TT

Employer’s and Contractor’s Information / Project Name
2x500 MW NEYVELI NEW THERMAL POWER

PROJECT (NNTPP)
NEYVELI, TAMILNADU, INDIA

Space for Stamping (Review and Validation status - if needed)
Participant
Scale Other Document Code (if any)
Responsible dept. Created by Checked by Approved by Format

CC-CM T. Wende C. Hotze H. Nagel A4
Originator Document Type Project Document Code
NLC/01/B/G1-04-0300/OI/106
Title, Subtitle Document Status
Unit 01 Released
Identification number
Operating Manual 148760_00108_7106

GE Boiler Deutschland GmbH Rev. Date Lang. Sheet
Soot blower & Water lance blower
00 25.08.17 En 1/32
© General Electric 2016. All rights reserved. Please consider the environment before printing this document
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
SYSTEM OPERATING MANUAL
SOOT BLOWER & WATER LANCE BLOWER
REVISION HISTORY
Revision history
Rev. Revision Date Created by Checked by Approved by Description
00 25.08.2017 T. Wende 1st issue
Originator Identification number Rev. Date Lang. Sheet

GE Boiler Deutschland GmbH 148760_00108_7106 00 25.08.17 En 2/32
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
INDEX
1 PART 1 – General ................................................................................................................ 8

1.1 Purpose of the document ................................................................................................................... 8
1.2 Purpose of the system ........................................................................................................................ 8
1.3 Health and safety ................................................................................................................................ 8
1.3.1 General safety instructions ............................................................................................................ 9
1.3.2 System specific safety instructions .............................................................................................. 11
1.4 System delimitations ......................................................................................................................... 11
1.4.1 Water Lance Blower HCC ........................................................................................................... 11
1.4.2 Sootblower System HCB ............................................................................................................. 11
2 PART 2 - Control panel operating instructions ................................................................13
2.1 Function description.......................................................................................................................... 14
2.1.1 Water Lance Soot blowers .......................................................................................................... 14
2.1.2 Retractable steam soot blowers .................................................................................................. 15
2.1.2.1 General Data for Retractable steam soot blowers ................................................................. 17
2.1.3 RAPH sootblower ........................................................................................................................ 17
2.2 Preparation for starting ..................................................................................................................... 18
2.2.1 Water Lance Blower .................................................................................................................... 18
2.2.2 Steam Sootblower ....................................................................................................................... 18
2.3 Start-up and Operation ..................................................................................................................... 19
2.3.1 Operation of the water blower system ......................................................................................... 19
2.3.2 Operation of the rotary long retractable and part retractable soot blower plant .......................... 20
2.4 Operation .......................................................................................................................................... 21
2.5 Shutdown .......................................................................................................................................... 22
3 PART 3 - Field operations ..................................................................................................23
3.1 Recommissioning ............................................................................................................................. 23
3.2 Preparation for starting ..................................................................................................................... 24
3.2.1 Basic position of valves and dampers ......................................................................................... 24
3.2.1.1 Water Lance Blower (HCC) .................................................................................................... 24
3.2.2 Water Lance Blower (HCB) ......................................................................................................... 25
3.3 Start-up ............................................................................................................................................. 27
3.4 Operation .......................................................................................................................................... 27
3.5 Shutdown .......................................................................................................................................... 28
4 PART 4 – Special operation ...............................................................................................30
4.1 Online isolation for Permit To Work .................................................................................................. 30
4.2 Alarms description and troubleshooting ........................................................................................... 30
4.2.1 Alarm list ...................................................................................................................................... 30
4.2.2 Steam blower ............................................................................................................................... 30
4.2.3 Water lance blower ...................................................................................................................... 31
4.2.4 Troubles in the movement ........................................................................................................... 31

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
LIST OF REFERENCE DOCUMENTS

System Alarm Sheets:
Operation instructions Boiler alarm sheets NLC/01/G4-01-0300/111

Operation instructions Boiler Protection alarm sheets
NLC/01/G4-01-0300/112
Operation instructions Air / Flue gas alarm sheets NLC/01/G4-01-0300/113
Operation instructions Water / Steam alarm sheets NLC/01/G4-01-0300/114
Operation instructions Coal Firing alarm sheets NLC/01/G4-01-0300/115
Operation instructions Oil Firing alarm sheets NLC/01/G4-01-0300/116
Operation instructions Sootblower & Water Lance Blower alarm sheets
NLC/01/G4-01-0300/117
Operation instructions Ash Handling alarm sheets NLC/01/G4-01-0300/118
System Design Manual:

Operation Instructions Boiler NLC/01/G4-01-0300/101
Operation Instructions Boiler Protection NLC/01/G4-01-0300/102
Operation Instructions Air / Flue Gas NLC/01/G4-01-0300/103
Operation Instructions Water / Steam NLC/01/G4-01-0300/104
Operation Instructions Coal Firing NLC/01/G4-01-0300/105
Operation Instructions Oil Firing NLC/01/G4-01-0300/106
Operation Instructions Sootblower & Water Lance Blower
NLC/01/G4-01-0300/107
Operation Instructions Ash Handling NLC/01/G4-01-0300/108
Firing system process design NLC/00/B/G2-X2-1000/ER/101

Process description water / steam NLC/00/B/G2-X5-2000/DM/530
Pre-control curves of the firing system NLC/00/B/G2-X2-2000/DM/063
Piping & Instrumentation Diagram (P&ID):

P&ID Eco and Evaporator NLC/00/B/G2-X7-11--/FD/001
P&ID Superheater NLC/00/B/G2-X7-11--/FD/002
P&ID Reheater NLC/00/B/G2-X7-11--/FD/003
P&ID Drain and Venting Station NLC/00/B/G2-X7-11--/FD/004
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
LIST OF REFERENCE DOCUMENTS

P&ID Condensate System NLC/00/B/G2-X7-11--/FD/005
P&ID Combustion Air Distribution NLC/00/B/G2-X7-11--/FD/021
P&ID Furnace Air and Flue Gas NLC/00/B/G2-X7-11--/FD/022
P&ID Coal Burner NLC/00/B/G2-X7-11--/FD/023
P&ID Oil firing, Ignition and support NLC/00/B/G2-X7-11--/FD/024
P&ID Burner Valve Arrangement NLC/00/B/G2-X7-11--/FD/025
P&ID Sootblower NLC/00/B/G2-X7-11--/FD/030
P&ID Water Lance Blower NLC/00/B/G2-X7-11--/FD/031
P&ID Wet ash conveying system NLC/00/B/G2-X7-11--/FD/061
P&ID Beater wheel bearing lubrication mill 1 NLC/00/B/G2-X7-11--/FD/250
P&ID Air canon bunker mill 1 NLC/00/B/G2-X7-11--/FD/300
P&ID Gear coupling oil circuit NLC/00/B/BK-02-03--/851
Manual from supplier and partners:
To be completed during commissioning by BHEL

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS

List of abbreviations:
Standard:
- BCM Lignite quality with maximum calorific value and minimum moisture content
- BHEL Bharat Heavy Electricals Limited
- BMCR Boiler maximum continuous rating
- FC Function Control
- FG Function Group
- DC Lignite quality for guarantee calculations (design coal)
- DCS Digital control system
- FG Function Group
- LI Lahmeyer International
- LTG Longitudinal travelling grate
- NCV Net calorific value
- SG Sub Group Control
- SSC Submerged scraper conveyor
- TMCR Turbine maximum continuous rating
- WCA ESP Lignite quality with the minimum calorific value and 10% ash content for
designing ESP
- WCA.S Lignite quality with the minimum calorific value and the maximum ash content
and maximum sulphur content for designing WFGD
- WCM Lignite quality with minimum calorific value and maximum moisture content
System specific:
- KKS Tag numbers (Kraftwerkskennzeichnungssystem - German abbreviation)

- OFA Over fire air
- P&ID Piping and instrumentation diagram
- WLB Water Lance Blower
- SBL Sootblower
KKS description:
- HBK Furnace
- HCB Steam Sootblower System
- HCC Water Lance Blower System

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS

Symbols:
 Display the corresponding mimic
 See the corresponding section
 Cross check when the action is completed
Note indicates an important instruction or the best practices
Timing note indicates long duration activity which should be initiated early
enough to avoid extended downtime.
Freeze protection note indicates instruction to be followed in order to protect
the system against freezing risks.
Caution is used to alert against imminent or potential mechanical damage to
the equipment.
Warning is used to alert of imminent or a potential danger, which could result in
death or serious injury.
Note
Changes from previous revisions of this operation instructions document are highlighted in
yellow allowing easy-to-follow document updates.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS
1 PART 1 – General
1.1 Purpose of the document
The operation manual for the Sootblower & Water Lance Blower System provides the operator a
detailed description for the system specific design and explains the necessary aspects for the
operation modes of the boiler (start-up, operation and shut-down).
➢ PART 1. This first part gives general information about the system.
➢ PART 2. The second part gives the System Operating Manual for the control panel
operator.
➢ PART 3. The third part gives the System Operating Manual for the field operator.
➢ PART 4. The fourth part gives the system special operating instructions for both
operators.
1.2 Purpose of the system

The Sootblower and Water Lance blower are regularly used to clean the heating surfaces,
evaporator wall and the RAPH. They ensure a sufficient heat transfer the firing into the water
steam cycle and from hot flue gas downstream heating surfaces to the hot air system.
1.3 Health and safety
The safety instructions included in this operator’s manual, which may cause
dangers to persons in case of any non-observance, are specially marked
with the general danger symbol.
Any discovered failures and malfunctions should be immediately notified to

the responsible superior. Any plant components, which were shut down by
means of an emergency shutdown, may only be switched on again upon
instruction as well as after the elimination of the cause of the shutdown and
inspection of the plant component on site.
Any danger areas caused by disturbances must be delimited, identified and
monitored. These danger areas may only be entered upon instruction of the
responsible person and after the performance of the necessary safety
measures.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

1.3.1 General safety instructions
The site Health and Safety Instructions shall be read and fully understood before performing any
actions detailed within the whole System Operating Manual.
The operator shall also comply with the Special Precautions mentioned herewith.
HAZARDS POTENTIAL CONSEQUENCES MEASURES
Organizational • Personnel injuries Any maintenance work
deficiencies • Component damages may only be started, after
the responsible person
has laid down the
required safety measures
as one part of the Permit-
to-work procedure,
checked the performance
of the relevant measures
and released the place of
work. After completion of
the work any safety
measures may only be
cancelled upon
instruction of the
responsible person. As a
rule, a written release
procedure shall be
required for such work.
Hydraulic • Injuries due to high pressue leakages All pipes, hoses, valves
• Injuries due to loose connections and screwed connections
• Risk of fire in case of relevant oil leakages are to be checked for any
in the area of hot surfaces damage and leakages at
regular intervals, and any
damaged parts are to be
replaced. Prior to
disassembly the motor is
to be disconnected and
all pressure pipes and
accumulators in the
hydraulic circuit are to be
depressurized. Any
hydraulic oil splashing
out under pressure may
lead to serious injuries,
burns and fires.
Any maintenance and

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

repair of hydraulically and
pneumatically operated
plants may only be
performed by specially
trained personnel who
are familiar with the
plants.
Oil, grease and • The inexpert handling of the stated Manufacturer’s data
chemical substance substances may cause damage to health. (safety data sheet) and
the operating instructions
must be checked prior to
use and the prescribed
protective measures
need to be reached.
Noise • Hearing disorders for operator personnel Noise reduction
• Personnel can get into dangerous situations measures need to be
because of not hearing acoustic warning defined
Sign giving orders need

to be installed to indicate
where it is necessary to
wear noise reduction
equipment
Fire risk due to • Damages to persons (burnings, The employees must be
- deposit of asphyxiation due to CO, …) trained in the handling of
combustible dust or • Damages to Equipment that leads to plant combustible substances
whirl-up of dust unavailability or ignition sources and
- leakages of pipes the behaviour after the
with comustible outbreak of a fire.
media
- storage and
handling of
combustible media
in improper way
- missing safety
measures for
welding, burning
and soldering work
(hot work permit)
Environmental • The non-observance of environmental In particular, the relevant
damages protection measures during the operation of safety data sheets and

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

the plant as well as in case of maintenance operating instructions for
and inspection work can cause hazardous materials are
environmental exposures to be observed when
handling dangerous
substances.
1.3.2 System specific safety instructions

If any of the following hazard is observed by the field operator or any other person, he has to
inform immediately the unit control panel operator, who must ask the concerned maintenance
specialist in order to take appropriate measures and/or corrective actions for the personnel
protection and equipment integrity as soon as possible:

•
•
•
•
•
•
•
•
1.4 System delimitations

The attached list of system components with the associated KKS numbers is not complete, but
comprises the components, which are required for the description of the systems and need to be
descripted by GE.
1.4.1 Water Lance Blower HCC

▪ Service water supply HCC01BR010
▪ Pumps HCC01/02AP010
▪ Water Lance Blower Level 1 HCC11-HCC14
1.4.2 Sootblower System HCB

▪ Steam supply line from RH1 inlet HCB01/03 BR010
▪ Steam reduction station and supply HCB01/03
▪ Sootblower left side wall Level 8 HCB11 AT071-AT075

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

▪ Sootblower right side wall Level 8 HCB13 AT071-AT075

▪ Warm-up & drain line HCB11/13 BR604
▪ RAPH blower steam supply HCB70 BR010

▪ Compressed air for AH startup HCB75
▪ Start-up sootblowing supply HCB74
▪ RAPH sootblower HCB071/72 AT001
▪ Warm-up & drain line HCB70 BR604

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
2 PART 2 - Control panel operating instructions

Contents:
Instructions to the CONTROL PANEL operations.
➢ Displays to observe and control
➢ Instructions for start-up preparation.
➢ Instructions for start-up.
➢ Instructions for operation.
➢ Instructions for shutdown.
To insert during commissioning

Screenshot of DCS screen with system overview,
Main Air & Flue gas function groups
and the linked DCS screen to operate the sub systems
Figure 1: DCS screenshot with marked up controls

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
2.1 Function description
2.1.1 Water Lance Soot blowers

The 12 water lance soot blowers (WLBs) HCC11 – 14AT011, HCC21-24AT011, HCC31-
34AT011 are arranged in three levels with four blowers a level of 24.98 m, 48.0 m and 69.03 m,
one in each furnace wall. Each blower lance head is positioned in vertical and horizontal
direction by means of a positioning drive. With this positioning of the lance a wide area of the
opposite furnace wall can be covered by the water beam.
The water for the blowers is provided out of the Service Water System by water supply line
HCC01BR010, boosted up in pressure by one of two redundant booster pumps
HCC01/02AP010. After the pumps the flow of water is measured and the water is distributed to
the headers of the three blower levels.
A strainer HCC11-14 AT10/20/30 in front of each blower prevents the blower nozzle from
blocking. With a pneumatic shut off valve HCC11-14 AA151/HCC21-24AA151/HCC31-34AA151
the non-operated blowers are shut off. In front of the nozzle the pressure is checked by means
of a pressure switch HCC11-14 CP011/HCC21-24 CP011/HCC31-34 CP011. To seal off the
soot blower wall opening a small sealing air fan is installed at each blower HCC11-14
AN011/HCC21-24 AN011/HCC31-34 AN011.
General Data of Water lance blower system

Water lance blower
Number of blowers 12
Power consumption per Blower 1.0 KW
Blower Valve
Valve Type 2/2 Way-Valve
Flange Design DN/PN 65/40
Valve Set 8499806.9101.02400
Pressure 0-40 bar
Valve body material DIN-W.-No. 1.0619
Blowing Tube
Outer Diameter 40 mm
Material DIN-W.-No. 1.4541

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
Prearranged Nozzle
Nozzle Diameter 16 mm
Material DIN-No. 1.4021
No. of Nozzles 1
Blowing Medium
Blowing Flow per Blower 11,58 kg/s
Consumption per Blower 5211 kg
Design Blowing Pressure 18 bar
Cooling and Sealing Air

Fan with one fan per blower
Cooling Air Flow per Blower 100 Nm³/h
Booster pumps
Designed flow rate 45.3 m³/h
Pump medium water, condensate
Power consumption 60.78 KW
Permissible operating pressure 63.0 bar,g
Discharge pressure 32.5 bar.g
Suction pressure min 1.5 bar.g
2.1.2 Retractable steam soot blowers

To clean the heat exchanger panels of SH1 to 4, RH1 and 2 as well as ECO in total 60
soot blowers are installed. 55 of those blowers are travelling into the boiler from left side
wall and 55 from right side wall. The upper levels and reserve blowers are equipped
with part retractable blower lances (ECO, RH2, and SH3).
The four levels within higher flue gas temperatures (RH2, SH1 and SH3) are equipped
with long retractable blowers.
Level Total Sootblower type KKS-No. left wall KKS-No. right wall
no.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
Level Total Sootblower type KKS-No. left wall KKS-No. right wall
no.
110.07 m HCB11 AT081-085 HCB13 AT081-085
ECO (reserve)
106.06 m
ECO
102.71 m ECO 10 RK – SB HCB11 AT071-075 HCB13 AT071-075

part retractable
blower
100.67 m 10 RK – SB HCB11 AT061-065 HCB13 AT061-065
RH1 part retractable
blower
97.42 m 10 RK-SL HCB11 AT051-055 HCB13 AT051-055
RH1 long retractable
blowers
93.99 m RK – SB HCB11 AT041-045 HCB13 AT041-045
SH2 part retractable
blower
RH2 long retractable
blowers
84.8 m RK – SB HCB11 AT021-025 HCB13 AT021-025
RH2 (reserve) part retractable
blower
SH3 long retractable
blowers
SH1 long retractable
blowers
The steam for the cleaning of the heating surfaces is taken out of the Reheater steam
system from RH1 inlet. The supply lines are independent for left and right sootblower.
The steam from cold reheat line enters the two steam reduction stations (one for each
boiler site wall) with following equipment:
• Connecting pipes HCB01 and HCB02
• Flow meter HCB01/03 CF001
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
• Shut off gate valve HCB01/03 AA001

• Motor controlled valve HCB01/03 AA101
• Strainer HCB01/03 AT001
• Mechanical pressure reducer HCB01/03AA451
• Pressure switches HCB01/03 CP001 and CP002
• Shut off gate valves HCB11/13 AA101
• At reduction station of right side wall, an additional gate valve HCB70AA101 is
installed downstream of pressure reduction, which supplies steam to RAPH soot
blower
Downstream pressure reduction at 77.3 m, the steam supply is separated in three
vertical supply lines which connects the individual blower. Downstream the lowest
sootblower level, the steam lines of each blower wall arrangement are guided together
to one draining station for left side wall and one for right side wall, each equipped with:
• Temperature measurement HCB11/13CT001 to evaluate warm-up and draining
conditions
• Warm-up shut off valve HCB11/13AA102
• Bypass flow control valve HCB11/13AA051
• Check valve HCB11/13AA201
• Connecting pipe to flash tank HCB11/13BR604
2.1.2.1 General Data for Retractable steam soot blowers
To be added during commissioning.
2.1.3 RAPH sootblower

The two retractable soot blowers of the RAPH HCB71AT001 & HCB72AT001 are arranged in
radial travelling direction to the rotor, one at the cold and one at the hot end of the RAPH. The
steam is supplied from the soot blower steam control station and distributed to the respective
blower via steam line HCB70BR010, HCB71BR010 and HCB72BR010, each equipped with a
shut off valve (HCB71AA603 and HCB72AA604), a throttled valve (HCB71AA203 and
HCB72AA204) and a pressure measurement (HCB71CP501 and HCB72CP501). Via a check
valve during none operation time air is sucked into the blower lance as sealing against flue
gases. The condensate and warm-up steam is led to the flash tank via line HCB70BR601 after
its temperature was measured. The condensate pipe can be shut off by a motor driven valve
HCB70AA102 which is bypassed by a small control valve HCB70AA051.
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
2.2 Preparation for starting

The following sections describe which preparatory measures have to be taken in order to establish
readiness of the boiler for start-up.
All necessary preparations for bringing the manual valves & dampers into the right position for
starting of the system are listed in the sections 3.2.
2.2.1 Water Lance Blower

• All electric drives and solenoid valves shall be ready for operation.
• All protection interlocks (pressure, flow, etc.) have to be operational.
• Remote and local measuring equipment needs to be activated.
• Existing leaks have to be repaired.
• After repair or exchange of valves and fittings check proper direction of flow.
• Hoses shall be checked for leaks.
• Water nozzles shall be checked for fouling and plugging.
• The booster pumps shall be ready for operation.
• The process water supply system shall be in running condition.
• Filters before solenoid valves have to cleaned.
• Dust and other deposits shall be removed from all movable components.
2.2.2 Steam Sootblower

• Visual check of suction and discharge side duct if manholes have been open.
• Dust and other deposits shall be removed from all movable components, e.g. linkages of
dampers.
• Checking expansion joints for exterior damage.
• All electric drives shall be ready for operation.
• All protection interlocks (pressure, temperature, etc.) have to be operational.
• Remote and local measuring equipment needs to be activated.
• Existing leaks have to be repaired.
• After repair or exchange of valves and fittings check proper direction of flow.
• Inlet of sealing air fans shall be checked for foreign matter and plugging.
• Filters before pressure reducing valves have to be cleaned.
• Limit switches and cable running alongside of steam soot blowers shall be checked for
damage.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

• Dust and other deposits shall be removed from all movable components. Proper lubrication
needs to be ensured.
• Insulation of pipes and ducts shall be checked for damages.
• Steam available, instrument air available
2.3 Start-up and Operation
➢ Check that the preparation for start-up and filling of the system is done
 PART 3 - Field operations - 3.2 Preparation for starting
For the cleaning of the furnace and convection heating surfaces and air heater, the following
concept is provided: The boiler is blown from bottom to top in the direction of the flue gas flow.
First, the furnace, then the convection heating surfaces and finally the air heater. The soot
blowing equipment of the furnace (water lance blowers) operates with service water. The
heating surfaces and the air heater are cleaned with steam, extracted from the reheater 1 inlet
header. In the furnace, only one (1) water lance blower is in operation at a time, whereas max.
four (4) soot blowers can be operated in the convection heating surfaces at the same time,
however, only 1 blower on each side in a staggered arrangement. The air heater is blown
consecutively (first hot side, afterwards cold side). The soot blowing program can be selected as
automatic program. Each group, each level, each individual blower can be switched on and
switched off in the control program by the operator.
The sootblowing intervals of the air heater can be operated on a cyclic basis, the time intervals
will be design at the commissioning time.
2.3.1 Operation of the water blower system

Before the sequence of the water lance blowers can be started the following release criteria have
to be fulfilled:
starting criteria:
➢ service water pressure > Pmin.allowable (0,15 MPa)
➢ shut-off valve closed
➢ firing rate > 50% load
➢ ash extraction in operation (to be verified by operating staff)

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

The water lance blower sequence comprises the following steps:
start-up procedure:
The selected pump starts running with closed shut-off valve until the required pressure is reached.
After expiration of the run-up time of the pump, the shut-off valve HCC03 AA101 is opened. If the
signal of the pressure monitor HCC03CP001&002 has reached a minimum pressure (2,2 MPa),
the first water lance blower is started according to the pre-selection program by opening of the
water supply (HCC11-34 AA151) and starting of the swivel drives (HCC11-34 AT011A & AT011B).
Description of the normal operation

The first water lance blower is displaced in accordance with the pre-programmed traversing path.
After completion, the associated solenoid valve is closed. The operation of the other water lance
blowers is started analogously according to the pre-selection program, always a complete level.
Description of shutdown
After a complete cycle of the water lance blower program, the pump is switched off and the shut-off
valve is closed.
2.3.2 Operation of the rotary long retractable and part retractable soot blower plant
Before the sequence of the steam soot blowers can be started the following release
criteria have to be fulfilled:
starting criteria:
• firing rate > 50% (in fact > 55% due to RH pressure requirement)
• level condensate tank < max
• air heater in operation
• ash extraction in operation (to be verified by operating staff)
The steam soot blower sequence comprises the following steps:

start-up procedure:
- the soot blowers are activated from standstill to off-position
• opening of the shut-off valves HCB01/03 AA101 in the line from RH2 inlet and the
drain valves HCB11/13AA102, while the shut-off valves HCB11/13AA101 are
opened on stepwise to avoid thermal shocks on the piping..
• If the pressure Pmin ≥ 2,2 MPa downstream of the shut-off valve in the supply line
is reached and the temperature in the drain pipes exceeds 290 °C, the drain
valves will be closed. Afterwards the blowers can be started. Once the required
blowing temperature is reached, the piping system is maintained hot and must not

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

fall below 270 °C, otherwise the drain valves will be opened again and a heat-up
start a until 290°C reached, before the next blowers can be started.
• If the pressure decrease below 1,6 MPa, the sootblowers will get a stop signal and
start retracting.
Description of the normal operation
The valves of the rotary long retractable and part retractable soot blowers are opened
according to the soot blowing program. After completion of the cleaning process, the
soot blowing valves are closed one after the other, the temperature in the next line
sections is checked for min. value, and the heating surfaces are cleaned successively in
flue gas direction.
Description of shutdown
During boiler shutdown, the main valves are closed. The drain valves are opened for
draining the piping system.
2.4 Operation
During operation of the unit the operator has to check all operation parameters of the systems
periodically, to make sure the steady operation of the plant is ensured and to be able to determine
disturbances and malfunctions as soon as possible.
Note
 ➢ Check for alarms
➢ Check for warnings
➢ Check for all important parameters (temperature, pressure, level, …)
➢ Request the field operator to carry out in the field, the routine checks following the
instructions given in Part 3:
 PART 3 - Field operations - 3.4 Operation (Routine checks)
A description of normal operation mode is given in Chapter 2.3.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

2.5 Shutdown
A description of shut-down procedure is included in Chapter 2.3.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
PART 3 – FIELD OPERATIONS
3 PART 3 - Field operations

Contents:
Instructions to the FIELD OERATIONS.
➢ Instructions for recommissioning.
➢ Instructions for start-up preparation.
➢ Instructions for start-up.
➢ Instructions for routine checks during operation.
➢ Instruction for shutdown.
3.1 Recommissioning
Note
The decision to recommission may be triggered by a long time outage or numerous
 instruments and drives failures on the system.

Follow reference document instruction for recommissioning of the instruments and
components (e.g. fans, valve & damper drives, RAPH motors, etc.)
For the recommissioning of the the equipment after a trip the operator has to make sure that
▪ all failures and disturbances that caused the trip have be resolved,
▪ all automated dampers & valves are in AUTO mode,
▪ all system function groups, sub control groups etc. are properly reinitiated, to be able to
start up the boiler in automatic mode
▪ and all manual dampers & valves are in operation position according to section 3.2.1
Basic position of valves and dampers and following.
After a longer outage accompanied by maintenance work at the systems or system specific
components it needs to be checked. Additionally to the upper mentioned points, which are still
valid…
▪ all manholes or inspection openings of the system and its components are safely
closed again
▪ all piping and ducting supports must be deblocked and ready for operation
▪ all insulation on piping, ducting and components must be reinstalled to prevent
personnel hazards due to hot surfaces
▪ all relevant work permits are closed and given back to permit office

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

▪ manual (control/throttle) valves & dampers are adjusted to the right position according
to the valve list in the following chapter
3.2 Preparation for starting

Note
The instructions below have to be followed in cooperation with the local control panel
operator.
The following sections give the instructions to the field operator in order to prepare the systems for
start-up. The tasks described in this section shall be executed in parallel with those of the “control
panel preparation for starting” section.
➢ Wait that local control panel operator has performed the following section and request
field operator actions:
 PART 3 - Field operations - 2.2 Preparation for starting
➢ Perform the following check lists.
➢ Confirm to the local control panel operator that line up is done.
3.2.1 Basic position of valves and dampers
3.2.1.1 Water Lance Blower (HCC)
KKS – No Description Position Add.

information
01HCC01AA001 S-V WTR TO WTR BLO LNE open
01HCC01AA003 S-V WTR TO WTR BLO PMP SFV open
01HCC01AA501 INSTR ISOL V open
01HCC01AA620 WTR TO WTR BLO LNE DR ISOL V closed
01HCC03AA053 S-V WTR TO WTR BLO LNE LW open

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

01HCC03AA701 WTR TO WTR BLO RW LNE VENT V closed
01HCC03AA711 WTR TO WTR BLO LW LNE VENT V closed
01HCC03AA721 WTR TO WTR BLO LW LNE VENT V closed
closed
01HCC03AA731 WTR TO WTR BLO LW LNE VENT V
01HCC11AA011 LW WTR BLOW INL ISOL V open
01HCC12AA011 RW WTR BLOW INL ISOL V open
3.2.2 Water Lance Blower (HCB)

KKS – No Description Position Add.
information
01HCB01AA001 S-V SB ST INL LNE open
01HCB01AA501 INSTR ISOL V open

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

shut-off valve, general (for open
01HCB01AA513 measurement)
01HCB01AA601 SB ST INL LNE DR ISOL V closed
01HCB03AA001 S-V SB ST INL LNE open
Adjustment
during
01HCB11AA051 SB LW DR BYP CTRL V Approx. 30% commissioning
01HCB11AA201 SB LW DR ISOL V De-blocked Check valve
Adjustment
during
01HCB13AA051 SB RW DR BYP CTRL V Approx. 30% commissioning
01HCB13AA201 SB RW DR ISOL V De-blocked Check valve
Adjustment
during
01HCB70AA051 SB RAPH DR BYP CTRL V Approx. 30% commissioning
01HCB70AA201 SB RAPH DR ISOL V De-blocked Check valve
01HCB70AA210 straightway check valve De-blocked Check valve
01HCB71AA603 S-V SB RAPH open

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
01HCB71AA611 S-V SB RAPH DR open

01HCB72AA604 S-V SB RAPH open
01HCB72AA612 S-V SB RAPH DR open
Check list Sootblower
3.3 Start-up
Note
operator.
➢ Confirm that the local control panels for the RAPHs are ready for operation and that all
equipments are set to auto mode
➢ Checks rotating equipment start-up (any abnormal vibration, noise or overheating,

leaks…)
➢ Carry on a routine check as per following chapter:
 PART 3 - Field operations - 3.4 Operation routine checks
3.4 Operation
Note
Recommended periodicity for routine checks: (finally to define by plant operator)

1/8h (Once per shift) or 1/24h (Once per day of operation).
Warning
A systematic inspection of the equipment should be made, for faults and signs of
deterioration. Any defects or abnormalities should be reported for attention/
correction.
It’s recommended to the boiler operators to do a walkdown on the boiler in regular intervals to
check the components for proper conditions for boiler operation.
The following checks of the boiler are based on experiences of the operation of comparable plants
In due course the checks are to be adapted to new operational experiences.
General checks:
➢ Check cleanliness and tightness of the pipe network.
o Check pipework and vessels for :

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

o Leaks,
o Loose pipework supports,
o Loose, damaged or oil soaked thermal insulation,
o Vibration or liquid hammer.
➢ Check rotating auxiliaries and drive motors for :
o Correct oil levels in oil filled bearings or thrust bearings,
o Pump shaft seals leakage,
o Any abnormal vibration, noise or overheating,
o Motor cables for security of fixings and freedom from damage,
o Motor air intake cowls for freedom from obstruction,
o Check of the air intake grills of electric motors
o Check air intake filters on sealing air fans
o Leakage check of the compensators of the air and flue gas ducts
o Motor terminal boxes are dry by inspection or the moisture indicators (where
fitted).
➢ Check instrument panels for :
o Damage to the panel and mounted instrumentation,
o Obviously faulty indications,
o Faulty alarm/indication lamps (where test facility is provided).
➢ Check plant/valve mounted instrument for :
o Damage to instruments or to pipework and cabling,
o Plausibility of pressure and temperature indications
o Obviously faulty indications.
➢ Check for abnormal noises
3.5 Shutdown
Note
operator.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

➢ The shut down of the air & flue gas system is initiate is explained in chapter 2.5 by the
control room operator
➢ After a walk down of the system according to chapter 3.4 the field operator should confirm
to the control room operator the proper shut off of all part systems and equipments

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)
PART 4 – SPECIAL OPERATION
4 PART 4 – Special operation

Contents:
Instructions to the CONTROL PANEL AND FIELD OPERATORS.
➢ Instructions for Permit to work isolation during operation
➢ Alarms description and troubleshooting
4.1 Online isolation for Permit To Work

Needs to be added during commissioning in accordance to the valid permit to work system of the
power plant operating company.
4.2 Alarms description and troubleshooting

Alarms can be issued by different systems and function groups. In the following tables the
designed alarms are listed and described.
4.2.1 Alarm list
interlock
KKS Description criteria Remark / action
Pressure Water Before Pump < 0,1
01HCC01CP001 Station Water Blowers < MIN 1 kg/cm2 check water supply to pump
minimum flow required for operation, check
01HCC03CF001 Flow Water Blowers > MAX 1 > 14 kg/s pump and strainers if < MIN
Pressure Water Behind Pump < 30 required minimum pressure; check pump,
01HCC03CP001 Station Water Blowers < MIN 2 kg/cm2 feeding lines and strainers in case of < MIN
< 35 required minimum pressure; check pump and
01HCC03CP002 Pressure Water Blowers < MIN 1 kg/cm2 strainers in case of < MIN
4.2.2 Steam blower

If a disturbance occurs during the blowing sequence due to a mechanical blocking or
electrical fault, an alarm is set.
The defective soot blower has to be retracted immediately by a crank handle. In no case
the soot blower can be left inside the boiler, since the heating surface would be
damaged if blowing permanently at the same spot. At the same time it is not pertinent to
stop the steam supply to the soot blower. A loss of steam supply would lead
immediately to an overheating and irrevocable damage of the soot blower lance.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

Condition Automatic Operator action
action
Mechanical blocking of a soot Alarm is given 1. Try to retract the soot blower by
blower during soot blowing in DCS using the off progra
2. If this is not possible, de-energize the
operation
drive of the affected sootblower
3. Use the crank handle to retract the
soot blower manually from the
furnace
4. Investigate the reason for
mechanical blocking
5. Clear the disturbance
6. Energize the soot blower motor
7. Try to operate the soot blower from
DCS
Electrical fault of soot blower Alarm is given 1. De-energize the affected soot blower
during blowing operation in DCS motor
2. Use the crank handle to retract the
soot blower manually from the
furnace
3. Investigate the reason of power
failure
4. After clearance of disturbance
5. Energize the soot blower motor
6. Try to operate the soot blower from
DCS
4.2.3 Water lance blower

For release of starting the water lance blower pump the suction pressure of the pump
must be > MIN (0,2 MPa). During pump in service an inadmissible pressure drop on the
suction side leads to a pump trip. In this case the suction pressure has to be increased
to a level above minimum.
4.2.4 Troubles in the movement

• If, during forward movement, the blower is mechanically disturbed, the slipping clutch
installed in the spur and worm gear is actuated. The blower stops. After exceeding the
normal operation time, the sootblower control must reverse the sense of direction of the
drive motor and return the blower carriage in its rest position. The slipping clutch is blocked
while the blower carriage is travelling back. In the same time alarm-signal "operation time
exceeded" is given and the blowing program is interrupted, to allow check-over of the faulty
blower.
• If, during forward movement, the drive motor is electrically overloaded, the sootblower
control must immediately switch-over to backward movement. In case of trouble at
backward travel the sootblower will stop travelling. The sootblower control must give an
Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

alarm signal and the blower is to be retracted from the boiler immediately by hand in order
to avoid damage to the lance tube.
• In case of breakdown of the control system or voltage supply during blowing operation, the
blower will stop operating. The lance tube is staying in the boiler and must be retracted by
hand using the retracting device. The blowing medium may only be shut down if all
sootblowers are back in rest position.

Form No. 168170E - 04.08 1.48760 A4 Hoch (01.16)

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Employer’s and Contractor’s Information / Project Name

2x500 MW NEYVELI NEW THERMAL POWER

NEYVELI, TAMILNADU, INDIA

Scale Other Document Code (if any)

Responsible dept. Created by Checked by Approved by Format

Operating Manual 148760_00108_7106

Originator Identification number Rev. Date Lang. Sheet

1 PART 1 – General ................................................................................................................ 8

Originator Identification number Rev. Date Lang. Sheet

LIST OF REFERENCE DOCUMENTS

Operation instructions Boiler alarm sheets NLC/01/G4-01-0300/111

System Design Manual:

Firing system process design NLC/00/B/G2-X2-1000/ER/101

Piping & Instrumentation Diagram (P&ID):

LIST OF REFERENCE DOCUMENTS

Manual from supplier and partners:

To be completed during commissioning by BHEL

Originator Identification number Rev. Date Lang. Sheet

LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS

- KKS Tag numbers (Kraftwerkskennzeichnungssystem - German abbreviation)

Originator Identification number Rev. Date Lang. Sheet

LIST OF ABBREVIATIONS, KKS DESCRIPTION & SYMBOLS

 Display the corresponding mimic

 See the corresponding section

 Cross check when the action is completed

Note indicates an important instruction or the best practices

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

1.2 Purpose of the system

1.3 Health and safety

Any discovered failures and malfunctions should be immediately notified to

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

HAZARDS POTENTIAL CONSEQUENCES MEASURES

Sign giving orders need

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

HAZARDS POTENTIAL CONSEQUENCES MEASURES

1.3.2 System specific safety instructions

HAZARDS POTENTIAL CONSEQUENCES MEASURES

1.4 System delimitations

1.4.1 Water Lance Blower HCC

1.4.2 Sootblower System HCB

▪ Sootblower left side wall Level 8 HCB11 AT071-AT075

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

▪ Sootblower right side wall Level 8 HCB13 AT071-AT075

▪ Warm-up & drain line HCB11/13 BR604

▪ RAPH blower steam supply HCB70 BR010

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

2 PART 2 - Control panel operating instructions

➢ Instructions for start-up preparation.

➢ Instructions for start-up.

➢ Instructions for operation.

➢ Instructions for shutdown.

To insert during commissioning

Figure 1: DCS screenshot with marked up controls

Originator Identification number Rev. Date Lang. Sheet

PART 2 – CONTROL PANEL OPERATING INSTRUCTIONS

2.1 Function description

2.1.1 Water Lance Soot blowers