C 14/10/03 Jp Ch Bad Reviewed further to Client’s letter n°3407(17.09.

03) FUS
B 08/07/03 Jp Mo Bad Reviewed further to Client’s letter n°1886(21.05.03) FUS
A 21/03/03 Jp Ch Bad First issue PRE
REV DATE AUTH. CHECK. APPR. BY MODIFICATIONS STATUS
BY

TEAS
TÜRKIYE ELEKTRIK ÜRETIM - ILETIM A. S.
SANTRALLAR PROJE VE TESIS DAIRESI BASKANLIGI
TURKISH ELECTRICITY GENERATION - TRANSMISSION Co.

2 x 160 MW ÇAN THERMAL POWER PLANT

ALSTOM Power Centrales – ALSTOM Power Boiler GmbH. – ALSTOM Enerji-Nakil A.S. – TEKNOTES Ltd. Sti.

CONSORTIUM

PROJECT DWG. N° :

DESIGN SUBCONT.

DRAWING OVERALL OPERATING INSTRUCTIONS

TITLE
BOILER PREPARATION

TÜRKIYE ELEKTRIK ÜRETIM - ILETIM A. S.

ÇAN THERMAL POWER PLANT

SCALE : - Rev. No
Drawing N° CNK 1 2 M - - - OV EO I 10 5
SIZE : C

ALSTOM Power
ALL RIGHT PERTAINING TO THE REPRODUCTION, TRANSFORMATION AND USE OF THIS DOCUMENT
IN ANY FORM OR MANNER REMAIN THE EXCLUSIVE PROPERTY OF ALSTOM POWER
abcd
Power
Plant Segment
Engineering

ÇAN THERMAL POWER PLANT

2 x 160 MW

OVERALL OPERATING INSTRUCTIONS

BOILER PREPARATION

SUMMARY

_____

1 INTRODUCTION

2 REQUIREMENTS AND CONSTRAINTS

3 PREPARATION FOR STARTING

CNK 12 M OVE --- OI 105 C October 2003

1 INTRODUCTION

This document is a general guidance for experienced and authorised operators.

It lists the main operations to be carried out for preparation of the unit for start-up.

To start the different equipment, the operator refers to the system operating instructions of the
relevant systems.

Actual operation conditions may dictate the requirement to implement changes to this
document.

1.1 Scope of the procedure

The purpose of this procedure is to prepare the boiler plant prior to its start-up.

The procedures required with this document are the following :

- CNK 12 M OVE --- OI 101 : Electrical distribution start-up,

- CNK 12 M OVE --- OI 105 : Condensing and feedwater plant preparation,
- CNK 12 M OVE --- OI 106 : Steam turbine and generator preparation,
- 1.47720/00 017-7201 : Boiler operating instruction

1.2 Preparation scheduling

1.2.1 Preliminary verifications

Before first starting, check if the equipment and their control loops have been tested to avoid
any error or and bug.

In order to avoid time delay and over consumption of energy and fluids during the preparation
of the start-up :

- check if the circuits are empty or full to determine which exceptional operations must be
carried out (filling of capacities, etc.),
- enquire from the concerned staff that :
. outage works will be complete in order to return the equipment available at time for start-
up (scaffolding and temporary safety devices removed, working areas cleaned, etc.),
. the power supply from the external grid is available,
. the service fluid production units are ready to supply at the correct rate and quality the
necessary operation fluids (compressed air, demineralised water, service water, etc.).

1.2.2 Delay and Chronology

The delay of the preparation steps depends on the necessity (or not) to perform some
operations.

The chronology of the preparation steps should be adapted to the situation of the plant. The
order given in chapter 3 is only indicative and can be modified according to the unit status.

1.3 Initial state

The initial state described here is given as an indication. Differences with the initial state will
not prevent the application of the procedure.

The operation staff must adapt their actions according to real status and with respect for the
safety rules.

CNK 12 M OVE --- OI 105 C 2/7

1.3.1 Systems or equipment in operation

- Control systems
- Electrical Supply Switchboards (power and control)
- Fire protection and detection systems
- HVAC systems
- All systems according the start categories

1.3.2 Systems and equipment shutdown

- Boiler and auxiliaries

2 REQUIREMENTS AND CONSTRAINTS

The upstream start-up requirements and constraints concern :

- The common electrical systems allowing to supply :

. the common mechanical systems,
. the electrical equipment allowing the unit supply during start-up or incidents,
- the common control and communication systems,
- the common mechanical systems which :
. supply the service fluids for the starting unit systems,
. ensure the general safety and comfort of the personnel and equipment.

2.1 Electrical systems

Check that the following systems / equipment are energised and available for operation :

- kV handling and their control systems,

- VAC handling - their control and UPS systems,
- VDC handling and their control system,
- diesel generators available,
- normal and emergency lighting available.

2.2 General auxiliaries

Check that the following systems are either available or in operation :

- filtered water available,

- demineralised water treatment plant available,
- demineralised water storage tanks at least 50 % full,
- compressed air system in operation (service air and instrument air pressure normal),
- waste water pumping and drainage system available,
- oil contaminated water drain collection system available,
- one HFO/LFO storage tank at least 30 % full and at least one HFO/LFO pump available,
- bottom ash all cleared from the furnace and ash handling system available,
- precipitator hoppers emptied and heaters in and fly ash handling system available,
- fuel handling systems HFO/LFO and coal,
- fire detection and fire fighting systems for all the general auxiliaries listed above,
- control building fire protection system available,
- control room heating ventilation and air conditioning (HVAC) system in operation,
- Limestone handling systems,
- Air handling systems,
- Chemical conditioning (injection) and sampling systems.

CNK 12 M OVE --- OI 105 C 3/7

2.3 Measuring and control systems

Check that the following systems are in operation :

- DCS,
- data treatment,
- PLC,
- alarm treatment,
- energy counting,
- telephone,
- clock.

All indications related to the systems available, especially the following :

- boiler steam and metal temperatures,
- boiler steam pressure,
- boiler drum water level indication,
- boiler furnace pressure
- boiler air flow,
- boiler fuel flow,

3 PREPARATION OF START-UP

3.1 Summary of general principle

The arrangement of circulating Fluidised bed boiler is a natural circulation, drum type steam
generator unit. The single leg combustion chamber is rectangular. Entrained solids exiting the
of the combustion chamber with the gas stream are captured by four cyclones and are recycled
back to the lower combustion chamber via loop seals (seal pot). The outlets of the cyclones join
together and enter a common convection pass.
The heart of a Circulating Fluidised Bed (CFB) boiler is the combustor, which receives the
coarse-ground Coal, together with the limestone necessary for sulphur removal.

Combustion and desulfurisation take place within a large mass of highly agitated fine ash
particles.These particles (or solids) are held in suspension - "fluidised" - by an upward flow of
air blown into the bottom of the combustor. Combustion air is mainly divided in primary air (air
through nozzle grid), and secondary air (air through air nozzles above grid), bed material
consists of approximately 98% ash or sand.. Nozzle grid causes for a homogenous fluidization
of bed material. Primary air transport bed material in direction of ceiling, coarse bed material
falls down along sidewalls, other material is separated in cyclones, separated material returns
to furnace through loop seals with fluidization air, flue gas leaves cyclones through exit tubes to
2nd pass, fly ash is separated in electrostatic precipitator. Crushed raw lignite is stored in four
coal bunkers., then coal is discharged through coal feeders to 8 feeding points of four double
ash loop seals for a uniform distribution of the fuel across nozzle grid, mixing with hot ash in
loop seals predries coal already.
The pre-cleaned flue gas and uncollected fine particules exit at the top of cyclone outlets and
flow through the convective section of the second boiler pass to air preheater and electrostatic
precipitator and induced draft fan to the stack settled inside the cooling tower.
The flue gas then flow through a conventional heat recovery section, the air heater and the dust
collecting system, before being send to the stack.

A CFB combustor operating in the optimum fluidisation regime is a superior "reactor" (in the
chemical engineering meaning). This regime is characterised by very strong agitation and
mixing, high solids internal recirculation, high gas/solids slip velocity and long residence times.

All this results in excellent conditions regarding heat transfer and chemical reactions.

This achieves both efficient combustion of the most difficult fuels and very efficient
desulfurisation. In addition, very low NOx emissions are ensured by the moderate bed
temperature and the staged air introduction.

CNK 12 M OVE --- OI 105 C 4/7

3.2 Normal operation of installation

3.2.1 Ballast

The total mass of solids in circulation is kept constant.

As the continuous supply of inert products (from the products of the desulfurisation) is much
greater than the mass of very fine particles entrained by the flue gas, it is necessary to
continuously extract solids.

The quantities of ash to be extracted account for 20 % to 60 % of the total ash produced by the
reactor, the other part being collected in the dust collector.
The bed ash discharge system extracts the bed ash from the furnace automatically depending
on the pressure above primary air nozzle grid.

3.2.2 Air circuits and flue gas circuits

- Primary air /

The role of the primary air is to fluidise the solids in the combustor.

The primary air flow is adjusted to a constant value when boiler is between 0 and 60% of full
load, and then increases with the load up to its nominal value.

The primary air represents 45% of the total air supplied to the combustor in nominal
operation.

- Secondary air :

The secondary air fan delivers the quantity of air necessary for combustion to complement
the air already supplied for fluidisation (primary air, fluidising air, seal pots and ash coolers).

The secondary air is then distributed to injection points in the lower part of the combustor
and injection points in the upper part. Two dampers control the flow to each level.

- The fluidising air and ash coolers is delivered by 4 fans. Control and hand trimm dampers
distribute these flows between the various compartments.

- Combustor temperature adjustment :

The combustor temperature must be held at approximately 850 °C which is a good optimum
considering desulfurisation reaction.

The furnace temperature results from the balance between heat supplied by the fuel, heat
transfer to the steam-generating tube-walls in the combustor and heat transfer to the
exchangers in the bed.

Ash extracting valve regulation is done the following way :

The bottom ash discharge via horizontal L-valve is done discontinously. The horizontal L-
valve is set into a basic position. The opening sequence and amplitude of the horizontal L-
valve is controlled by reference value, pressure above primary air nozzle grid. During
normal operation both horizontal L-valves are in operation and work alternating for each
sequence. The horizontal L-valve is kept at its basic position when the reference value is
below a specified minimum set point.

CNK 12 M OVE --- OI 105 C 5/7

3.2.3 Limestone injection

The flow of limestone injected into the combustor is proportional to the fuel flow, and adjusted
from the sulphur-dioxide measurement in flue gas.

The role of the limestone is to neutralise at least 95% of the sulphur in the coal and to maintain
the SO2 content in flue gas below 1000 mg/nm3 (dry basis and corrected to 5% O2). The
limestone flow is automatically corrected to maintain the SO2 content at the set value
determined by the operator.

3.2.4 Sand injection

The sand is only necessary for the first filling.

3.2.5 Water steam circuits

- The economiser is installed and arranged in second pass flue gas, last heating surface
upsteam flue gas air heater.

- The superheaters are split in two parallel steam lines :

. SH 1/1 supporting tubes of the second pass,
. SH ½ walls of second pass,
. SH 1/3 convective heating surface in second pass.
. SH 2 platen heating surface in furnace
. SH 3 convective heating surface in second pass.

- Desuperheaters are installed between SH1/3 and SH2 and between SH2 and SH3.

- The reheaters are split in two parallel steam lines :

. RH1 convective heating surface in second pass,
. RH2 platen heating surface in furnace.

- One desuperheater is installed at the RH2 inlet

- The steam pressure in normal operation is controlled by turbine inlet valves and fuel flow to
the boiler.

- During the boiler start, steam pressure is controlled by the opening of the HP bypass.

3.2.6 Filling of combustor

The initial quantity of sand or ash to be introduced into the combustor before the start must be
at least 60 t which represents a height of the bed above the grate of more than 0.7 m (bed
slumped). For the first filling of the loop seals and ash coolers additional about 110 t are
needed.

The filling level of the combustor is estimated after having started the secondary and primary
air fans.

The secondary air fan running is needed to avoid build up of any deposits of solids in the
secondary air injectors and the primary air fan running provides the total delta P information.

A minimum of 4000 Pa must be obtained from this measurement to begin the actual start
operations (start of burners, see cold start).

CNK 12 M OVE --- OI 105 C 6/7

3.3 Start categories

Boiler cold start is defined in its procedure.

Boiler warm start is defined in its procedure.

Boiler hot start is defined in its procedure.

3.4 Pre-starting check

The pre-starting check must be performed following the boiler conditions according their start
categories.

CNK 12 M OVE --- OI 105 C 7/7