 356.242
11.572 322.514 14.71 341.088 17.848 356.688
11.67 323.154 14.808 341.066 17.946 357.134
11.768 323.785 14.906 342.124 18.044 357.581
11.866 324.416 15.004 342.646 18.142 358.027
11.964 325.04 15.102 343.16 18.24 358.473
12.062 325.663 15.2 343.678 18.338 358.919
12.16 326.279 15.298 344.196 18.437 359.366
12.258 326.994 15.396 344.714 18.535 359.812
206
Appendix 11 Sliding parameter shutdown curve
207
Appendix 12 Fixed parameter shutdown curve
208
Chinese English
滑参数停机曲线 Sliding parameter shutdown curve
定参数停机曲线 Fixed parameter shutdown curve
负荷 Load
转速 Rotating speed
压力 Pressure
温度 Temperature
Main, Reheat steam temperature steam
主、再热蒸汽温度
temperature
主汽压力 Main steam pressure
再热汽压力 Reheat steam pressure
时间 Time
209

Chapter 1 Operation Manual of Boiler

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Chapter 1 Operation Manual of Boiler

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Indonesia 1×660MW Paiton

Coal Fired Thermal Power Plant

Operating and Maintenance Manual

Volume II: Operation Manual

Harbin Power Engineering Company Limited

1 Main steam flow t/h 2187.13 2064.1

2 Drum pressure MPa 19.00

3 Main steam pressure MPa 17.40 17.40

4 Main steam temperature ℃ 541 541

5 Reheated steam flow t/h 1839.8 1742.4

6 Reheated steam inlet pressure MPa 4.025 3.81

7 Reheated steam outlet pressure MPa 3.835 3.63

8 Reheated steam inlet temperature ℃ 338.1 332.3

9 Reheated steam outlet temperature ℃ 541 541

10 Boiler’s feed water temperature ℃ 281.4 282.7

Air preheater’s inlet primary wind

17 Theoretical air amount Nm3/kg 4.327 4.196

18 Coal-fired quantity of the boiler t/h 375.9 358.6

19 Guarantee thermal efficiency of boiler % 93.28 93.01

20 Feedwater Pressure MPa 19.49 19.22

21 Total Air Amount Nm3/kg 2609.6 2489.3

1.2.3. Performance parameters of main components of boiler body

3.6 一 Primary air rate / wind speed 25%/28m/s

Outlet working substance

maximum metal wall temperature

Outlet working substance

Elemental Fixed carbon F.Car % 31.5 27.8

Received based sulfide Snet.nr % 0.23 0.24

Received based ash A % 3.5 3.9

Dry ash-free basis volatiles Vdaf % 50 52.69

Received basis gross heating value QHHV kcal/kg 4200 4070

Received basis low- calorie capacity Qnet.nr kcal/kg 3849 3706

Abradable coefficient HGI 60 50

Ash melting Ash softening temperature ST ℃ 1200

Air amount 172.84/120.48/94.57 Total wind pressure

Rotating speed 1470r/min Quantity 2 sets

Coal mill speed 27.7 r/min Guarantee output 89.64t/h 79.56t/h

Service life of grinding Raw coal particle size

Distributor type of the

Coal mill’s motor

Rated voltage 6000V Rated current 111A

Rated speed 982r/min Rated frequency 50Hz

Class number 6 class Insulation Class F class

Cooling way IC611( Air-air cooling ) Power Factor 0.79

Rated load efficiency 93% Bearing type Rolling Bearing

Starting current/rated Bearing’s lubrication

Mode KMP360 Transmission ratio 35.6:1

Spiral bevel gear -planetary

Pump model OWTS11 Pump type Gear pump

Lubricating oil flow 287L/min Gearbox capacity L

Pump’s motor model Pump’s motor speed r/min

Pump’s motor voltage 380V Pump’s motor power 15kW

Oil supply pressure 0.45MPa Pump number 1set

Electric heater voltage 380V Electric heater power 1.7kW

Lubricant oil cooler

Mode EG2490 Quantity 6 sets

Main drive motor voltage 380V Output range 11～110t/h

sealed volume 10Nm3/min Raw coal warehouse m3

Type Horizontal Mode KQP-B-220L

Boiler water pump

Air preheater’s motor

Flame check cooling fan

Instrument air compressor