POINTS OF DISCUSSION

SUB CRITICAL & SUPER CRITICAL BOILER SIPAT BOILER DESIGN BOILER DESIGN PARAMETERS

CHEMICAL TREATMENT SYSTEM

OPERATION FEED WATER SYSTEM

BOILER CONTROL
BOILER LIGHT UP START UP CURVES

WHY SUPER CRITICAL TECHNOLOGY

To Reduce emission for each Kwh of electricity generated : Superior Environmental

1% rise in efficiency reduce the CO2 emission by 2-3%

The Most Economical way to enhance efficiency To Achieve Fuel cost saving : Economical Operating Flexibility Reduces the Boiler size / MW To Reduce Start-Up Time

UNDERSTANDING SUB CRITICAL TECHNOLOGY Water when heated to sub critical pressure, Temperature increases until it starts boiling This temperature remain constant till all the water converted to steam When all liquid converted to steam than again temperature starts rising. Sub critical boiler typically have a mean ( Boiler Drum) to separate Steam And Water The mass of this boiler drum, which limits the rate at which the sub critical boiler responds to the load changes Too great a firing rate will result in high thermal stresses in the boiler drum

Role of SG in Rankine Cycle

Perform Using Natural resources of energy .

UNDERSTANDING SUPER CRITICAL TECHNOLOGY

When Water is heated at constant pressure above the critical pressure, its temperature will never be constant No distinction between the Liquid and Gas, the mass density of the two phases remain same No Stage where the water exist as two phases and require separation : No Drum The actual location of the transition from liquid to steam in a once through super critical boiler is free to move with different condition : Sliding Pressure Operation

For changing boiler loads and pressure, the process is able to optimize the amount of liquid and gas regions for effective heat transfer.

Circulation Vs Once Through

No Religious Attitude

540C, 255 Ksc

568C, 47 Ksc
FUR ROOF I/L HDR

492C, 260 Ksc 457C, 49 Ksc

ECO HGR O/L HDR

HRH LINE MS LINE 411C, 277Ksc

411C, 275 Ksc

SEPARATOR
S T O R A G E T A N K HPT

FINAL SH FINAL RH DIV PANELS SH PLATEN SH LTRH

VERTICAL WW 305C, 49 Ksc

ECO JUNCTION HDR

G
LPT
C O N D E N S E R

LPT

IPT

ECONOMISER

ECO I/L

BWRP

FEED WATER

290C, 302 KSC

FUR LOWER HDR

FRS

Steam

Partial Steam Generation Steam

Complete or Once-through Generation

Heat Input Heat Input Water

Water Water

Boiling process in Tubular Geometries

SEPARATOR TANK

PENTHOUSE

Eco. O/L hdr (E7)

LTRH O/L hdr (R8)

2nd pass top hdrs (S11) Back pass Roof o/l hdr (S5)

SH final I/L hdr (S34)

1st F19 pass top hdrs

SH final O/L hdr (S36)

RH O/L hdr (R12)

RH I/L hdr (R10) F28 Platen I/L hdr (S28) Div. Pan. I/L hdrs (S20) Back pass Roof i/l hdr Separator (F31) F8 S2 F28 Div. Pan. O/L hdrs (S24)

Platen O/L hdr (S30)

1st pass top hdrs

Storage Tank (F33)

SIPAT SUPER CRITICAL BOILER

BOILER DESIGN PARAMETER DRUM LESS BOILER : START-UP SYSTEM

TYPE OF TUBE
Vertical Spiral

SPIRAL WATER WALL TUBING Advantage Disadvantage over Vertical water wall

Vertical Tube Furnace

To provide sufficient flow per tube, constant pressure furnaces employ vertically oriented tubes. Tubes are appropriately sized and arranged in multiple passes in the lower furnace where the burners are located and the heat input is high. By passing the flow twice through the lower furnace periphery (two passes), the mass flow per tube can be kept high enough to ensure sufficient cooling. In addition, the fluid is mixed between passes to reduce the upset fluid temperature.

Spiral Tube Furnace

The spiral design, on the other hand, utilizes fewer tubes to obtain the desired flow per tube by wrapping them around the furnace to create the enclosure. This also has the benefit of passing all tubes through all heat zones to maintain a nearly even fluid temperature at the outlet of the lower portion of the furnace. Because the tubes are wrapped around the furnace to form the enclosure, fabrication and erection are considerably more

complicated and costly.

SPIRAL WATER WALL

ADVANTAGE Benefits from averaging of heat absorption variation : Less tube leakages Simplified inlet header arrangement

Use of smooth bore tubing

No individual tube orifice Reduced Number of evaporator wall tubes & Ensures minimum water flow Minimizes Peak Tube Metal Temperature

Minimizes Tube to Tube Metal Temperature difference

DISADVANTAGE Complex wind-box opening Complex water wall support system tube leakage identification : a tough task More the water wall pressure drop : increases Boiler Feed Pump Power Adherence of Ash on the shelf of tube fin

BOILER OPERATING PARAMETER

FD FAN 2 NoS ( AXIAL ) 11 kv / 1950 KW 228 mmwc 1732 T / Hr PA FAN 2 Nos ( AXIAL) 11 KV / 3920 KW 884 mmwc 947 T / Hr ID FAN TOTAL AIR SH OUT LET PRESSURE / TEMPERATURE / FLOW RH OUTLET PRESSURE/ TEMPERATURE / FLOW SEPARATOR OUT LET PRESSURE/ TEMPERATURE ECONOMISER INLET MILL OPERATION COAL REQUIREMENT SH / RH SPRAY BOILER EFFICIENCY 2 Nos ( AXIAL) 11 KV / 5820 KW 2535 T / Hr 256 Ksc / 540 C 2225 T / Hr 46 Ksc / 568 C 1742 T / Hr 277 Ksc / 412 C 304 Ksc / 270 C 7 / 10 471 T / Hr 89 / 0.0 T / Hr 87 % 3020 T / Hr

Coal Analysis
Parameter High Heating Value Total Moisture Proximate Volatile Matter Analysis Fixed Carbon Ash Fuel Ratio (FC/VM) Combustibility Index Carbon Hydrogen Nitrogen Ultimate Analysis Oxygen Sulfur Ash Moisture Grindability ASTM Coal Classification Unit kcal/kg % % % % % % % % % % % HGI Design Coal 3,300 12.0 21.0 24.0 43.0 1.14 2,067 39.53 2.43 0.69 6.64 0.45 43.00 12.00 50 HiVol. C Bituminous Worst Coal 3,000 15.0 20.0 20.0 45.0 1.00 2,353 31.35 2.30 0.60 5.35 0.40 45.00 15.00 47 HiVol. C Bituminous Best Coal 3,750 11.0 24.0 29.0 36.0 1.21 2,476 40.24 2.68 0.83 8.65 0.60 36.00 11.00 52 HiVol. C Bituminous Young Hung #1,2(800MW) 6,020 10.0 23.20 52.89 13.92 2.28 2,781 63.03 3.60 1.53 7.20 0.72 13.92 10.00 45 Midium Vol. Bituminous Tangjin #5,6(500MW) 6,080 10.0 26.53 49.26 14.21 1.86 3,492 62.15 3.87 1.29 7.80 0.68 14.21 10.00 48 HiVol. C Bituminous

1.

High erosion potential for pulverizer and backpass tube is expected due to high ash content.

2. Combustibility Index is relatively low but combustion characteristic is good owing to high volatile content.

Ash Analysis
Parameter SiO2 Al2O3 Fe2O3 CaO Ash Analysis MgO Na2O K2O TiO2 P2O5 SO3 Others Ash Fusion Temp. (oC) (Reducing Atmos.) Ash Content Basic / Acid Initial Deformation Softening Hemispheric Flow Unit % % % % % % % % % % %
o o o o

Design Coal 61.85 27.36 5.18 1.47 1.00 0.08 0.63 1.84 0.54 0.05 1150 1400 1400 130.3 0.09

Worst Coal 62.40 27.31 4.96 1.42 1.03 0.08 0.32 1.88 0.55 0.05 1100 1280 1280 150.0 0.09

Best Coal 61.20 27.32 5.40 1.52 0.97 0.08 1.22 1.80 0.44 0.05 1250 1400 1400 96.0 0.10

Young Hung Tangjin #1,2(800MW) #5,6(500MW) 57.40 29.20 4.40 2.70 0.90 0.30 0.70 1.30 3.10 1200 57.40 29.20 4.40 2.70 0.90 0.30 0.70 1.30 3.10 1200

1.

Lower slagging potential is expected due to low ash fusion temp. and low basic / acid ratio.

C C C C

2. Lower fouling potential is expected due to low Na2O and CaO content.

kg/Gcal B/A

23.12 1.63

23.37 1.63

AIR AND FLUE GAS SYSTEM

AIR PATH : Similar as 500 MW Unit

FLUE GAS PATH : No Of ESP Passes No Of Fields / Pass : : 6 Pass 18 1-7 fields 70 KV. 8&9 field 90 KV

No Of Hopper / Pass
Flue Gas Flow / Pass

:
:

36
1058 T/ Hr

M M

TO PULVERISER SYSTEM

PA FAN # A

PAPH # A
M

HOT PRIMARY AIR DUCT

AIR MOTOR

AIR MOTOR

SAPH # A

FD FAN # A
M M M M

SAPH # B
M

AIR MOTOR

PAPH # B
M

HOT PRIMARY AIR DUCT TO PULVERISER SYSTEM

PA FAN # B

LHS WIND BOX

FURNACE
FINAL SUPERHEATER DIVISIONAL PANEL FINAL REHEATER PLATEN COILS ECONOMISER BACK PASS LTRH

RHS WIND BOX

FD FAN # B

AIR MOTOR

AIR PATH

FUEL OIL SYSTEM

Type Of Oil : LDO / HFO

Boiler Load Attainable With All Oil Burner In Service

Oil Consumption / Burner Capacity Of HFO / Coal Capacity Of LDO / Coal HFO Temperature

:
: : : :

30 %
2123 Kg / Hr 42.1 % 52.5 % 192 C

All Data Are At 30 % BMCR

DESIGN BASIS FOR SAFETY VALVES :

1. Minimum Discharge Capacities. Safety valves on Separator and SH (excluding power operated impulse safety valve) Combined capacity 105%BMCR

Safety valves on RH system

(excluding power operated impulse safety valve)

Combined capacity 105% of Reheat flow at BMCR

Power operated impulse safety valve

40%BMCR at super-heater outlet 60% of Reheat flow at BMCR at RH

outlet

2. Blow down

4% (max.)b

BOILER FILL WATER REQUIREMENT

Main Feed Water Pipe ( FW Shut Off Valve to ECO I/L HDR) Economizer Furnace ( Eco Check Valve to Separator Link) 28.8 m3 253.2 m3 41.5 m3

Separators & Link

13.8 m3

OXYGENATED TREATMENT OF FEED WATER

WATER CHEMISTRY CONTROL MAINTAINS PLANT HEALTH.

Dosing of oxygen(O2) or Hydrogen peroxide in to feed water system.

Concentration in the range of 50 to 300 g/L. Formation of a thin, tightly adherent ferric oxide (FeOOH) hydrate layer.

(H2O2)

This layer is much more dense and tight than Magnetite layer.

that of

39

All Volatile Treatment

Oxygenated Water Treatment

40

DOSING POINTS

41

AVT Dosing Auto Control

42

OWT Dosing Auto Control

43

FUR ROOF I/L HDR VENT HDR N2 FILL LINE

SAMPLE COOLER

U#1
VENT HDR N2 FILL LINE
SAMPLE COOLER

WATER LINE N2 FILLING LINE VENT LINE DRAIN LINE SAMPLE COOLER LINE

SEPRATOR #1

SEPRATOR #2

2 VENT HDR

VENT HDR

FUR WW HDR

FUR INTERMITTENT HDR

STORAGE TANK DRAIN HDR

FUR BOTTOM RING HDR

DRAIN HDR FLASH TANK

MIXING PIECE VENT HDR WR ZR

BACK PASS ECO O/L HDR

N2 FILL LINE

ECO JUNCTION HDR

BRP

ECO MIXING LINK

BACK PASS ECO I/L HDR BLR FILL PUMP FROM FEED WATER

TO DRAIN HDR

WATER CIRCULATION SYSTEM

FEED WATER SYSTEM

MODES OF OPERATION
1. BOILER FILLING

2.

CLEAN UP CYCLE

3.

WET MODE OPERATION (LOAD < 30 % )

4.

DRY MODE OPERATION (LOAD > 30 %)

5.

DRY TO WET MODE OPERATION ( WHEN START UP SYSTEM NOT AVAILABLE)

BOILER FILLING LOGIC

If the water system of the boiler is empty (economizer, furnace walls, separators), then the system is filled with approximately 10% TMCR ( 223 T/Hr) feed water flow. When the level in the separator reaches set-point, the WR valve will begin to open. When the WR valve reaches >30% open for approximately one minute, then increase feed water flow set-point to 30% TMCR ( approx 660 T/Hr). As the flow increases, WR valve will reach full open and ZR valve will begin to open. The water system is considered full when: The separator water level remains stable for two(2) minutes and The WR valve is fully opened and ZR valve is >15% open for two(2) minutes After completion of Filling, the feed water flow is again adjusted to 10 % TMCR for Clean up cycle operation

BOILER INITIAL WATER LEVEL CONTROL (UG VALVE)

The boiler circulating pump is started following the start of a feed water pump and the final clean-up cycle.

This pump circulates feed water from the evaporator outlet back to the economizer inlet.
Located at the outlet of this pump is the UG valve which controls economizer inlet flow during the start-up phase of operation. Demand for this recirculation, control valve is established based on measured economizer inlet flow compared to a minimum boiler flow set point.

Boiler Clean-up
When the feedwater quality at the outlet of deaerator and separator is not within the specified limits, a feedwater clean-up recirculation via the boiler is necessary. During this time, constant feedwater flow of 10% TMCR ( 223 T/Hr) or more is maintained. Water flows through the economizer and evaporator, and discharges the boiler through the WR valve to the flash tank and via connecting pipe to the condenser. From the condenser, the water flows through the condensate polishing plant, which is in service to remove impurities ( Like Iron & its Oxide, Silica, Sodium and its salts ), then returns to the feed water tank. The recirculation is continued until the water quality is within the specified limits.

FEED WATER QUALITY PARAMETER FOR START UP

MODE OF OPERATION WET MODE :

Initial Operation Of Boiler Light Up. When Economizer Flow is maintained by BCP.

Boiler Will Operate till 30 % TMCR on Wet Mode.

DRY MODE :
At 30 % TMCR Separator water level will become disappear and Boiler Operation mode will change to Dry BCP Will shut at this load Warm Up system for Boiler Start Up System will get armed

Boiler will turn to once through Boiler

ECO Water flow will be controlled by Feed Water Pump in service

SYSTEM DESCRIPTION ( WET MODE OPERATION)

1. Flow Control Valve ( 30 % Control Valve )

Ensures minimum pressure fluctuation in Feed Water Header

It measures Flow at BFP Booster Pump Discharge and compare it with a calculated flow from its downstream pressure via a function and maintains the difference 0

2. 100 % Flow Valve To Boiler

Remains Closed

3. BFP Recirculation Valve

It Measures Flow at BFP Booster Pump Discharge

Ensures minimum Flow through BFP Booster Pump

Closes when Flow through BFP Booster Pump discharge > 2.1 Cum Open When Flow through BFP Booster Pump Discharge < 1.05 Cum ( Minimum Flow will be determined by BFP Speed via BFP Set limitation Curve)

4. BFP Scoop
It measures value from Storage tank level Transmitter Maintain Separator Storage Tank Level

5. UG Valve
Maintain Minimum Economizer Inlet Flow ( 30 % TMCR = Approx 660 T/Hr) Maintain DP across the BRP ( Approx 4.0 Ksc) It Measures Flow Value from Economizer Inlet Flow Transmitter

6. WR / ZR Valve
Maintains Separator Storage Tank Level It Measures value from the Storage tank Level

7. Storage Tank Level

3 Nos Level Transmitter has been provided for Storage tank level measurement 1 No HH Level Transmitter has been provided At 17.9 Mtr level it will trip all FW Pumps also MFT will act

1 No LL Level Transmitter has been provided At 1.1 Mtr level MFT will Act

SYSTEM DESCRIPTION ( DRY MODE OPERATION)

1. Following System will be isolated during Dry Mode Operation

FCV ( 30 % ) Start Up System Of Boiler WR / ZR Valve Storage Tank BRP BRP Recirculation System

BFP Recirculation Valve

2. Following System will be in service

UG Valve ( Full Open) 100 % FW Valve ( Full Open) Platen / Final Super-heater spray control Start Up System Warming Lines Separator Storage Tank Wet Leg Level Control

SYSTEM OPERATION ( DRY MODE OPERATION)

1. START UP SYSTEM
In Dry Mode Start Up System Of Boiler will become isolated Warming System for Boiler Start Up system will be charged Separator Storage Tank level will be monitored by Separator storage tank wet leg level control valve ( 3 Mtr)

2.

TRANSITION PHASE :- Changeover of FW Control valve (30 % to 100 % Control ) 100 % FW Flow valve will wide open During the transition phase system pressure fluctuates The system pressure fluctuation will be controlled by 30 % FW Valve. After stabilization of system 30 % CV Will become Full Close

3.

FEED WATER CONTROL It will be controlled in three steps Feed Water demand to maintain Unit Load Maintain Separator O/L Temperature Maintain acceptable Platen Spray Control Range

FEED WATER DEMAND ( DRY MODE OPERATION)

1. FINAL SUPER HEATER SPRAY CONTROL 2. Maintain the Final Steam Outlet Temperature ( 540 C)

PLATEN SUPER HEATER SPRAY CONTROL Primary purpose is to keep the final super heaer spray control valve in the desired operating range Measures the final spray control station differential temperature It Compares this difference with Load dependent differential temperature setpoint Output of this is the required temperature entering the Platen Super Heater Section (Approx 450 C)

3.

FEED WATER DEMAND 1. FEED FORWARD DEMAND It is established by Boiler Master Demand. This Demand goes through Boiler Transfer Function where it is matched with the actual Evaporator Heat Transfer to minimize the temperature fluctuations FEED BACK DEMAND Work With two controller in cascade mode

2.

FEED WATER DEMAND ( DRY MODE OPERATION)

2. FEED BACK DEMAND Work With two controller in cascade mode FIRST CONTROLLER One Controller acts on Load dependent average platen spray differential temperature Its Output represents the desired heat transfer / steam generation to maintain the desired steam parameters and Flue gas parameters entering the Platen section

SECOND CONTROLLER Second Controller acts on the load dependent Separator Outlet Temperature adjusted by Platen spray differential temperature This controller adjust the feed water in response to firing disturbances to achieve the separator O/L Temperature

THE RESULTING DEMAND FROM THE COMBINED FEEDFORWARD AND FEEDBACK DEMANDSIGNAL DETERMINED THE SETPOINT TO THE FEED WATER MASTER CONTROL SETPOINT

DRY TO WET MODE OPERATION ( START UP SYSTEM NOT AVAILABLE)

1. The combined Feed Forward and Feed back demand ( as calculated in dry mode operation) will be compared with minimum Economizer Flow This ensures the minimum flow through Economizer during the period when start up system is unavailable

2.

Output of the first controller is subjected to the second controller which monitors the Separator Storage tank level ( Since the system is in Wet Mode now)
The output of the second controller is the set point of Feed water master controller. The Feed back to this controller is the minimum value measured before the start up system and Economizer inlet.

3. 4.

WATER & STEAM PATH

BLR PATH ( WHEN WET MODE) Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH HP By-pass - Cold R/H Line - Primary R/H (Lower Temp R/H) - Final R/H - LP Bypass - Condenser BLR Path (When Dry Mode)

Primary Eco - Secondary Eco - Ring HDR - Spiral W/W - W/W Intermediate HDR Vertical W/W - Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH - HP TBN - Cold R/H Line - Primary R/H (Lower Temp R/H)- Final R/H - IP and LP TBN - Condenser

Wet Mode and Dry Mode of Operation

DIV SH

PLATEN SH

FINAL SH

406

451

440 DSH1 15%

486

480 DSH2 3%

540

BOILER LOAD CONDITION Constant Pressure Control Above 90% TMCR The MS Pressure remains constant at rated pressure

The Load is controlled by throttling the steam flow

Below 30% TMCR the MS Pressure remains constant at minimum Pressure

Sliding Pressure Control Boiler Operate at Sliding pressure between 30% and 90% TMCR The Steam Pressure And Flow rate is controlled by the load directly

CONSTANT PRESSURE VS SLIDING PRESSURE

Valve throttling losses occur because the boiler operates at constant pressure while the turbine doesn't. The most obvious way to avoid throttling losses therefore is to stop operating the boiler at constant pressure! Instead, try to match the stop valve pressure to that existing inside the turbine at any given load. Since the turbine internal pressure varies linearly with load, this means that the boiler pressure must vary with load similarly. This is called .sliding pressure operation.. If the boiler pressure is matched to the pressure inside the turbine, then there are no valve throttling losses to worry about! While sliding pressure is beneficial for the turbine, it can cause difficulties for the boiler.

ADVERSE AFFECT
As the pressure falls, the boiling temperature (boiling point) changes. The boiler is divided into zones in which the fluid is expected to be entirely water, mixed steam / water or dry steam. A change in the boiling point can change the conditions in each zone. The heat transfer coefficient in each zone depends upon the pressure. As the pressure falls, the heat transfer coefficient reduces. This means that the steam may not reach the correct temperature. Also, if heat is not carried away by the steam, the boiler tubes will run hotter and may suffer damage.

CHALLANGES The heat transfer coefficient also depends upon the velocity of the steam in the boiler tubes. Any change in pressure causes a change in steam density and so alters the steam velocities and heat transfer rate in each zone.

Pressure and temperature cause the boiler tubes to expand. If conditions change, the tubes will move. The tube supports must be capable of accommodating this movement. The expansion movements must not lead to adverse stresses.
The ability to use sliding pressure operation is determined by the boiler

Boilers can be designed to accommodate sliding pressure.

When it is used, coal fired boilers in the 500 to 1000 MW class normally restrict sliding pressure to a limited load range, typically 70% to 100% load, to minimize the design challenge. Below this range, the boiler is operated at a fixed pressure. This achieves an acceptable result because large units are normally operated at high load for economic reasons. In contrast, when sliding pressure is used in combined cycle plant, the steam pressure is varied over a wider load range, typically 50% to 100% load or more

 As stated, in coal-fired plant, sliding pressure is normally restricted to a limited load range to reduce design difficulties. In this range, the boiler pressure is held at a value 5% to 10% above the turbine internal pressure. Consequently, the governor valves throttle slightly.

The offset is provided so that the unit can respond quickly to a sudden increase in load demand simply by pulling the valves wide open.
This produces a faster load response than raising the boiler firing rate alone.The step in load which can be achieved equals the specified margin ie 5% to 10%.

The throttling margin is agreed during the tendering phase and then fixed.
A margin of 5% to 10% is usually satisfactory because most customers rely upon gas turbines, hydroelectric or pumped storage units to meet large peak loads. The throttling margin means that the full potential gain of sliding pressure is not achieved. Nevertheless, most of the throttling losses which would otherwise occur are recovered.

ADVANTAGES
Temperature changes occur in the boiler and in the turbine during load changes. These can cause thermal stresses in thick walled components. These are especially high in the turbine during constant-pressure operation. They therefore limit the maximum load transient for the unit. By contrast, in sliding pressure operation, the temperature changes are in the evaporator section. However, the resulting thermal stresses are not limiting in the Once through boiler due to its thermo elastic design.

In fixed pressure operation , temperature change in the turbine when load changes, while in sliding-pressure operation ,they change in the boiler

 The enthalpy increase in the boiler for preheating, evaporation and superheating changes with pressure. However, pressure is proportional to output in sliding pressure operation In a uniformly heated tube, the transitions from preheat to evaporation and from evaporation to superheat shift automatically with load such that the main steam temperature always remains constant.

Sliding Pressure
At loads over 25% of rated load, the water fed by a feed-water pump flows through the high pressure feed-water heater, economizer ,furnace water wall, steam-water separator, rear-wall tubes at the ceiling, and super heaters, The super heaters steam produced is supplied to the turbine. At rated and relatively high loads the boiler is operated as a purely once through type. At partial loads, however, the boiler is operated by sliding the pressure as a function of load.

Turbine inlet pressure Mpa

25 20 15 10 5 0 0 25 50 75 100
Turbine load (%)

24.1 Mpa

9.0 Mpa

CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC Boiler Load % 20 +1 Efficiency Change % 0 -1 -2 -3 -4 Variable Pressure 40 60 80 100

Benefits Of Sliding Pressure Operation ( S.P.O)

Able to maintain constant first stage turbine temperature Reducing the thermal stresses on the component : Low Maintenance & Higher Availability No additional pressure loss between boiler and turbine. low Boiler Pr. at low loads.

WHY NOT S.P.O. IN NATURAL/CONTROL CIRCULATION BOILERS

Circulation Problem : instabilities in circulation system due to steam formation in down comers. Drum Level Control : water surface in drum disturbed. Drum : (most critical thick walled component) under highest thermal stresses

The Basis of Boiler Start-up Mode

Mode Basis
Stopped time SH Outlet Temp Separator Tank pr

Starting Time 2Hr Within 465 above 120200/

Restart

Hot
6~12Hr 300 above 30120/

Warm
56Hr Within 100 above 30/ below

Cold
96Hr Above 100 below 0/

STARTING TIME Light off TBN Rolling(minutes)

120 90 30

Startup Mode Cold Warm Hot Restart

Light off Full Load(minutes)

420 180 90
Except Rotor and Chest Warming Time "

PURGE CONDITIONS
No Boiler Trip Condition Exists All System Power Supply Available Unit Air Flow > 30 % BMCR Nozzle Tilt Horizontal and Air Flow < 40 % Both PA Fans Off The Following Condition Exist At Oil Firing System The HOTV / LOTV Should Be Closed All Oil Nozzle Valve Closed The Following Condition Exists at Coal Firing System All Pulverisers are Off All Feeders are Off All Hot Air Gates Of Pulverisers are closed All Flame Scanner on all elevation shows no Flame Aux Air Damper At All Elevation should be modulating

After Purging Boiler Light Up activites are same as in 500 MW plant

MFT CONDITIONS
Both ID Fans Off
Both FD Fans Off Unit Air Flow < 30 % TMCR All Feed Water Pumps Are Off For More Than 40 Sec

2 / 3 Pressure Transmitter indicate the furnace pressure High / Low for more than 8 sec ( 150
mmwc / -180 mmwc)) 2 / 3 Pressure Transmitter indicate the furnace pressure High High / Low - Low ( 250 mmwc / - 250 mmwc) Loss Of Re-heater Protection EPB Pressed All SAPH Off Economizer Inlet Flow Low For More Than 10 Sec (223 T/Hr) Furnace Vertical Wall Temperature High For more than 3 Sec (479 C) SH Pressure High On Both Side (314 KSc) SH Temperature High For More Than 20 Sec ( 590 C) RH O/L Temperature High For More Than 20 Sec ( 590 C) Separator Level Low-Low During Wet Mode ( 1.1 M)

Separator Level High-High During Wet Mode ( 17.7 M)

 MFT Relay Tripped Loss Of Fuel Trip : It Arms when any oil burner proven. it occurs when all of the following satisfied All Feeders Are Off HOTV Not Open or all HONV Closed

LOTV Not Open or all LONV Closed

Unit Flame Failure Trip : It Arms when any Feeder Proves it occurs when all 11 scanner elevation indicates flame failure as listed below ( Example is for only elevation A)

Feeder A & Feeder B is Off with in 2 Sec Time Delay

following condition satisfied Any oil valve not closed on AB Elevation 3 /4 valves not proven on AB Elevation Less Than 2 / 4 Scanner Shows Flame

Both Of The Following Condition Satisfied Less Than 2 / 4 Scanner Flame Shows Flame 2 / 4 Oil Valves not open at AB Elevation

Boiler Light Up Steps

Start the Secondary Air Preheater
Start one ID fan, then the corresponding FD fan and adjust air flow to a min. of 30% TMCR Start the scanner air fan.

Adjust fan and SADC to permit a purge air flow of atleast 30% of TMCR and furnace draft of approx. -12.7 mmWC.
When fans are started, SADC should modulate the aux. air dampers to maintain WB to furnace DP at 102 mmWC(g).

Check that all other purge permissives are satisfied.

Place FTPs in service. Check The MFT Conditions For First Time Boiler Light Up do the Oil Leak Test Initiate a furnace purge.

SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP FURNACE READINESS PRESSURE PARTS SCANNER AIR FAN BOTTOM ASH HOPPER READINESS FUEL FIRING SYSTEM START UP SYSTEM SEC AIR PATH READINESS FD FAN SAPH WIND BOX / SADC FLUE GAS SYSTEM ESP PASS A , B ID FAN

SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP CONDENSATE SYSTEM CONDENSER CEP CPU FEED WATER SYSTEM D/A MDBFP # A VACCUME SYSTEM SEAL STEAM SYSTEM TURBINE ON BARRING

Evaporator heat absorption

Reduced number of evaporator wall tubes. Ensures minimum water wall flow.

SPIRAL WALL ARRAMGEMENT AT BURNER BLOCK AREA :

Support System for Evaporator Wall

Spiral wall

Horizontal and vertical buck stay with tension strip

Vertical wall Horizontal buck stay