UNIT SHUT DOWN PROCEDURE

January 21, 2024 PMI Revision 00 1

 Presentation outline
Planned Shut Down procedure

APH Washing

Hydrogen purging

ATT

January 21, 2024 PMI Revision 00 2

 UNIT SHUT DOWN
• Planned shutdown- For overhauling
• Emergency shut down- Boiler tube leakage, major
problems in Turbine, Generator etc, Transmission
constraints.
• Reserve shut down –Low demand

January 21, 2024 PMI Revision 00 3

 Planned shutdown
Preparation for shut down.
 Mobilization of resources for overhauling- Manpower ,
Spares, consumables
 Identification all Jobs to be carried out.
 Carry out performance testing and identify performance
gaps, parameter deviations and action plan for rectification.
 Necessary clearance from RLDC/bulk customers .

January 21, 2024 PMI Revision 00 4

Activities
• All coal bunkers should be preferably made empty before
long shut down. Stop/ regulate coal feeding to bunkers
accordingly.
• Charging of auxiliary steam from other unit.
• Ensure availability of all oil guns.
• Take trial run of all emergency equipments like Dc Scanner
air fan, DC EOP,DC SOP, DG set etc.
• Ensure SGC oil and SLC of oil system is ON

January 21, 2024 PMI Revision 00 5

• Reduce coal firing in mills and bring down the unit
load to 160 MW
• Gradually reduce boiler steam parameters (steam
pressure and temp.) for force cooling. Rate of
reduction to be controlled as per the permissible
limits. Ensure that the TSE margins are OK.
• Carryout boiler soot blowing and APH soot blowing.

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• Set turbine load gradient at 5 MW/min.
• Bypass turbine steam temp. low protection.
• Check HP/LP Bypass operation.
• Charge D/A pegging steam from CRH.
• Cut out the top mill .Make the bunker/feeder belt
empty before stopping the mill.

January 21, 2024 PMI Revision 00 7

• Cut out HP heaters 5&6
• Reduce unit load to 120MW after taking oil support
in AB elevation.
• Carryout ATT.
• Cut out one more mill and reduce unit load to 80
MW.
• Ensure that turbine gland sealing steam temp.
>250o C and change over from leak steam control
to seal steam controller.

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 • Change over unit bus power supply from
UATs to station Bus .
• Monitor and record all turbine supervisory
parameters like turbine bearing and shaft
vibrations, Diff expansion of HPT, IPT &
LPT ,Axial shift , Over all expansion Turbine
brg temp. at different loads.
• Monitor boiler drum Top/Bottom differential
temp. while reducing pressure and load.

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• One set of ID ,FD, PA fans and one BFP can be
stopped.
• Cut out one more mill and reduce load to 50 MW.
• Reduce load to 30MW. Open HP bypass to
maintain boiler pressure.
• Cutout LP heaters.
• Ensure change over of drum level control from high
range to low range.

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• Trip the turbine through trip push button on desk
and open the HP/LP bypass.
• Control boiler drum level.
• Ensure the following after turbine trip.
 Generator circuit breaker opened
 Generator Field breaker opened.
 Turbine AOP has taken start at 2850 RPM and Lub.
Oil pressure is normal.

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 Turbine ESVs and IVs closed.
 HP ,IP control v/vs closed
 CRH NRV and all extraction valves and NRVs
closed
• Monitor turbine speed, bearing vibrations, brg
temp. and turbine supervisory measurements
during coasting down.
• Monitor hotwell level, D/A level,Cond vacuum.

January 21, 2024 PMI Revision 00 12

• ENSURE opening of the following drains:
• HP casing drain.
• Drain after CRH NRV's
• Drain before/after IV's. NRV's.
• Drain before extraction NRV's
• Seal steam header drain.
• Drain before ESV's.

January 21, 2024 PMI Revision 00 13

• Stop the last mill after ensuring the feeder is
empty.
• Stop the PA fans and trip the boiler. (Boiler can be
tripped by checking any of the boiler protections.)
• Ensure the closure of HOTV,LOTV
• Close HP/LP bypass and close boiler stop valves

January 21, 2024 PMI Revision 00 14

• Purge the boiler for 5 minutes and scavenge all the
oil guns which were in service
• Isolate HFO ,LDO stations and all oil guns
• Isolate SH/RH spray stations.
• Fill boiler drum level upto max. level.
• Stop ID /FD fans if boiler force cooling is not
required (During boiler cooling ensure that boiler
TOP Bottom differential is <50oc

January 21, 2024 PMI Revision 00 15

• Ensure that scanner air fan emergency damper has opened
after stopping both FD fans.
• Switch of all ESP fields and rapping system.
• Ensure turbine JOP has taken start at 510RPM and jacking
oil pr is >110 KSC
• Ensure Gate gearing valve has opened at 210RPM
• Ensure speed ref. zero
• Ensure turbine has come on barring and speed >100 RPM

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• MOT level is normal and duplex filter not choked.
• Open generator bkr isolators on 220 KV side.
• Depressurize MS, HRH steam lines .open
MS ,HRH strainer drains to IBD tank
• Stop condenser vacuum pump and kill vacuum.
Open vac. Bkr at 200 mm of Hg condenser vacuum

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• Isolate seal steam supply to turbine glands and
stop GSE.
• Isolate generator Hydrogen coolers Stator water
and seal oil coolers.
• Stop one CW pump.
• Monitor LP turbine exhaust hood temp. and stop
CEP after 4 hours
• CW system can be stopped after 4 hours from unit
shut down

January 21, 2024 PMI Revision 00 18

• Stop BFP and ECW pump after drum top up
requirement is completed.
• Isolate auxiliary steam header.
• Isolate power supply to all HT drives and ESP.
• Generator hydrogen can be purged after the
turbine coming to barring gear.
• At 2ksc drum pressure open boiler drum vents, SH
vents and SH hdr drains

January 21, 2024 PMI Revision 00 19

• Drain the boiler when the boiler water temp. is
below 90oC.
• Stop APH and scanner air when flue gas temp.
below 100oC.
• Isolate all steam supply to Deaerator and drain
Deaerator after opening the vents.
• Monitor turbine expansions and casing temp.
during cooling down.

January 21, 2024 PMI Revision 00 20

• Turbine barring gear can be stopped at HP
shaft/casing temp. less than 130 oC.
• TG oil system can be stopped at turbine casing
temp. of 95oC after ensuring that hydrogen is
purged out from generator.
• Seal oil system can be stopped after hydrogen
purging and stopping of barring.

January 21, 2024 PMI Revision 00 21

 APH WASHING.
• Purpose- for cleaning of baskets of air heater
• High pressure water jet is used
• Washing to be carried out when the air heater is in
hot condition (Temp.about 200oC).immediately after
boiler shut down
• Open the r plugs of APH ash hopper
• Open the duct drains of SA and PA ducts

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• Start the APH water washing pumps
• Open the water washing lines of the air heater .
• Keep the air heater rotating.
• Continue the washing till the PH of inlet and outlet
water is same.
• Run the ID /FD fans to dry out the baskets

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 Hydrogen Purging.
• Ensure that the generator is tripped condition
• Reduce the Hydrogen pressure to 0.5 KSC by opening the
purge valve.
• Connect CO2 cylinders to the filling manifold.
• Start filling CO2 through the CO2filling valve
• Crack open the purge valve to maintain the casing pr. At 0.5
ksc
• Continue filling CO2 till purity of 95% is achieved.

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• Purge out CO2 by opening the air filling valve and
purge out valve.
• Continue air filling till CO2 concentration is Nil.
• Disconnect the air connection after purging.

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 Automatic Turbine Testing
(ATT)
• To check the healthiness of turbine protections
during normal operation
• Turbine protections can be periodically tested on
load.
• Provides full protection to the turbine during the
testing.

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SALIENT FEATURES
 Individual testing of each protective device and stop/control
valve assembly.
 Automatic functional protective substitute devices that
protect turbine during ATT.
 Only its pretest is carried out without any faults i.e. if the
substitute circuit is healthy, the main test begins.
.

January 21, 2024 PMI Revision 00 27

 Monitoring of all programme steps for execution within a
predefined time.
 Interruption if the running time of any programme step is
exceeded or if tripping is initiated.
 Automatic re-setting of test programme after a fault
 Full protection of turbine provided by special test safety
devices.

January 21, 2024 PMI Revision 00 28

The testing system or ATT is sub divided in two
functional sub-groups.
1. ATT STOP AND CONTROL VALVES
2.ATT PROTECTIVE DEVICES

January 21, 2024 PMI Revision 00 29

 AUTOMATIC TESTING OF
PROTECTIVE DEVICES
ATT sub group for protective devices covers the following
devices.
1. Remote trip solenoid-1.
2. Remote trip solenoid-2.
3. Over speed trip device.
4. Hydraulic low vacuum trip device.
5. Thrust bearing trip device.

January 21, 2024 PMI Revision 00 30

 Turbine actual over speed
testing.

January 21, 2024 PMI Revision 00 31

 SHUT DOWN TO HOTSTAND BY
• When the unit is to be shut down for short duration
the boiler can be kept in Hot stand by.
 Shut down due to grid restriction
 Shut down due to problems in electrical systems,
Generator , GT, UAT ,Turbine etc (problems which
requires short duration to attend )

January 21, 2024 PMI Revision 00 32

• Boiler pressure and temp. are maintained substantially to
facilitate quick start up.
• Turbine metal temp. can be brought down to reduce start up
time during re rolling.
• Shut down procedure is similar to normal shut down except
reduction in pressure and temp.
• Reduce the load to 120 - 140MW at rated steam parameters

January 21, 2024 PMI Revision 00 33

• Subsequent load reduction along with pressure and
temp. drops should be decided by the turbine
limitations
• Trip the boiler when the desired parameters
reached.
• After tripping the boiler to be boxed up.
 Close boiler stop valves

January 21, 2024 PMI Revision 00 34

 Close all boiler drains and vents (CBD, IBD, EBD)
 Stop ID/FD fans after boiler purging.
 Close all dampers and gates in flue gas path.
 APH can be stopped after the flue gas at APH inlet
is below 200oC

January 21, 2024 PMI Revision 00 35

 SWITCHYARD OPERATION
• Co-ordination with RLDC for unit synchronization,
line charging etc.
• Line up of electrical systems
• Ensuring healthiness of switchyard equipments like
transformers, breakers, isolators, CTs etc.

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SHUT DOWN OF TRANSMISSION LINE
• Obtain written message code for shut down of the feeder
from RLDC.
• Intimate the other end station before opening the breaker.
• Open the Tie Bkr of that bay and then open the main bkr.
• Ensure that the sequential isolator opened on auto
• Open the remaining isolators (Bus and line isolators) of the
bay

January 21, 2024 PMI Revision 00 37

• Give message to the other end about opening of
the isolators and confirm that the line is isolated at
their end.
• See the line voltmeter and ensure that the voltage
has become zero
• Ensure the earthing at both ends

January 21, 2024 PMI Revision 00 38

 Charging of transmission line
• Ensure the PTW has been returned and inspect the
bay physically
• Ensure that no Discharge rod/earthing connected
on that bay
• Give message to the RLDC and other end station
and obtain clearance for charging the line.
• Ensure opening of both end earthing

January 21, 2024 PMI Revision 00 39

• After getting written confirmation from other end
close all isolators of the line and check their
alignment.
• Synchronize the feeder through the main Bkr and
then close the tie bkr.
• Check the line power flow .

January 21, 2024 PMI Revision 00 40

 THANK YOU

January 21, 2024 PMI Revision 00 41