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Soot Blowers

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Soot Blowers

Grommes - 20170116

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Note:
This training book provides a detailed overview of all training topics. It was issued with the
intention to support the trainees with basic and detail knowledge about coal fired steam
generators and the applied technique. However it must be read in conjunction with the
project specific descriptions, drawings and manuals of the steam generator manufacturer.

Depending on the training class, slides applied for training might differ from those shown
in this document.

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Contents
1 General ...................................................................................................... 1
2 Water lance blowers (WLB) for furnace cleaning .................................. 2
2.1 System description............................................................................................................... 3
2.2 Operation ............................................................................................................................. 8
2.2.1 Furnace optimisation system FACOS .................................................................................. 8
2.3 Control of water cannons ................................................................................................... 11
2.3.1 Operation modes ............................................................................................................... 11
2.4 Compensation of load due to water cannon operation ...................................................... 15
3 Steam soot blowers for HP and RH surfaces and economiser .......... 16
3.1 Arrangement of steam soot blowers .................................................................................. 16
3.2 Principle and design of RK-SL ........................................................................................... 19
3.3 Holding steam temperature ............................................................................................... 19
3.4 Flushing and sealing air fans ............................................................................................. 20
3.5 Arrangement of sootblowers .............................................................................................. 20
3.6 Operation of the Steam Sootblower System ..................................................................... 20
3.6.1 Start Conditions for Sootblowing ....................................................................................... 21
3.6.2 Soot blowing procedure ..................................................................................................... 21
3.6.3 Soot blowing cycle ............................................................................................................. 21
3.7 Temperature maintaining during operation ........................................................................ 22
3.7.1 Alarms during sootblowing ................................................................................................. 22
3.7.2 Interruption during sootblowing .......................................................................................... 22
3.8 Shutdown ........................................................................................................................... 23
3.9 Principle and design of RK-SB .......................................................................................... 24
4 Air heater sootblowers ........................................................................... 27
4.1 System Description and Design parameters ..................................................................... 28
4.2 Design data and equipment of the air heater sootblower system ..................................... 28
4.2.1 Bases (Design data) (HCB60-64) ..................................................................................... 28
4.3 Pressure Reducing Station (HCB 60) ............................................................................ 29
4.4 Operation of the air heater steam sootblower system ....................................................... 29
4.4.1 Soot blowing procedure ..................................................................................................... 29
4.4.2 Conditions for start of steam sootblowers.......................................................................... 30
4.4.3 Start-up of steam sootblowers ........................................................................................... 30
4.4.4 Interruption of air preheater soot blowing operation .......................................................... 30
4.5 Alarms ................................................................................................................................ 31
5 Operation of sootblowers ...................................................................... 32
5.1 Disturbances during boiler soot blowing ............................................................................ 32
5.2 Operation of the steam soot blowers ................................................................................. 33
6 Maintenance ............................................................................................ 34
6.1 General: ............................................................................................................................. 34
6.2 Smart Cannon System ....................................................................................................... 34
6.3 LONG RETRACTABLE SOOT BLOWER.......................................................................... 39
6.4 HELICAL SOOT BLOWER ................................................................................................ 43

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1 General
The soot blower system for the boiler is designed to clean the furnace walls, the econo-
miser (Eco) tubes, and the HP and RH heating surfaces of ash deposits.

8x half retractable soot blower – RK-SB -

for the ECO – travel: 1.100 m

40x long retractable soot blower – RK-SL –

for superheaters 1,2,3 & reheaters 1 & 2
travel : 11.790 m

8x water lance blowers CB 100

for the furnace chamber

Figrue: Soot blower installation Kusile

The following types are installed:

 8x Cannon CB 100 water blowers for the furnace

 40x Long retractable sootblowers RK-SL for the superheater 1,2,3 and reheater 1 & 2
 8x Half retractable sootblowers RK-SB for the economiser

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2 Water lance blowers (WLB) for furnace cleaning

B114116-10-01-IB01-00002-AC Water Sootblower system
B114115-10-01-IB01-00002-AF

The WLB-CB 100 water lance blower is specifically designed for the removal of slag de-
posits from furnace walls of coal-fired boilers.

water jet

fouling & slagging

tube wall

water / steam

Figure: Removal of deposits

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The cleaning effect is based on the fact that the impinging water which penetrates the top
layer evaporates abruptly, thus the slagging is broken up and removed from the surface.

2.1 System description

Water lance blowers (WLB) are installed in the boiler to clean fouled furnace walls. With
their assistance, any deposits can be removed while the boiler is in operation.

connection box

drive module

blowing tube

frame

construction of water lance lower

Figure 2.1.1 – Water lance blower construction

By means of a high-pressure nozzle, a WLB produces a concentrated jet of water which

impinges on the opposite wall and half of the side wall of the combustion chamber.

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Figure 2.1.2 – WLB blowing pattern

The blowing jet is produced in a special nozzle in the head of the blowing tube.
The blowing tube can swivel horizontally and vertically with the help of the 2 drive modules
so that the water jet impinging on the furnace wall describes a meander-shaped path.
This is controlled by heat flux sensors.
The heat flux measurements will be analysed with a frequency and amplitude function, to
determine the slagging characteristics. Due to the result the area will be cleaned. Due to
the evaporation of the water within the deposit, it chips off in blocks from the tube wall.
Time and place of cleaning are software-controlled. To prevent pipe damage due to unin-
tentional cleaning of correspondingly risk-prone boiler sections, individual boiler areas can
be marked with "NO CLEANING“. In the other areas, all sensors are permanently in use
the effects of the cleaning cycles in terms of fatigue phenomena are calculated and incor-
porated in the control.

To cover the entire combustion chamber, the installation of 8 water lance blowers in 2
levels is necessary: at the rear wall at level 27,1m and 60,5m and at the front wall at level
30,7m and 60,5m.

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Figure Location of Water Lance Blowers

The water for the water cannons is taken from the potable water system. Movements,
nozzle cross section, and cleaning effect are to be optimised upon commissioning. The
blower pressure is adjusted for the appropriate blower level by two redundantly set-up,
speed-controlled booster pumps HCC02/03 AP001. The pressure downstream of the
pumps is set within FACOS, measured and shown in the control room. Opening of the
electro-pneumatic valves (e.g. HCC31 AA201) in front of the water cannon is controlled by
control pulses, as a function of this pressure.
The necessary equipment, including piping, booster pumps, valves and strainers are de-
signed on the basis of the water cannon application conditions.

Design parameters
Pressure [MPa] Temperature [°C]
Upstream pump 1,0 60

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Dowmstream pump 4,0 60

Only one water cannon is used at once, and therefore the volumetric flow of this case was
used as basis for the design.

euipment for water lance blowers – WLB -

electro pneumatical valve

instrument air

sealing & cooling air fan potable water from booster pumps

water lance blower

pressure measurement

Start of a water sootblowing cycle

In order to start the water sootblowing cycle, the respective water cannon level must be
selected and the following conditions fulfilled :

Set - up of water lance blower

live steam mass flow (HAH40FF901) > 255 kg/s

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motor shut-off valve downstream the booster (HCC10 AA101) open

pumps
one of the potable water booster pumps (HCC02/03 in operation
AP001)
temperature upstream of the booster pump (HCC01 CT001) < 40 °C
pressure downstream of the booster pump (HCC10 CP001) > 1,9 MPa < 3,2
MPa

Each of the eight WLB is equipped with its own sealing/cooling air fan (e.g. HCC 21 AN
001). This fan must be in continuous operation and is only shut down if FD-Fan and ID-
Fan are off. During start-up these fans are put into operation before starting the ID and
FD-fan.
Operational data
Upstream of pump Downstream of Min blowing pres-
pump sure
Potable water pres- 0,2 – 0,5 MPa 1,9 – 2,7 MPa 1,6 MPa
sure
Operating temperature = 20 °C operating mass flow = < 11 kg/s

Downstream of the pumps the system is united again. The minimum flow is ensured for
the pump in operation by means of free-wheel non-return flaps. By means of drain valve
HCC10 AA501 the total system may be drained and vented by means of the valves
HCC11/12 AA451.
On each level a supply line branches off from the main line. From these lines branches
lead to the respective water lance blowers.
The water supply is controlled by means of the pneumatically pilot-controlled quick-closing
valves ( e.g. HCC21 AA 201). During operation of the water cannons the following disturb-
ances may occur:
 Deposits in the nozzle and the respective nozzle is to be replaced
 Pressure drop after the quick-closing valves due to dirt in the dirt trap. This requires
closure of shutoff gate valve prior to the dirt trap and replacement/cleaning of filter.
 Malfunction of the pump in operation. This requires change-over to other pump and
repair of defective pump.

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2.2 Operation

2.2.1 Furnace optimisation system FACOS

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FACOS detects the fouling condition of the individual furnace section by means of the 28
heat flux measurements.
FACOS determines individual areas of the combustion chamber for cleaning depending
on signals of the heat flux sensors.
Possible detections are:
Area clean Area lightly contaminated Area contaminated

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Criteria for identification of the sintering point:

- changed signal frequency
- negative gradient process
- reduced amplitude

The condition is communicated to the boiler monitoring system (BMS) in order to guaran-
tee a co-ordination of all cleaning operations. Time and place of cleaning are software
controlled.
Each WLB is programmed with a specific number of blowing patterns.
Blowing patterns are also activated automatically through the signals received from the
heat flux sensors.

Figure: Furnace screen

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The furnace screen shows, e.g. the boiler load, furnace exit temperature, average and
individual heat flux as well as conditions of cleanliness.

2.3 Control of water cannons

The water cannons are subdivided into 2 levels with 4 blowers on the front and rear wall
each. Each blower cleans the half of the opposite wall and half of the left and right side
wall. The blowing sequence within the single levels is determined as follows:
- front wall
- rear wall
- right side wall
- left side wall
Each is programmed with a specific number of fixed cleaning zones. Only one water can-
non is in operation at any point in time. First the water supply is activated by starting the
pump. After that the water cannon is put into operation. The stop time between the cleaning
zones can be adjusted as per requirement in the FACOS system.

2.3.1 Operation modes

The following operation modes of the water lance blowers are possible:
Manual operation, Local operation, Operation by time criteria and Automatic operation with
the boiler monitoring system and FACOS.
This operation can also be carried out independently of FACOS.

2.3.1.1 Manual operation

In this operating mode the boiler cleaning is carried out by activation of the WLB’s control
from the DCS (manual operation by the operator from main control room).
The manual operation should be used only in case of malfunction of the automatic control.
The furnace is essentially subdivided into 5 cleaning levels, the controller can select or
deselect every level.
Each level consists of several blowing patterns associated with the WLB’s.
A default blowing program is available in the PLC. This program cleans the combustion
chamber
from the bottom up. This means, first all cleaning zones of the lowest level are carried out
followed by all cleaning zones of the next level and so on. The operator can select or
deselect every level. Within the control parameters of each level, every cleaning zone can
be selected or deselected individually. If no cleaning zone of a water cannon is selected
the respective blower is skipped.

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2.3.1.2 Local operation

Local operation is possible by means of a joystick. Interlocks prevent simultaneous oper-
ation from the control room or by FACOS.
The abovementioned modes of operation would only be used if the automatic furnace op-
timisation system – FACOS is not functioning.
Operation by time criteria
In this operating mode the boiler cleaning is carried out based on time criteria.
These criteria are distributed over 24h. Up to 10 programs can be used.
These programs can be modified during commissioning or during operation.

2.3.1.3 Automatic operation with boiler monitoring system and FACOS (normal
operation)
During operation with boiler monitoring and FACOS, the cleaning zones are activated au-
tomatically through the signals received from the heat flux sensors. FACOS detects the
fouling condition of the individual furnace section by means of the 28 heat flux easure-
ments. The fouling is communicated to the boiler monitoring system (BMS) in order to
guarantee a coordination of all cleaning operations. The areas are cleaned with optimised
blowing parameters determined by FACOS. If FACOS determines an area requires clean-
ing, it requests a permission release from the BMS before it continues. In the event that
there is no permission response from the BMS for a period exceeding 30 minutes, FACOS
is deactivated and all queued items are cleared. If permission is granted, blowing time and
water pressure are set by FACOS depending on the required cleaning effect. The opti-
mised parameters determined during the cleaning are stored and used as initial starting
parameters for the next cleaning cycle.
FACOS transmits information about the fouling rate to the DCS. During this operation FA-
COS determines individual areas of the combustion chamber for cleaning.
The blowing control assigns the water cannon to specific dirty areas. The control of the
water pumps are carried out by DCS with the optimum operating pressure of the water
cannon defined by FACOS system.
Facos starts the potable water booster pumps and will set the blowing time and water
pressure depending on the required cleaning effect.
The amount of water introduced into the furnace during cleaning is approx. 10-12,5 kg/s,
with one WLB in operation.
The condition is communicated to the boiler monitoring system (BMS) in order to guaran-
tee a co-ordination of all cleaning operations. Time and place of cleaning are software
controlled.

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Each WLB is programmed with a specific number of blowing patterns.

Blowing patterns are also activated automatically through the signals received from the
heat flux sensors.

Figure: Heating surface status furnace screen

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The furnace screen shows, e.g. the boiler load, furnace exit temperature, average and
individual heat flux as well as conditions of cleanliness.

Figure: Furnace screen (overview)

2.3.1.4 Automatic operation with boiler monitoring system but without FACOS

Boiler monitoring can only assist in detecting the overall furnace condition. A complete
clean of the furnace could markedly affect the furnace exit gas temperature with corre-
sponding effects on the water/steam side. For this reason only a limited number of areas
should be cleaned at once. The following procedure is foreseen for commissioning pur-
poses and can be optimised through operational results.
The cleaning cycle for the complete furnace consists of 5 levels with 28 cleaning zones. A
new cleaning cycle starts, when all sections have been cleaned once.
When the cleaning request for the complete furnace from the boiler monitoring system is
given all cleaning zones of one level are activated via the water cannon control and
cleaned. Preferably the latest blowing parameters that were optimised by FACOS are used
for the cleaning actions.
Otherwise standard parameters are used, which must be determined during commission-
ing.

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2.4 Compensation of load due to water cannon operation

During water cannons in operation the injected amount of water must be evaporated addi-
tionally and the firing load must be increased accordingly to avoid a reduced steam pro-
duction. The firing load is increased as soon as one water cannon get the signal for oper-
ation according to actual firing load as shown in the figure below.
After operation the firing load is decreased accordingly.

Figure: Steam soot blowers for HP and RH surfaces and economiser

B114115-10-01-IB01-00001-AG Steam Sootblower System Boiler HCB

B114116-10-01-IB01-00001-AC

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3 Steam soot blowers for HP and RH surfaces and

economiser

3.1 Arrangement of steam soot blowers

40 long retractable soot blowers (RK-SL) are used for cleaning SH1, SH3, RH2, SH2 and
RH1 and 8 helical blowers (RK-SB) are used for cleaning the economizer.
For cleaning of the convective heating surfaces of the steam generator steam sootblower
are used. Long retractable sootblowers (type: RK-SL; area: SH1, SH3, RH2, SH2 and
RH1) and helical blowers (type: RKSB; area: ECO) are used for cleaning the convective
heating surfaces of the steam generator. The required superheated steam is taken from
the cold RH at RH1 inlet headers HAJ05 BB012/14. In the reducing station HCB10 AA001,
the pressure applied there is reduced by a control valve to the pressure required for the
sootblower. The sootblowers of the left and right side wall are supplied by a joint pressure
reducing station

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Figure: Arrangement of steam soot blowers

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Soot Blowers

Figure: Long retractable blower RK-SL

When the drive motor is switched on, the sootblower carriage moves forward and pushes
the lance tube helically into the flue gas pass.
The sootblower valve is opened as soon as the two nozzles have passed the boiler wall.
Blowing process starts.
Technical data :
Travel speed 2,7m/min Blowing time 400s Blowing mass flow
2,188kg/s
Travel 9628mm Design blowing pressure 1,6 MPa
The long retractable soot blowers (RK-SL) of the SH1/SH3, SH3/RH2, RH2/SH2,
SH2/RH1 and RH1 are arranged at the levels 75,6m; 78,5m; 81,6m, 86,0m, 89,4m in
groups of four on the left and right side wall (LSW/RSW).

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The eight helical blowers (SB) of the economiser at level 92,85m are arranged on the left
and right side wall (LSW/RSW).
Downstream the pressure reducing station, the supply line HCB10 BR010 is divided into
two supply lines, HCB20 BR010 to supply the steam blowers of the left and HCB40 BR010
so supply the steam sootblowers on the right side wall or, respectively, the related soot-
blowers of the ECO on the rear wall. The steam is distributed in each supply line to the
sootblowers in operation which are arranged over 7 levels.
The blowing pressure is adjusted at each sootblower individually to approx. 0.6 – 1.0 MPa.
However under no circumstances the blowers are allowed to be operated individually be-
low the minimum required blowing pressure due to lance protection reasons. The steam
is superheated sufficiently, that after relaxation downstream the nozzle the steam doesn’t
drop too much the saturation temperature.
The heating surfaces are cleaned level by level, with 2 sootblowers maximally on the same
level being used simultaneously. In operation via central control, the levels are normally
cleaned in flue gas direction.
The steam sootblower system is preheated via a connecting line via the fully opened
shutoff valve HCB51 AA101 to the BBDV. In standby mode, it is kept hot to reduce the
thermal losses via a line to the feed water tank. In this case, the shutoff valve HCB51
AA101 is closed and the shutoff line to the BBDV is drained via the steam trap HCB51
AA601

3.2 Principle and design of RK-SL

Long retractable soot blowers (RK-SL) are used for cleaning SH1, SH3, RH2, SHE and
RH1.

BMCR 100% 80% 60% 40%

Up- Down Up- Down- Up- Down- Up- Down-
strea strea stream stream stream stream stream stream
m m
Pressure 5,42 1,7 4,2 1,7 3,1 1,7 2,09 1,7
[Mpa]
Temperature 333 290 330 302 334 319 341 337
[°C]

Design pressure of steam sootblower system 6.71 MPa

Design temperature of steam sootblower system 365 °C

3.3 Holding steam temperature

The steam soot blowing system is kept permanently hot via the permanently open line to
the feed water tank.

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For warming-up after prolonged standstill, the drain and warm-up pipe to the BBDV will be
used.

3.4 Flushing and sealing air fans

Every steam blower is provided with a flushing and a sealing air fan HCB20/30 AN011-
14/21-24/31-
34/41-44. During start-up, they are started up before the FD fan and the ID fan. They will
only be shutoff when the following conditions are met:
 FIRE OFF
 both FD fan (HLB) and ID fan (HNC) OFF
 Flue gas temperatures at the economiser outlet HAH11 HNA11/21 CT901 < 70 °C

3.5 Arrangement of sootblowers

The long retractable sootblowers (type: RK-SL) of the SH1/SH3, SH3/RH2, RH2/SH2,
SH2/RH1 and RH1 are arranged at the levels 75.6 m; 78.5 m; 81.6 m; 86,0 m; 89.4 m in
groups of four on the left and right side wall (LSW / RSW). The eight helical blowers (SB)
of the economiser at level 92.85 m are arranged on the left and right side wall (LSW /
RSW).

3.6 Operation of the Steam Sootblower System

In the normal case, operation of the LRS and the helical sootblowers will be run according
an automatic boiler monitoring system. However, the sootblowers can also be operated
according a predefined program or by manual operation.
Start-up of the Sootblower System
First, the pressure control valve HCB10AA001 and the main shutoff valve HCB10 AA101
are closed and switched to manual control. After a boiler start, the motor shutoff valve
HCB52 AA101 to the feed water tank is closed; the motor shutoff valve HCB51 AA101 to
the BBDV LCL10 BB001 is opened.
For system heating, the main shutoff valve HCB10 AA101 and the pressure reducing valve
HCB10 AA001 are opened. The soot blowing system is now charged with steam. To guar-
antee safe operation, a pressure increase limit of 0.3 MPa/min should be maintained.
If a pressure of > 1.1 MPa is reached downstream of the reducing station HCB10 CP001
and a temperature of > 250 °C downstream of the last steam blowers HCB20/40
CT001/002, the motor shutoff to the BBDV LCL10 BB001 will close, and it will be switched
over to temperature maintaining to the feed water tank.
The pressure increase is limited to 1.7 MPa. The pressure control valve keeps the pressure
constant. The soot blowing system is ready for operation and can start operating.

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3.6.1 Start Conditions for Sootblowing

The appropriate blowing program has to be selected to start the cleaning cycle. Release
is given when the following conditions are met:

Description KKS Condition

live steam mass flow HAH40 FF901 160 kg/s
temperature before drain- HCB20/40 CT001/002 > 240 °C
age
pressure behind reducing HCB10 CP001 < 2.0 MPa (30sec.)
station
pressure behind reducing HCB10 CP001 > 1.6 MPa (30sec.)
station

3.6.2 Soot blowing procedure

Normally all long retractable sootblowers except of SH1/SH3 sootblowers (HCB20/40
AA061-064) are
operated with two sootblower of one level in parallel. The blowers start with a delay of 15
s; the steam flow upon starting and stopping the blowers is thereby halved. To reduce the
current consumption of steam coming from the cold RH, the sootblowers of every level can
also be applied individually. However, the cleaning time for the cleaning cycle will be dou-
bled thereby.

3.6.3 Soot blowing cycle

3.6.3.1 for HCB20/40 AT021-024/031-034/041-044/051-054

Soot blowing cycle Sootblower groups Sootblower groups
1 Group 1 LSW x 1 + RWS x 3
2 Group 2 LSW x 2 + RSW x 1
3 Group 3 LSW x 4 + RSW x 2
4 Group 4 LSW x 3 + RSW x 4

The SH1/SH3 sootblowers (HCB20/40AT061-064) and the economiser sootblowers

(HCB20/40AT011-014) operate individually as shown in following table.

3.6.3.2 for HCB20/40 AT011-014 /AT061-064

Sootblowing cycle Sootblower groups Steam blowers

1 Group 1 LSW x 1

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2 Group 2 RSW x 3
3 Group 3 LSW x 2
4 Group 4 RSW x 1
5 Group 5 LSW x 4
6 Group 6 RSW x 2
7 Group 7 LSW x 2
8 Group 8 RSW x 4

3.7 Temperature maintaining during operation

When the system is heated up, it is maintained at the temperature via the flow through to
the feed water tank; only a volume of 1.08 kg/s is necessary for it. This amount must also
be available for maintaining the temperature during soot blowing. The temperature behind
the last sootblowers HCB20/40 CT001-CT002 is continuely monitored; should it drop be-
low 230 °C, the current sootblower program is run to the end.
All pending cleaning requests are delayed until a temperature of > 250 °C is reached again.
This is to prevent that condensate will form in the sootblower system.

3.7.1 Alarms during sootblowing

If the control detects one of the following error messages, a collective alarm is sent to the
control room:
Alarm Event KKS Condition
live steam mass flow at HAH40 FF901 < 160 kg/s
feeding of the
sootblowers from CRH
pressure downstream of re- HCB10 CP001 <1,25 MPa (30 s)
ducing station
pressure downstream of re- HCB10 CP001 > 2,05 MPa (30 s)
ducing station
operating time of the soot- exceeded
blower

3.7.2 Interruption during sootblowing

Any interruption of soot blowing is reported via an alarm and documented.

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An interruption is triggered by the following events:

FIRE OFF
Soot blowing is terminated temperature downstream of last sootblower
HCB20/40 CT001-002
< 230 °C

Run of current soot blowing, then reheating of the system live steam mass flow
HAH40 FF901
< 150 kg/s

Run of current soot blowing and then further soot blowing is terminated pressure down-
stream of reducing station
HCB10 CP001
> 2.1 MPa
(30 s)

Soot blowing is terminated pressure downstream of reducing station < .2 MPa Soot blow-
ing is terminated
HCB10 CP001 (30 s)
pressure cold reheat HAJ05 CP001
< 1.6 MPa (30 s)
Soot blowing is terminated

Utmost caution is required in case of an alarm due to the pressure downstream of the
reducing station HCB10 CP001 in case of any malfunction of the pressure control the
sootblowers may cause great damage in the heating surfaces!

3.8 Shutdown
After termination of a soot blowing process, the sootblowers are shutoff. The system is
continued to be kept hot. Depending on the steam temperature, the steam is either dis-
carded or returned to the feed water cycle (regular case in normal operation). The system

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is entirely shut down only in case of a boiler standstill. In that case, first the pressure control
valve HCB10 AA001 is closed, and then the motor shutoff valve HCB10
AA101. Temperature maintaining to the feed water tank is closed, and the connection to
the start-up flash tank / blow-down vessel LCL10 BB001 is opened.

3.9 Principle and design of RK-SB

Helical blowers (RK-SB) are used for cleaning the economiser tubes.

The helical sootblower is equipped with a blowing tube installed in the flue gas pass and
is helically moved forward and backwards.
The blowing tube is on its entire length equipped with Venturi nozzles and the rear end of
the blowing tube is fastened to a lance tube.

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Some technical data:

Travel speed 0,72m/min Blowing time 198s Blowing mass flow
3,226kg/s

Travel 1265mm Design blowing pressure 1,6 MPa

Steam supply and blowing pressure

The required superheated steam is taken from the cold RH, design pressure 6,81 MPa
and 365oC reduced by a control valve to the pressure required for the soot blower.

Figure: Blowing pressure as a function of Boiler Load.

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Figure: Sootblower-valve

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4 Air heater sootblowers

Figure: Rake sootblower

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4.1 System Description and Design parameters

The air heater is provided with one sootblower each for the hot and the cold flue gas path.
The blowing tube remains in the flue gas pass.
Temperature maintaining is provided via a connection line to the start-up flash tank / blow-
down vessel LCL10 BB001.
Permanent hot holding is not planned due to the regular blowing cycles with long breaks
in between. Prior to using the sootblowers at steam supply from RH2, the motor valve for
system heating HCB61/64 AA101 is opened and the line heated up until a temperature
HCB61/64 CT002 of > 350 °C is reached. The temperature maintaining steam and the
collecting condensate are diverted via a bypass throttle to the boiler BBDV.
The required superheated steam for sootblowers of air heaters is taken from the inlet
header of RH2. In the reducing station, the pressure applied there is reduced by a control
valve to the pressure required for the sootblower.
The required blowing pressure is monitored. Upstream of the single sootblowers the pres-
sure is means of throttle once again reduced to 0.6 MPa at steam supply from RH2.

4.2 Design data and equipment of the air heater sootblower

system

4.2.1 Bases (Design data) (HCB60-64)

The design parameters are in accordance with those of the RH 2 inlet. Design parameters
in front of reducing station:
 P Design: 6.64 MPa
 T Design: 487 °C
Operating parameters upstream and downstream of pressure reducing station HCB60
AA001 during steam supply from HRH:
BMCR 100% 80% 60% 40%
Up- Down Up- Down- Up- Down- Up- Down-
strea strea stream stream stream stream stream stream
m m
Pressure 5,32 1,7 4,1 1,7 3,08 1,7 2,05 1,7
[Mpa]
Temperature 482 462 487 474 490 483 487 485
[°C]

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4.3 Pressure Reducing Station (HCB 60)

The pressure reducing station reduces the pressure from the RH2 inlet the required pres-
sure for the
sootblowers. It comprises of the following components in flow direction:

4.4 Operation of the air heater steam sootblower system

The operation of the air heater is started by means of the control by selecting the respec-
tive cleaning program.

4.4.1 Soot blowing procedure

The standard blowing program provides the cleaning of the heating surfaces in the follow-
ing order:
 cold side
 hot side
 cold side
Unplanned blowing procedures may be initiated by means of the control and changes of
the program can be made.

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4.4.2 Conditions for start of steam sootblowers

To be able to start-up the sootblowers the following conditions must be fulfilled:

KKS Condition
Live steam mass flow HAH 40 FF 901 > 160 kg/s
Air temp. downstream of air heater HCB 61/64 CT 002 > 330 °C
Pressure in cold RH system HAJ 05 CP 001 > 1,7 MPa (30 sec)
Pressure downstream reducing station HCB 60 CP 001 > 1,5 MPa (30 sec)
< 1,8 MPa (30 sec)
Air heater rotation HLD 10/20 GH 001 rotating

4.4.3 Start-up of steam sootblowers

At first the main shutoff valve HCB 60 AA101 and the pressure control valve HCB 60
AA001 are closed and changed over to manual control. The motor valves HCB61 AA101
and HCB64 AA101 to the BBDV LCL10 BB001 are opened. Then at first the main shutoff
valve to the reducing station is opened. The control valve changes over to automatic op-
eration and the soot blowing system is supplied with steam. To ensure a safe operation a
pressure increase of 0.3 MPa/min should not be exceeded. The system is safely drained
by means of shutoff valve and/or the bypass throttle.

4.4.4 Interruption of air preheater soot blowing operation

The soot blowing program is interrupted, if one of the following criteria is occurred:
Fire off
Pessure downstream reducing station > 1,9 MPa
HCB 60 CP 001
Live steam mass flow < 150 kg/s
Temp. downstream of air preheaters < 330 °C
HCB 61/64 CT 002
Air heater rotation not rotating
HLD 10/20 GH 001 XG06

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4.5 Alarms

operator action KKS Condition

Live steam mass flow at feeding of the sootblow- HAH 40 FF901 < 160 kg/s
ers from reheat supply
Alarm, if air preheater is in operation with any HCB 60 CP 001 > 1,8 KPa
steam supply
Alarm, if air preheater sootblower is in operation HCB 60 CP 001 < 1,5 MPa
Alarm, if sootblower (HCB62/63AT001) in opera- HCB 61 CT 001 < 330°C
tion
Alarm, if sootblower (HCB65/66AT001) in opera- HCB64 CT002 < 330°C
tion

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5 Operation of sootblowers
The appropriate blowing program can only start when the following conditions are met:
 Release criteria for boiler soot blowing
Live steam mass flow HAH40FF901 > 160 kg/s
Temperature before drainage HCB20/40 CT001/002 > 240 °C
Pressure downstream of reducing station HCB10 CP001 < 2,1 MPa.
(30 sec.)
Pressure downstream of reducing station HCB10 CP001 > 1,7 MPa.
(30 sec.)
The heating surfaces are cleaned level by level, normally in flue gas flow direction.
All boiler steam soot blowers are operated with two soot blowers of one level simultane-
ously.
The blowers of SH1/SH3 (HCB20/40AA061-064) and the economiser soot blowers
(HCB20/40AT011-014) are however operating individually because of the higher steam
consumption.

5.1 Disturbances during boiler soot blowing

Any interruption of soot blowing is reported via an alarm and is documented.
An interruption is triggered by the following events (OR logic operation) :
KKS
temperature downstream of last soot HCB20/40 < 230 °C run of current
blower CT001/2 blower then
termination
live steam mass flow HAH40FF901 < 150 kg/s
pressure downstream of reducing HCB10 CP001 > 2,2 MPa (30 termination of
station s)
sootblowing
pressure downstream of reducing HCB10 CP001 < 1,3 MPa (30
station s)
pressure cold reheat HAJ05CP001 < 1,7 MPa (30
s)

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5.2 Operation of the steam soot blowers

In the normal case, operation of the steam soot blowers will be run according to an auto-
matic boiler monitoring system. However, the soot blowers can also be operated according
to a predefined program or by manual operation.

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6 Maintenance

6.1 General:
The supplier’s instructions for maintaining the equipment to enable the recommended
maintenance to be performed must be followed.

6.2 Smart Cannon System

Figure: TYPE: WLB-CB100

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Water cannons are permanently installed on the boiler to clean slagged furnace walls by
means of a high pressure water jet.
The water cannon’s, using a high pressure nozzle, produces a greatly concentrated jet of
water which impinges on the targeted boiler wall across the combustion chamber, and
cleans off any slag deposits which may have accumulated.
The water cannon can be swiveled horizontally and vertically, and cleans specifically the
fouled areas identified by heat flux sensors.
If the heat flux drops below a certain value in the area of a measuring point, the area is
cleaned by jetting with the water cannon, causing thermal shock within the deposits and
their removal from the furnace wall.
There are 8 water cannons per boiler installed:

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SAFETY REQUIREMENTS:
Before attempting work on any equipment, it is essential that all requirements of the Eskom
Plant Safety Regulations (GGR 0992) are met – i.e. plant is correctly isolated and safe to
work on, and a permit to work document has been issued and signed by the person re-
sponsible for the work.
It is a further requirement that all dangerous conditions and incidents must be reported as
soon as possible to the person in charge of the plant.
SPECIAL SAFETY CONSIDERATIONS:
The water cannon operates at a blowing pressure of 1,5-2,0 MPa, and is powered by two
drive motors – one for vertical movement, and one for horizontal movement of the cannon
and nozzle assembly.
The operation of the water cannons is automatically triggered by signals from the heat flux
measurement devices, and the system is therefor to be considered as LIVE at all stages
of boiler operation.
NOTE: Service frequencies are based on an 8 hour blowing interval

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6.3 LONG RETRACTABLE SOOT BLOWER

Figure: TYPE: RK-SL

The long retractable soot blower is used for cleaning of platen and bank heating surfaces
of the Superheater 1, Superheater 3, Reheater 2, Superheater 2 and Reheater 1 banks of
tubes.
The blowing element of the long retractable soot blower is a lance tube at the tip of which
is a nozzle head with two Ventui nozzles arranged180˚ apart.
The lance tube moves into the flue gas pass, changes the direction of movement in the full
forward position and returns to its initial position whilst the lance tube (and nozzles) is
rotating. Thereby the nozzles carry out a helical movement.
Since the nozzles are offset by 180˚, the distance of the helicoids formed by the blowing
jet of steam is only half of this distance. Due to the conical spreading of the blow jets, a
closed cleaning effect across the entire blowing distance is ensured.
The lance tube is driven by the soot blower carriage which is guided in the track beam.
The blowing medium is fed to the lance tube through the soot blower valve and the fixed
feed tube.
There are 40 long retractable soot blowers per boiler, each supplied with steam from either
Cold Reheat system or from the auxiliary steam system at pressure between 15 and 18
bar and 290-365˚C.
The Nash-Elmo sealing and scavenging air fan is considered maintenance free.

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SPECIAL SAFETY CONSIDERATIONS:

The soot blower range operates with a steam pressure in excess of 1,8 MPa and temper-
ature in excess of 290˚C and is always “charged” at this pressure and temperature.
Great care must be taken in ensuring proper isolations prior to the commencement of any
work.
NOTE: Service frequencies are based on an 8 hour blowing interval

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6.4 HELICAL SOOT BLOWER

Figure: TYPE: RK / SB

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The retractable soot blower is used for cleaning the tube bank heating surfaces of econo-
miser.It is equipped with a blowing tube installed in the flue gas pass and is helically moved
forward and backwards.
The blowing tube is equipped on its entire length with Venture nozzles, and the rear end
of the blowing tube is fastened to a lance tube. The helical movement of the lance tube is
effected by the chain drive at the soot blower carriage, which is driven by a geared motor.
There are 8 Helical soot blowers per boiler, each soot blower having 11 nozzles of 16mm
diameter and a blowing pressure of 0,6-0,8 MPa.
The sealing/scavenging air fans are considered maintenance free.
SPECIAL SAFETY CONSIDERATIONS:
The soot blower range functions with a steam pressure greater than 6.0 MPa, and temper-
ature greater than 350˚C and is fully charged at all times during Unit operation.
Great care must be taken in ensuring proper isolations prior to the commencement of any
work.
NOTE: Service frequencies are based on an 8 hour blowing interval

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