Basics of Thermal Power Plant

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Thermal Training Institute
STEAM GENERATOR
OBJECTIVES To acquaint the participants with the safe and efficient operation of Boiler and its Auxiliaries and also Preventive & Breakdown maintenance procedures. PROGRAMME PROFILE

Working principle, function and classification of Boilers. Description of Boiler components. Function and working principle of Boiler auxiliaries-Mills and Feeders, Fans, Air Preheaters, Soot blowers etc., Boiler Mountings; safety valves, drains and vents. Operation of Boiler Auxiliaries. Alkali boil out and Acid cleaning. Hydraulic Test. Boiler startup and shut down. Interlocks and Protections including F.S.S.S. Efficiency and Performance monitoring of Boiler and its auxiliaries. Important do's and Don'ts under emergency condition
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CONTENTS CHAPTER 01 02 DESCRIPTION STEAM GENERATOR PAGE 3
AIR PREHEATING SYSTEM DRAUGHT SYSTEM
20
03
26 41 76
04
FUEL FIRING SYSTEM
05
ELECTROSTATIC PRECIPITATOR
06
SOOT BLOWER SYSTEM
90
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STEAM GENERATOR
CHAPTER - I
STEAM GENERATOR
INTRODUCTION The term steam generator has come into existence to replace the term boiler as it includes the furnace, boiler drum, water walls, super heaters, reheaters, economizer etc. The boiler in our Power Station are all conventional single drum natural circulation, radiant, dry bottom, balanced draft, reheat out door type. The scarcity of fuel, steep increase in fuel costs and worsening of quality of fuel lead to pay more attention for the increase in efficiency of the steam generating system. The heat released in the furnace is received by the water / steam / air to the maximum extent to have boiler efficiency of the order of 86%. DRUM & DRUM INTERNALS: The boiler drum serves the purpose of storing water for conversion to steam through the water wall connections. The water and steam mixture entering the drum through the up risers may contain one part of steam with about 5 to 8 parts of water by weight. Hence natural circulation in the boiler water walls is based on thermo siphon principles. The circulation number, which is the ratio of quantity of water & steam mixture flowing through the circuit to the quantity of the steam produced, is designed to be around 8 for natural circulation. The water from boiler drum takes a path through 6 nos down corners to the bottom ring header and rises through the water wall tubes, absorbing heat in the furnace. The steam and water mixture are collected at the upper header and through the up rises enter the drum again.
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STEAM GENERATOR
Inside the drum, turbo separators with screen driers are placed for separating saturated steam from water. In the axial flow turbo separator rotary motion is accomplished by the configuration of the vanes. The spinner blades impart centrifugal motion in the flowing mixture and the plate type corrugated sheet placed at the outlet of the turbo separator provides torturous path for the separation of the steam. The final separation of the dry saturated steam is achieved in the screen drier, having wire mesh boxes, with more wetting surfaces. For proper operation of drum internals, controlling the normal water level is utmost important, because once the turbo separators are immersed in water proper separation of steam will not be possible. The drum is provided with spring -loaded safety valves to relieve the pressure in case of abnormal increase in pressure above a present value. Drum level transmitters are provided for remote indication in UCB, in addition to 2 Nos. Inside the drum, turbo separators with screen driers are placed for separating saturated steam from water. In the axial flow turbo separator motion is accomplished by the configuration of the rotary vanes. The spinner
blades impart centrifugal motion in the flowing mixture and the plate type corrugated sheet placed at the outlet of the turbo separator provides torturous path for the separation of the steam. The final separation of the dry saturated steam is achieved in the screen drier, having wire mesh boxes, with more wetting surfaces. For proper operation of drum internals, controlling the normal water level is utmost important, because once the turbo separators are immersed in water proper separation of steam will not be possible. The drum is provided with spring -loaded safety valves to relieve the pressure in case of abnormal increase in pressure above a present value. Drum level transmitters are provided for remote indication in UCB, in addition to 2 Nos. hydrasteps (L) & (R). Local gauge glasses on both sides of the drum have also been provided. To maintain the required phosphate value and PH in the boiler water, the phosphate dozing line is connected to the drum. Both these lines are extended almost throughout the length of the drum with perforated holes, but in opposite directions, so that the phosphate will have much time to react. Drum vents are provided on both (L) (R) sides, for controlling drum level,
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STEAM GENERATOR
during swelling, the emergency blow down is connected to the drum and is protruding inside the drum up to the normal working level, which is 250mm below the drum geometric center line. The drum is inclined down by 2 deg on the right side. FURNACE: The furnace of the boiler is formed by water walls for combustion of fuel a n d th e o pe n in g a t t h e b ot t om f o r a sh re m o va l. Th e ent ire la t e n t he at of vaporization of water is added here. The space between the tubes is fusion welded to form a complete gas tight water wall, thus eliminating there factory work for insulation of the furnace. Sufficient height between the top row of fuel nozzle and the furnace exit is provided to obtain proper furnace retention time for the fuel to have complete combustion. The boiler is a tangentially fired boiler having the fuel burners in all the four corners. There are four elevations of oil burners for firing heavy oil with the bottom most elevation has the option of firing light oil also. Six sets of coal burners are arranged corresponding to each mill, with provision to admit combustion air around the burners. The bottom ash hopper is open hopper type where in heavier products of combustion (ash and slag) are collected. The front and rear walls slope towards the center of the furnace to form the inclined sides of the hopper. The bottom ash is continuously removed by two sets of scrapper feeders and disposed by clinker grinders. Fouling of the water wall by gradual building up of slag is cleared by wall blowers using superheated steam, to avoid increase in furnace exit gas temperature. The water wall assembly is free to expand downwards, as the furnace temperature increases. But to avoid air ingress into the furnace, which is maintained at a negative pressure, suitable water seal assembly by providing a 'seal through is arranged. ECONOMIZER: The economizers were initially introduced to recover the heat available in flue gas that leaves the boiler, there by increasing the efficiency of the steam generator. This resulted in saving in fuel consumption and hence the name Èconomizer'. The heat from flue gas is absorbed to raise the sensible heat to feed water before the same enters the evaporative circuit 'of the
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STEAM GENERATOR
boiler.The economizer is located just above air preheaters. The feed water flow is in counter flow direction with respect to flue gas, giving higher heat transfer rate. Feed water is supplied to the inlet header of the economizer after the feed isolation valve and NRV. From the outlet header, it is fed to the drum through economizer outlet links. Drain and vents are also provided for the economizer. Economizer recirculation line taken from the down comer to eco inlet is provided to prevent steaming in economizer coil for which they are not designed. Through the recirculation line flow is created during start up, whenever there may not be any feed water flow through the eco, from BFP. Ash hoppers below the economizer are provided as the flue gas duct takes from vertical to collect and dispose off the ash. SUPERHEATERS: Super heaters are meant to raise the steam temperature above the saturation temperature by absorbing heat from the furnace and flue gas to increase the cycle efficiency. The maximum temperature to which the steam can be heated is limited by the metallurgy and economy in initial cost. Present trend is to limit the temperature at 540. A super heater which can 'see' the furnace flame and absorbs heat y radiation is radiant and low temperature super heaters receive the heat by convection, and they are placed either horizontally or allowed to be hung vertically. The vertical arrangement is simpler in supporting and allowing for expansion and this type is called pendant SH. The superheaters are also arranged as ceiling for the furnace (ceiling SH) and as wall of the second pass (steam cooled wall SH). The horizontal or low temperature SH (LTSH) is located in the rear vertical gas path above the economizer. The pendant SH is the final assembly of superheaters from which the main steam lines (L) & (R) to turbine are taken. REHEATERS: Reheater is used to raise the temperature of the comparatively cold steam, which is exhausted from HP turbine after doing work (Cold Reheat steam). This is another method of raising the cycle efficiency. Because of higher initial costs involved, reheater system will be used as the unit sizes increase beyond 100MW. The reheater is composed of two stages viz. The
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STEAM GENERATOR
front pendant and rear pendant sections. The front pendant reheater is located above the furnace, between the rear water wall hanger tubes and the platen SH section. The rear pendant section is located between the water wall screen tubes and before the final SH section. In other words the reheater coils are placed in between the platen and final SH. STEAM TEMPERATURE CONTROL: The metal temperature at all section in the super heater and reheater also in the turbine should be maintained within permissible values. Attemperation by feed water injection is used to limit the temperatures of steam at boiler outlet. The design margin in temperature control may get deviated and may result in higher outlet temperatures due to slag formation in water wall, high excess air, low feed water temperature, low load operations, and top tier mills in service. The cause has to be identified and action taken to keep the SH and RH temperature at 540C at boiler out let always. Wall blower operation and burner tilt adjustment are in addition to adjusting total air flow, coal firing etc. Temperature control by feed water injection has to be resorted to as a final measure. For SH steam temperature control, the required quantity of feed water is injected at the SH connecting links between LTSH and platen SH and platen to final SH into the path of the steam, through a nozzle at the entry end of the desuperheater. Normally spray type desuperheaters are provided with renewable liners to protect the main super heater shelled with renewable liners to protect the main super heater shell from erosion of spray water and thermal shock. Since they are placed before platen super heater, the water particles entry to turbine is remote. For reheater temperature control, burner tilting is carried out. Reheater spray injection is carried out as a last resort at the cold reheat pipe before entering the reheater coils. A control valve linked to an automatic control drive unit regulates the flow of spray water quantity supplied to the desuperheaters for main steam and RH steam temperature control. A 100% stand by spray control valve is provided for RH & SH temperature control. Both the main and stand by spray control valve are provided with electrical isolation valve at the upstream side and hand valve at the down stream end.
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STEAM GENERATOR
SAFETY VALVES: The pressure in the drum, super heater or reheater may suddenly rise to abnormal limits, due to operational emergencies or due to load throw off conditions. To safeguard the pressure parts, safety valve are provided. The boiler drum is provided with 3 Nos. spring loaded safety valves, to relieve approximately 547T/hr. Similarly the super heaters are safeguard by providing one no. spring loaded and one no. electromatic safety valves, at the super heater outlet pipes. For reheating system there are totally 4Nos safety valves, one no in cold reheat line and 3 Nos. in hot reheat line at the boiler end. VENTS AND DRAINS These are important in the sense that proper operation of vents and drains is essential during initial operating condition and during shut down. The steam line drains should be kept open before charging, in order to avoid water hammering and uniform warming up. The drum, the economizer, super heaters and reheaters are provided with vents at suitable locations. They are grouped and the valves are provided at drum level for ease of operation. Similarly the super heater drains are provided at 16m level and the drains are connected to the IBD expander. For controlling drum level during start up, the emergency drum drain valves and down comer drain are provided. These valves can be operated from UCB. The main steam line is provided with a drain before the boiler stop valve, so that the line can be warmed up to the stop valves during start up. The continuous blow down from boiler drum is provided to remove the sludge's and impurities continuously. The silica in steam should be kept below 0.02 ppm and in the boiler water, by suitable blow down it shall be maintained below 0.25 ppm for a drum pressure of 165 kg/sq.cm. The normal drain through CBD will be around 1% of rated steam flow. In order to use the steam from the CBD quantity, a CBD expander is provided, while the condensate is wasted through IBD tank, by means of a level controller.
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STEAM GENERATOR
MAIN PARAMETERS Fuel: Coal Generator MW Flow Primary SH OIL Flow RH outlet Total heat to SH/RH Pr. at SH OIL Temp at SH O/L Pr. At RH I/L Temp a RH I / L Pr. At RH OIL Temp at RH OIL Feed water temp Ambient air temp Combustion air temp (sec) Fuel quantity Air quantity FG temp at boiler Efficiency based on BOILER PROTECTIONS: A boiler trip command stops all fuel inputs by tripping all the pulveriser, all the feeders and all the oil guns. Closing the HO trip valve, IO trip valves and LP trip valve and tripping of PA fans also will accompany boiler trip out, boiler trip is initiated by any one of the following conditions. a. Loss of DC power (2 sec) b. Less than fire ball and loss of AC at any elevation in service c. Drum level very low for more than 5 sec d. Drum level very high for more than 10 sec T/hr T/hr 693.6 618.6 Unit 100% MCR 100% TMCR 210 693.6 572 420.6 154.1 540 38.1 347 36.6 540 248 30 312 125.8 779 132 86.74 60% TMCR 126 384.5 349.1 263.8 150.8 540 23 334 22 540 222 30 281 78.9 550 119 86.72 HPH OUT 210 589.3 582.2 439.6 153.2 540 39.4 357 37.8 540 167 30 268 130.8 806 112 87.66
M Kcal/hr 420.6 Kg/sq.cm 155 deg.C deg.C deg.C deg.C deg.C deg.C deg.C T/hr T/hr deg.0 % 540 350 39.7 540 250 30 317 135.2 837 133 86.71 Kg/sq.cm 41.3
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STEAM GENERATOR
e. Both FD fans off f. Both ID fans off g. Unit air flow < 30% h. Furnace pressure very low i. j. l. Furnace pressure very high Loss of all fuel trip E m e rge n cy t rip
k. Flame failure trip m. Loss of reheat protection trip BOILER FILLING UP The boiler may be required to be filled up for conducting hydraulic test or for lighting up or for wet preservation. For hydraulic test and preservation, the e n t ire syst em ha s t o f illed be u p vi z. E co n o m ize r, wa t e r wa ll, d rum a n d superheaters, upto boiler stop valves. But for the lighting up of the boiler, it is sufficient that the economizer, water walls and drum upto normal level are filled up. It is always preferable to fill up the boiler, with maintaining some pressure in deaerator by pegging steam for deaeration. However, sometime, if it is not possible to have deaerated water for filling up, water which is chemically treated for removal of dissolved oxygen will be used. In this case, hydrazine is used for this purpose. For filling up the system with boiler feed pump, deaerator shall be pressurized with steam, obtained from other unit, and make up for feed tank carried out through condensate pump. Boiler fill pump cannot be used in this case for making up deaerator level. Since it is admitted into feed tank only and not to the deaerator. But while conducting, hydraulic test, the hot water can not be used for filling up, because the boiler tube leak can not be checked up by entering into the boiler. In this case, it is preferable to use chemically treated cold water. After the hydraulic test is declared OK, the entire water shall be drained and then filled up with deaerated water. Filling the system for wet preservation can be carried out either with boiler fill pump or with boiler feed pump. The required chemical (200 ppm hydrazine and required ammonia for raising PH) shall be fed in CST, assuming the water filling capacity of boiler. Using the boiler fill pump the boiler can be
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STEAM GENERATOR
filled up through Economizer, water wall and SH drains. In order to prevent entry of impurities from water walls, entering the superheaters, water wall drain shall be closed at normal level. In the other case when filling up, using boiler feed pump chemicals shall be fed in feed tank and circulated with BFP and boiler filled up with200 ppm hydrazine. Addition of required quantity of chemicals in feed tank shall be done as and when the values drop. LI NI NG UP THE S YS TE M FO R FI LLI NG UP THRO UG H BOILER FILL PUMP (PRESERVATION): 1. Check that no line clear is pending in boiler, and the boiler is cleaned for filling up. 2. Check the level is CST and if necessary raise the level to more than 70%. 3. Check that the following vents are open in 52m levels. a. Drum vents b. ECO vents c. SH vents 4. Check that the following drains are in closed condition a. Emergency drum drain (EBD) b. Continuous blow down c. Drain before boiler stop valves d. Attemperation line drains e. SH drain header drain to IBD tank 5. Check that the following drains are open a. SH drain header-filling valve from boiler fill pump b. SH drain valves (for filling the SH also) c. Eco drain (for filling through ECO) d. Down comer and bottom ring header drain (for filling through water walls) 6. Check that the valve in the 2m level from boiler fill pump line to feed tank is closed. 7. Check that the filling valve at 2.0m level from boiler fill pump line is open. 8. Check that the suction valve to fill pump is open and pump primed. 9. Check that the pump is properly lubricated and oil level available. 10.Check that the supply module for the pump is switched on and local PB
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STEAM GENERATOR
released. 11. Check that the chemical dozing valve at the filling line is closed. 12. Check that the isolation and regulation valves of start up vent are closed. 13. Check that the shoot blower line isolation valves at 52m level from tenth header is closed. 14. Check that the boiler stop valves (L) & (R) and their by pass valves (L) & (R) are closed. 15. Check that the drain line before stop valves are in closed condition. 16. Check that all sampling valves are closed. 17. Check that the hand valves and electrically operated valves of the turbine side drain lines to IBD tank is closed. 18. Check that the ECO inlet and ECO, RC valves are closed. After lining up system for filling up, carry out the following: 1. Arrange for dozing the required chemicals in CST. However it should be ensured that this chemical added water should not go to the other CST. 2. Start the pump with recirculation valve fully open, and the discharge valve clo se d . A llo w so m e t im e , sa y 1 0 t o 1 5 m t s. Fo r mixin g u p o f the chemicals. 3. Then open the discharge valve gradually, to maintain the discharge pressure at 10 kg/sq.cm. The load current at the module should be checked for about 85 Amps. It is sufficient to open by about 4 to 5 turns. 4. Check the flow of water to boiler and drop in level to the CST. The level can be dropped to a minimum of 10%. 5. If it is required to raise the CST level again, check the value of N99
110
2H4 and doze chemical as per requirement. Then continue the filling up operation. 6. Once normal level is reached in drum, stop filling through water wall drains and down comer drain. 7. Observe free flow of water in vents at 52m level and close the vents one after the other, after releasing of air. 8. Allow some time for the pressure to build up after closing of all the vents. Then close the discharge of boiler fill pump and stop the pump. 9. If the boiler is to be preserved for longer duration, the system should be filled up atleast twice in a week, so as to keep the system in completely filled up state in order to prevent entry to atmospheric air. 10. It is preferable to cap the system with nitrogen pressure (inert gas) if provision is
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available and maintain the pressure continuously. 11. The drains and other valve positions need not be disturbed if filling up is to be done periodically. If not, the system can be made ready for operation as per requirement. LINING 1. 2. UP AND FILLING UP THROUGH UP THROUGH BFP FOR
PRESERVATION: Check that the line clears on boiler pressure parts, air preheaters, bottom ash Raise the deaerator level using boiler fill pump. For this purpose check that the hopper etc., are returned with men and materials are cleared. isolation valves at the 2m level and at deaerator level are open. ACW make up pump should not be allowed to overflow if make up is done through boiler fill pump, by suitably throttling the make up valve. Check that filling valves to boiler are all kept closed. 3. 4. 5. 6. 7. 8. 9. Line up the boiler feed pump for filling the boiler Check that ECO, SH and drum vents are open at 52m level. Check the SH drains at 16m level are closed Check that EBD, IBD, down comer, water wall and Eco, drain are closed. Check that the isolation and regulation valves of start up vent are closed. Check that the soot blower line isolation valves at 52m level from tenth header Check that the boiler stop valves (L) & (R) and their bypass valves (L) & (R) are closed. 10. Check that the drain line before stop valves are in closed condition. 11. Check that all sampling valves are closed. 12. Check that all feed line drain valves are closed. 13. Check that HP bypass injection hand valve and the PRDS injection hand valve are closed. 14. Check that the HP heaters are in bypassed condition. 15. Check that the SH & RH attemperation block valves and isolation valves are closed. 16. Through the chemical feeding funnel available at feed tank add Hydrazine and Ammonia for maintaining 200 ppm N2H4 and pH>9.5 17. Start any of the BFP's which has been line up (for filling the boiler) on recirculation.
is closed.
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18. Take sample at BFP suction and see that required values are obtained. If. not, add chemicals to the required level in feed tank. Take care that the isolation valve of the chemical feeding funnel is kept closed after dozing chemicals. 19. After attaining the required chemical values, feed the boiler through low load FCV, by opening the BFP discharge valve, isolation valves of low load FCV and Economizer inlet valve. 20. After observing free flow of water through drum vents, ECO, vent and SH vents, close the vents one by one. Ensure that no air pockets are formed. 21. After raising the pressure to say 70 Kg/Sq.cm., stop the feed pump and level they system for preservation. 22. Once in 2 or 3 days, the system may be kept repressurized, if no water flow through vents is noticed, when opened for inspection. 23. During filling up, if the hydrazine value drops the required chemicals shall be added to maintain around 200 ppm , throughout filling. 24. Ensure that the chemicals added to the water, particularly ammonia does not enter the condenser or LP heaters. LINING UP THE BOILER THROUGH BFP FOR HYDRAULIC TEST: 1. Line up the system for filling up the boiler using BFP as done earlier for preservation. However, for hydraulic test, it is sufficient that the hydrazine value is maintained at 10 to 15 ppm and the required ammonia for maintaining PH 9.5. 2. The required chemicals shall be fed in feed tank as stated earlier. 3. Start the BFP and fill up the entire boiler including SH. Close the vents after observing the free flow of water. 4. If it is required to conduct hydraulic test at operating pressure, the drum and SH safety valves need not be gagged or blanked. 5. If the hydraulic test is to conducted at elevated pressures, then drum and SH safety valves are to be gagged or blanked. 6. Raise the pressure by raising the BFP discharge pressure by increasing scoop position, such that the rate of rise will not exceed about 10kg/sq.cm per minute. 7. Keep the test pressure at required level (say 145 kg/sq.cm if hydraulic test is being conducted at the rated pressure so that there will be margin in not
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exceeding the rated pressure) for about 5 minutes. And then reduce the p re ssu re to 7 0 kg/ sq. cm gra d u a lly. Ma in t a in at t h is pre ssu re f or maintenance staff to check the boiler for any leak. 8. If the hydraulic test is declared OK, the boiler pressure can be allowed to be killed by itself, after stopping the BFP. 9. The vents and SH drains can be opened, if the boiler is to lighted up shortly, after the pressure is killed. FILLING UP THE BOILER FOR LIGHT UP THROUGH BFP: - LINE UP: 1. Check than no line clear is pending on boiler, APH, bottom ash hopper etc., so that lighting up of the boiler will not be held up. 2. Check that the following vents are open in 52m level. a. Drum b. ECO Vents c. SH vents d. RH vents 3. Check that the following drains are in closed condition a. Emergency drum drain (EBD) b. Continuous blow down (CBD) c. All attemperation line drains d. Bottom ring header drain e. Down corner drain f. Economizer drain 4.Check that the following drains are open condition a. SH drains and header drain to IBD b. Drains before boiler stop valves c. Boiler drains to IBD isolation valve at 2.5m level near IBD tank. 5. Check that the boiler fill up valve from boiler fill pump discharge line is kept closed. 6.Check that SH filling valve from boiler fill pump discharge line is kept closed. 7. Check that the start up vent isolation and regulation valves is open. 8. Check that boiler stop valves and their by pass valves are closed. 9. Check that the soot blower line isolation valve is closed.
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10.Check that ECO, inlet and re-circulation valve are open. FILLING UP: -
A) CHEMICAL ADDED WATER: If the boiler is to be filled with chemically treated water, add the required chemicals (10 ppm N2H4 and ammonia to the required level) in feed tank. Start the BFP on RC. After attaining the required chemical values, feed the boiler through low load FCV (Similar to filling the system for hydraulic test), upto the drum normal level. Then top feeding and keep BFP on recirculation, if the boiler is going to be lighted up immediately. If some undue delay is expected the BFP can be stopped.
B) DEAERATED WATER:
If the boiler is to be filled up with deaerator water, heat the feed tank and raise the deaerator pressure of about 3 Kg./Sq.cm using foreign steam. The BFP shall be kept on re-circulation on the above period and when the pressure is achieved, start feed the boiler. The hydrazine dozing shall be carried out to the running BFP suction line for scavenging dissolved oxygen. The deaerator level shall be maintained with any one of the CEP in service, maintaining hot well level by hot well make up pump. The feeding shall be so controlled that the pressure in deaerator is maintained almost constant and the make up is sufficient for maintaining deaerator level. At normal drum level, the feeding to boiler shall be cut out. The steam admission to deaerator shall also be so controlled that the pressure will not rise. Filling the boiler using deaerated water is always better. DRAINING THE BOILER: a) The boiler is required to be drained: 1. If there is going to be sufficiently long shut down, in which case the water remaining in the boiler may lead to corrosion. 2. If there is any puncture in the boiler tubes. 3. If the boiler is programmed to be filled up for preservation. b) After shut down of the boiler, open the SH drains at a pressures of 5kg/sq.cm. c)Open the SH vents, drum vents and ECO. vents when the pressure in the drum is about 1 to 2kg/sq.cm.
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d) Open water wall drains down comer drains and ECO drains. e) Care must be taken while draining the boiler that the turbine side drains are kept closed, in order to prevent back up. CORROSION IN BOILERS AND ITS PREVENTION: It is necessary to keep the tubes clean internally and externally free of deposits that could impair heat transfer and lead to corrosion, ultimately causing tube failures. Corrosion damage is always experienced inside tubes of t h e b o ile r, e co n om ize r a n d sup e rhe a t e r, wh e n wa t e r ch em ist ry is n ot maintained properly. To avoid the corrosion, one should understand the importance of maintaining the iron oxide coating on the internal surfaces of the boiler tubes. The oxides Fe304 (Magnetite) a normal corrosion product that forms on steel is protective to corrosion caused by boiler water. Once it is formed, further inside corrosion of the tube stops. But if it is destroyed, corrosion will resume until conditions favorable to oxide formation (magnetite coating) are re established in the system. A) Water Side Problem: (1) Hydrogen Induced Brittle Fracture: This occurs when boiler pH is too low, H 2 atoms are produced between the deposits and the tube surface and react with cementite (hard iron compound) at the grain boundaries of the tube material to form methane gas. The formed methane gas removes carbon from metal, weakening it by creating fissures in its grains structure. This type of damage is common where condenser leakage occurs. (2) Bulk Deposit Corrosion: This is caused by concentration of soluble corrosive compounds, as alkalis (sodium hydroxide). Due to capillary action of the porous deposit formed on the surface of the tubes, the alkaline liquid is drawn towards the tube surface and then it attacks on the metal and the metal is eaten. The term caustic gauging is used for such type of corrosion and tube failure. (3) Corrosion Fatigue: Materials that undergo cyclic strains may suffer fatigue failure. The
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strain may be mechanical (vibration) or thermal (corrosion). The reason for the above mentioned failure is that the corrosion product on the surface cracks and acts as wedges during boiler cooling down, causing the cracks to extend. Corrosion attacks the newly exposed surface when the boiler if fired next time, forming still deeper wedges in the next cooling phase. (4) Stress Corrosion Cracking: The super heater elements containing residual stress are susceptible to cracking at high temperature, when there exist the presence of corrosion forming agents in steam such as chloride or hydroxide compounds and oxygen. (5) Oxidation: All materials commonly used in high temperature super heater and re heater are subject to oxidation. When the oxides scale on the inner surface of the tubes become sufficiently thick, the differential expansion between the oxides and the parent metal results in spalling of the oxide from the metal surface a process called "Exfoliation". The loose flakes are hard and brittle and generally range from 1mm to 5mm in size. The loose scale can clog the tubes at bends, causing their failure by over heating and can damage nozzle and turbine blades if carried along the flow path of the steam. (B) FIRE SIDE PROBLEM: Major corrosion problems in coal fired boilers are caused by coal ash. The fireside deposits are classified as fouling and slagging. Slagging is the deposition of molten or fused particles on furnace tube surface. This will occur in the radiant surfaces but slagging also occurs on the superheater or reheater tubes when molten ash is carried with the hot flowing gases. On the other hand, fouling is the condensation of combustible constituents, such as sodium sulphate, in areas where temperature is such that, the constituents remain in liquid state. The combustibles, fly ash and flue gases react chemically to form the deposits. These are generally found on convection zone of the boiler. Slagging and fouling on the heat transfer surfaces retard heat flow and therefore they should be cleaned periodically to maintain the efficiency. Erosion is another problem faced by the boiler tubes. It is generally
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caused by an excessive amount of abrasive ash in the coal. This is generally caused in the low temperature section of the sueprheater. Deflection baffles help to reduce this type of erosion. S U P E R H E AT E R S A N D R E H E AT E R S P R O T E C T I O N A N D CONTROL: As long as there is a fire in the furnace adequate protection must be provided for the superheater and reheater elements. This is especially important during periods when there is no demand for steam, such as starting up and shutting down. During these periods of no steam flow through the turbine, adequate flow through the superheater is assured by means of drains and vents in the headers, links and main steam piping. HP / LP by pass system shall be kept in service, during hot start of boiler, to maintain steam flow through RH, in order to avoid starvation. Du rin g a ll st a rt up s ca re m u st b e t a ke n no t t o o ve rh e a t t he superheater or re-heater elements. The firing rate must be controlled to keep the maximum exit gas temperature in the furnace from exceeding 538C. To measure this temperature two furnace temperature probes (L) & (R) are provided in the furnace outlet zone which can be operated from remote for extending or retracting. The temperature display will be available in control room during advanced position. We can stop the probe at any position as per our requirements between its stroke length.
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AIR PRE HEATING SYSTEM
CHAPTER - 2

INTRODUCTION: Air heater is a heat transfer surface, in which air temperature is raised by transferring heat from the flue gas. Since air preheater can be employed successfully to reclaim heat from flue gas to low temperature levels, than is possible with economizer, the heat rejected to chimney can be reduced to higher extent. For every 20C drop in the flue gas exit temperature the boiler efficiency increases by about 1.0%. In addition to increasing boiler efficiency, the other advantages are: Stability of combustion by increased temperature of air admitted for combustion. The hot primary air is used for drying coal in the mill for better grinding and carrying coal powder. Better combustion of poor quality of coal, having low volatile content. Reduction incombustibles in flue gas. The regenerative Ljungstrom air pre heater is used in the flue gas path for heating both primary and secondary air. The heat from the flue gas that is at higher temperature is transferred to incoming cold air by means of continuously rotating heating surface elements of specially formed metal plates. As the rotor slowly revolves, the mass of heating surface elements alternates through the gas and air passages. Heat is absorbed by the air preheater elements while passing through flue gas streams, then as these same elements pass through the air path, they release the stored up heat. This increases the temperature of the incoming cold air.
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DESCRIPTION: The air preheater employed has three sectors, having separate paths for 1. Flue gas 2. Primary air 3. Secondary air There are two nos trisector APHs for each boiler. Each air preheater consist of the following components. a. Connecting ducts which connect the top and bottom ends of APH. b. Rotor housing is located in between the top and bottom connecting plates and it encases circumferentially the rotor. c. Rotor is an open ended drum which contains the heating surface elements. The rotor is divided into 12 sectors, which are further divided into compartments for housing heating surface elements. d. The heating surface elements are formed from numerous undulated metal sheets and are packed in reversible containers called baskets. These are arranged in three tiers viz-hot end, intermediate and cold end. e. The rotor is supported by and rotated on a spherical roller thrust bearing at bottom called support bearing. At the top there is a guide bearing which is free to allow axial movement of the rotor, as the rotor expands. f. There are six nos. sector plates spanning across the open ends of the rotor, sealing the gas and air from each other. g. Sealing arrangements: The sealing system consists of radial, axial and circumferential seal plates, to prevent or minimize leakage of air from one sector to the other sectors. Rotor post seals are also provided to avoid leakage through the rotor post. h. There are two Nos. main drives for the APH for rotating the air preheater elements. For initial rotation of the air preheater or for inspection of elements, there is an air motor driven by service air. This is also used as emergency stand by while both the main drives fail. i. j. Lubrication system: Separately for support bearing and guide bearing there is a lub oil unit, having 2Nos. pumps, cooler, strainer etc. Soot blowers are provided on both top and bottom end of the APH for cleaning the heating surface elements using steam.
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k. Three nos. access doors are provided APH one each in gas inlet, primary air and secondary air outlet duct. Another set of access doors is provided in the duct, one each in flue gas outlet, secondary air inlet and primary air inlet ducts. l. For observing the cold end elements, a glass faced observation port is provided in each APH, with electric lighting bulb for easy inspection, while the APH is in service. m. Two numbers stationary APH washing manifolds are provided in the gas inlet and outlet duct for water washing the heating elements. These can also be used for flooding the APH with water in case of fire. n. Rotor stoppage alarm is provided by using a proximity switch which is mounted in the support bearing area. o. Fire sensing devices for giving alarm are provided in the APH flue gas path, by providing thermo couples at various locations across the width of the APH, for sensing any abnormal rise in temperature due to fire in APH. STEAM AIR PREHEATER The SCAPH on each at the outlet of the FD fans are used to control the cold end temperature of the APH, for corrosion control and also for raising secondary air temperature during cold start up of the unit. These must be brought into service, only after starting FD fans, and preferably before light up of the boiler. The SCAPH uses auxiliary steam from PRDS for controlling the temperature. The drain from SCAPH can be sent to atmosphere through IBD expander. The steam lines should be properly drained, before charging, in order to avoid hammering, leakages, and damage to the system. PRESTART CHECKS FOR Ljungstorm APHs 1. Check that all work permits and permission are canceled covering APH, its drives, lub oil pumps, duct and dampers. 2. Check that all access doors are closed. 3. Check that the APH inlet / outlet dampers are open, if the boiler is going to be lighted up. 4. Line up the lub oil pumps as indicated below: a. Check lub oil level in the support and guide bearing oil sumps for normal level
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using dipstick. b. Check that the suction, discharge valves are open. c. Check that the pump is free to rotate. d. Check that the cooler is charged on water & oil side. e. Check that the oil flow meter and the temperature indicators and pressure gauges are available. The ACW pressure shall be around 2.5 to 3.0kg/sq.cm. f. Check that the local stop push buttons are released. g. Switch on the module for the lub oil pumps. 5. Establish the supply for APH rotor stoppage alarm and verify in UCB that the alarm persists in annunciation window before starting APH. 6. Check that the service air is available and the air supply valves to APHs are kept closed. (If not the APHs will start rotating once air supply is established) Open the drain valve in the service airline to remove the water collected in the service airline. 7. Establish supply to APH solenoids for APH & B 8. Switch on supply modules for APH A & B main drives and stand by drives. 9. Keep the APH soot blower system ready for service, by switching on the respective modules, and keeping open the steam line drains for charging the steam. 10. Check the availability of inspection light. Note: APH should be in service, preferably before starting the ID fan, but necessarily before starting FD fan. TAKING INTO SERVICE APHs 1. The lub oil pumps of support and guide bearings can be started from UCB or from local. 2. Start any one of the pump locally and see that there is no oil leakage. 3. Check the lub oil flow and pressure. Normal Flow: 5 Lit / min for guide bearing and 10 Lit/min for support bearing at pressure of about 1.5 to 2kg/sq.cm. 4. Stop the pump and start the other pump and see that the flow and pressure is normal, and that there is no oil leakage. Note: All the 8Nos. pumps shall be started locally and checked before giving clearance for remote operation from UCB. The stop push buttons shall be kept in released
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condition. 5. Now open the air valve for starting the air motor of APH A or B as the case may be. As the main drives are not in service, the solenoid will supply air-to-air motor. 6. Check the operation of APH for any abnormal sound or abnormal seal rubbing. 7. If the performance is normal, the main drive can be started locally or from UCB. 8. Check the performance of APH on main drive-the local current and abnormal sound and vibrations are to be watched. 9. On starting the main drive, the air motor shall stop. This can be verified in UCB by the indication given from the service air pressure switch, provided in the line. 10. Now stop the main drive from UCB and check that the air motor comes on auto. 11. Start the stand by drive motor from UCB and check the performance. 12. The main drive can be kept in continuous service keeping the stand by drive ready. 13. The air preheater soot blowers are to operated at regular intervals, after lighting up of the boiler. 14. The DP across air preheaters has to watched closely to see that the APHs are free from choking. The oxygen and carbon dioxide levels in flue gas, before and after APH have to be Abnormal drop in carbondioxide level after APH shall indicate poor performance of the APH seals. Normal drop: 2%. SHUT DOWN OF APH DRIVES: 1. In normal course of operation, the APH can be stopped after shutting down of the boiler and stopping of ID, FD and PA fans and the flue gas temperature at APH inlet less than 100C. 2. In case of fire in APH, the boiler shall be fired out immediately, and the ID, FD and PA fans stopped. The APH shall be stopped and its isolation dampers will be closed. The APH shall be flooded with water using APH wash pump and the APH washing lines. LINING UP OF SCAPH: 1. Ensure that there is no work permits are pending in the steam lines, drains etc of SCAPH. 2. Open the drains in the inlet steam line (L) & (R) before the isolation valves.
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Document Title
3. Open the isolation valves of the SCAPH inlet pressure control valves (CV2A & CV2B). 4. Open the drains after control valves. 5. Open the inlet valves (4Nos) to the SCAPH A & B. 6. Open the drain valves to the SCAPH drain tanks A & B. If the drains from SCAPH A & B are to be made through to IBD tank open the isolation valves of the steam trap. Ensure that the by pass valves of the steam traps are kept closed. 7. For taking into service, the SCAPH drain Tanks: a. Open the isolation valves of the SCAPH drain tank level control valves. b. Check that the by pass valves of the level control valves A & B are kept closed. c. Open the inlet isolation valves to the SCAPH drain tanks A & B. d. Ensure that instrument air supply is available for the level control valves A & B.
TAKING INTO SERVICE: 1. Check that before SCAPHs are taken into service, secondary airflow is available i.e. FD fans are in service. 2. Open the inlet pressure control valves (CV2A & 2B) by about 5% for warming up the lines. 3. After sufficiently warming up the lines open the control valves as per requirement. Normally, the control valves openings shall be so adjusted to get the total of flue gas temperature at APH outlet and secondary air temperature at APH outlet equals about 175C. The control valve opening / closing is carried out from UCB on auto or manual. 4. The drain valves provided in the steam lines, which were kept open for warming up should be closed after sufficient warming up. 5. The level in the SCAPH drain tanks are controlled by the self -regulation pneumatic control valves. CUTTING OUT OF SERVICE: 1. The SCAPHs can be cut out, as and when the flue gas temperature at APH outlet reaches about 125 to 130C. 2. For cutting out the SCAPH, it is sufficient that the inlet pressure control valves are kept closed.
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DRAUGHT SYSTEM
CHAPTER - 3
DRAUGHT SYSTEM
INTRODUCTION: The difference of pressure causing flow of air and hot gases through the boiler furnace, economizer, air heater, flue ducts and chimney to atmosphere is termed as draft. The draft system in a boiler plant serves the following functions. 1. Supplies required quantity of air for combustion. 2. Removes the product of combustion continuously from the furnace to the atmosphere for the effective combustion of incoming fuel. 3. Overcomes the pressure losses when the burnt product passes through the superheaters, reheaters, economizer, airheaters, flue ducts, ESP and chimney and discharges it to the atmosphere at the required velocity. 4. Maintaining a balanced draft in the furnace. In power plant boilers, the draft is obtained by means of fans namely forced draft and induced draft fan. The FD and ID fans develop enough draft to move the tremendous volume of air and gases through the flue gas ducts and stack to atmosphere maintaining a balanced draft in the furnace. FANS IN THE SYSTEM: In a balanced draft system the FD fan supplies the secondary air for proper and complete combustion while the ID fan removes the flue gases from the furnace maintaining a pressure in the furnace just below the atmosphere. Balanced draft facilitates opening of inspection windows for the inspection of fire inside the furnace and avoids the air / gases blowing out.
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DRAUGHT SYSTEM
In order to improve the combustion and efficiency of the boiler a portion of secondary air is preheated in the regenerative air heater before it reaches the furnace wind box known as hot secondary air. The cold secondary air is sent after filtering to the suction of the scanner fan which boosts up the secondary air pressure for cooling the scanner head which is exposed to the hot furnace zone. Additionally an emergency air supply connection from atmosphere is provided for supplying the cooling air in case both FD fan trips. Two Nos of ignitor air fans with tap off from FD fan outlet inter connecting duct supplying the necessary air for the eddy plate ignitors. The air required for transporting the pulverized coal from the mills to the furnace is known as primary air and supplied by the primary air fan. Part of the primary air is also preheated in the regenerative air heater to dry the coal that is fed to the mill. The cold primary air is used as tempering air by which the temperature of the coal air mixture leaving the mills can be controlled. The heat carried away with the flue gases is transferred to superheaters, reheaters, economizer, air heater on the way to the chimney. The gates mounted in the ducts are used to stop the air / gas supply completely where as the dampers regulate the air / gas flow according to the requirement. INDUCED DRAFT FAN: Two numbers of NDZV31 SIDOR type fans are used as ID fan to handle the hot gases from the boiler. These fans are of double suction single stage centrifugal type in which the flue gases enters the impeller axially and after passing through the impeller leaves radically. A large part of the energy transferred to flue gases is converted into pressure energy as the gases pass through the impeller. The spiral casing converts part of the kinetic energy in the flue gases to pressure energy. These fans are driven by a constant speed 6.6KV, 1500 KW, 50 Hz induction motor. The output of the fan is controlled by the variable speed hydraulic coupling or inlet damper control. The spiral casing, suction chamber, rotor shaft with fan impeller, bearing assemblies and shaft seals are major subassemblies of ID fan. The spiral casing rests on its foundation an with respect to the rotor during expansion the spiral casing is guided by central, side and control
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DRAUGHT SYSTEM
frames to maintain the orientation. Suction cone provided on either side help to achieve the accelerated inlet flow to the impeller. The impeller sealing rings fixed on the suction zone over lap the impeller rings maintaining a specific clearance which provides necessary sealing of the impeller inlet flow from its discharge. The rotor assembly consists of impeller and shaft supported by spherical roller bearings located on either side the impeller. The bearings are lubricated by means of forced oil from hydrant coupling. The blades of the impeller are common to both suction flows and the blades are so designed that the two suction flows are allowed to mix within the impeller itself. Sealing for the shaft where it passes through the spiral casing on both the sides is achieved by labyrinth seals for axial sealing. The labyrinths are housed in a seal housing which is mounted on the bearing pedestal. The seal housing is connected to the spiral casing by flexible asbestos cloth for radial sealing. HYDRAULIC COUPLING: The ID fan is driven by constant speed squirrel cage induction motor. The fan and motor are coupled by a variable speed hydraulic coupling of voith make, West Germany. The hydraulic coupling serves as a starting device as well as regulating device, and is a self-supporting unit. The speed control of the fan is performed by a scoop control unit of the hydraulic coupling and is operated by an external actuator, hooked up to the fan control system. A filling pump, a scoop tube, primary shaft with primary wheel, secondary shaft with secondary wheel, bearing assemblies and the housing are the main parts of the hydraulic coupling. The base of the housing forms the oil tank. The primary shaft and the secondary shaft are supported by antifriction roller and ball bearings. The primary shaft drives the filling pump through a gear train. An electrical driven actuator drives the scoop tube and controls the position of the scoop tube to vary the speed of the driven equipment. The filling pump supplies the variable speed turbo coupling with oil whereas the scoop tube takes the working oil out from the turbo coupling back into the oil tank and determines the oil filling in the variable speed turbo coupling and thus the output speed.
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DRAUGHT SYSTEM
OPERATION OF HYDRAULIC COUPLING: The filling oil draws the working oil from the tank and pumps it through the oil cooler, the working oil orifice plate and filling pipe into the primary wheel collecting channel. The centrifugal force of the primary wheel forces the oil through bores into the working chamber of the coupling between primary and secondary wheel. This chamber is connected by oil openings of the scoop chamber formed by shell. Under the action of the centrifugal force an oil ring builds up in the working and scoop chamber. The thickness of this ring is determined by the position of the scoop tube. The scoop tube supplies the scooped oil back into the oil tank utilizing the pressure head. ID FAN PRESTART CHECKS: 1. Ensure that there is no pending work permit in the ID fans, ESP or in the furnace and APH. 2. Ensure the manholes are closed. 3. Check the water flow to the cooler of the hydraulic coupling. 4.Check the oil flow to the bearing and the oil level in the hydraulic coupling oil tank. 5 . Ch e ck t h e a va ila b ilit y o f in st ru men t s t o me a su re f low, p re ssu re , temperature etc of the ID fan, HC and drive motor. 6. Check the closing and the opening of the suction and discharge gates. Keep them closed before starting the ID fan. 7. Ensure operation of the scoop tube of the hydraulic coupling from UCB and keep the scoop at minimum position. 8. By simulation checks confirm all the protections and inter lock functions properly. 9. Ensure the operation of inlet guide vane from UCB and keep the vane at minimum position. 10. Ensure the local push button is in the released position. 11. Check that the discharge dampers of blower motors are open and the modules are kept ON. 12. Check that the flue gas circuit is made through i. APH outlet flue gas dampers are open (GD-3, GD-4)
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DRAUGHT SYSTEM
ii. APH inlet flue gas dampers are open (GD1 & GD-2) iii. ESP inlet gates are open GG5, 6, 7 & 6) iv. ESP outlet gates are open (GG9, 10, 11 & 12) 13. Check that the seal through is filled with water and overflow is maintained. 14. Start the ID fan after checking the protections when the fan is started after long shutdown. START PERMISSIVE FOR INDUCED DRAFT FAN: Check that the final start permissive is available in the control desk. The final start permissive will be coming if the following conditions are satisfied. 1. ID fan stopped. 2. Cooling water to the coolers of the hydraulic coupling adequate. 3. Suction gate closed. 4. Discharge gate closed. 5. Control actuator of hydraulic coupling and IGV minimum. 6. Scoop tube outlet temperature normal for oil. 7. DP across twin filter normal for oil. 8. ID fan tripped indication should not exist lockout relay in the 6.6 KV breaker should be reset. To start the first ID fan (say ID fan A) both the ID fans A and B should be in stopped condition and the 220 V DC control supply for the breaker of other ID fan switched ON, either in test position or in service position. Now the first ID fan can be started. POST START CHECKS: 1. Check the opening of gates on interlock, after 10secs. 2. Check the performance of the motor. 3. After raising the scoop position check for smooth operation of the fan. 4. Check the lub oil pressure. 5. Check the starting of both the discharge gate blower motors on interlock. If not start manually. 6. Maintain the furnace vacuum at 5mm WC by suitable loading of the fan.
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DRAUGHT SYSTEM
ID FAN TRIP INTERLOCKS: 1. Motor drive end bearing temperature very high : 90C 2. Motor non-drive end bearing temperature very high : 90C 3. ID fan drive end bearing temperature very high : 82C 4. ID fan non-drive end bearing temperature very high : 82C 5. Oil temperature at cooler inlet (for hydraulic coupling) : 110C very high 6. Differential pressure of oil across twin filter high 7. ID fan motor winding temperature high 8. ID fan running with lub oil pressure low 9. Electrical protection of motor. a. Load current IB b. Locked rotor I stall c. Standing time TS d. Phase unbalance Si e. Earth fault Ic f. Differential g. Winding temp h. Repeated start trip TSV (1/2 hr > 3 times). STARTING SECOND ID FAN: 1. Before starting the second ID fan the prestart checks and permissive for the fan shall be verified. 2. One of the FD fans shall be in service before starting the second ID fan. 3. The isolation gates for ESP paths shall be checked for open condition if any of the path is closed, while starting the first ID fan. INTERLOCK OPERATIONS: a. When any one of the ID fan is started. 1. The suction and discharge gates will open after 10 secs. 2. The discharge gates blower motors of both the ID fans shall start. 3. Permissive shall be available for starting any of the FD fans. b. When any one of the ID fans trip, while both the fans are in service. : 0.3kg/sq.cm. : not connected : > 10 sec
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DRAUGHT SYSTEM
1. The suction and discharge gates of the fan will close 2. The corresponding FD fan will trip. 3. Leaving three mills at the top, other bottom mills will trip. c. When both ID fans trip. 1. The boiler will trip. 2. Both FD fans will trip. 3. The suction and discharge gates of both the fans will remain open. 4. Blower motors, will continue to run. FORCED DRAFT FAN: The main purpose of forced draft fan is to supply the required amount of air to the furnace at the required pressure for combustion of fuel. There are two nos FD fans available for supplying the secondary air or combustion air to the furnace, through secondary air dampers. DESCRIPTION: The fresh air drawn from atmosphere passes through a filter, suction chamber, inlet nozzle, inlet guide vanes, suction nozzle and enters the fan impeller of this axial fan. A large part of the energy transferred to the air as velocity energy after the impeller is converted into pressure energy in a set of outlet guide blades and the diffuser. The fan is driven by a constant speed squirrel cage induction motor. The fan is connected to the motor by means of a pin type flexible coupling. The airflow is controlled by changing the direction of air entry to the impeller blade, which is achieved by the inlet guide vane control unit. The major subassemblies of forced draft fan are as follows: a. Stator parts b. Impeller with shaft assembly and bearings. c. Flow regulating device. a. STATOR PARTS: The stator parts comprise of suction chamber, shaft protecting tube and core of inlet guide vane, impeller housing, diffuser, stabilizer blades and free / slidable supports.
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DRAUGHT SYSTEM
The split type suction chamber and diffuser are of welded sheet metal construction which are placed on suitable supports to accommodate expansion. The impeller housing is an undivided construction fabricated from sheet metal. A conical piece is provided in the housing which is supported by a set of outlet guide blades. The conical blades support the inner bearing assembly. The blades are designed for the energy conversion from kinetic energy and to serve as a support for the inner bearing. The stabilizer is a set of stationary blades, placed between inlet guide vane unit and impeller. At low loads there is circulation of flow media between impeller and stabilizer. The maintains the flow in the impeller in an optimum level so that starving does not occur while delivering the required quantity of air. b. IMPELLER WITH SHAFT ASSEMBLY AND BEARINGS: The impeller hub is of welded sheet metal construction on which the non-profiled solid twisted blades are welded. The impeller hub is fitted to the flange welded to the rotor shaft. The fan rotor is supported in between a fixed bearing (Inner bearing) near the impeller side and a free bearing (Outer bearing) near the coupling end. These are self -aligning type antifriction grease lubricated bearings. c. FLOW REGULATING DEVICE (IGV UNIT): The inlet guide vane control assembly of the fan consists of a number of aerofoil vanes fixed to individual shafts. These guide vane shafts are connected to a regulating ring which is guided to rotating mechanism by a set of rollers and spring assemblies called suspension assemblies. A control lever is connected to the regulating ring which can be operated by the external actuator. PRE START CHECKS: 1. Ensure No line clears are pending. 2. Ensure the electric supplies to the drives and equipment are available. 3. Ensure the air heater flue gas inlet dampers GD1 and GD2 outlet damper GD3, GD4 and the gas gates GD5 to GD12 before and after ESP are kept open. 4. Ensure the secondary air dampers SAD5 & SAD6 and outlet dampers SAD7 & SAD8 of air heaters A & B are kept open. Atleast one pair should be kept
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DRAUGHT SYSTEM
open for starting the first FD fan. 5. Ensure the SADs in wind boxes are in open position as per FSSS logic. 6. Do simulation checks to confirm that all protections and inter locks are functioning properly. 7. The inlet guidance and discharge damper of the FD fan should be checked for its operation and kept closed before starting the fan. 8. Ensure at least one ID fan is in service to start the first FD fan. Both ID fan should be in service to start IInd FD fan. 9. Scanner fan shall be in service with its suction chamber open to atmosphere. 10. Ensure bottom ash hopper seal water trough is filled with water and make up available. F D F AN S T AR T P E R M I S S I V E S 1. Inlet guide vanes in minimum position fully closed. 2. FD fans discharge dampers in closed position. 3. FD fans in stopped condition. 4. FD fan A stopped with FD fan B running and ID fans A & B running (for FD fan A) (or) FD fan A stopped and ID fan A stopped and ID fan B running (for FD fan B) (or) FD fan B stopped and ID fan A running and ID fan B stopped (for ID fan A) 5. Bearing temperature of motor or fan are not very high. When any FD fan is started impulses shall given for. 1. Opening the outlet damper of the corresponding FD fan after the motor reaches its rated speed. (After 10secs). 2. Connecting the inlet guide vanes control drive of the fan to auto control, if auto/manual station is selected on auto. 3. Closing the atmospheric suction damper of scanner fan. TRIPPING OF FD FAN: (Typical for FD fan A) a. FD Fan A shall trip on the following conditions: 1. FD fan A bearing temperature very high at 105C (Prior to this, FD fan A
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DRAUGHT SYSTEM
bearing temperature high will be annunciated in UCB at 95C. 2. FD fan A motor bearing temperature very high at 90C. (Prior to this, FD fan A motor bearing temperature high will be annunciated in UCB at 85C.) 3. FD fan A motor winding temperature very high (Prior to this, FD fan A motor winding temperature high will be annunciated in UCB). This is not connected to trip at present. 4. Both ID fans trip. For any one of the ID fans tripping condition, if both FD fans are in service one of the FD fans will trip. 5. Vibration level of fan/motor very high (Prior to this, vibration shall be annunciated in UCB (Not connected to trip at present). 6. Electrical protection of motor. a. Load current IB b. Locked rotor I stall c. Starting time TS d. Phase unbalance Si e. Earth fault Ic. f. Differential g. Winding temp. 7. When both FD fans are off, with FD fan B already in tripped condition impulse shall be given for. 1. Disconnecting the inlet guide vane control drive from auto control system (output signal from A/M station). 2. Bringing the inlet guide vanes of FD fan A to the maximum position. 3. Bringing the inlet guide vanes of FD fan B to the maximum position. 4. Opening the outlet damper of FD fan B. 5. To open the atmospheric damper to the scanner air fan. 6. To trip the boiler. 7. The outlet damper of FD fan A shall remain open. POST START CHECKS: 1. Check the performance of the motor and fan locally. Any abnormal sound or vib ra t io n sh a ll be ch e cked up p rom pt ly a n d t he f a n sho u ld b e sto pp ed immediately, if necessary. 2. The fan should be loaded slightly by opening the IGV immediately after the
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DRAUGHT SYSTEM
discharge damper is opened fully, so that flow is established for the fan. 3. Check the rise in the bearing temperature. Continuously monitor the same, by taking readings every hour. 4. Check the pressure indicators, flow recorders etc are working satisfactorily by varying the load on the fan. 5. Before light up of the boiler, it should be ensured that atleast 30% of the full load airflow is admitted to the boiler. About 150 T/Hr airflow in each of the flow indicators (L) & (R).
PRIMARY AIR FAN: Two number of NDZV 20 radial fans are used for supplying the required primary air for transporting the pulverized coal from the mills to the furnace. The quantity of cold primary air taken before the APH, and the hot primary air at the outlet of the APH are controlled in such a manner, that the flow to the mills is maintained at 55 T/Hr and the coal air temperature at the outlet of the mills at about 80C. These fans are of double suction single stage centrifugal type in which the fresh air from the atmosphere enters the impeller axially and after passing through the impeller leaves radically. A large part of the energy transferred to the air is converted into pressure energy as the air passes through the impeller. The spiral casing converts part of the kinetic energy in the air to pressure energy. These fans are driven by constant speed squirrel cage induction motor. The output of the fan is controlled by an inlet guide vane damper assembly. Each fan is provided with a shut off gate at the discharge duct. The fan and the motor shafts are coupled with pin type flexible coupling. The spiral casing, suction chamber, rotor shaft with impeller, bearing assemblies and shaft seals are major sub-assemblies of PA fan. The spiral casing rests on its foundation and with respect to the rotor during expansion the spiral casing is suitably guided by the frames to maintain its orientation. Suction cone provided in the casing helps to achieve accelerated inlet flow to the impeller. The impeller sealing rings fixed in the suction cone overlaps the impeller ring maintaining a specific clearance which provides necessary sealing of the impeller inlet flow from its discharge.
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DRAUGHT SYSTEM
The rotor assembly consists of impeller and shaft, supported by spherical bearings located on either side of the impeller. The bearings are lubricated by separate lub oil system. Sealing for the shaft where it passes through the spiral casing on both sides is achieved by labyrinth seals for axial sealing. The labyrinths are housed in a seal housing which is mounted on the bearing pedestal. The seal housing is connected to the spiral casing by flexible asbestos cloth for radial sealing. Lub oil system for cooling and lubrication of fan bearing consists of one pair of pumps, filters and coolers, one each being standby. The system is fitted with thermometers, pressure gauges and pressure switches L.O. system can be operated in remote. Three pressure switches provided in the lub oil header before bearing are set at 0.8, 0.6 and 0.4 kg/sq.cm. for alarm, auto -change over and protection of the fan respectively. PRE-START CHECKS: 1. Ensure that there is no pending work permit in the PA fans, air heaters, PA ducts, mills, furnace and flue gas ducts. 2. Ensure the manholes are closed. 3. Check that air preheater inlet & outlet dampers for the particular fan side are open. 4. It is preferable to have the APH in service before taking any PA fan into service. 5. Ensure that air circuit is made through atleast in one mill to the furnace, by opening cold air gate and damper and the mill discharge valves. 6. Check the oil level in the lub oil tank. 7. Ensure the cooling water flow through the cooler. 8. Check the availability of the instruments to measure the flow, pressure, temperature of the PA fan and its lub oil system. 9. Check the opening and closing of the discharge gate. Keep it closed before starting the PA fan. 10. Ensure that the local push button is in released position. 11. Check the operation of vane control from UCB. 12. By simulation checks confirm all the protections and interlock functions properly. Especially when the PA fan is started after long shut down, all the
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protections must be checked. PA FAN LUB OIL SYSTEM: Line up and taking into service: 1. Ensure oil level in the tank. Level should be between the maximum and minimum marks in the oil tank gauge glass. 2. Ensure the suction and discharge valves of lub oil pump are kept fully opened. 3. Commission one of the coolers and ensure water flow through it. 4. One of the L.O. filters may be made through. 5. Check for full opening of the needle valve before bearing in L.O. line. 6. The L.O. pump may be started from local or remote. 7. Ensure the power supply and control supply to the control panel. 8. Ensure local push buttons for the pumps are released. 9. Ensure the pressure switches and temperature gauges are intact. Start one or two L.O. pump manually from control panel putting the selector switch in manual position and observe the L.O. pressure low annunciation in the control panel gets reset. Check that there is no oil leak in the system. After resetting the L.O. pressure low annunciation the selector switch may be turned to auto. Now trip the running L.O. pump and observe that stand by pump starts on auto. The L.O. pump starts on auto when the L.O. pressure drops to 0.6 -kg/ sq.cm annunciation will appear in the panel window. Thus any one of the pumps may be kept in service. Ensure adequate oil flow to the bearing by seeing the return oil flow in the view glass. a. Normal working pressure of lub oil inlet is 0.8 to 1.2 kg/sq.cm. b. Normal working pressure of cooling water inlet is 3 to 6 bar. c. Differential pressure across filter should be less than 0.3 kg/sq.cm normally the DP will be 0.1 kg/sq.cm. The lub oil pressure can be varied by adjusting the recirculation valve in the oil line. PA FAN START PERMISSIVES: 1. Primary air fan discharge gate closed. 2. Inlet guide vane control actuator minimum.
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3. Lub oil pressure to the fan bearings adequate, should be more than 0.8kg/sq.cm. 4. No master fuel trip relay is actuated. 5. PA fan 'stopped' condition is established. 6. PA fan tripped indication should not exist lock out relay in the 6.6 KV breaker should be reset. 7. Seal air fan in service. 8. All the cold air dampers to the mills should be less than 5% open. 9. Both ID fans running. Any ID fan ON and PA fan A stopped. Then PA fan B can be started. If all the above permissives are available, start permissive for both PA fans will be present, if atleast one ID fan is running. So any of the PA fans can be started, with one ID fan in service. Once one of the PA fans is started the start permissive for the other fan will vanish. The start permissive for the other fan will appear, after taking into service the other ID fan. POST START CHECKS: 1. Note the starting current of the motor. 2. Check the opening of the discharge gate on interlock or open the gate by switching on from UCB control desk. Approximately 3 min duration for full open of gate. 3. Immediately after the discharge gate is opened load the fan slightly by opening the inlet guide vane by about 5 to 10%. 4. Check the fan and the motor for smooth running. 5. Check the bearings for proper lubrication, and monitor regularly the bearing temperatures. 6. Maintain the PA header pressure at 850mm WC by suitable loading of the PA fan, for taking mills into service. PA FAN TRIP INTERLOCKS: 1. Motor drive end bearing temperature very high 2. Motor non drive end bearing temperature very high 3. PA fan drive end bearing temperature very high 4. PA fan non drive end bearing temperature very high 90C 90C 82C 82C
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5. P A f an run n in g wi t h lu b o il p re ssu re lo w ( wit h t im e dela y o f 2 m in ) 0.4kg/sq.cm. 6. If boiler master fuel trip relay acts both PA fans will trip. 7. Electrical protection of motor. a. Load current IB b. Locked rotor I stall c. Starting time TS d. Phase unbalance Si e. Earth fault Ic. INTERLOCK OPERATIONS: 1. When one PA fan trips, the running mills will trip, leaving top three mills in service. 2. When both PA fans trip, all the mills will trip on header pressure very low, less than 490mm WC. Alarm 620mm WC. 3. When the boiler trips, both PA fans will trip on MFT protection. 4. When any one of the PA fans trip, the vane control will come to minimum and the discharge gate will close automatically. 5. The discharge gates of both PA fans will close, when both PA fans trip.
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FUEL FIRING SYSTEM
CHAPTER - 4
FUEL FIRING SYSTEM

INTRODUCTION: The selection of fuel firing equipment for a boiler furnace is governed by the factors such as required heat input, characteristics and availability of fuel etc., Most of the utility boilers burn coal as the prime fuel for steam generation. Fuel oils are also burnt in these furnaces to light use the unit, to bring the unit up to temperature and pressure up adjacent elevation of coal nozzle and for stability purposes. Boiler burning, fuels are either pulverized into fine powder or finely atomized as the case may be and burned under suspension in boiler furnace. The functions of fuel firing system are: 1. Preparing and supplying fuel and air. 2. Introducing the correct fuel air mixture into furnace and ignite the same. 3. Creating turbulence to ensure even distribution and high degree. Of mixing of air with fuel for complete combustion in a short period and also to sweep away the products of combustion to expose fresh fuel particles for successive Combustion. 4. Making the furnace to maintain a heat supply to prepare and ignite the fuel particles for sustaining combustion. 5. Firing the fuel / coal with wide range of quality. The single drum natural circulation reheat 210MW BHEL boiler has direct firing tangential burner system for its furnace. The fuel and air from the fuel preparation plant is being directly fed into the furnace through the burners housed in the four wind box assemblies located in the furnace corners. These burners discharge the fuel air mixture tangentially to an
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imaginary circle at the center of the furnace. The swirling/rotating action produces sufficient turbulence. In this tangential firing system the furnace itself acts as a burner ensuring good turbulence and complete combustion in a short period at a fairly low flame temperature level. WIND BOX ASSEMBLIES AND BURNER ARRANGEMENTS The fuel firing system equipment consists of four -wind box assemblies located in the furnace corners, one at each corner of the furnaces. The wind box assembly is a tall structure divided in its height into thirteen compartments which houses 6Nos coal nozzles and 5 auxiliary air nozzles alternatively at different elevations from top to bottom. End air nozzles are placed at the top most and bottom most compartments. The secondary air admitted in the coal nozzle compartment is called as fuel air, the air admitted in the other compartments is auxiliary air and end air. The coal nozzle elevations are designated a A,B,C,D,E,F elevation from bottom to top, the bottom end air and top end air elevations as AA and FF respectively. The auxiliary air nozzles in between coal elevations are d e sign a t ed as e le va t io n s AB , B C, CD, DE , E F. T he f u rn a ce co rne rs a re designated as corner 1,2,3 and 4 in clockwise direction looking form top and counting front water wall left corner as 1. The same elevation of the coal nozzles at four corners are fed from a single coal mill. Thus 6Nos. bowl mills supply pulverized fuel / coal for the coal burners at different elevations of the wind boxes in the furnace corners. The bowl mills are named after the elevations to which they supply the pulverized coal. Each pair of coal nozzle elevations is served by one elevation of oil burners (4Nos / elevation) located in the auxiliary air nozzle. Thus 16 oil guns, non retractable type are accommodated in the four elevations AB, CD, DE and EF. Heavy fuel oil can be fired at the oil guns of all these four elevations, whereas light fuel oil (High speed diesel oil) can also be fired at AB elevation. Each oil gun is associated with ionic flame monitor ignitor, arranged at the side of the oil gun in the auxiliary air compartment and they directly light up the oil guns. Flame sensing scanners are installed in flame scanner guide pipe assemblies in all the 20 auxiliary air compartments. The safe scan II TM is
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used to detect flame from two different sources using one scanner heat. It will discriminate an individual oil gun flame and a background fireball flame. If discriminates between the two flames by sensing characteristics (frequency and intensity) of visible light they emit. As the scanner heads are exposed to visible light they emit. As the scanner heads are exposed to high temperature of the furnace, cooling air is supplied to them by means of 2Nos AC scanner fans. The coal and air nozzles are tiltable by + 01 - 30 degrees about horizontal, in unison at all elevations and corners. This shifts the flame zone across the furnace height for the purpose of steam temperature control, especially for reheat steam temperature. SECONDARY AIR DAMPER CONTROLS: The operation of the auxiliary and fuel air dampers in the wind box assemblies are effected by the FSSS. AUXILIARY AIR DAMPERS: During the furnace purge period and initial operations upto 30% boiler loading all elevations of auxiliary and end air dampers modulate a predetermined (approx 40mm WC) set point differential pressure between wind box to furnace 30 to 40% of total air flow to have an air rich furnace will be supplied during the above period to avoid unhealthy furnace conditions. a. AUXILIARY AIR DAMPERS: During the furnace purge period and initial operations upto 30% boiler loading all elevations of auxiliary and end air dampers modulate a predetermined (approx 40mm WC) set point differential pressure between wind box to furnace 30 to 40% of total air flow to have an air rich furnace will be supplied during the above period to avoid unhealthy furnace conditions. When the unit load exceeds 30% MCR, the differential pressure set point is changed and ramps to a higher setting (approx 100mm WC). Simultaneously, the aux. Air dampers associated with coal or oil elevations not in service close in timed sequence starting with the upper elevation of dampers and progressing to the lowest elevation. When the unit loading is reduced below 30% loading, the aux. Air dampers o p en in a t im ed se qu e n ce sta rt in g wit h t h e lo we st e le va t ion of d a mp e rs. Simultaneously, the differential set point changes to its lowest setting.
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All the aux. Air dampers maintain the status quo upon a boiler trip and will open fully when both the FD fans are off. The bottom end air damper is normally kept open to a fixed predetermined position to reduce unburnt coal dust fall out. b. FUEL (OIL) AIR DAMPERS: Elevation AB, CD, DE and EF dampers modulate according to the oil header pressure when heavy oil is being fired. Otherwise they open and close with the rest of the aux. Air dampers. Elevation AB dampers are kept at a fixed opening when light oil is being fired. c. FUEL (COAL) AIR DAMPERS: Their operations are independent of boiler load. All coal air dampers are normally closed. They open fifty seconds after the associated feeder is started, and modulate as a function of feeder speed. Fifty seconds after the coal feeders are removed from service, the associated fuel air damper close. The fuel (coal) air dampers open fully, when both FD fans are off or when the boiler trips on master fuel trip. LIGHT FUEL OIL SYSTEM: Light fuel oil is normally used for cold start up of boiler because of low sulphur content and low viscosity at ambient temperature requiring no heat tracing or preheating. This fuel is also referred as warm up fuel and it can be air atomized. High-speed diesel oil is used for start up of boiler. Being a distillate the fuel can be burnt completely in a cold furnace without any unbumt oil carryout. Even though fuel oil can be fired in three elevations the LFO can be fired only in elevation AB. LIGHT OIL SYSTEM LAYOUT AND DESCRIPTION: Two now. Screw pumps with simplex basket type suction strainers are installed to supply the HSD for each boilers. The HSD pumps draw the oil from HSD tank and discharge the oil to burners through pipeline. The LFO pressure control valve (LPCV), trip valve (LOTV) and a flow control valve (LFCV) with
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FUEL FIRING SYSTEM
necessary isolation valves are located successively in the pipeline at appropriate places in between the pump discharge valve and LFO burner trip valve or nozzle valve. After FCV the oil line branches into 4 lines leading to the oil guns in the furnace corners through a burner valve (LONV) in nozzles each line. The pump and LO pressure control valve are at the fuel oil pump house, the other valves are installed at 18m boiler firing floor. The screw pump when coupled to an induction motor with constant speed is a constant quantity pump, the delivery pressure is controlled by the LOPCV. These pumps can be started from UCB or locally at FOPH. a. LIGHT OIL PRESSURE CONTROL VALVE (LOPCV): LOPCV, a relieving type back pressure pneumatic operated single element control valve, installed after the LO pump maintains a constant pressure at the upstream of the LOPCV at all loads by returning the excess oil back to the HSD tank. A manual operating by pass valve is also provided for this LOPCV. b. LIGHT OIL TRIP VALVE: LOTV installed before the LOFCV is a pneumatically operated isolation valve which shuts off the oil supply to the LOFCV in case of boiler fire off. This valve is linked with the furnace safeguard supervisory system (FSSS) and can be opened or closed by the push buttons in the UCB control desk. c. LIGHT OIL FLOW CONTROL VALVE (LOFCV): The LOFCV is a pneumatically operated control valve and it maintains a present constant downstream pressure irrespective of the number of oil burners in service, through a pressure control loop. The pressure controller is located in control room with set point variator. Thus the controller set point can be varied from control room to vary the control valve operation range and to increase or decrease the firing rate on the operating burners. This valve can be operated on manual control also. A manual operating by pass valve is also provided for LOFCV. Isolation valves before and after LOFCV are provided. d. LIGHT OIL BURNER TRIP VALVE OR LIGHT OIL NOZZLE VALVE (LONV):
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The pneumatic operated LO nozzle valves are located one no. in each corner or the furnace before the oil guns. The valve closing is instantaneous where as the opening is slow. Thus the valves assure instantaneous closing of fuel to the burners and the slow opening will assure a reduced pressure dip of fuel oil and atomizing medium during opening. Similar type of valve is used for admitting the atomized air into the gun, one no. is provided in each corner. Compressed air from service air compressor is used for atomization of light oil/HSD. These valves are also linked with FSSS and can be operated from the control desk in UCB. Each light oil burner station, of one LONV and an isolation valve before LONV, one atomizing air nozzle valve and its isolation valve, and one no. Scavenge valve, (common for both light oil and heavy oil). The piping of light oil goes below the main operating floor and connected to the oil gun through flexible oil and atomizing fluid hoses with U-bends. FURNACE PURGE: Lighting up a furnace with unburnt fuel and air accumulation may lead to a high rate of burning, furnace pressurization and explosion at the worst. This can be avoided by furnace purge operation during which 30% of total air 9250 to 300 tons/hr) flow is maintained for about 5 minutes to clear off such fuel accumulation and fill the furnace with clear air before light up. During furnace purge all the elevations of auxiliary and end air dampers are opened to have an uniform and thorough purging across the furnace volume. The furnace purge is hooked up with FSSS and before any fuel firing can take place, initially or after a boiler trip, furnace purge cycle must be completed. To start furnace purge cycle, it should be ensured that the following conditions are satisfied. 1. AC / DC supply to FSSS panel and related equipments are :ON'. 2. Drum level is normal. 3. Atleast one ID fan and FD fan are in service. 4. The air flow is more than 30%. 5. LOTV (Light oil trip valve) is proven closed. 6. All LONV's (Light oil nozzle valve) are proven closed.
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7. HOTV (Heavy oil trip valve) is proven closed. 8. All the HONV's (Heavy oil nozzle valve) are fully closed. 9. Both PA fans are off. 10. All the raw coal feeders are off. 11. All the hot air gates are fully closed. 12. All the flame scanners show 'No flame' 13. No boiler trip signal is present. 14. All the ignitor nozzle valves are fully closed. 15. The ignitor trip valve is proven closed. Depressing of the furnace purge start push button, energizes a purge timer as indicated by the 'WHITE' purging light coming ON. At the end of 5 minutes, the BOILER TRIP circuit is reset. During this time the white purging light goes out and 'YELLOW' purge complete light comes ON. Once the boiler trip circuit is reset (Purging is complete) the close circuit of light oil trip valve and heavy oil trip valve are deenergised permitting the operator to open it as desired. LINING UP & CHARGING OF LIGHT OIL SYSTEM: 1. Ensure the following before starting the light oil pump and taking the system into service. a. No line clear is pending. b. Sufficient oil level in the HSD tank. c. Availability of the electric supply to the LFO pumps. d. Availability of instrument air. e. Availability of service air for oil guns. f. Closure of light oil trip valve and all the light oil nozzle valves in ÀB'elevation. g. Opening of suction and discharge valves of the LFO pumps. h. Closure of isolation valve to LOPCV. i. Full opening of by pass valve to LOPCV available at FOPH.
8. The line may be charged, air vented out and pump started follows: a. Open the oil tank outlet valve and allow oil to fill up the pump. Use vent valves available at the strainer line for complete removal of air. If necessary rotate the
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Document Title
pump impeller by hand and fill it with oil. b. Open the re-circulation hand valve keeping open the air vent at 18m level of boiler. The air vent shall be closed immediately after observing oil flow. c. Start the light oil pump and establish oil flow circuit through the LOPCV by pass, back to the HSD tank. d. Close the LOPCV by pass slowly and check whether the pump built in relief valve operates at required set pressure. e. Open the isolation valve to the LOPCV. f. Now vary the opening of the LOPCV by pass valve and check for proper functioning of LOPCV. If found satisfactory close the by pass and put the PCV in service. g. The oil pressure in the header can be maintained according to the set point in the controller. h. The light oil is available upto the light oil trip valve. After opening the LOTV, the LOFCV maintains a constant down stream oil pressure for the oil guns, LOFCV can be operated from UCB. LFO SYSTEM OPERATION: 1. Complete furnace purging. 2. Selection of Light / Heavy Oil firing. Oil elevation 'AB' is provided with LO/HO firing, LO firing can be selected from the console insert by pressing the appropriate push button provided "pairs Stop Time Expired" and "all HO and LO Valves are closed" in elevation 'AB'. 3. The LOTV can be opened by "Pressing the LOTV 'Open' Push button, once the boiler trip circuit is reset and all the light oil nozzle valves (LONV's) are proven closed, provided LO header. Pressing the LOTV 'close' push button will close the valve. The LOTV also closes automatically under following conditions. i. Master Fuel Trip ii. Any LONV not closed when a. Light oil header pressure very low for more than two seconds. Or b. Atomising air pressure very low for more than 2 seconds and no LO elevation in start or stop.
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FUEL FIRING SYSTEM
4. Light Oil Elevation Start (Elevation AB-Pair Mode) Light oil can be fired at elevation AB only and in pair basis. Corner 1 and 3 make one pair, while corner 2 and 4 make the other pair. The corners making up a pair are diagonally opposite. To place the LO guns in service proceed as follows. a. Select light oil firing. b. Establish light oil elevation start permit by the following conditions being satisfied. I. No master fuel trip II. LOTV proven fully open III. Air flow adjusted between 30% to 40% MCR IV. Burner tilt horizontal Note: Conditions (c) and (d) are not required when any feeder is proven ON. iii. CORNER START: At each corner to be placed in service ensure the following permissive: a. The oil gun is properly positioned at firing position indicated by OIL gun engaged red light ON in the control desk. b. Local oil gun maintenance switch is placed in 'Remote' position. (This switch has got 3 positions viz. remote, scavenge and off). c. Light Oil manual isolation valve before LONV is open. d. Atomising air manual isolation valve before atomizing air nozzle valve is open. iv. Pressing the associated pair start (1 -3 or 2-4) push button will initiate a 90 seconds start time to place the associated pair of light oil guns in service. The sequence of introduction of oil gun in service will be as follows: a. During first 10 sec of the paint start, the associated Ignitor is started. Ignitor ÒN' indication come on proven of ignitors. b. A start command is sent to oil corner 1 (when corner 1 and 3 have been started) or to oil corner 2 (when corner 2 and 4 have been started). c. Twenty five seconds later, a start command is given to cor 3 or to oil cor 4 (when cor 1-3 or cor 2-4 have been started respectively). d. When an individual oil corner receives a start command, the atomizing air nozzle valve will open upon receiving the open command provided the scavenge nozzle valve is closed. e. If the flame is established within 15 secs then the oil gun is said to have
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been successfully placed in service and will continue to operate. f. If the flame is not established by the end of 15 secs, corner trip will be initiated, which will close the LONV, atomizing valve and scavenge valve of particular corner. g. At the end of 90 secs, LO pair start time trial, a corner tri is initiated for any corner when the LONV is not proven fully open (LONV 'open' red light not coming) or where the associated atomizing air valve is not proven fully open. Light oil elevation trip occurs on any of the following conditions: a. Master fuel trip b. LOTV not open c. Unit critical power not available for more than 2 secs. Note: LOTV, LONV's etc are being pneumatic operated valves the drop in instrument air pressure or failure of instrument air compressor may result in closure of these valves slowly. 5. Pair Mode Shut down: The LO elevation is shutdown manually from the oil console insert panel on a pair basis. a. During the first 10 sec of pair stop, the associated elevation of ignitor is started. b. At the end of lOsec, a stop command is sent to LO corner 1 (or) 2. c. 15sec Later stop command is sent to LO corner 3 (or) 4 d. When the pair stop (1-3) push button is depressed will initiate 375 sec. Stop time trial for shut down and scavenge. e. "Start Scavenge" signal which opens the scavenge valve. f. Scavenge is carried on for 300 seconds. After 300 secs. "Scavenge complete" signal will initiate a corner trip which will close atomizing air valve and scavenge valve. The sequence of shut down of pair 2-4 is similar to that of pair 1-3. A backup trip command is generated 360 seconds after both pairs are stopped which will give close command to all the nozzle valves, atomizing valves and scavenge valves. An unsuccessful elevation shutdown alarm is annunciated under the following conditions. All the conditions should be fulfilled. 1. Elevation back up trip 2. Pair 1-3 stop time expired
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3. Pair 2-4 stop time expired 4. Any oil nozzle valve in the elevation not closed 5. Any corner HEA rod not retracted 6. Elevation AC power available. HEAVY FUEL OIL SYSTEM: The prime function of the HFO system are 1. During the HFO from the oil tank and pumping into the boiler front for safe firing in the furnace. 2. Heating the heavy oil to the proper temperature utilizing auxiliary steam to maintain the required viscosity of 15 CST for better fuel atomization before firing. 3. Filtering the heavy oil to remove any dust, dirt sediments, sludge etc to reduce wearing and clogging of atomizer nozzles. An unsuccessful elevation shutdown alarm is annunciated under the following conditions. All the conditions should be fulfilled. 1. Elevation back up trip 2. Pair 1-3 stop time expired 3. Pair 2-4 stop time expired 4. Any oil nozzle valve in the elevation not closed 5. Any corner HEA rod not retracted 6. Elevation AC power available. HEAVY FUEL OIL SYSTEM: The prime function of the HFO system are 1. During the HFO from the oil tank and pumping into the boiler front for safe firing in the furnace. 2. Heating the heavy oil to the proper temperature utilizing auxiliary steam to maintain the required viscosity of 15 CST for better fuel atomization before firing. 3. Filtering the heavy oil to remove any dust, dirt sediments, sludge etc to reduce wearing and clogging of atomizer nozzles. Before the heavy oil can be fired it must be heated to reduce viscosity to 15 CST from 370 CST. Hence the heavy oil is utilized as a start up fuel in a cold boiler if steam is available for heating the oil in the storage tank and the internal heaters, for atomizing the oil at the oil guns and for preheating the combustion air at the SCAPH, to avoid cold end corrosion. The HFO can be
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fired by means of oil burners housed in the wind box assemblies at elevations AB, CD, DE, EF of the boiler. These are external mix type steam atomized oil guns known as J-tip. The atomizer assembly consists of nozzle body welded on to the gun body, back plate, spray plate and cap nut. The heating of the oil is accomplished by recirculating the oil through recirculation system known as short RC loop and long RC loop. HEAVY OIL SYSTEM LAYOUT AND DESCRIPTION: Each boiler is provided with two numbers screw pumps which draw the HFO from the tank through the oil strainers (500 micron mesh) and supply it to the oil burner by pipelines. Through the return line from the boiler to HFO tank, excess oil delivered from the pump is sent back when only a small quantity of oil is fired, or during a boiler trip out. The screw pump is driven by an induction motor at constant speed and delivers constant quantity of oil. A pneumatic operated pressure control valve (HOPCV) installed between pump discharge valve and the HO heaters, maintains a constant set pressure at the down stream of the valve (ie. Upstream of the HOTV or HOFCV in the system) by returning the excess oil back to the HFO tank or pump suction, through the cold oil return line. The HOFCV located after HOTV in the supply line at boiler operating floor, maintains a constant down stream pressure in the HO line irrespective of number of oil guns in service through a pressure controller located in the UCB control desk. Manual isolation valves and by pass are provided for both HOFCV. The HOTV is a pneumatic operated isolation valve installed between the fine mesh filter (250 micron) and HOFCV. This valve shuts off oil supply to the HOFCV in case of boiler fire off and can be operated by the push buttons in the FSSS console at UCB control desk. A manual operated valve connects the HFO supply line with return line, called short recirculation valve the tapping for which is taken before HOTV and connected after HORCV in the return line. The short RC valve is kept open essentially for warming up the main lines and closed after putting the long recirculation loop into service. The long reciruclation loop is through HOTV, supply flow meter and
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HOFCV in the HFO supply line, oil supply vertical risers, ring headers, return oil down pipe and HFO return line where a pneumatically operated reciruclation valve (HORCV) is installed. The HORCV is linked with FSSS and can be operated from the UCB control desk. Opening of HORCV enables opening of HOTV even before commencing the furnace purge cycle. The heavy oil burner stations at different corners in each elevation receive the oil from the respective ring headers provided at elevations AB, CD and EF. The HO burner station consists of HO line with HONV and an isolation valve before it, one steam line with atomizing steam nozzle valve and an isolation valve before it, an one no scavenge valve. These are located nearer to the individual burners. The piping of heavy oil and atomizing steam is connected to the oil gun through hoses with U-bends. The pneumatically operated HONV's ASNV's and scavenge valves assure instantaneous closing and slow opening, and are operated according to the FSSS logic. Steam pressure regulating station is located at the boiler -operating floor. Steam pressure regulating valve with its isolation valves maintains the required set point pressure in the atomizing steam valves. A manual by pass valve is provided for this regulating valve. Heat tracing steam line with necessary steam traps and drains runs along the HFO supply line and they are combinedly insulated. Two 100% duty steam-oil heaters, HFO temperature control valve and steam trap stations for heaters are also accommodated at the fuel oil pump house. The heat exchangers are of stationary tube sheet U -type with oil on shell side and steam through the tubes. The HOTCV is a pneumatically operated valve which admits the steam to the heaters and maintains oil temperature at the heater outlet according to the set point. A manual by pass valve to the HOTCV is also provided. A low lifting spring loaded safety valve is mounted in the heater to relieve the excess pressure. The HFO system draws the required steam from PRDS station. Also electric heat tracing is resorted for the oil lines from the HFO tank to the pump and from the strainer to the HONV's at the operating floor. Depending upon the oil line temperature, the resistance of the electric heat tracing line varies, thus limiting the heating rate, as required.
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Instruments to measure the pressure, temperature, flow etc are mounted on the HFO line at appropriate locations. LINING UP AND CHARGING OF THE SYSTEM: 1. Ensure the following before starting the heavy oil pump and taking into service. a. No line clear is pending b. Sufficient oil level in the HFO tank c. Availability of electric supply to the HFO pumps & FSSS. d. Availability of instrument air. e. Availability of heating steam for the HFO tank and heat exchangers. f. Closure of HOTV and all the HONV's in elevations AB, CD, EF. g. Opening of suction and discharge valves of HFO pumps. Unless one pump is under line clear the valves of both the pumps must be kept open. h. Closure of inlet and outlet valves to suction strainer. i. Closure of isolation valve to HOPCV available at FOPH. j. Full opening of by pass valve to HOPCV available at FOPH. k. Closure of inlet and outlet valves to heat exchanger on oil side. l. Opening of short recirculation valve and closure of pneumatically operated recirculation valve ie long RC valve. m. The temperature of the oil in the HFO tank should be around 55 to 60C otherwise it should be heated by using heating steam. n. The air vents in the oil strainers must be kept open. o. The air vents in the heat exchanger must be kept open. p. Closure of inlet and outlet valves of the oil strainers, after the HO heaters, located in the operating floor. q. Opening of the steam drain valves in the oil steam heat exchanger. r. Opening of steam traps and drain valves in the heat tracing line. s. Closure of steam temperature control valve and its by pass valve to oil heaters. Opening of the valve in the return line to fuel oil tank. t. Opening of the isolation valves of the steam trap, which is going to be kept in service. u. Switch on the electric heat tracing system in pump house & operating floor. 2. The HFO line may be charged, air vented out and pump started as follows: a. Ensuring the HFO oil temperature open the oil tank outlet valve and strainer
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inlet valve slowly and observe oil flows out through the air vent in the strainer. The other strainer may also be charged in the similar way. The air vent may be closed immediately. b. Allow oil to fill up the pump by opening the strainer outlet valve, if necessary rotate the pump impeller by hand to fill it. c. The oil in HFO tank flows by gravity and is available upto the inlet of heaters. On opening the inlet valve, the heater may be charged and air vented out. Then the outlet valve can be kept open. Similarly the other heater may also be charged and the inlet/outlet valves can be kept closed to keep the heater as stand by. d. Start the heavy oil pump and establish oil flow circulation through the HOPCV by pass, back to the HFO tank. e. Close the HOPCV by pass slowly and check whether the pump built in relief valve operates at required set pressure. f. Open the isolation valve to the HOPCV. g. Now vary the opening of HOPCV by pass valve and check for proper functioning of HOPCV. If found satisfactory close the by pass valve and put the HOPCV in service. h. The oil pressure in the system can be maintained according to the set point in the controller. i. j. If the oil header is not charged earlier, the heater may be charged, air vented out Slowly charge the oil strainer at the operating floor by opening the inlet isolation and then the heater outlet valve opened to fill the supply oil line with HFO. valve. Vent out the air and close the vent valve. k. Open the oil strainer outlet valve to charge the HFO upto HOTV. 1. Now the heavy oil starts flowing to the return line leading to HFO tank, through the electrical operated recirculation valve already kept opened. Thus the short RC loop of HFO system is put into service. 3. The HFO heater may be charged on steam side as follows: a. Open the PRDS steam isolation valve at 27m deaerator operating floor, feeding to FOPH and heat tracing lines, slowly for warming up. The heater may be warmed up by draining the condensate in the system due to previous charging. The steam may be admitted through oil TCV by pass valve. b. The oil temperature control valve may be checked for proper functioning by
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va r yin g t h e o pe n ing of T CV b y p a ss va l ve a n d kep t in se rvice if f o und satisfactory. c. After sufficient warming, all the drains in the tracing line and heater system may be closed fully. The isolation valves of steam traps may be kept opened, for the steam tracing lines. The steam trap of the oil heater will also be taken into service, for the heater which is going to be in service on oil side. Note: On any occasion the oil heaters should not be charged with steam before oil circulation is established in the HFO system. The heavy oil temperature must be maintained between 105 to 130C. 4. The FSSS permits the opening of HOTV for oil recirculation purpose following a boiler trip and prior to starting a furnace purge cycle as follows. a. Depressing the HORCV push button will open the HORCV (Heavy Oil Recirculation Valve) provided all the HONV's are fully closed. The open position of HORCV will be indicated by red light on FSSS console at UCB control desk. b. On seeing the "HORCV Open" red light indication, depress the HOTV open push button and HOFCV sufficiently. This will open the heavy oil recirculation system in service. c. Before furnace purge cycle can be started, the HOTV must be proven closed. To close this press its associated close push button. When the trip valve is fully closed, "HOTV Closed" green indication light comes ON. d. To reestablish the oil recirculation after the furnace purge cycle has been completed, open the HOTV, after a time lag of 30 sec. e. The HORCV remains open until the first HONV opens, at which time, the RC valve close. Note: When the long RC is put into service close the electrical operated short RC valve. Otherwise the hot oil return to FO tank will heat up the oil and the temperature in the tank will go up, which is not desirable. TAKING FUEL OIL ATOMISING STEAM SYSTEM INTO SERVICE: 1. Ensure instrument air supply to the pneumatic steam pressure control valve. 2. Keep open the isolation valves of the steam pressure control valve (PCV). 3. Keep the by pass valve to the PCV in closed condition. 4. Open the drain valves in the system. 5. Open the inlet steam isolation valve at boiler firing floor.
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6. After sufficient warming up close all the drains. 7. Check the performance of the PCV by checking the steam pressure at the down steam of the PCV. 8. The normal atomizing steam pressure maintained is about 6 to 7.5kg/sq.cm. HEAVY OIL TRIP VALVE CONTROL: Once the boiler trip circuit is reset (on completion of furnace purge only the boiler trip circuit gets reset) and all the HONV's are fully closed, pressing the HOTV open push button will open the HOTV, provided the HO header pressure and HO temperature are adequate (greater than 5kg/cq.cm 105C). W hen the HOTV is moved from the fully closed position the (green) "HOTV Closed" light goes out. When the HOTV reaches the fully open position, the (red) "HOTV Open" light comes ON. Pressing the HOTV close push button will close the HOTV. The HOTV also closes automatically under the following conditions. i. Master Fuel Trip and RC valve not open. ii. HORCV not open and any HONV not closed and a. Atomizing steam pressure very low and no oil elevation in start or stop for more than 2 secs. OR b. H.O. header pressure low and HONV"s not closed for more than 2 secs. OR c. H.O. temperature very low and any HONV' s not closed for more than 2 secs. HE AVY OIL ELEVATION START (ELEV ATION AB, CD, EF PAIR MODE): Heavy oil can be fired at elevations AB and/or CD and/or DE and/or EF. H.O. elevation is placed in service on pair basis when associated feeders are off. Corners 1 and 3 make one pair while the corners 2 and 4 make the other pair. Corners making up a pair are diagonally opposite. To place the H.O. guns in service at any elevations proceed as follows: i. Select heavy oil firing when the boiler is for hot start. When the boiler is in service with light oil firing in AB elevation start the HO firing from the elevation CD. Once elevation CD oil guns are proven, light oil firing may be with drawn from AB elevation and selected for H.O. firing. ii. Establish heavy oil elevation start permit by ensuring following conditions: -
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a. No Master fuel trip b. Heavy oil trip valve proven open c. Air flow adjusted between 30% and 40% MCR d. Burner tilt horizontal Note: Conditions (c) and (d) above are not required if any feeder is proven ON. At each corner which is going to be placed in service see the following are satisfied. a. The HO guns are properly positioned at firing position. b. Local oil gun maintenance control switch is placed in remote position. c. Heavy oil manual isolation valve before HONV is open. d. Atomizing steam manual isolation valve before atomizing steam nozzle valve is open. iv. Pressing the associated "Pair Start' push button (for corners 1 and 3 or for corners 2 and 4) when the above conditions are satisfied will initiate a 90 sec start time trial to place the associated pair of heavy oil guns in service, as already explained for light oil system. ELEVATION MODE OPEATION: TYPICAL FOR HEAVY OIL The elevation mode of operation is selected automatically when either of the adjacent feeder associated with the HFO elevation is "Proven on" (feeder on for more than 50 secs). When the elevation mode is selected, the HFO elevation is placed in service as follows assuming the "Oil Elevation Start Permit" remains established. i. An 'elevation start' command is established for corner 1 and 3 on the associated elevation an described for pair mode operation. ii. After the 'elevation start' command is established, a 40 sec counting period is started to establish an 'elevation start' command for corners 2 and 4. iii. After 40 secs counting period expires, corners 2 and 4 are placed in service. iv. At the end of 90 secs H.O. pair start time trial of the second pair of oil guns, a minimum of 3 out of the 4 HONV's at the elevation start alarm is initiated. This will stop cor 1-3 and 45 secs later cor 2-4 as described in shut down procedure. (This scheme has since been modified by M/s. BHEL, to keep in service, whatever gun has got proven)
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d. HEAVY OIL ELEVATION SHUTDOWN: The HP elevations can be shut down in either the 'Pair' mode or in the Èlevation Mode'. When all the feeders are off, then 'pair' mode is selected and HO elevation can be shutdown manually. If either feeder associated with HO elevation is proven ON, then the elevation mode is selected. e. HEAVY OIL PAIR MODE SHUTDOWN: The HO elevation is shutdown manually from the oil console insert panel o n a p a ir basis. Co rn e rs 1 and 3 o r co rne rs 2 a n d 4 ca n b e sh u t do wn , b y depressing the concerned push button. a. During first 10 sec, associated elevation ignitor is started. b. Corner 1 HONV is closed and scavenge valve is opened providing atomizing steam valve is open. At the end of the ignitor start time, a stop command sent. c. 15 secs after the stop command is sent to corner 3 gets the same command as corner 1. d. 'Start Scavenge' signal opens scavenge valve, and light oil valve closes. The atomizing air valve remains open. e. Scavenge is carried out on 300 secs. After 300 secs "Scavenge Complete" signal will initiate a corner trip which will close ASNV and scavenge valve. f. The sequence of shutdown of pair 2-4 is similar to that of pair 1-3. g. A back up trip command is generated 360 seconds after both the pairs are stopped which will give close command to all the nozzle valves, atomizing valves, and scavenge valves. An unsuccessful elevation shutdown alarm is annunciated under the following conditions. i. Elevation back up trip AND ii. Pair 1-3 stop time expired AND iii. Pair 2-4 stop time expired
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AND iv. Any oil nozzle valve not closed AND v. Elevation AC power available. PULVERIZED COAL FIRING SYSTEM: The direct firing pulverized fuel system consists of HP803 PX bowl mills to pulverize the crushed coal, and its feeders to feed the coal at a controlled rate from the bunkers and tilting tangential burner assembly to admit the pulverized coal together with the secondary air for combustion. Current of air is supplied by the primary air fans and preheated in APH, dries the coal as it is being pulverized. The pulverized coal is transported by the primary air, to the coal nozzles in the wind box assemblies, through the pulverized fuel piping system, to discharge the coal air mixture tangentially to an imaginary circle at the center of the furnace. The trisector rotating air heaters are utilized to preheat the secondary air and a portion of the primary air. The preheated secondary air for combustion enters the furnace around the coal nozzles and through the auxiliary compartments directly adjacent to the coal nozzle compartments. The heated primary air from the air heater enters the hot primary airbus duct where as the cold primary air is admitted to the cold primary airbus duct. Branch ducts with necessary isolation gates and controlling dampers, from the hot and cold primary air bus admit the air to each mill, after proportionally mixing the hot and cold primary air to dry the coal such that the mill outlet temperature is in between 70 to 90C and also to maintain the required air flow to transport the coal from the mill to the burners. The hardness, volatile matter and the moisture content of the crushed coal decides the mill outlet temperature. The total primary airflow constitute approximately 30% of the total unit combustion air requirement. The coal air mixture entering the furnace is initially ignited by the oil flame at the nozzle exit, when the boiler is comparatively cold. After a certain loading conditions the combustion becomes self-sustaining. The speed of ignition of the coal air mixture largely depends upon the amount of volatile after in the
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fuel. The swirling / rotating / cyclonic action produces sufficient turbulence in the furnace to complete the combustion. The products of combustion spiral up and leave the furnace to enable fresh coal air mixture to enter, the heat released while doing so is utilized for steam generation in the boiler. A large portion of the ash, being one of the products of combustion, is carried out of the furnace with the flue gas, he remainder is discharged through the furnace bottom ash hopper. HP803 PX BOWL MILL: The bowl mill consists of essentially a grinding chamber known as separator body with a classifier mounted above it. The pulverizing takes place in a rotating bowl to the center of which the crushed coal is delivered through the center feed pipe by its feeder. The centrifugal action of the rotating bowl moves the coal outward towards the perimeter of the bowl against the grinding ring, known as bull rings, the replaceable wear liners placed on the bowl to protect it. Vane wheel segments are attached throughout the circumference of the bowl to direct the primary air from the air inlet housing to carry the pulverized coal. The separator body is fitted to the top flange of the air inlet housing and encase the bowl and vane wheel assembly with suitable annular clearance throughout the circumference. Three numbers of roller journal assemblies are attached to the separator body, at 120 degrees apart. The rolls revolving on the journals pulverize the coal sufficiently to enable the primary air to pick it up. Heavy springs mounted in the journal-opening door, acting through the journal saddles provide the necessary pressure for grinding the coal which passes between the bullrings and the rolls. The rolls do not touch the bullrings when the pulverizer is empty. It revolves in the journal due to the friction as the coal passes between the rings and roll. In the upper portion of the mill, the classifier is located which consists of curved deflector blades, mounted vertically through hinged shafts, supported in the windows of the inner cone drum section. There are twenty-eight such deflector vanes and the hinged shafts are connected circumferentially with each other by links outside the mill body. These can be operated by two levers each one operating one half segment. By operating these levers the window opening may be varied
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from minimum to maximum and locked at the desired position as indicated in a graduation form 0 to 10. Zero position indicates maximum opening of classifier. The deflector blades in the openings cause the coal air mixture to spin and the angle of the blades determines the velocity of the spin resulting in variation of fineness of the pulverized fuel output. The hot primary air entering the air inlet hosing from the mill air duct is directed upward around the bowl by the vane wheel segments and the annular clearance. As the air passes upward it picks up to pulverized coal into the classifier where the direction of the flow is changed abruptly. The change in direction & velocity cause the coarse particles to be returned to bowl for further grinding, through the inverted inner cone attached to the classifier drum section. The fine coal powder, remaining in suspension leave the classifier and passes through the venturi outlet at the mill top and enters the multiple port outlet. From the multiple port outlet, coal powder is carried to the coal nozzles by the primary air through 4 nos coal pipes for combustion in the furnace. Mill discharge valve available in each coal pipe can be used for isolating the mill, from the furnace. Any tramp iron or denser foreign materials in the coal is thrown out of the bowl due to the centrifugal force and gets dropped through the air stream to the mill bottom. Pivoted scrapers attached to the bowl hub sweep the foreign material through a discharge opening (spout) into a pyrites hopper. Valves, for collection and removal of these rejects from mills are provided before and after the hopper. Provision is available for taking pulverized coal sample at the discharge pipe of the mills. The air inlet housing is assembled to the top flange of the gear housing in which the worm wheel and a worm shaft are placed. The worm shaft is directly coupled to a 6.6 KV, 50 Hz, 380 KW induction motor through coupling. The worm wheel is mounted on a vertical shaft supported by a thrust bearing and two radial bearings. The bowl hub is fitted to the top of the vertical shaft and rotates at 52 RPM as gear ratio is 1:79/7 and the motor RPM is 590. The base of the gear housing forms the oil tank. The worm wheel and worm shaft with its bearings are partly immersed in the oil in the tank and gets lubricated. The vertical shaft bearings are lubricated by means of a lub oil pump assembly erected near by the mill, which draw the oil from the gear housing and supply to the bearings. Duplex oil filter and oil coolers are also provided. The oil from the
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bearings are collected in the oil sump itself. Relay panel for protection, inter locks and starting of the lube oil pump is installed at the mill bay. The LOP can be started from the FSSS console at UCB also. Mechanical seal prevents entry of coal or dust entry into the vertical shaft bearings and to the oil sump. Apart from this, seal air is admitted to the mechanical seal for sealing out the dust and cooling the seal. Seal air is also admitted to the journal shaft assemblies through the trunnion shaft. There are three nos seal air fans installed. These fans draw the primary air from the cold air duct through filter and boost the air pressure and discharge into a common header. The seal air is taken to each mill through separate pipeline and pneumatic operated discharge valve and manual operated suction valve. These pneumatic operated valves are operated as per the logic in the FSSS console. GRAVIMETRIC FEEDER: In order to deliver the crushed coal at a controlled rate the Gravimetric feeder is installed below the raw coal bunker. The gravimetric feeder is capable of supplying 9 to 45 tons of coal to the pulverizer per hour, by an endless conveyor belt. The coal is fed from the bunker down spout pipe to the center feed pipe of the bowl mill. The gravimetric feeder is envisaged with electronic weighing and control system to obtain the reliable and accurate feed rate control and speed measurement of the belt. FEEDER DRIVE: The drive system for the belt consists of a 4 pole, 3 -phase induction motor, coupled to a speed-reducing gearbox through an eddy current clutch. The motor is 5.5 KW, 1440 RPM, TEFC. The clutch controls the power transferred to the conveyor, and belt speed. The causes power losses in the clutch and to dissipate the heat generated in the clutch the assembly has an integral fan. To limit the power loss in the clutch to a safe value, the minimum speed for the output shat of the clutch is 120 RPM. A speed feed back for the feeder is provided by an AC generator attached to the output shaft of the clutch. This generator provides an output of 45 volt per 1000 RPM and generates 12 pulses per motor revolution. The motor speed is controlled by the amount of current delivered to the clutch coil.
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The feeder is equipped with a reversing motor starter which enables the belt to be driven forward, for normal operation, or reverse. The reverse/off/forward mode is selected by means of a selector switch in the feeder control cabinet. FEEDER BODY: The parts of the feeder which are in contact with coal flow are fabricated out of stainless steel and the body is capable of with standing an explosion pressure of 7kg/sq.cm. Side skirting is provided to contain the coal on the belt and a leveling bar near the feeder inlet sheers the coal column to form a profile conducive to maximum weighing accuracy. Dust tight doors are provided at both ends and each side of the feeder for access to critical components. The feeder interior can be observed through the bull eye viewing ports in the door with the help of a work light provided inside. The feeder belt is supported by a machined drive pulley near the outlet, a slotted take up pulley and a six belt support rollers at the inlet end, a weighted idler pulley in the middle of the feeder. A counter weight scrapper of the belt after the coal is delivered to the outlet. Proper belt tracking is accomplished by crowning the take up pulley. In addition all three pulley faces and the inlet span rollers are grooved to accept the moulded V-guide of the belt. Belt tension is applied through downward pressure exerted by the tensioning idler on the return strand of the belt and can be adjusted by turning the two belt take up screws which protrude through the inlet end access door. A paddle type alarm is mounted above the center of the belt to detect the absence of the coal on the belt. The alarm consists of a stainless steel paddle mounted on one end of a horizontal shaft and a dust tight switch housing on the other end. The switch in the housing is actuated by adjustable cam mounted on the end shaft inside the switch housing. Loss of coal on the belt results in a contact closure of limit switch which is used to stop the belt motor. WEIGHT SENSING COMPONENTS: The feeder-weighing signal is generated by two load cells which support a weighing roller. On each side of the weighing roller, two weigh span rollers which accurately define a given length of belt on which coal is weighed, are located. Each load cell supports half the weight of coal on the span. The output
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of the load cell is scaled into signal which represents grams of coal per centimeter of belt. Weight (gms/cm) x Belt speed (cm/sec) = feed rate (gms/sec). CLEAN OUT CONVEYOR: Two strands of malleable iron drag chain with alternately spaced wing links are used to automatically clean coal from the bottom pan of the feeder where the coal falling from the belt scrapper, coal dust settling out of the air, coal removed from the self cleaning take-up pulley gets accumulated. This prevents interference with belt and remove stagnant coal, which may otherwise ignite spontaneously. The clean out conveyor is driven by a 0.25KW totally enclosed non-ventilated drive motor through a 5 to 1 ratio gear head and a reduction gearbox to an operating speed of approximately 60 cms per minute. A three-position switch is used to energize the clean out conveyor drive motor. This selector switch mounted on the power cabinet door has continuous/off/timed selections. Continuous or timed operation should be selected based on the quantity of dust accumulation at the bottom pan of the feeder whenever the feeder is in service. Timed mode should be selected when the feeder is not operating. FEEDER START MODE OFF/RUN SELECTOR SWITCH (SLF): This two-position selector switch is mounted on the feeder control supply cabinet. It enables operation of the feeder when placed in the RUN position providing the selector switch (SSF) at the power cabinet is in the local mode. This switch is disabled when the switch (SSF) is in the remote mode. FEEDER MODE LOCAL/OFF/REMOTE SELECTOR SWITCH (SSF): This 3 position selector switch is mounted at the power cabinet at UCB Electronic Control Room and enables the feeder to be operated in the mode as desired. During remote operation the feeder operates under the control of the combustion control system. Remote operation starts by placing the feeder mode selectors switch is remote and providing a start command from the FSSS
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console. After every start command the feeder first operates in the volumetric mode. This means that it is controlled by a direct feed back from the belt drive motor. The feed rate display indicates motor RPM and the feeder operates in this mode until limit switch LSFB detects coal on belt. At this time, the coal totalizer circuit and the "Feeding Coal" relay are energized. If a status signal generated by the electronic controller indicates no fault, the feeder operates in the Gravimetric Mode. The feed rate display LED then changes to indicate delivery in Tons/hour. If there is fault in the status signal but there is coal on belt, the controller energizes the "Feeding Volumetric Relay". Local operation of the feeder is provided either to calibrate the feeder or check its operation, such as belt tracking. In the local mode, the feeder is operated volumetrically. When the mode selector switch in Local, and the Local mode selector switch (SLF) is in the Run position, the feeder controller energizes a relay K4 and starts the belt drive motor. The federate display indicates motor RPM and the feeder operates continuously with no coal on the belt until either the mode selector switch (SSF) or the local mode switch (SLF) is turned off. Local operation with coal on belt trips the feeder after a two second delay. The trip is reset by placing the feeder selector switch in the OFF position. COAL MOTION MONITOR (CMM): The coal motion monitor senses the motion of the feeder belt and energizes an output relay or annunciator when the belt speed falls below a preset minimum value. The system consists of a transducer/sensor which converts the rotary motion of the weigh span roller shaft into digital signal, an instrument package which receives and processes the signal. The instrument package first furnishes a regulated output voltage via a two wire system to the speed sensor which consists of a light source (LED) and a light detector (Photo Transistor) separated by thin rotating slotted disk driven by the weigh span roller shaft. As it rotates the light is alternately interrupted and allowed to pass through holes in the disk. This occurs 60 times per revolution and a small current pulse is generated in the supply line. This current pulse is detected by the electronic package, which maintains a output relay in a de-energized state as long as the feeder belt speed remains the preset minimum. Any reduction in speed or stoppage of the belt actuates the output relay and any annunciation connected to it.
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OPERATION OF GRAVIMETRIC FEEDER: If the Gravimetric feeder start permissives from FSSS logic are satisfied, the feeder may be started by pressing the start push button in the FSSS console at UCB desk. Before starting ensure that the gates at feeder inlet and the bunker outlet are kept opened. On starting or on receipt of a demand input from the combustion control system feeder operation beings and 'Feeder Run' indicators are energized. As coal fills feeder belt while the feeder is running, the amber light 'Feeding coal' is energized. The continuous operation of feeder is possible only if coal on belt indicator is energized. Otherwise the feeder stops on auto. Turn the feeder mode selector switch to the local position, and turn the local mode selector switch (SLF Feeder start mode off/run) to the run position till the coal on belt is ensured. By this method the feeder can be operated as long as desired. Once the coal on belt is ensured turn the feeder mode selector switch to the remote. Initially the amber feeding volumetric indicator and the LED on the feed rate display at UCB are energized. W hen the status signal generated by the electronic controller indicates 'no fault', the tones per hour LED is energized in place of RPM. The feed rate indicators and total coal integrators are now activated. Manually turn the clean out conveyor selector switch (SSC) to the continuous mode, if not done earlier. The feeder is thus put into operation and it will respond automatically to the changing of the combustion control system until is deenergized or the loading can be done manually by varying the feed rate from the control switch from the UCB desk. To operate the feeder without reference to the demand signal, turn the key operated selector switch (SSDS) to the 'Bypass' position and control the speed of the feeder with manual 'Speed Control Potentiometer' (MSCL). The feeder reverse mode operation is done as follows: Turn the feeder mode selector switch (SSF) to the OFF position.
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Turn the belt travel selector switch (SSL) to the REVERSE position. Then turn the feeder mode selector switch (SSF) to the LOCAL position. Turn the feeder local start mode selector switch (SLF) to the 'RUN' position. TAKING MILLING SYSTEM INTO SERVICE: T he p u lve rize r a n d t h e a sso cia t ed e qu ip m en t ca n b e st a rted e it h e r automatically or manually. Auto/Manual mode of pulverizer start can be selected by means of selector push button provided on coal elevation console insert. Prior to starting a pulverizer either on auto or manual, start permit conditions for the respective pulverizer must be established by checking whether the following conditions are satisfied. i. Elevation DC power available. ii. Nozzle tilts placed in horizontal position. iii. Air flow adjusted between 30 to 40% MCR. iv. At respective pulverizers, the pulverizer ready conditions are to be satisfied. Each condition is indicated by a white light on FSSS console. v. Pulverizer ignition permit available. Note: Conditions (ii) and (iii) are not required to be satisfied for a pulverizer ready start permit when any feeder is already proven on, or 3 out of 4 HONV open in any oil elevation. However the minimum airflow above 30% is still to be maintained. PRESTART CHECKS: Check the following conditions for taking any pulverizer into service. a. Pulverizer discharge valve open. b. Pulverizer outlet temperature (less than 93C) Not high c. Cold air gate open. d. No pulverizer trip. e. Tramp iron hopper valve open. f. Bunker outlet and feeder inlet gate open. g. Primary air adequate --PA header pressure more than 600mm WC.
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h. Pulverizer/Feeder start permit. i. Pulverizer lub oil start permit. When all the above conditions are satisfied for the respective pulverizer, its associated PULVERIZER READY LIGHT (white) comes on. 1. Ensure the raw coalbunker is filled with coal. While filling the bunker with coal, when it is empty keep the inlet gate in closed position to avoid compaction of the coal at the feeder inlet. 2. Ensure all the line clears are returned. 3. Main disconnect switch for feeder control to be energized, green lights feeder off indicators at power cabinet and at control cabinet coming on. 4. Place the feeder mode selector switch (SSF) in remote position (Local / Off / Remote switch). 5. Ensure that the belt travel selector switch (SSL) (Feeder Reverse/Off/ Forward Switch) is selected for forward position. 6. Select the key operated selector switch (SSDS) in the enable position. 7. Put clean out conveyor continuous/Off/Timed selector switch (SSC) in continuous mode. 8. The seal air valve to the feeder shall be kept opened. 9. Feeder start conditions that are to be fulfilled from the FSSS logic should be satisfied except the coal on belt. 10. Feeder speed demand shall be kept at minimum. 11. Establish power supply to the hot air and cold air damper controls and keep these dampers in closed condition. PULVERIZER IGNITION PERMIT: Prior to starting any pulveizer, the pulverizer ignition energy must be adequate to support coal firing. Any one of the following conditions ensures the required ignition permit for starting a pulverizer. i. A minimum of 3 of the 4 associated oil elevation (directly adjacent to the coal elevations top of bottom) nozzle valves proven open. (Eg) with AB elevation A and B coal elevations may be started. OR ii. Boiler loading greater than 30% with the directly adjacent elevation top
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or bottom pulverizer is in service at greater than 50% loading (Eg) Mill C gets ignition permit with mill B or D more than 50% load and boiler load is greater than 30%. iii. Adjacent bottom elevation pulverizer is in service at greater than 50% loading with atleast 3 of the 4 nozzle valves of its associated oil elevation proven open. (Eg) Mill C gets ignition permit with mill B more than 50% load and AB oil elevation proven open. PULVERIZER START - MANUAL MODE: By establishing ignition energy available and pulverizer ready conditions for the respective pulverizer, it may be placed in service as follows i) Ensure pulverizer ready and ignition energy available conditions are present. Start Pulverizer by pressing its associated ON push button. First seal air valve opens and after the seal air to blow DP OK is established pulverizer will start. The seal air to bowl DP should be greater than 200 mm WC otherwise the mill will not start. When the DP is less than 125 mm the running mill will trip. ii) When the pulverizer is proven ON as indicated by the red PULVERIZER ON light coming on, open the hot air gate by pressing its open push button and allow the pulverizer to come up to the temperature. iii). When the pulverizer comes upto temperature (appro.60C) start the feeder by pressing its ON push button (The associated elevation of fuel air damper will be in closed condition initially. The feeder will start only when the feeder start conditions are fulfilled. Coal flow must be proven either by the coal flow detector or satisfactory pulverizer current within 5 secs after the feeder is started. 15 seconds after the feeder is started, the feeder output is released to the fuel totalizing circuit. When the feeder is ON for 50 secs., the feeder speed is released to auto control and the fuel air dampers are opened to modulate as a function of feeder speed. When a minimum of two feeders are established greater than 50% loading, the associated oil elevation may be shut down (when the fireball conditions are ensured
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stable) provided the feeder has been on for a minimum of 3 minutes. A single feeder in service for more than 50 secs. at its minimum speed setting will establish a fireball in the furnace. A single fireball is established when a coal elevation is placed in service and the single fireball is merely enlarged when additional coal elevation is placed in service. If the support ignition energy is removed, the fireball will be monitored by the associated elevation FLAME SCANNER / FIREBALL SCANNER. Feeder Start-For Manual Mode: To start the raw coal feeder the following conditions should be fulfilled.
i) No Master Fuel Relay Trip ii) Elevation DC power available iii) Feeder Local / Remote switch in Remote iv) Pulverizer Ignition permit available v) Pulverizer Ready vi) Hot air gate open vii) Feeder speed demand at minimum viii) Coal on feeder belt ix) Pulverizer outlet temperature not low
Ensuring the above feeder start conditions the feeder can be started and continued to run by depressing the feeder start push button in the pulverizer FSSS console. Interlocks and Protections: When the pulverizer/feeder is in service, several operational parameters are monitored. When an unsafe or abnormal condition exists, corrective (or preventive) action is automatically taken by the FSSS. It is left to the operators discretion to investigate and take further corrective action. An operating pulverizer and feeder are subjected to the following operational interlocks.
a) The feeder speed will be RUN BACK to minimum if the pulverizer bowl DP is
high.
b) If the pulverizer outlet temperature is high (greater than 95C) then the hot air
gate will close.
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c) No coal flow will trip the feeder d) High mill outlet temperature will open CAD and closed the Hot air gate if the control
is in auto mode.
e) The following conditions will initiate a pulverizer Trip command i) Pulverizer discharge valve (any one) not open ii) Loss of unit critical power supply (24V DC) iii) Pulverizer ignition permit is not satisfied, that is, support ignition is required and
less than 3 of the 4 associated oil guns in service.
iv) Master Fuel Trip. v) Primary air header pressure low trip vi) Seal air header to pulverizer DP low for more than 60 secs. less than 125mm WC. vii) Pulverizer shut down due to pulverizer lub oil system (PLOS) trouble.
g). When one PA fan or one FD fan trips and four or more pulverizes are in service, a trip command will be given starting from the mill servicing bottom most coal elevation, until the no. of pulverizes remaining in service is reduced to 3 mills. PULVERIZER SHUT DOWN (MANUAL MODE): When manual pulverizer control mode is selected, the manual shut down of a pulverizer is accomplished as follows: i). Start the associated oil elevation if it is not in service, when the load is less than 120MW. ii. Reduce the feeder speed to minimum. iii. Close the hot air gate by depressing CLOSE push button. iv. When the mill outlet temperature is reduced to 50C and the mill is completely empty coal, then shut down the pulverizer by actuating the OFF push button. PULVERIZER START - AUTO MODE: The selected pulverizer can be placed in operation automatically if all the following conditions are satisfied. a. The associated 'Pulverizer Ready' condition remains satisfied. b. The 'Auto' mode is selected for the associated pulverizer. The mill is started by momentarily depressing the 'Start' push button. The events will occur as follows:
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a. A 2 5 6 s e c o n d c o u n t i n g p e r i o d i s s t a r t e d t o p r o v e t h e a s s o c i a t e d pulverizer/feeder in service. b. If the pulverizer ignition energy permissive is not satisfied an 'Auto start support ignition' command is given to the associated HFO elevation (oil guns) automatically. c. When the associated support ignition elevation start time has expired (both 70secs 'pair start' counting period have expired) or the pulverizer ignition permissive is satisfied, the 'Auto start pulverizer' command is established and the pulverizer is started in the same manner as previously described. d. When the pulverizer is proven ON, the following events occur. i. The HAG is opened, provided the mill outlet temperature is less than 95C. ii. A 60 seconds counting period is started to establish an 'Auto Start Feeder' command.
e. When 60 seconds counting period expires, an 'auto Start Feeder command is

established for 5 secs.
f. After '256 seconds Elevation Start counting period' expires and the pulverizer is
ON and the feeder is OFF, the unsuccessful start memory is reset. When the feeder is OFF for more than 3 minutes the mill receives an 'Auto Stop Pulverizer' command and is shut down. PULVERIZER SHUT DOWN AUTO MODE: When in the auto mode of the operation the pulverizer is shut down as described below. a. The operator initiates a pulveizer auto shut down sequence by momentarily depressing the associated 'Stop' push button. The following events will occur.
i. The 'Auto Stop Memory' signal is established and the 'Auto Start Memory' is
reset.
ii. If the associated pulverizer ignition permissive is not satisfied, an 'Auto Start
Support Ignition Energy' command is established to start the associated HFO elevation.
iii. A 10 minutes 'Elevation Stop' counting period is started.

b. When the support ignition start time expired (Both 70 sec. HD pair start time) and
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the pulverizer ignition permissive is satisfied, then the following commands are established simultaneously.
i. Run the feeder speed demand to minimum. The feeder speed will be removed from
A.C.S. Auto Control.
ii. 'Auto Close Hot Air Gate' command is established and the associated HAG is
closed. c. When the HAG is closed and the mill outlet temperature is reduced below 50C, the associated feeder will receive an 'auto Stop Feeder' command. The feeder will not be shut down. d. When the feeder is off for 3 minutes (180 secs), the associated pulverizer will receive an 'Auto Stop' pulverizer command. The pulveizer will now be shut down in the same manner as previously described.
e. If the pulverizer is to remain on "Standby' then the discharge valve should

remain open to allow air to flow through the pulverizer. If required, the discharge valve is closed by depressing the associated close push button in the FSSS console.
f. The associated H.O. elevation can be shut down when the furnace and the boiler
conditions have stabilised. UNSUCCESSFUL ELEVATION SHUTDOWN: When the ten minutes (600 secs) 'Elevation Stop' counting period is expired, an 'Unsuccessful Elevation Shutdown' signal will be sent to the alarm if any of the following conditions exist at the associated coal elevation.
i. The pulverizer is ON. ii. The feeder is ON. iii. The hot air gate is not closed.
OPERATIONAL GUIDE LINES:
1. Before taking into service any pulverizer, observe all safety precautions, and inform
the maintenance staff on shift.
2. The ring roll setting and spring compression setting shall be arranged to be
carried out by maintenance staff regularly.
3. Check the fineness of the pulverized coal at mill outlet, which shall be carried out
in chemical lab. If necessary, adjust the classifier setting with the help of
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Document Title
maintenance staff.
4. Check the mill rejects. If the quantity is reported high, check all the mill parameters.
If necessary, release the mill for under bowl inspection or ring roll setting.
5. Maintain the primary airflow at about 55 T/hr. If it is too high, fineness of coal
powder is affected and wear rate is more. If it is low, spillage may be more and chocking of mill may take place.
6. Maintain the optimum coal air temperature at mill outlet say 70 to 90C, depending
upon volatile content.
7. Try to load the mills nearer to full load say more than 30T/hr, to have furnace
stability.
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CHAPTER - 5
ELECTROSTATIC PRECIPITATOR INTRODUCTION: The environmental pollution caused by particulate emission is assuming greater importance as the number and size of coal fired thermal sections are increasing. The limit of 150 mg/cu.Nm prescribed for the stack emission of particulates, puts much strain on the dust separation control systems. The Electrostatic Precipitators are the principal system used for the separation of ash particles from fly ash. The EP utilizes electro static forces for the separation. The flue gas is admitted to a chamber containing vertical plates, which form a no. of parallel gas passages. In between each pair of plates the wire fully secured in a frame is located. To the same frame, other wires situated in between other plates are also connected in a field. High Direct Current Voltage is applied between the wires and plates. The negative of DC supply is connected to the wires, and the positive to the plates, which are earthed. The high DC voltage causes corona discharge and ionizes the ash particles, which get collected in the plates. The frame containing the wires and the plates are periodically rapped for dislodging the deposited dusts. The advantages of Electrostatic Precipitators are: 1. The efficiency is high, in the order of 99%. 2. The system is easy to maintain. 3. Ability to treat large volume of gases at high temperature.
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4. Ability to work in corrosive atmosphere. 5. Offers low resistance path for the gas flow. The electronic controller and high voltage transformer rectifier provide high voltage DC across the precipitator electrode Viz. plates, and wires. DESCRIPTION: MECHANICAL SYSTEM: i. PRECIPITATOR CASING: There are totally 2 nos. fields with 6 nos. fields in each path and 4 nos paths. The precipitator casing is an all welded construction, consisting of prefabricated wall and the roof panels. The casing is provided with inspection doors for entry into the chamber. The doors are of heavy construction with machined surfaces to ensure a gas tight seal. The roof carries the precipitator internals, insulator housings, transformers etc. The casing rests on supports which allow for free thermal expansion of the casing during operation. Galleries and staircases are provided for easy access to rapping motors, inspection doors and transformers. ii. HOPPERS: The hoppers into which the dust collected in the plates are rapped and dropped, are liberally sized. Suitable slope is provided on the sides to prevent choking of ash in the hopper, and to allow for free ash controlled heating elements are arranged at the bottom portion of the hopper to avoid stickiness of ash. iii. GAS DISTRIBUTION SYSTEM: The good performance of the precipitator depends on even distribution of gas on the entire cross section of the field. Guide vanes, splitters and screens are provided in the inlet funnel to direct the flue gas evenly on the entire cross section of EP. Isolation gates are available before and after each path of the EP in order to iso la t e t he sam e a s a n d wh e n re qu ire d. Pa t hs A & B ha ve no se p a ra t in g arrangement on gas side, similarly between C&D also.
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iv. COLLECTING ELECTRODE SYSTEM: The collecting plates are made of 1.5 mm cold rolled mild steel plate and shaped in one piece by roll forming. The collecting electrode has a unique profile designed to give rigidity and to contain dust in a zone free from re entrainment. The collecting plates are provided with hooks at their top edge for suspension. The hooks engage in the slots of the supporting angle. All the collecting plates in a row are held in position by a shock bar at the bottom. The shock bars are spaced by guides. v. EMITTING ELECTRODE SYSTEM: The most sensitive part of the EP is the Emitting Electrode system. This is supported by four insulators. The frames for holding the emitting electrodes are located centrally between collecting electrode plates. The entire discharge frames are welded to form a rigid box like structure. The spiral emitting electrodes are fixed by hooks after pulling to the required tension in the emitting electrode holders at the top and bottom of the frames. VI.RAPPING SYSTEMS: Rapping mechanism are provided for collecting and emitting electrodes. The rapping mechanism are driven by geared motors. The system employs tumbling hammers, which are mounted on a horizontal shaft. As the shaft rotates slowly, the hammers tumble on to shock bar/shock beam, which transmits the blow to the electrodes. One complete revolution of the rapping shaft will clean the entire field. The programmer available with electronic control decides the f re qu en cy o f rap p in g. Mo d e of rap p in g f requ e n cy ca n be a d ju ste d . T he disposition of tumbling hammers and the periodicity of rapping are selected in such a way that less than 2% of the collecting area is rapped at any instance. This avoids re-entrainment of dust and puffing at the stack outlet. The rapping shaft of emitting electrode system is electrically isolated from the geared motor drive by a shaft insulator. The space around the shaft insulator is continuously heated to avoid condensation. The emitting electrode rapping motor with gear assembly is mounted at the top roof of ESP. The collecting plate rapping motors are mounted in the platform A,B,C & D. A
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geared motor drive actuates the rapping mechanism of each row in the A,B,C and D fields. Therefore there are 24 collecting plate-rapping motors. There are 24 emitting electrode rapping motors, one each for individual fields. Viii. INSULATOR HOUSING: The support insulators, supporting the emitting electrode system are housed in insulator housings. The HVDC connection is taken through a bushing insulator mounted on the insulator wall. In order to avoid the condensation on the support insulator which will reduce element. Heating elements of one pass, are controlled by one thermostat. Similarly the shaft insulators insulate the rapping system from the supply. ELECTRICAL SYSTEM: i. High Voltage Transformer Rectifier (HVR) and Electronic Controller (EC): The transformer rectifier supplies the power for particulate charging and collection. The basic function of the EC is to feed the precipitator with maximum power input under constant current regulation. Should there be any flash over between collecting and emitting electrodes, the EC will sense the flash over and quickly react by bringing the input voltage to zero and blocking it for a specific period. After the ionized gases are cleared, and the dielectric strength restored, the control will quickly bring back the power to a preset value and raise it to the original non-sparking level. Thus the EC ensures adequate power input to the precipitator while reckoning the electrical disturbances within the precipitator. Regulated AC power from EC is fed to the primary of the transformer which is stepped up and rectified to give a full wave power output. The transformer-rectifier is mounted on roof of the precipitator while the EC is located in and air conditioned control room. The transformer-rectifier unit (HVR) consists of an oil immersed step -up transformer, AC reactor, high voltage rectifier, high frequency choke, measuring and protection components. The Electronic Controller (EC) contains the antiparallel connected thyristor pair for controlling input voltage to the rectifier unit along with the Intelligent Controller for Electrostatic Precipitator (ICE-C), a micro processor based control module, enabling to supply 0-415 AC to the primary of the step-up transformer-rectifier through AC
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reactor. The complete equipment is designed to provide continuously adjustable DC output voltage upto 70 KV peak across the precipitator electrodes. The controls are arranged such that the unit operates as constant current source adjustable upto rated DC output of 1000 mA. Occurrence of spark at the electrodes is sensed and made to block the output voltage for 20 milli secs and voltage is built up again in a specified manner to provide optimum operational efficiency of the precipitator. The Electronic Control (EC) houses the complete control equipment of power supply and is located in the ESP control room. However, the transformer, HV Rectifier and AC reactor are housed in oil filled tank and located in the top roof of EP. The incoming power supply is connected to the control circuit through a switch fuse unit. The operating handle of the switch is mechanically inter locked with cubicle door. So that door can be opened only after the power supply is switched off. With the closing of the switch power supply is connected to the control circuit for build up of reference signal at fixed rate, current regulator, spark detection, spark control and firing circuit. The power circuit is energized by closing the contactor. The thyristor phase controller output is connected to the HV transformer through linear reactor. The primary current is measured by CT with two secondary one winding is used for measuring actual current, and other winding is used for metering and protection. The output of the HV transformer is connected to the rectifier. The positive output of the rectifier is connected to the earth through a current measurement shunt, while the diode provides a back up protection in case shunt resistor opens. An ammeter is connected across the shunt for indication of DC current on high voltage side. The negative of DC output of the rectifier is brought to the bushing of the support insulator through a radio frequency choke, which suppresses the high frequency transient voltage generated during sparking. The output DC voltage is measured through a chain of high voltage resistor divider. The voltage is connected to the KV meter protected by a neon glow tube. The maximum current value can be set with Im potentiometer. The ramp circuit output builds upto the level set by Im.
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The current value can further be set anywhere from zero to Im level by the set reference Is potentiometer. The set reference value is connected to the current regulator through a spark rate control circuit. The spark rate circuit reduces the reference on occurrence of the spark by a level S and allows it to build up back to Is at a rate selected by 'T'. By selecting S&T parameter a check on frequency of occurrence of spark is achieved. The reference value is compared with actual value in the current regulator and the error signal controls the phase angle of the gate pulses from firing circuit. The actual current value is selected either from AC or DC side by a selector switch. A blocking pulse is generated by frequent sparks (dv/dt) which blocks the current regulator output, and at the same time reduces the reference value in the spark rate control circuit. As a protection against short circuit at the electrodes, an under voltage circuit is provided. When such a short circuit takes place, the transformer primary voltage becomes low and voltage-sensing circuit senses the persistent low voltage and initiates the tripping of the supply after a preset time. II. TRANSORMER / REACTOR / CHOKE / RECTIFIERS: The transformer is double wound and is of core type construction, with the limbs joined at the top and bottom yokes. The windings are arranged in concentric formation with LV coil next to the core and HV coil over LV coils. Paper insulated copper conductors are used for both LV/HV coils. Adequate size of oil ducts are provided between the coils in order to provide proper cooling for the coils. The AC reactor is provided for limiting the primary current in the event of flash over or short circuit on DC side. It also helps in improving the form factor of current. The reactor is specially designed to provide linear inductance upto 300% of rated current. It is a two limb, core type reactor, provided with gaps on legs and thus provides linear reactance even at the increased input current. Copper conductors are used as winding material. Adequate cooling ducts are provided for better cooling. The high frequency choke provides high impedance to high frequency currents that may be generated due to sparking/arcing at the electrode due to their
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capacitive effect. It also provides limiting effect on di/dt for the rectifier diodes. The high voltage rectifier modules, consist of an integrated series connection of avalanche diodes. Electric terminals of the module are screw connected in such a way that anodes are having threaded holes while cathodes threaded bolts. The diodes are assembled on a printed circuit board and are embedded in epoxy resin for oil cooling. The seven modules are connected in series by screw-in connections, to form an arm of single -phase bridge rectifier. The complete assembly is fitted inside the oil filled transformer tank. III. INTELLIGENT CONTROL SYSTEM FOR EP (ICE): The system is intended for regulating the power input to the EP for different gas temperatures, dust compositions, gas flows etc. ICE maintains the sp a rk ra te at op t im um le ve l. A vo lt age wh ich m a y b e high wi ll ca u se an unacceptable level of spark rate, but a too low voltage will give a low dust separation. ICE controls the EP power by controlling the firing angle of the rectifier thyristors. EP current and voltage as well as phase angle of the primary voltage are used as control inputs. Initially current increases with `To' rate for 5 secs, then build up follows the 't' setting in order to reach set current limit. When a spark occurs, the EP current is blocked for one cycle 20 ms, and then the EP current is restarted. At this point the EP current suddenly raises to IS level, slightly lower the current at which spark has occurred. This current decrease is called `step'-S. The spark rate will be controlled by the set values of S&T parameters. IV. PEAK & SEMI PULSE MODE: The high resistivity dust gives an abnormally high electrical field strength in the dust layer on the collecting electrodes. The high field strength may lead to spurious discharges, within the dust layer. These discharges or back corona, can decrease the voltage between the electrodes in spite of an increasing current. The `peak mode' decreases the current to a value where peak EP voltage occurs. The number of half cycles the thyristor should conduct can be selected
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by setting charge ratio parameter at 3,5,7,9,11,13,15 charge ratio. The selected number indicates the number of half cycles the thyristor should conduct. Semipulse operation can, depending upon the process type, be selected for improving precipitation or energy saving. Semi pulse and peak mode can be selected at the same time. Generally the charge ratios in semi pulse operation are selected in increasing order with respect to field numbers, (eg) 3,5,7,9,11 & 13 for field, 1,2,3,4,5 & 6 respectively. These are only guidelines for experience. Whenever charge ratios are selected, oscillation in meters may be seen. This is because of obvious reasons that the input to controller is pulsating. Oscillations will increase further if charge ratio is increased. V. AUXILIARY CONTROL PANEL: The ACP houses the power and control circuits required for rapping motors and heating elements of the precipitator. The complete ACP is of modular type with individual module for each feeder. Each module independently contains the power and control circuits, with meters, push buttons, switches and indication lamps. Following are the modules for the outgoing feeders: a. Hopper heaters for each field. b. Support insulator heaters. c. Shaft insulator heaters. d. Collecting electrode rapping motor for each field. e. Emitting electrode rapping motor for each field. The program control circuit for the sequence and timing of operation for rapping motors is included in ACP. For continuous operation of the rapping motors, the programmer is by passed through a switch. Thermal over load relay is provided for over load protection to the rapping motors. Local push buttons are available for tripping the motors to meet the exigencies and for maintenance purposes. Ammeters with selector switches to read line currents of incoming and heating element feeders are provided. Indicating lamps are provided for 'Main Supply ON', 'Programmers ON', Local Push Bottom Actuated', 'Space Heater ON', and 'Control Supply ON".
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INTERLOCKS & PROTECTIONS: i). Interlocks: 1. Time to build up current initially upto : 60 10 secs. lm set value 2. Rate of current build up with T/O control : 10 2 secs. 3. Duration of blocking at each spark 4. Control circuit is energized 5. Supply to Thyristor is connected : 20 5 secs. : When HT interlock switch is closed. : When the main contractor is closed. A mechanical key interlock scheme is provided for the precipitator to ensure adequate safety of the operating personnel. The design of the system guards against inadvertent contact of the live HV system by personnel. Although master keys to bypass the interlock sequence are supplied, the same shall be used only under exigencies. The master keys shall be in possession of the AEE/General. Attempts shall never be made to bypass the interlock. ii). Protection: a) Short Circuit Protection: By under voltage relay 10 to 50% of primary volts with time delay from 10 to 80 secs. adjustable. b) Overload protection insulators: The chopper outlet shall be kept open for easy discharge of water without stagnation in the hopper. The water shall be free from chloride or chemicals which may cause corrosion. c) Main contactor trips in control panel of the following reasons i) Under voltage for more than preset time (10 to 80 sec. adjustable) ii) Thermal overload iii) Transformer oil temperature High-High iv) Operation of Bucholtz bottom relay The following faults initiate alarm
i) Bucholz top float acted ii) Transformer temperature High
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OPERATION GUIDE LINES: 1. Air load Test: The EP air load test is normally carried out after boiler overhaul, during which, water washing of EP or other maintenance work would have been carried out. This test will reveal any left out debris / handing pieces which may limit the applied voltage or result in short circuit of the field. The healthiness of insulators and electronic controller will also be tested, before actual operation on dust load. The procedure for conducting the test is given below:
a) Remove all temporary earth connections made with discharge rods. b) Close all insulator housing, disconnecting switch and inspection doors,
adopting the interlock sequence and return the key to the electronic controller.
c) Check the IR value of individual field, preferably with 2.5 KV

Megger.
d) Extend supply to Auxiliary control panel and ICE. e) Switch on all rapping motors on continuous mode f) Switch on ICE and slowly raise current. Note the meter readings in steps
of 50 mA DC. Raise upto rate current of 1000 mA and watch for any spark or flash over.
g) The rapping motors are to be changed to intermittent rapping mode after

taking the voltage and current readings.
h) Keep all the fields energized for about 8 hrs. i) Then switch off the system
2. During Start up:
a) Since the precipitator will contain moisture, it is essential to give the

precipitator sufficient time to heat up and dry out prior to operation. Switch on the heaters at least before 24 hrs. before light up.
b) The rapping motors shall be switched on before the gas is passed

through. Hence the rapping mechanisms shall be kept in service as soon the boiler is lighted up. c) Initially the system will be put in continuous mode, and the ESP operator shall go round locally to personally see that all the rapping motors are in service. Then the system shall be selected for intermittent operation.
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d) The frequency and sequence of rapping of collecting and emitting electrodes have been programmed by the synchronous programmer / master controller. Any change in the above shall be carried out, by the maintenance Engineer, if required, based on experience. e) Too high a rapping frequency will dislodge the dust layer before formation of agglomerates resulting in re-entrainment and puffs through the stack. f) The oil firing or mixed firing with predominantly oil as fuel, can have an important impact on precipitator operation. Unburnt oil, if passed through EP, seen as black smoke through the stack, can get coated in the collecting / emitting electrodes. This reduces the precipitator operating voltage due to high electrical resistivity and consequently the EP performance deteriorates. g) For a few days, till the oil coating is rapped off, or leaves off EP as vapour, keep the current setting at a low value in order to prevent the unbumt oil in EP causing fire hazard due to flash over. h) If the precipitator is energized in cold condition, with high moisture content the ash coming along with flue gas may form deposits in electrodes as ashcake which will be difficult to dislodge. Hence it is preferable to charge the EP after the flue gas temperature reaches about 100 deg. C after APH. SCAPH shall be kept in service suitably to achieve this temperature, before cutting in milling system. i) The optimum amperage setting depends upon various factors such as flue gas conditions, dust concentrations etc. If the system is on charge ratio 'one', then the following setting is preferred. Field Current in mA 1 150 2 300 3 450 4 5 6 900
600 750
j) However on semi pulse mode on different charge ratios, the

optimum voltage / precipitator current will be selected automatically by ICE.
k) The preferable setting for the charge ratios for the fields will be as
follows Field Charge ratio 1 1 2 3 3 5 4 7 5 11 6 15
l) In the ICE-panel, the following controls are available
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i) Three digit display of measured or set value of the parameter being

monitored or controlled.
ii) System health indication by flickering LED. iii) One digit for 'Display Select' number iv) Increment / Decrement push buttons for changing the 'Display Select" v) Fire LED indications for alarms and one LED each for 'Peak Reached'
and 'Remote' command.
vi) To control push button for fast increase of EP current. vii) Reset push button for alarm reset. viii) HT 'ON', 'OFF' push button for ON/OFF. ix) Push button for "Peak Mode" ON/OFF. x) 'Current limit', setting by potentiometer xi) Remote or local selection by switch. xii) Non-reset table six digit counter for Accumulates sparks. m) For switching on the system, after selecting 'local', get parameter no.1
and set the current limit potentiometer. Then push the HT ON/OFF switch so that the LED in the switch lights. The contractor switches 'ON' and the precipitator voltage and current start increasing.
n) Push the `To' switch so that the LED in the switch lights. The `To'
function is automatically stopped after 5 secs time or after one more pushing 'ON'switch.
o) Push the 'Peak mode' ON/OFF switch so that the LED in the switch
glows. This is selected during back corona conditions.
p) The following displays are available in ICE.
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Precipitator Curi. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. i. rent Precipitator Voltage Sparks per min I m limit I S limit S control T control Slope after spark UV limit Charge ratio Pulse current limit Loop gain Address -E -m -0 -1 -2 -3 -4 -5 -6 -7 -8 -9
q. The following alarm indications are available in ICE. Transformer temperature high ii. Bucholtz top float acted. iii. Bucholtz bottom float acted iv. Under voltage v. Th-overload/Tr.temperature very high vi. V-peak reached vii. Remote IMPORTANT: i. All line clears are returned and cancelled, with men and material cleared. ii. The earth connections provided have been removed. iii. The mechanical interlock keys for the an-hole doors are returned and the panels are ready for switching on, with these keys. iv. The isolator at the top of EP are closed. v. Rapping motors and heaters are in service. vi. Milling system has just been cut in/or in the process of taking into service. vii. Ash water is available for wetting pots with sufficient pressure and quality. viii. The ash hopper plate gates are open.
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SHUT DOWN OF EP:
a. The Eps should not be switched off immediately on tripping of boiler or shut
down of the unit.
b. The HV rectifier transformer, ICE can be switched off, after about 4hrs. from
the time of boxing up of boilller or when the flue gas temperature at APH outlet drops to 10 deg C.
c. The rapping motors and the heaters will be in service till the ash in hoppers is fully
evacuated as reported by ah handling staff. Allow at least 8hrs for evacuating the ash from hoppers.
d. Then switch off the heating supply and rapping motors. e. Before switching off the rapping motors, keep in 'continuous mode' for about 30
mts.
f. When the precipitator internals are sufficiently cooled down to a safe level, the
man hold doors can be opened by maintenance staff, after availing line clear. PROCEDURE FOR WATER WASHING: The opening to the shaft insulators and support insulators shall be covered prior to water washing to avoid any direct flushing on the inside of the quality of the effluent shall be analyzed and recorded for future reference. The water pressure for flushing shall be about 3 kg/cm. The water shall be sprayed to the internals through a nozzle. Fire service hoses and nozzles can be employed and care should be taken to avoid direct hitting of water jet on the elements and plates. The flushing shall commence from the top of internals and proceed towards the bottom. All the fields in the casing shall be flushed without stopping in the middle. If a field is left unflushed, high humidity inside the casing may leave sticky deposit in that field. After completion of the water washing process the field should be dried, by keeping ID fans in service, preferably with FD fans and all EP man hold doors closed. The fields should be meggered and cleared for charging well advance, before lighting up boiler.
SOOT BLOWER SYSTEM
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CHAPTER - 6
SOOT BLOWER SYSTEM INTRODUCTION: Whenever fossil fuels are burnt they leave a combustion residue broadly known as ash. The fouling of the boiler by fly ash assumes several forms.
i) Fused ash or slag deposits can occur on water walls and other surfaces exposed
to high gas temperature
ii) Sintered ash deposits on the convection surfaces, though the temperature of the
gas in the area is far less than the ash softening temperature.
iii) Fuel oil ash: The main constituents which cause troubles are the sulphates and
Vanadium pentoxides. These compounds have low melting temperatures to form a thin coating on the tubes. The effects of the deposits are:
i) Reduction in heat transfer as the ash deposits act as an insulator. The pattern of
heat transfer in various areas in the boiler will vary from the design aspects.
ii) Accumulation of deposits on the tube banks may block the flue gas path and
hence increase the draft loss in the flue gas flow.
iii) Corrosion of the tubes due to the corrosive components of ash. iv) Slag accumulation at the burner mouth may affect the combustion / distribution of
fuel in the furnace.
v) In order to remove the ash / slag, which the boiler is in service, the soot blowers
are employed. WALL BLOWERS: These are used for cleaning the furnace water walls. The wall blower consists
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SOOT BLOWER SYSTEM
of a stationary body and rack housing and a traveling gearbox to which the swivel tube is attached. When the blower is started, the rack pinion moves the rack and rotary gearbox towards the boiler. Operation of the traveling gear cause rotation of the shaft-extending out from the rack gear housing. In the near fully extended position the rack strikes the cam, operating the lever than opens the valve head. At this position, the traverse motor is stopped and rotary motor is started to admit steam blowing. When the blowing sweep is finished, the cam on the swivel actuates limit for the traversing motor to start, for retraction of the blower. Once the retraction process is started, the lever is actuated for closing the steam valve head. LONG RETRACTABLE SOOT BLOWERS: These blowers are normally employed for cleaning the superheater and reheater zones of the boiler, where the flue gas temperature would be more than 780 deg C. The complete assembly of the soot blower is enclosed in the supporting case. The supporting case forms the base of the blower, which is connected to the wall box through a lance and yoke bearing assembly. As the start push button is pressed, or start pulse is initiated from the control panel, the lance tube begins to extend and rotate. When the nozzle moves inside the boiler wall, the carriage strikes the 'V' shaped lever, opening the valve head, thus admitting steam for blowing. At the fully extended position, the traveling carriage strikes the reverse limit switch, and the blower starts retracting. During the course of retraction also steam is admitted for cooling the tube and cleaning the ash. APH SOOT BLOWERS: Each air preheater is provided with 2 Nos. soot blowers. APH soot blowers are required to be operated during the initial period of firing of the boiler, using furnace oil, in order to clear the unburnt oil soot. Therefore there is provision for using either auxiliary steam from PRDS header or the self-steam from the tenth header through the soot blowing PRS header. There are pneumatic control valves provided for admission of steam, to the soot
SOOT BLOWER SYSTEM
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blowers. STEAM FOR SOOT BLOWERS: The steam required for soot blowing is taken from superheater header 10 (SHH 10). The pressure control valve employed for reducing the pressure from 150 Kg/Sq.cm. to about 22 Kg/Sq.cm. is a self -regulating valve. Its pressure is set at 22 Kg/Sq.Cm. The safety valve is set at 42 Kg/ Sq.Cm. For air preheater, steam is taken from superheater header 10 and APRDS, with suitable NRV's. The drain valves provided, in the soot blower system, as selfregulating temperature control valves. The valves are provided in the line so as to prevent condensed water particles, entering the soot blowers and causing erosion of pressure parts. Initially, the line should be suitably warmed up through these valves to avoid water hammering and consequent damages. There is one hand operated isolation valve provided in the steam line taken from 10th header for soot blower system. The hand valve is followed by an electrically operated isolated valve which can be operated from the control room. The selfregulation pressure control valve reduces the pressure to the required level. There is a flow measuring orifice provided after the pressure control valve to measure the steam flow. As it is to be ensured that the long retractable soot blowers are cooled sufficiently by the steam flowing through the same, the flow through the soot blowers has to be kept above a set value. Similarly the pressure in the system should be equal to the prescribed limits. As already explained, no moisture / condensate should enter the blowers. Hence the drain temperature should be about 200 deg C. These are to be checked before starting soot blower operation. In case, during operation of soot blowers, if the pressure or steam flow falls below the set value, the soot blower will retract automatically. LINE UP AN D O P E R AT I O N OF W AL L BLOWERS AN D LR
BLOWERS SYSTEMS: 1. As far as possible, the boiler to be cleaned should be operating at or over the maximum control load, say > 180 MW. When soot blowers are operated at low boiler loads, clouds of soot may be blown into the gas stream to form explosive mixtures which may be ignited by the heat from the furnace walls or by smoldering soot fires. Soot blower operation at low boiler load, may result in
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SOOT BLOWER SYSTEM
colder furnace, leading to flame instability. Some of the unburnt combustibles escaping from the furnace may collect in pockets in the second passes, getting ignited at times, resulting in secondary combustion. 2. Soot blowers should be used with the burners operating at the higher possible burning rate maintaining even and stable combustion. Soot blowing schedules should take place during the heaviest load periods, or the burner firing rates should be increased during soot blowing. 3. Before operating soot blowers the furnace draft shall be increased by suitably loading the ID fans, if on manual control. The furnace draft setting can be increased slightly, if on auto control. Increased furnace draft improves cleaning by moving soot particles through gas passes rather than redepositing them on adjacent surfaces. 4. The normal sequence for operation of LR blower is to follow the gas flow through the boiler. The first soot blower to be operated should be nearest the burners then in turn along the gas patch to complete the cleaning cycle. 5. In case of wall blowers operate the wall deslaggers at the highest elevation first and then follow downwards, so that, heavy slag's dislodged and deposited at lower elevation will be cleared by further soot blowing operation and fall to the ash hopper due to its weight. 6. For Air preheaters: a. During start up when pressure of main steam at boiler outlet is less than 50 Kg/Sq.Cm, it is preferable to operate the air preheaters shoot blowers from auxiliary steam system. i. Keep the system warmed up by opening the drains to IBD. After warming up close the drain valves. ii. Ensure that the isolation valves for drawing steam from 10 th header are closed. iii. Check that the supply for the APH soot blowers are switched ON. iv. Check that instrument air supply is available for the pneumatically operated steam valves. v. Select the operation of APH soot blower from remote control panel on auto or from FKB (CRT operation), as per operating instructions. vi. On completion of the soot blowers operation, close the steam
SOOT BLOWER SYSTEM
Page 94
isolation valves. b. After attaining stable boiler operation say after MS pressure of 50 kg/ sq.cm, the self-steam from tenth header can be utilized for soot blower operation. This is to ensure that sufficient degree of superheat is available for soot blowers. i. Check that isolation valves to the drain temperature control valves are open.
ii. Ensure instrument air supply to the drain temperature control valves. iii. Check that the 'BELLS' control valve operation set point is set at 200
deg. C so that the drain valves will close as and when the set value is reached.
iv. Check that the pressure control valve is in operating condition with
instrument air supply available.
v. Open the hand isolation valve at the soot blower pressure reducing
station. vi.Open the electrical isolation main valve from UCB.
vii. Check that the isolation valve to LR and wall blowers is kept closed. viii. Check that the isolation valve in the auxiliary steam line to APH soot
blowers is kept closed.
ix. Ensure that the APH soot blowers are ready for operation as already
discussed.
x. Operate the blowers on auto mode from control panel (UCB) or from
FKB.
xi. On completion of operation of APHSB close the electrical isolation valve

from UCBA and hand valve at the soot blower PRS. 7. For LR Blowers/Wall blowers: Normally LR/Wall blowers are operated above 180 MW. So there is no provision available for operating these blowers from auxiliary steam system.
i. Check that the drain temperature control valves are available for service, the
instrument air supply.
ii. While LR/Wall blowers operated, check that the isolation valve to APH soot
blowers is kept closed.
iii. Open the hand valve to LR/Wall blowers steam line.
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SOOT BLOWER SYSTEM
iv. Open the hand valve and electrical isolation valve in the soot blower PRS and wait
for the drain temperature to pick up. v. Check that the pressure control valve is maintaining the set pressure, say 25 kg/ sq.cm. vi. Check that the steam flow meter and pressure switch are available for service. vii. Now operate the LR/Wall blowers as per the operating instructions. viii. During operation TA/Boiler 18m will supervise the operations, along with the boiler maintenance staff so that any problem faced will be brought to the knowledge of the boiler operator. ix. Any blower got mechanically jammed shall be retracted manually after switching off the power supply. x. If left unattended for longer duration or operated without sufficient steam flow, the LR blower lance tube shall get bent, and manual retraction will not be possible. xi. After completion of the operations, the hand valve and the electrical isolation valve shall kept closed. xii. It is preferable to switch off the electrical supply modules after completion of soot blowing. xiii. It shall be physically verified that no blowers is left inside partially or fully, after each soot blower operation. 8. The wall blowers and L/R blowers shall be operated as per the schedule given below, if units IV and V are available in service. 1. Monday 2. Tuesday 4. Thursday 5. Friday 6. Saturday - Wall blowers Unit I & II - Wall blowers Unit II LRSB Unit.I - Wall blowers Unit II LRSB Unit.II - Wall blowers Unit I & III - Wall blowers Unit II LRSB Unit.III
3. Wednesday - Wall blowers Unit I & III
8. Whenever reheat temperature is going high even after tilting down the
burners, then the operation of the wall blowers can be restored to, for temperature control.
SOOT BLOWER SYSTEM
Page 96
9. S O O T
BLOW E R
CO NTRO L
O PE R ATI NG
P RO CE DURE
FRO M
CONTROL PANEL (UCB): 1. ENABLE OPERATION: The purpose of the ENABLE is to make a soot blower available for service for reasons of operator preference or after maintenance or repair. To enable a soot blower dial the blower number on 'Thrust Wheel Switch', press the EXECUTE push button and ENABLE push button. To verify enabling of soot blower, press ENABLE CHECK push button. MIMIC diagram lights will glow for all the blowers enabled. 2. DISABLE OPERATION: The purpose of the Disable is to make a soot blower unavailable for service. To disable a soot blower dial the blower number on 'Thrust Wheel Switch', press the EXECUTE push button and DISABLE push button. To verify disabling of soot blower, press DISABLE CHECK push button. MIMIC diagram lights will glow for all the blowers disabled. 3. MANUAL START: For manual start of a blower a. MANUAL START push button light should be ON b. Blower must be enabled. MANUAL START push button will be on if following conditions are satisfied. a. LOCAL/REMOTE switch is in remote position. b. No fault in system The faults provided are i. Blower over run ii. Steam pressure low iii. Steam flow low iv. Sequence interrupted v. Blower motor over run vi. Valve motor over run vii. LR blower mech jam. c. No auto sequence selected d. Main valve position open e. All blowers in initial position
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SOOT BLOWER SYSTEM
For manual start of any blower dial blower number on 'Thumb wheel switch' press EXECUTE push button and manual start push button till manual start push button light goes out. 4. AUTOMATIC SOOT BLOWING OPERATION: Each automatic program consists of a group of blowers arranged to operate in sequential steps. a. Sequence P1 b. Sequence P2 c. Sequence P3 d. Sequence P4 e. Sequence P5 - Blowers 1 to 78 - All wall blowers 1 to 56 - All LR blowers 59 to 74 - All APH blowers 75 to 78 - All future provision blowers FPI to
f. Sequence P6 to P9 spare SELECTION OF AN AUTOMATIC PROGRAM - SEQUENCE A desired sequence can be selected by pressing the program select push button. 'Program Select' push button light will glow. Only one sequence can be selected at a time. 'Program operating' display indicates the number of the program in operation or the last program performed. During switching ON of the power supply this lamp will reset to 'Zero'. STARTING OF AN AUTOMATIC PROGRAM: An automatic program can be started if the following conditions are satisfied. i. Local/Remote switch in remote position. ii. No fault in system iii. All blowers in initial position iv. Main valve in open position. To start an automatic program press and hold the designed 'Program Select' push button and 'Start Program' push button until. i. Start program push button light glows. ii. Manual start push button light turns off. iii. Reset push button light turns off. iv. 'Program operating' will display the number of the selected sequence.
SOOT BLOWER SYSTEM
Page 98
Completion of an automatic sequence will have the following effects. i. Start program push button will go off. ii. Reset push button light will be ON. iii. Manual start push button will be ON. iv. Program operating display will indicate the number of the program last operated. STOPPING OF AN AUTOMATIC SEQUENCE: An automatic sequence gets interrupted before completion, if there is a fault in the system. Program operation will remain suspended at that particular step where fault has occurred. In the event of a fault the following indications will be there. i. Corresponding alarm lamp on mimic will be ON. ii. Lamp on the mimic diagram will flash showing the exact step where the fault has occurred. The fault can be reset by pressing the reset push button after fault is cleared. RESTART OF THE SEQUENCE: Any program which has been stopped before normal completion due to fault may be restarted from the next stem from where it was stopped after resetting the fault by pressing 'program select' push button and 'start program' push button. RESET OF AN AUTOMATIC PROGRAM: Any program which has been stopped before normal completion of that program or an undersigned program already selected, can be reset to the beginning of the program by pressing and holding its 'program sequence' push button and `reset' push button until program select push button light goes off. SEQUENCE CHECK: Before starting of an automatic program, to know the blowers selected in that sequence, press and hold the 'Program select' push button and 'Sequence check' push button. On mimic diagram lights will be ON for all the blowers put in that sequence. Release of any push button will terminate the check.
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SOOT BLOWER SYSTEM
PROGRAM CHECK: Program check is done in the middle of an automatic program. To do so press and hold 'Program select' push button and 'Program check' push button. On mimic diagram lights will glow steadily for all blowers that have already been operated, and light will flash for all blowers, that have not yet been operated. Releasing of any push button will terminate the check.
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Basics of Thermal Power Plant

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Basics of Thermal Power Plant

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Page 1

Thermal Training Institute

Thermal Training Institute

CONTENTS CHAPTER 01 02 DESCRIPTION STEAM GENERATOR PAGE 3

AIR PREHEATING SYSTEM DRAUGHT SYSTEM

FUEL FIRING SYSTEM

SOOT BLOWER SYSTEM

Thermal Training Institute

Thermal Training Institute

Thermal Training Institute

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AIR PRE HEATING SYSTEM

AIR PRE HEATING SYSTEM

Thermal Training Institute

AIR PRE HEATING SYSTEM

Thermal Training Institute

AIR PRE HEATING SYSTEM

Thermal Training Institute

AIR PRE HEATING SYSTEM

Thermal Training Institute

AIR PRE HEATING SYSTEM

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FUEL FIRING SYSTEM

FUEL FIRING SYSTEM

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FUEL FIRING SYSTEM

Thermal Training Institute

FUEL FIRING SYSTEM

Thermal Training Institute

FUEL FIRING SYSTEM

Thermal Training Institute

FUEL FIRING SYSTEM

Thermal Training Institute

FUEL FIRING SYSTEM

Thermal Training Institute