Asiakirjan nimi - Name of Document Tunniste - Identification Rev.

SHUTDOWN CFBT-582-1 1

Osasto - Department Kohde - Subject

Power Generation RAPP PB3 PROJECT 1 (8)

Systems CFB MULTIFUEL BOILER

TABLE OF CONTENTS

7. SHUTDOWN.......................................................................................................... 2
7.1 Shutdown of boiler plant generally......................................................................... 2
7.2 Boiler shutdown ..................................................................................................... 4
7.2.1 Normal shutdown of the plant ................................................................................ 4
7.3 Shutdown at disturbances ..................................................................................... 5
7.4 Shutdown of fluidized bed...................................................................................... 6
7.5 Stop oil firing .......................................................................................................... 7
7.6 Stopping of the air and flue gas system................................................................. 8

1 2005 - 08 - 30 Tuomo Keinonen

0 2005 - 02 - 10 Tuomo Keinonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder
1\07shutdown_rev1.doc
This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 2 (8)

Systems CFB MULTIFUEL BOILER

7. SHUTDOWN

7.1 Shutdown of boiler plant generally

When the boiler shutdown is executed the various systems are taken
out of service and this is usually carried out in the following order:

1. Stop sootblowing
• sootblowing can be usually stopped in good time before the
boiler shutdown, so that the actual need of sootblowing can be
seen at shutdown inspections.

2. Shutdown of the fuel handling equipment

• emptying of coal silos and bark silos if that is necessary
• emptying of conveyors

3. Stop fluidized bed firing

• when fuel feeding has been stopped, the thermal effect of bed
firing decreases very quickly
• stop limestone feeding when coal feeding has been stopped
• when bed temperatures are decreased at least 50 °C the primary
air fans can be stopped and the sand bed can be kept ready to
start (> 600 °C).
• If internal inspection is needed the sand bed must be cooled
down to about 100 °C by fluidizing air. Also loop seal sand
cooling have to be taken care of.

4. Stop oil firing

• the boiler can be used with oil firing during shutdown if
necessary
• after stopping the burners ignition gas (2831449, 2831457,
2831441, 2831433, 2831473 and 2831465) and oil (2831455,
2831463, 2831447, 2831439, 2831479 and 2831471) manual
safety shut-off valves are closed.

5. After-purging of the furnace

• after stopping the last burner it is recommended to purge the
furnace through the secondary air ports.

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 3 (8)

Systems CFB MULTIFUEL BOILER

6. Stop ash systems

• stop bottom ash removal after bed firing has been ended
• stop the electrostatic precipitator and fly ash transport system, if
fluidized bed firing is not used.
• if the furnace bottom will be inspected, the bed material must be
removed using bottom ash removal system. Before removal bed
is cooled by fluidization
• if the loop seal(s) will be inspected inside, the sand must be
drained to containers through valves (2831262, 2831264,
2831272, 2831274, 2831282 and 2831284). Before draining
sand is cooled by fluidization

7. Shutdown of the boiler water-steam circuit

• when use of steam is stopped, main steam valve (HV-1198) is
closed
• start-up valves (HS-1192 and HIC-1193) should be open as long
as steam generation continues. Steam flow in the superheaters
will be assured on this way and over heating of superheaters will
be prevented
• smooth decrease of pressure/temperature shall be carried out
and if new start is expected soon the boiler “bottling” can be
performed.

8. Shutdown of the air system

• stop steam coil air preheater for primary air
• stop fans when after-purging has been completed
• when fluidizing air fans have been stopped the loopseal fluidizing
air compressor can be stopped

9. Shutdown of the feedwater system

• stop chemical dosing
• stop feedwater pumps when evaporation ends
• stop make-up water pumps
• cooling and emptying of feedwater tank, if required .

10.Shutdown of the flue gas system

• stop the fans
• arrange natural draft if necessary or close flue gas dampers.

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 4 (8)

Systems CFB MULTIFUEL BOILER

11.Boiler preservation
• preserve the water/steam circuit according to the duration of the
boiler shutdown.

7.2 Boiler shutdown

There are several variations of boiler shutdown. One of the extreme

cases is predicted shutdown, when instructions for action are fairly
easy to follow. The opposite of this situation is a complete blackout,
which occurs quite unexpectedly.

Between these extreme cases there are shutdowns caused by some

disturbance or malfunction, hazardous situation or interlocks and the
measures related to them.

In these cases a general guideline is that the shutdown should be

carried out in such way that the normal operating condition can be
restored safely as soon as possible.

7.2.1 Normal shutdown of the plant

The plant is left out of service for some time and the time for the
shutdown is fixed in advance.

In the beginning of the plant shutdown, stop oil and fluidized bed
firing first and decrease capacity at a certain speed. The evaporation
of the boiler starts to diminish.

Measures at the boiler:

• Before boiler evaporation falls to zero open the start-up valves
(HV-1192 and HIC-1193) slightly, so that the flow through the
superheaters continues and prevents superheater material
overheating.
• After the steam flow has ended, close the main steam valve HI-
1198 and the start-up valves (HV-1192 and HIC-1193). When
boiler is kept pressurized the start-up time will be considerably
shorter compared to cold start-up
• Stop chemical dosing or arrange conservation chemical dosing
at the end of heating.

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 5 (8)

Systems CFB MULTIFUEL BOILER

• When the pressure in the boiler drum has fallen to abt. 2 bar,
open the venting valves (2831631 and 2831632) of the drum
gradually and let the boiler release the pressure.

NOTE! Slow pressure decrease (125 bar → 2 bar abt. 1 day) is

advantageous to pressure parts and refractory
structures, unless cooling of the boiler is urgent.

7.3 Shutdown at disturbances

When a disturbance occurs at the boiler it must be established first,

at which part of the process the disturbance lies.

Depending on the situation the shutdown is carried out at the speed

and the extent required.

When the disturbance is at the boiler or in its control system, the

safety interlock system takes care of the boiler shutdown, so that
harm is minimized

Shutdown by interlocks can be caused by the following factors:

• drum level is below the lower limit interlock < -250 mm
• drum level is over the upper limit interlock > +250 mm
• fluoseal air flow is below lower interlock limit < 0,15 Nm3/s
• flue gas pass is not open or fans have stopped
• furnace pressure is above maximum > + 3,5 kPa
• "EMERGENCY-STOP" push-button has been actuated.

The cause of the disturbance must always be established and

removed, before the boiler is started again.

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 6 (8)

Systems CFB MULTIFUEL BOILER

7.4 Shutdown of fluidized bed

In normal and scheduled shutdown the combustion is stopped:

• Decrease fluidized bed capacity to minimum.
• Stop fuel feeding.
• Burn the bed empty by keeping the primary air fan on, after
which the bed temperature starts to fall.

NOTE ! In coal firing it may take 10 - 15 min to burn all coal from the
bed

• When the bed temperature has fallen abt. 50 oC after stopping

fuel feeding, the primary air fan and fluoseal air compressor can
be stopped, if the intention is to leave the bed hot (to make
subsequent start-up easier).
• Take off the steam coil air preheater for primary air
• If the intention is to cool the bed for maintenance measures, for
example, it can be done by fluidizing the bed sufficiently long
time. Cooling below 100 oC takes several hours.
• Electrostatic precipitator is taken out of service.

NOTE ! It is not allowed to drain boiler water before the bed

temperature is below 200 oC

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 7 (8)

Systems CFB MULTIFUEL BOILER

7.5 Stop oil firing

Stopping the oil firing is normally carried out from the control room
by diminishing the burner capacity gradually and by extinguishing it
by the stopping sequence, when the oil lance becomes purged by
steam blowing.

The shut-down sequence carries out the following measures (for

example start-up burner 1):
• In the beginning the burner is normally on.
• When the interlock conditions are fulfilled, the shutdown program
starts.
• Igniter is started.(igniter go inside and gas line quick-closing
valves HS-2112A and HS-2112C opens and HS-2112B
closes).
• Oil quick-closing valves (HS-2117A and HS-2117B) are
closed.
• Atomizing air/steam valve (HV-2116) is opened to blow the
lance.
• When the oil lance has become clean (abt. 45 sec. blowing), the
air/steam valve (HV-2116) is closed.
• After this the combustion air damper FV-1303 is closed.
• Igniter is extinguished (it is retracted into protective position.)
• Atomizing steam valve HS-2115 closed.
• Burner lance is retracted.
• Burner protection plate (HS-2121) is closed
• Clean and maintain the oil gun if necessary.

The corresponding measures can also be taken as individual control

from the local control box.

At a disturbance the burner interlocks prevent of a hazardous

situations by stopping the burners, if the interlocks for the burner in
question are not fulfilled.

NOTE ! In emergency situation the quickest way to stop the burner

(all at the same time) is to push “oil emergency stop “
button

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005
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Power Generation RAPP PB3 PROJECT 8 (8)

Systems CFB MULTIFUEL BOILER

7.6 Stopping of the air and flue gas system

When the boiler is at a minimum load, stop the combustion and other
systems, except the flue gas system, and purge the boiler for
minimum 2 min. with an air amount of abt. 45 Nm3/s.

Stop the air system after boiler purge and cooling, before stopping
the flue gas system.

Depending on the situation, the boiler is left cold or hot "bottled" and
to natural draft or with the flue gas pass closed.

Cooling can be improved by opening the burner air dampers (FV-

1303, FV-1304, FV-1302, FV-1301, FV-1306 and FV-1305) and/or
lower secondary air dampers (FV-1297 and FV-1299), but cooling is
not allowed take place too quickly, because rapid change in
temperatures causes stress to the boiler structures. After cooling the
air dampers can be left open, if natural draft in the boiler is wanted
during the shutdown. Otherwise they are closed.

If you like to leave the boiler hot, close all the air dampers after
purge.

Stop the flue gas system as the last system of the boiler (after
stopping the air fans). After the flue gas fan has stopped, leave the
dampers on the pressure side (HS-1373 and HS-1384) of the fans
open and as well as dampers before ESP (HS-1363 and HS-1374),
so that natural draft is possible. This is the procedure if you are
going inside the boiler for inspection or other purposes. If, again, you
want to keep the boiler warm as long as possible, close the above-
mentioned dampers and prevent the air flow through the boiler.

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