GVK POWER (GOINDWAL SAHIB) LIMITED 2x270MW

PUNJAB

FUEL OIL FIRING SYSTEM

BHARAT HEAVY ELECTRICALS LIMITED

1204, 1205; GVK POWER BHARAT HEAVY ELECTRIICALS LIMITED

TIRUCHIRAPPALLI

LIST OF CONTENTS

1. 2. 3. 4. 5. 6. 7.

PRIMARY GUIDANCE OIL BURNERS AND IGNITORS - TECHNICAL DATA PRESSURE AND TEMPERATURE SWITCHES SET POINTS SYSTEM, OPERATION AND CONTROLS OTHER SYSTEM FEATURES LIGHT FUEL OIL PUMPING, HEAVY FUEL OIL PUMPING AND HEATING UNIT FUELOIL SYSTEM BOILER FRONT EQUIPMENT

... ... ... ... ...

3 5 8 13 24

... 26 31

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1. PRIMARY GUIDANCE 1.1 Safety and Fuel Oil Handling An intelligent appreciation of the properties of the fuel is a better preventive of accidents than adherence to any set of rules. Fuel oil is inert, non-explosive, difficult to ignite in bulk and not capable of spontaneous combustion. The vapour is explosive when mixed with air and being heavier than air accumulates in low levels and confined spaces. It is always present in partly filled oil tanks and is given off through the vents from the tanks being filled. Leak in any of the oil burning system may result in an accumulation of this explosive vapour. Ignition of the vapour can be caused by an electric spark, smoking, spark caused by striking metal, the filament of a broken electric lamp, sparks from a chimney and from fires under boiler. An oil fire cannot easily be extinguished by water, but may be extinguished by sand, steam or chemical fire extinguishers which should always be available in the plant. Watch for tank oil temperatures, motor bearing temperatures etc., and prevent ignition of inflammable vapours in the vicinity. Attend to fuel oil leaks without delay. While operating with any fuel oil system equipment, observe the respective safety and fire regulations, as well as the regulations concerning the handling of inflammable liquids valid in the state of the user. Identify the areas prohibited for smoking and for entry of unauthorised persons. Display prohibition and other caution boards and notices at appropriate places both in local language and in English. 1.2 System and Equipment Care Be clear with system and equipment; without valid schematics and equipment layout diagrams do not start operation. Without service manuals and detailed drawings do not take any equipment for maintenance, the chances are more that you may spoil it. At the beginning of every shift, go around the equipment; keenly watch for any malfunctioning, defects and failures. Record the observations; let the equipment be attended to and the defect, however small it may be, set right immediately; slackness may cost a boiler. Keep environment clean; fuel leaks and accumulations could lead to havocs; stop them. Disconnect electric supply, remove spring or mechanical loading, release the pressure, isolate from other system/equipment, drain or vent the oil or gaseous fumes etc., before attempting to service or dismantle an equipment.

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Always employ only experienced, reliable and trained personnel who are familiar with the equipment, system and safety requirements for inspecting, cleaning or repairing any equipment. Do not over load or force any equipment. Have constant watch over the proper operating parameters like pressure, temperature, differential pressure and flow of fuel oil, atomising/heating steam, atomising air, combustion air, etc., and set right deviations timely. Always bear in mind safety and availability of equipment.

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2. OIL BURNERS IGNITORS TECHNICAL DATA 2.1 Heavy Furnace Oil Burners Service : Warming up boiler at controlled rate ; Ignition of pulverised coal fuel ; Stabilisation of coal flame at lower loads ; Turbine synchronisation ; Safe shutting down of the boiler. Tilting tangential; corner fired Parallel pipe design, Stearn atomised, External mixed; Constant pressure Atomiser, Rectangular
o 190 mm; 10 off 45 vanes with leading edge with scanner and ignitor cuttings.

Burner Oil Gun

: :

Air nozzle : Diffuser : Oil Gun Assembly Dimension : Atomiser Designation : Atomiser spray angle Fuel Capacity maximum : : : Number of oil guns Location of oil guns : :
OIL GUN PERFORMANCE DATA CHART
MAXIMUM

KF = K + 20.5 = 2308 mm Spray plate 90 J 16 900 Fuel oil to IS 1593; 1971, LSHS 7.5% MCR heat input per elevation 22.5% MCR total. 12 (4 per elevation) Aux. air nozzles AB,CD & EF.

MINIMUM

SCAVENGING

HFO per gun HFO pressure Atm. Steam flow/gun Atm. Steam pressure

1215 kg/hr 7.0 kg/cm2(g) 180 kg/hr 5.25 kg/cm2(g)

750 kg/hr 4.0 kg/cm2(g) 205 kg/hr 5.25 kg/cm2(g) : : : :

240 kg/hr 5.25 kg/cm2(g) 3.5 kg/cm2(g) 2.5 kg/cm2(g) 15 to 20 cst o 10 to 15 C Superheat

Minimum allowable HFO pressure Minimum allowable steam pressure Oil viscosity at the gun Steam quality

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NOTE: Pressure are measured at the oil gun connection. Minimum firing rate is the minimum energy required for coal fuel ignition and Stablisation. At no time the oil burners shall be operated below this rating. 2.2 Light Diesel Oil Burners Service Atomiser Fuel Capacity maximum Number of oil guns Location of oil guns : : : : : : Initial startup and warm-up. External mixed, constant compressed air atomised LDO to IS 1460/1974 7.5% MCR heat input & total 10%MCR 4 guns (in one elevation) In Auxiliary air nozzles AB pressure,

OIL GUN PERFORMANCE DATA CHART

MAXIMUM MINIMUM SCAVENGING

LDO flow / gun LDO pressure Atm. air flow/gun Atm. air pressure

1215 Kg/hr 7.5 Kg/cm2(g) 120NM/hr 5.25 Kg/cm2(g)

750 Kg/hr 4.2 Kg/cm2(g) 140 NM/hr 5.25 Kg/cm2(g)

160 NM/hr 5.25 Kg/cm2(g)

The same HFO gun is used for LFO firing also without changing the atomiser. Operating the respective burner valves in the burner section does change over of fuel. 2.3 Ignitors Make Service Type Location Input Output Retractor Stroke Flexible Spark Rod : : : : : : : : Unison Industries/USA Oil burner light off High Energy Arc Ignitor Burner Mounting Panel 230 VAC, 50 Hz Min. 4 sparks/second, 12 joules/spark 8 A= 100 inches

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2.4 HEAVY FUEL OIL SPECIFICATION

HFO

Service Standard Pumping temperature Flash point min. (pensky-martens closed cup) Firing Temperature Kinematic Viscosity Total Sulphur (max.) Specific Gravity Gross heating value

Oil burners IS-1593/1971Gr HV/OIL 50oC 50C 120oC

370 cst at 50oC 4.5% by weight 0.98 @ 50oC

10270 KCal/kg

2.5 LDO SPECIFICATION Service Standard Pumping Temperature Firing Temperature Viscosity Total Sulphur (max.) Density at 15oC High heating value : : : : : : : : Oil burners IS 1460 - 1974 35oC 35oC 2 TO 20 @ Firing temperature. 1.8% by weight 0.83 Kg/litre 10720 Kcal/kg approx.

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3. PRESSURE & TEMPERATURE SWITCHES SET POINTS 3.1 Pressure Switches

Function

Equipment Location

Set Value

Set Value measured at ______________

When ____________

LFO Pump suction header pressure low alarm XXHJF11/12/13 CP102

At LFO pump set suction header

-0.60 2 kg /cm (g) decreasing

At LFO pump set suction header

LFO Pump delivery header pressure low for standby At LFO pump set pump auto start delivery header (XXHJF20CP102&103)

19 kg /cm2 (g) decreasing

At LFO pump set delivery header, When LFO firing

HFO Pump suction header pressure low alarm (XXHJF41/42/43;CP102)

At HFO pump set suction header

-0.60 kg /cm2 (g) decreasing

At HFO pump set suction header

HFO Pump delivery header At HFO pump pressure low for standby set pump auto start delivery header (XXHJF50 CP102/103)

29 kg /cm2 (g) decreasing

At HFO pump set dely header. When HFO firing

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Continuation switches Function

of

pressure Equipment Location

Set value

Set value measured at.......................... when....................

LFO header pressure O.K Permissive (HJF30CP101)

LFO operating floor

16.0 kg /cm2 (g) Increasing

At LFO operating floor header. Local

LFO header pressure low alarm (HJF30CP102)

LFO operating floor

3.5 kg /cm (g) Decreasing

At AB-4 oil connection, all the four guns are firing.

LFO header pressure Low Trip. (HJF30CP103 to CP105)

LFO operating floor

3.0 kg /cm (g) Decreasing

At AB-4 oil connection, when all the four guns are firing

HFO header pressure O.K Permissive (HJF60CP101)

HFO operating floor before strainers.

20.0kg /cm2 At HFO operating (g) floor. header. Local Increasing

HFO header pressure low alarm (HJF63CP105)

HFO operating floor after FCV

4.5 kg /cm2 (g) Decreasing 4.0 kg /cm2 (g) Decreasing

When 12 guns are firing.

HFO header pressure Low Trip.(HJF63CP102 to CP104)

HFO operating floor after FCV

When 12 guns are firing.

(cond..)

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Continuation switches Function

of

pressure Equipment Location Set value measured at.......................... when....................

Set value

Atm air header pressure Low Trip. (HJN10CP201 TO 203)

Atm. air operating floor

3.5 kg /cm2 (g) Decreasing 3.5 kg /cm (g) Decreasing

2

At Atm. Air operating floor. when LFO is fired in AB-4 At Atm. Air operating floor. when LFO is fired in AB-4

Atm air header pressure Low Trip. (HJN10CP201 TO 203)

Atm. air operating floor

Atm. Steam header pressure low alarm (HJM31CP204)

Atm. Steam operating floor after ASPRV

4.0 kg /cm2 (g) Decreasing

At Atm. Steam operating floor. when HFO is fired

Atm. Steam header pressure Low Trip. (HJM31CP201 TO 203)

Atm. Steam operating floor after ASPRV

3.5 kg /cm2 (g) Decreasing

At Atm. Steam operating floor. when HFO is fired

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3.2 Temperature Switches Continuation of Temperature switches Function Equipment Location Set value Set value measured at....................... ... when................. ... At HFO operating floor header. Local

HFO header Temperature O.K Permissive (HJF50CT201)

HFO operating floor before strainers.

120 C for HFO

HFO header Temperature low alarm (HJF50CT202)

HFO operating floor after FCV

115 C for HFO HPS Decreasing

At HFO operating floor header. Local

HFO header Temperature Low Trip. (HJF50CT203to CT205)

HFO operating floor after FCV

105 C for HFO Decreasing

At HFO operating floor header. Local

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3.3 Differential Pressure Switches Set value measured at....................... ... when................. ... At LFO pump set. Local

Function

Equipment Location

Set value

LFO Suction Strainer Choked alarm (HJF20 & HJF21: CP201) HFO Suction Strainer Choked alarm (HJF01& HJF02 CP201) HFO Discharge Strainer Choked alarm (HJF50 CP202) Scanner air duct to furnace DP low (annunciation and fan auto start)

Across LFO Suction Strainer

0.35 kg /cm (g) Increasing

Across HFO Suction Strainer

0.35 kg /cm (g) Increasing

At HFO pump set. Local

Across HFO Discharge Strainer Scanner air duct before branching to corners

0.7 kg /cm2 (g) Increasing

At HFO OP.FLOORl

150 mmWC. Decreasing

Local.When ID & FD fans are running and boiler not firing

Scanner air No filter alarm (annunciation)

Across scanner air filter

4 mm WC. Decreasing.

Local When scanner air fan runs with normal pressure ranges. Local When scanner air fan runs with normal pressure ranges

Scanner air Filter Choked alarm (annunciation)

Across scanner air filter

15 mm WC. Increasing.

Notes :

a) b) c) d)

Pressure set points are measured in kg/cm2(g) unless stated. Temperature set points refer to Heavy Viscous grade oil. Use calibrated instruments. Make local tapings and connections wherever necessary. Adjust the set points as found necessary during initial trials.

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4. SYSTEM OPERATION AND CONTROLS 4.1 Fuels A coal fired unit incorporates oil burners to a firing capacity of 30% of boiler load for the following reasons : a) To provide necessary ignition energy to light-off coal burner. b) To stabilize the coal flame at low boiler/burner loads. c) As a safe start-up fuel and for controlled heat input during light-off. Heavy Fuel Oil HFO is recommended as a start-up fuel in a cold boiler, if steam is available for the following services : a) For atomising the HFO at the oil gun. b) For tank heating. c) To preheat the combustion air at the steam coil air pre-heater and to warm up the main air heater (this reduces sulphur oxide condensation). With the above provisions and with proper oil, steam and combustion air parameters at the burner, HFO also is safely fired in a cold furnace. For the system and fuels provided in this unit refer to technical data on Oil Burners and Ignitors. 4.2 Burner Arrangement In tangentially fired boilers, four tall windboxes (combustion air boxes) are arranged, one at each corner of the furnace. The coal burners or coal nozzles are located at different levels or elevations of the windboxes. The number of coal nozzle elevations are equivalent to twice the number of coal mills(TUBE MILLS). The same elevation of coal nozzles at 4 corners are fed from a one outlet of the single coal mill. The coal nozzles are sandwiched between air nozzles or compartments. That is, air nozzles are arranged between coal nozzles, one below the bottom coal nozzle and one above the top coal nozzle. If there are 'n' number of coal nozzles per corner there will be (n+1) number of air nozzles per corner. The coal fuel and combustion air streams from these nozzles or compartments are directed tangential to an imaginary circle at the centre of the furnace. This creates a turbulent vortex motion of the fuel, air and hot gases, which promotes mixing, ignition energy availability and thus combustion efficiency.
o The coal and air nozzles are tiltable 30 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.

The air nozzles in between coal nozzles are termed as Auxiliary Air nozzles, and the top most and bottom most air nozzles as End Air Nozzles.
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The coal nozzle elevations are designated as A, B, C, D and E & from bottom to top, the bottom end air nozzles as AA and the top end air nozzle as FF. The auxiliary air nozzles are designated by the adjacent coal nozzles, like AB, BC, CD, DE & EF from bottom to top. The four furnace corners are designated as 1, 2, 3 and 4 in clockwise direction looking from top, and counting front water wall left corner as '1'. Each pair of coal nozzle elevations is served by one elevation of oil burners located in between the auxiliary air nozzles. In this boiler with the 3 Tube mills or 6 elevations of coal nozzles, there are 12 oil guns arranged in 3 elevations, at auxiliary air nozzles AB, CD & EF. Heavy fuel oil can be fired at the all the oil gun elevations mentioned above and LDO can be fired only in AB elevation. Each oil gun is associated with an ignitor arranged at the side, as illustrated elsewhere. For wind box drawings, more descriptions and details refer to respective sections of this O&M manual. 4.3 Combustion Air distribution Of the total combustion air, a portion is supplied by primary air fans that goes to coal mill for drying and carrying the pulverised coal to the coal nozzles. This primary air flow quantity is decided by the coal mill load and the number of coal mills in service. The primary air flow rate is controlled at the air inlet to the individual mills by dampers. The balance of the combustion air, referred as Secondary Air, is provided from FD Fans. A portion of secondary air (normally 30% to 40%) called 'Fuel Air', is admitted immediately around the coal fuel nozzles (annular space around the casting insert) into the furnace. The rest of the secondary air called 'Auxiliary Air' is admitted through the auxiliary air nozzles and end air nozzles. The quantity of secondary air (fuel air + auxiliary air) is dictated by boiler load and controlled by FD Fan inlet guide vane regulation. The proportioning of air flow between the various coal fuel nozzles and auxiliary air nozzles is done based on boiler load, individual burner load, and the coal oil burners in service, by a series of air dampers. Each of the coal fuel nozzles and auxiliary and end air nozzles is provided with a louver type-regulating damper at the air entry to individual nozzle or compartment. On this unit, there will be 6 fuel air dampers, 5 auxiliary air dampers and 2 end air dampers per corner. Each damper is driven by an air cylinder positioner set, which receives signal damper from Secondary Air Damper Control System. The damper regulates on elevation basis, in unison, at all corners.

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Furnace Purge Traces of unburnt fuel air mixture might have been left inside the furnace; some fuel (particularly gas. or lighter fuels) might have entered the furnace through leaky valves during shutdown of the boiler. Lighting up a furnace with such fuel and air accumulation leads to high rate of burning, furnace pressurization and to explosions at the worst. This is avoided by the 'Furnace Purge' operation, during which 30% of total air flow is maintained for about 5 minutes to clear off such fuel accumulations and fill the furnace with clean air, before lighting 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. Boiler Low Load Operation During initial operations upto about 30% boilers loading (and also during furnace purge) all the auxiliary and end air dampers modulate to maintain a pre determined (approx. 40 mm WC) set point differential pressure between the windbox and furnace. During this period also, 30-40% of total air flow is maintained to have an air rich furnace and to avoid possible unhealthy furnace conditions. Again all the auxiliary and end air dampers are open to distribute the excessively admitted air away from the operating burners and to pass only the necessary air behind the operating burners at appropriate velocity, for successful burner light up and stable flames. Around 40 mm WC windbox to furnace differential pressure is the pressure estimated as required to admit 30-40% of air flow with all the auxiliary and end air dampers modulating with reasonable opening. Whenever one or more oil burners are put into service, the associated elevation of auxiliary air dampers modulate as a function of oil header pressure, to provide required combustion air. The other auxiliary air dampers continue to maintain 40 mm WC wind box to furnace differential. At boiler loads less than 30% MCR, each elevation of oil burners shall not be loaded more than 10-12% MCR (high capacity provided), since no adequate combustion air will be available behind oil burners, under this operating conditions. If found necessary total airflow may be marginally increased for better flame conditions. Boiler Load Above 30% When the unit load exceeds 30% MCR, each differential set point is changed and ramps to a higher setting (approx. 100 mm WC). Simultaneously, the auxiliary air dampers associated with the coal elevations not in service, close in timed sequence starting with the upper elevations of dampers and progressing to the lowest elevation. The above 100 mm WC differential is the predicted value required to admit the total secondary air at design air velocities with all dampers opened to reasonable percentage.

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When the unit load is reduced below 30% loading, the auxiliary air dampers open in a timed sequence starting with the lowest elevation of dampers. Simultaneously, the differential set point changes to its lower setting.. The auxiliary air dampers associated with the oil elevations, modulate as a function of oil header pressure when oil is being fired and opens more and more with increased firing rate. Otherwise they open and close with the balance of auxiliary air dampers. The bottom end air damper is normally kept open to a fixed pre-determined position, to reduce unburnt coal dust fall-out. All the auxiliary air dampers maintain the status-quo upon a boiler trip and will open fully when both the FD fans are off. Fuel Air Dampers Their operations are independent of boiler load. All fuel air dampers are normally closed. They open fifty seconds after the associated feeder is started and a particular speed reached; then it modulates as a function of feeder speed. Fifty seconds after the feeder is removed from service, the associated fuel air dampers close. The fuel air dampers will open fully when both the FD Fans are off. Secondary Air Damper Control Setting The following control ranges are normally field adjustable, and during initial operations these require finer adjustment: a) Auxiliary air dampers control Windbox to furnace DP at lower loads. b) Rate of opening of auxiliary air dampers of operating oil burner elevation with respect to fuel oil header pressure. c) Auxiliary air damper control-windbox to furnace DP at higher loads. d) Feeder speed at which fuel air damper starts opening. e) Rate of opening of fuel air damper with respect to feeder speed. f) Maximum opening of fuel air damper.

g) Feeder speed at which fuel air damper goes above the maximum opening. Of the above, first two have direct bearing on successfully establishing or lighting up of an oil burner and its stability. The need for keeping all the elevations of auxiliary air dampers open for initial purging and for air rich furnace volume at lower loads shall be borne in mind, while adjusting these. The other variables are mostly dictated by coal fuel quality and overall furnace condition. These are to be analyzed in totality and set appropriately during initial operations for the best ignition stability, distance of ignition point from coal nozzles, furnace stability, reliable and constant flame scanner pickup etc. Once the operating regimes of

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the damper controls is set for better performance, it shall not be disturbed thereafter, unless there is a major change in coal quality. Refer to Section 'Tilting Tangential Firing System for more details. 4.4 Fuel Oil Atomisation Atomisation is the process of spraying the fuel oil into fine mist, for better mixing of the fuel with the combustion air. While passing through the spray nozzles of the oil gun, the pressure energy of the oil converts into velocity energy, which breaks up the oil stream into fine particles. Poorly atomised fuel oil would mean bigger spray particles, which takes longer burning time results in carryovers and makes the flame unstable due to low rate of heat liberation and incomplete combustion. Other than pressure, viscosity of the oil is the major parameter, which decides upon the atomisation level. For satisfactory atomisation the viscosity shall be less than 15-20 centistokes. External mix type steam atomised oil guns have been provided. Atomizers of this type are widely known as Y-tips or J-tips. The atomiser assembly consists of nozzle body welded on to the gun body, spray plate and cap nut. 4.5 Fuel Oil Preparation Pumping the oil and heating it are the major preparatory functions required on heavy fuel oil for burning. Filtration of oil in one or more stages to remove any dust, dirt, sediments, sledge etc. also forms part of preparation. This renders long trouble free service life to pumps, valves and oil guns. It reduces wearing and clogging of atomiser nozzles. There are course strainers at pump suction. Heater succeeds the pump and fine strainers are arranged after heater. The pumps are of screw type and heaters are stationary tube sheet U-tube type, with oil on shell side. The pump delivery header pressure is varied for various firing rates by a pressure maintaining cum regulating valve that relieves the excessively pressurized oil to the pump suction (or) service tanks, which receives signal from UCB. Maintaining the HFO temperature constant, corresponding to the atomizing viscosity of 15 centistokes is essential for better fuel atomisation. A control valve on the heater steam line throttles the steam pressure in relation to HFO temperature fluctuations. There by it varies the steam saturation temperature and maintains the HFO temperature constant at all oil flow rates. A lower temperature of fuel oil impairs the burner performance and a higher temperature causes oil cracking. 4.6 Heavy Fuel oil Recirculation The HFO heater sets are located at a considerable distance from the boiler burner proper. Before putting in the first burner into service, it is necessary to warm up the long oil supply lines from the heater to the burners, so that the oil does not get cooled in the colder piping and that the oil at correct atomizing temperature becomes available at the burners. To achieve these the heated oil is
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circulated upto the oil tank through HFO return lines till adequate temperature is reached near the burners. For the above purpose there are HFO recirculation loops. One is called, the 'Long Recirculation' which is through the main trip valve, supply flow meter and flow control valve in the HFO supply line, supply ring header, corner risers, return ring header and HFO return lines. Long recirculation is the effective one, which circulates hot oil right upto the burner valve inlet, near the corner risers. Long recirculation is not possible if no control power is available and during master fuel trip. During such occasions the other partial recirculation loop called 'Short Recirculation' is employed. This later loop bypasses the boiler area piping and connects the HFO return lines to the HFO supply lines before the HFO main trip valve through a motorized gate valve. Short recirculation valve is opened when the main trip valve is closed, essentially for warming up the main lines. Before opening the main trip valve or the first burner trip valve the short recirculation valve is closed to 90% thereby allowing only a small amount of oil for recirculation. A three way HFO return trip valve (HORV) is installed in the long recirculation loop. With this valve open, large volumes of HFO can be circulated upto the burners and initial warming up of the piping can be faster. This valve is interlocked in the Burner Management System normally as follows: a) The HFO main trip valve could be opened even before furnace purge if this HFO return trip valve (HORV) is opened and all the burner valves are shut, for faster initial warming up of boiler area piping. b) Burner Trip Valve can be opened only if adequate temperature is proven at HFO supply header. c) As the first oil burner is cut in, HORV is auto closed to ensure sufficient HFO supply header pressure. d) HORV can be opened remote-manually if all the burner trip valves are shut and can be closed remote-manually at any moment. e) The HORV and target flow meter are connected so that the flow is measured only during firing i.e. at the time of return line part of HORV is closed. When one are more burners are firing (i.e. When HORV is shut), still a small amount of hot oil is constantly recirculated through the short recirculation valve. This constant recirculation keeps the HFO return line always warm. prevents solidification of oil at dead ends and ensures uniform temperature in the piping, This is done by keeping the short recirculation valve in crack open position. When the boiler is firing on coal and no oil burner is firing, HORV may be opened to have more hot oil circulation, in addition to constant recirculation, to enable faster cutting-in of oil burners during emergency needs. The amount of hot oil recirculation however has to be checked, not to shoot up the oil temperature at the oil storage tank. However to take care of the same an oil cooler is provided in the return line, near the pump house. When no oil burner is in service, the desired amount of recirculation through HORV can be maintained by varying the HFO flow control valve opening, thereby controlling the oil temperature rise in the storage tank.
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4.7 Oil Flow Control Since oil firing is provided only for startup purposes, the oil burner loading is looped to Boiler Combustion Control. But it is remote manually done by varying oil pressure cum flow control valve opening. The need for varying the oil burner load and the normally adopted practice is prescribed in the following lines. System Requirement The maximum total output of oil burners is 30 % of the boiler MCR heat input with HFO and 10% of boiler MCR heat input with LFO. This corresponds to turbine synchronisation needs before firing coal burners. Each oil burner capacity is 2.5 % of boiler MCR heat input with HFO & LFO. For coal burner ignition and coal flame stabilisation a minimum oil burner output, equivalent to 10-20% of maximum coal burner capacity is required. This roughly corresponds to 50-60% rating of an oil burner. For the exact capacities refer to Technical Data Sheet on oil burners and ignitors. The oil burner output is a function of oil pressure at the oil gun and the normal turndown range of the oil burner is 2:1, or less. For steam atomised oil burner, the oil pressure at the oil gun shall not fall below 3 kg/sq.cm(g) to ensure good atomisation and stable oil flames. The oil burners may have to be operated at loads lower than the maximum rating. a) During cold startups of the boiler, to have a controlled and gradually increasing heat loading, to avoid temperature stresses on pressure part materials, as directed by boiler startup curves. b) To conserve fuel oil by operating the oil burners just above the 'Coal flame stabilisation' requirements. Oil flow control function The pressure control valve essentially does the job of varying the header pressure through a pressure control loop. The pressure controller is located in the control room with a 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. When additional oil burners are introduced or a few burners removed from service, this pressure set point need not be disturbed and the pressure control loops adjust the flow control valve opening suitably. This avoids undue oil header pressure fluctuations during this operation. The limiter provided in the single line from set point variator to pressure controller prevents lowering of the controller set point below 3 kg/sq.cm (g), thus always ensuring the minimum oil pressure requirements at the gun. An UCB display of control valve outlet pressure could give correct guidance for an operator. The fuel oil flow meter readings in panel could also be of equal assistance.
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4.8 General Operating Sequence The following lines list the activities with respect to fuel oil system alone. It does not, however, cover all the finer aspects of each equipment. For operation of related systems and specific equipment refer to the respective sections of this Operation and Maintenance manual. Drain out completely the locked up condensate from atomizing steam and heater steam headers, HFO tracer lines, HFO pump and strainer jackets, HFO heater, steam coil air preheater etc., open trap by-pass valves for this purpose. After draining keep all the traps isolated and trap by-pass valves crack opened. Start ID and FD Fans, perform other operations and prepare the boiler for light up Charge all afore-said steam lines, tracers, jackets etc., except HFO heater. Use appropriate vents for air removal. After some time elapse, close each of the trap by-pass and check whether the traps function properly. Otherwise, leave trap by-passes crack open. Arrange for attending to faulty traps. Let the HFO lines and equipment be warmed up. If felt necessary open the drain valves at various sections of HFO systems and drain out the sledges and setting into the drain tray. (Before starting the pump and charging with oil, the heater should not be charged with steam. However, if warming up the heater for draining is felt necessary, take enough care to keep all oil sides vents, drains, isolating valves etc., open before charging steam. Steam shall be on only for a short while. Heater drain to be properly disposed.) Ensure opening or closing of appropriate air line dampers before charging steam coil air preheater, for hot air to reach wind boxes and flow through furnace passes. Charge steam coil heater timely, so that the hot air is around 80-100 C will be available at the windbox while cutting in the first HFO burner, during cold start up. Ensure that HFO at the tank is above pour point temperature. Charge the tank outflow heater with steam, if necessary. Isolate the HFO pressure and temperature control valves and heater steam traps. But for the above exception, check closure of all normally closed valves and opening of all normally open valves. Open oil tank outlet valve and allow oil to fill up to the pump. Use vent valves available at the strainer and lines for complete removal of air. If necessary hand rotate the pump shaft and fill it with oil. Close the heater inlet valve; open Heavy oil pressure control valve (HOPCV) bypass fully and start the pump. Establish oil flow circuit through pressure control valve by-pass back to the tank.
o

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Close the pressure control valve by-pass slowly and check whether the pump relief valve operates at required set pressure. Open the pressure control valve isolation valves. Vary the opening of the bypass valve. Check for proper functioning of pressure control valve. If found satisfactory close the bypass and put pressure control valve in service. (Do the above after establishing oil flow through heater set if the impulse for pressure control valve is taken after HFO heater). Close HFO heater set outlet isolation valves. Open HFO heater inlet isolation. Charge heater and strainer with oil slowly, taking care of air venting. Keeping heater trap bypass crack open, charge heater with steam through HFO temperature control valve bypass. Warm up for quite some time. Close inlet isolation of HFO supply flow meter. Open HFO short recirculation valve at the boiler and HFO discharge strainer outlet isolation valve. Charge the HFO main lines and establish HFO circulation in the short recirculation loop. Open heater trap isolation valves. Close its bypass. Check for proper functioning of trap. (If required opening up pressure control valve bypass, for this checking, can change heater loading). Otherwise leave trap bypass crack open and take up for service. Ensure burner trip valves closure. Open HFO three way return trip valve. Set flow control valve, pressure controller at minimum set point. Open HFO main trip valve.
o As the HFO temperature builds upto 70-80 C at the HFO short circulation branching slowly open the HFO supply flow meter inlet isolation valve and charge boiler front piping taking care of air venting. Close HFO short recirculation valve.

Establish long recirculation and warmup HFO lines. Changing HFO flow control valve pressure controller set point can vary the rate of firing. Open temperature control valve isolation valves. Vary the heater load by HFO flow control valve manipulation. Close temperature control valve bypass. Check proper functioning of the temperature control valve and put into circuit. Prepare for 'Furnace Purge'. Temporarily close HFO main trip valve. Perform furnace purge. On purge completion open HFO main trip valve and re-establish HFO long recirculation at desired rate. Initiate and successfully establish a pair of oil Burner elevations in a short time, following furnace purge. For starting With HFO, ensure that HFO return line temperature is above required value (corresponding to 15-20 CST viscosity). Set the pressure controller of HFO flow control valve for design firing rate.

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Ensure that atomising steam header is charged. Select the lower elevation of oil guns on HFO, followed by adjacent elevations of oil guns. Ensure that air dampers behind oil burners are adequately opened and modulate properly. During emergency trips, short recirculation of HFO need not be established if the MFT exists for less than 30-45 minutes. As soon as MFT is cleared open HFO main trip valve and maintain long recirculation through HFO return trip valve at desired rate as dictated by HFO flow control valve opening. 4.9 Fuel Oil Conservation Fuel oil is scarce, costlier and has better uses than firing in a utility boiler. Oil firing in the boiler shall be limited to the barest minimum. Oil burners or ignitors shall be in service for minimum. For flame/furnace instabilities observed at boiler loads above 30-40% MCR, focus attention to analyze and set right the firing system parameters or equipment, comprising mill circuit, air damper controllers, flame scanners, control and monitoring instruments etc., instead of simply resorting to oil support. It may not always be safe also, to have continued oil firing without tuning the unit's overall operation and protection. For any oil flame instability (without ignitor), check and set right oil atomising steam parameters, auxiliary air damper control setting, condition of atomizers and diffusers, relative position of oil gun atomiser with respect to diffuser and windbox air nozzle etc. For ignition and stabilisation of coal flame, oil firing rate around 20% of coal burner maximum capacity is adequate. (In a coal fired boiler, the oil burner rating corresponding to this ignition energy requirement is some times referred as 'Minimum rating'); Always operate the oil guns only at this minimum rating and not at maximum rating. (This minimum ignition energy requirement is usually interlocked into FSSS through oil flow switches or oil header pressure switches. Otherwise operator may go by oil flow meter readings and number of burners in service, to ensure this minimum energy). When two adjacent coal elevations are firing above 50% feeder speed, continued oil support is not required. The associated elevation of oil burners may be shut down, 3 minutes after the later of the above two coal feeders is started. Knowing the above fact, bring in two adjacent feeders to above 50% speed in a short time as possible, and as dictated by boiler startup curves and thus have minimum oil firing duration. Oil burners need not be brought into service for igniting of coal burner (or for stabilisation). a) If adjacent coal elevation fires above 50% feeder speed with its associated oil burner elevation firing above minimum rating (for example, if coal elevation B is working with AB oil guns, coal elevation on C can be started without bringing in CD oil guns).
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OR b) If boiler load is above 30% MCR and adjacent coal elevation fires above 50% feeder speed. Plan your boiler operation and programmed carefully for operating the coal elevations to utilise the above understanding for fuel oil economy. Aim at better mill availability by proper equipment care, spares control and planning. So also, ensure availability of all the HEA ignitors, oil guns and flame scanners in good working condition, all the time. Never operate an isolated coal-elevation. Always plan to operate or start adjacent coal elevations. During planned shut down of a coal elevation bring in oil burners at design firing rate for 5-10 minutes duration. (It is similar to oil gun scavenging with ignitor on). When only two adjacent coal elevations are firing in whole of the boiler, it is a good practice to maintain oil support at design rate, to take care of the situation of the mills tripping.

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5. OTHER SYSTEM FEATURES 5.1 HEA Ignitors High Energy Arc Ignitors, which can directly ignite either LFO or HFO, are provided in this project. The system essentially comprises of. a) An exciter unit, which stores up electrical energy and releases energy at a high voltage over a short duration. b) A pneumatically operated retracts mechanism, which advances the spark tip into oil spray to ignite it, and retracts back after ignition. Each discrete spark provides a large burst of ignition energy as the current reaches a peak value of around 2000 amps. These sparks are effective in lighting up a well-atomised oil spray and also capable of blasting off any coke particle or oil much on the surface of the spark rod. 5.2 Air Cooled Oil Guns The atomiser assembly of an operating oil gun is protected from the hot furnace radiation by the flowing fuel oil and steam, which keeps it relatively cool. Once the burner is stopped, there is no further flow of oil or steam. Under such situation, it is required to withdraw the oil gun from firing position or some other means provided, in order to protect the atomizers from damages due to over heating. The oil gun assemblies supplied for this project have been designed for aircooling provision. The cap nut that holds the atomiser to the oil gun body is provided with specially sized cooling fins. A sleeve over the capnut protects the fins and also directs the cooling air effectively over the atomiser spray plate. The oil gun guide pipe assembly and the vaned diffuser have been appropriately dimensioned to accommodate the finned capnut and for best cooling efficiency. The low pressure air tapped at FD fan cold air inter- connecting duct is piped to the individual oil gun guide pipe with flexible hoses at the required places. In this design, the oil guns can always be left in firing position and with cooling air the atomiser parts are kept clean, free from any dripping oil, coal etc.

5.3 Steam Scavenging of Fuel Oil Guns Before stopping the oil burner, the oil gun is scavenged with steam to keep the small intricate passages of the atomiser parts clean. Oil gun is always scavenged with associated ignitor in service, to burn out the oil. In the auto programmed burner stop sequence a planned shut down is followed by steam scavenging the oil side for quite sometime, to achieve this requirement. During emergency tripping of the burners or boiler the oil gun is not scavenged. Normally such emergency trips may last only for a short while and the fuel oil guns shall be restarted or manually scavenged immediately on resuming boiler operation.

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5.4 Burner Trip Valves To control the atomizing medium and fuel flow to the oil guns, pneumatically actuated burner trip valves are used. These are provided with reliable limit switch feed backs, which could be incorporated in the logic control system. The valve plugs are designed to, include an over travel "O" ring sealed plug extension where initial closure of the valve is made by the Teflon "O" ring and the final closer of the valves require another 10 mm of stem travel. This provides ample over travel to ensure positive limit switch action at the closed position of the valve and simplifies the settings of the switches. Valve closing is instantaneous whereas 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.

5.5 System Vents Fuel oil heaters, strainers and lines are provided with vent cocks or valves on oil and steam sides to get rid of air locks while charging system. Keeping open the cocks fully, fill in medium slowly. Once the volume is nearly filled, close down the vent to crack open condition and when traces of oil ooze out, tight-shut the vent, do not allow the oil to jet out of the vents making the surroundings messy. In a heat exchanger air locks reduce the effective heat transfer area and thus the heater efficiency. Air venting also helps to avoid the chances of forming fuel vapour air mixtures inside the system. 5.6 System Drains All oil lines are run with a slope of about 0.3 to 0.5% towards drain. Each section of oil line is provided with a drain valve or plug at the lowest point. All drain valves are normally kept closed during operation. When the oil system is taken out of service then it is necessary to open the respective drain valves and drain the fuel oil when hot.

5.7 Heat tracing of HFO lines: All the HFO lines are electrically traced. This system supplements the heat lost by fuel oil while flowing through the tubes.

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6.0 LIGHT FUEL OIL PUMPING, HEAVY FUEL OIL PUMPING AND HEATING UNIT 6.1 General Arrangement LDO System Two100% duty screw pumps and two 100% duty duplex basket type suction strainers are connected with necessary isolating and non-return valves. One pump can meet the oil requirement of one boiler. Units are located in the pump house, one set serve as a stand by. HFO& LDO System Two100% duty screw pumps and two100% duty duplex basket type suction strainers are connected with necessary isolating and non-return valves. One pump can meet the oil requirement of one boiler. Units are located in the pump house, one set serve as a stand by. Necessary pressure and temperature instruments are also mounted at appropriate location for operators guidance and control. All these equipment are laid out on a common fabricated steel frame of drip tray type. The drain points are to be suitably piped to the drain pit. 6.2 Commissioning and Operational Checks a) The pumps have running clearances and to ensure that the screw sets are not damaged by pipe scale or dirt. Take special care during erection and ensure that the pipelines are cleared of all foreign matter. b) If the lines have been filled with water for hydraulic testing take steps to clear the water from within the pumps and lines by blowing with compressed air and drying them out. c) The best practice is to remove the pump internals during such hydraulic tests. d) Before the pump is started for the first time, check the shaft alignments according to the pump manufacturer's instructions. e) Check for control clearances between the two halves of the couplings. It shall be around 3 to 4 mm. It is a severe requirement in case of vertical execution. Refer supplier's drawing. f) The pump should rotate freely by hand.

g) Ensure before starting that the drive has been coupled for the correct direction of the pumps; the pumps are not reversible. h) Keep all joints tight; tighten the bolts evenly. See particularly that no leak occurs on the suction side. Any air inducted into suction pipe tends to make the pump noisy and impairs the working of the pump. i) Do not run the pump dry.

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BHARAT HEAVY ELECTRICAL LIMITED

j)

During normal running, if the suction pressure falls below the NPSH requirement of the pump due to any reason, do not continue the operation. Refer pump data sheet.

k) Before starting, vent the suction lines and open the suction and discharge valves completely to ensure that the pump is flooded. To prime the pump it is a good practice to turn pump by hand until oil passes through it. l) The oil shall be adequately heated above pour point at the tank to make the oil freely flow and pumpable; Overheating the oil at the tank will result in vapour lock and affect the pump performance and life and the same shall be avoided.

m) The pump, strainer and lines may be warmed up by heat tracing system. n) Set the built in or separately available pump relief valve at a pressure 2 kg/CM2 (or as recommended by the pump manufacturer) above the normal operating delivery pressure. This valve prevents the pump being damaged, if it should be started with the valve on delivery side closed. o) Do not run the pump with all the oil being bypassed through this safety relief valve, as it will be rapidly heated up. Under normal operating conditions, this valve operates very occasionally. p) Keep the oil inlet and outlet valves of the stand-by pump open to enable the change-over of pump set during emergency. The non-return valves provided at the pump outlets prevent the high pressure oil entering the stand-by pump from the delivery line. q) Alternate the pump-strainer basket combination, in operation, from time to time so that one and the same set is not out of operation all the times. r) Inspect and check the sets periodically; lubricate the moving parts properly; attend to defective packing, leaking, gaskets and replace worn-out parts, which would give satisfactory performance over a long period.

6.3 Pressure Maintaining Cum Regulating Valve The screw pump when coupled to an induction motor with constant speed is a constant discharge pump with constant delivery pressure. When only a small quantity of oil is fired, the excess oil from the constant quantity pump should be by passed. This is done automatically by pneumatic operated pressure control valve by by-passing the excess quantity through the return oil line to storage tank and the delivery pressure of oil is maintained constant at the pump outlet, irrespective of the quantity of oil fired in the boiler. The pressure control valves for HFO & LDO are arranged in the pump house as indicated in the scheme of FO system. Set the pressure control valve for maintaining adequate pressure at the maximum firing rate.

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BHARAT HEAVY ELECTRICAL LIMITED

6.4 HFO & LDO Suction and Discharge Strainers Oil suction strainers are essential to prevent mechanical impurities reaching the small clearances and intricate passages in the screw pump. Two 100% duty duplex basket strainer of 500-micron filter mesh provided at pump suction with inlet and outlet isolating valves, vent valve and drain valve for HFO. Two 100% duty duplex basket strainer of 250-micronl mesh is provided for LDO at pump suction. The running pump will starve of oil, if the pressure drop across the suction strainers exceeds the allowable limit and will get damaged. When the 2 pressure drop across the operating strainer reaches about 0.15 kg/cm (corresponding to 50% clogged status), the standby strainer basket is brought into service. The change over valve is operated to gradually open to connect the unclogged strainer basket and the strainer basket is filled with oil. Filling rate shall be slow enough not to affect the running pump. As the strainer is completely filled and on ensuring complete air removal the vent valve is closed. Now the clogged strainer basket may be isolated, drained and the element removed, cleaned and fitted back ready for use. With tracing on, stand by strainer bakset may be filled and drains and vents closed. 6.5 Steam Heaters, Discharge Strainers, Temperature Control Valve etc., Two100% duty steam-oil heat exchangers, HFO temperature control valve and trap stations for heater and tracers are also accommodated on the HFO heater set for the boiler. The steam heaters are of fixed tube sheet, U tube type, with oil on shell side and steam on the tube side. The oil presure is protected against exceeding of allowable pressure by low lifting spring loaded safety valve. The exchanger is equipped with the valves needed for air release and draining. The duplex type discharge strainers are at the heater outlet, located at the operating floor, with fine mesh of 250 microns filtration. The fine filtering prevents choking of lines, valves and burner atomizers. The burner tip wearing rate is also reduced, when the pressure drop across the strainer 2 exceeds about 0.50 kg/cm (corresponding to 50% clogged status), the standby strainer basket is put into service and the clogged strainer element is taken for cleaning. 6.6 Steam Heater Operating Requirements a) Before putting into operation for the first time, check the flanged connections and tighten all the bolts evenly. b) Hydraulic test the unit after erection according to specifications for stationary pressure vessels. c) Check for the conditions of the safety relief valves and set the spring corresponding to the design pressure.
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d) At periodic intervals pop-up the safety valve lever and release the possible clogging to ensure its availability. e) Before charging with oil or steam, vent the air through the valves, open the valves slowly and charge the sections gradually. f) It is recommended to alternate the heat exchanger in operation from time to time so that one and the same heater is not out of service all the times.

g) Do not attempt to repair leakage or tighten the bolts during operation. h) During shut down slowly close the steam valve first, opening at the same time and desecrating valves on the steam channel. i) If the heater is out of operation for a short time, leave it filled with oil and maintain oil temperature at 60%. If the shutdown is for long duration, drain the lines. It is sufficient to close the inlet valve alone while the heater acts as a standby. Except during maintenance, never close both the oil inlet and oil outlet valves of the heater.

j)

k) It is dangerous to admit steam into heater space without oil passing through. Steam heating should never be turned on before the oil pumps are running and the necessary oil valves are open to establish flow through the heater. l) Heater safety relief valves are there merely as safety devices to relieve the pressure rise when steam to oil heater is on and both oil inlet and outlet valves are shut. No oil should flow through the relief valve during regular operation.

m) For more details refer separate section on Fuel oil Heat Exchangers.

6.7 Heavy Fuel Oil Temperature Control The result of inadequate heating of fuel is "higher oil viscosity" which impairs atomisation at the oil gun, leading to poor flames, sooting, increased carbon loss and finally flame failures. Over heating the oil is also not desirable, from the point of thermal cracking of oil. The formed solid carbon particles build up over the heater tubes, and plug up the strainer, intricate passages of control and shut off valves and atomizers. The solid carbon particles also cause faster atomiser wear out and sparkling in the flame. As seen, maintaining correct oil temperature cannot be overlooked and great attention is required. Since the oil flow rate through the heater depends on the oil burner firing rate and number of burners in service, quantity of heat to be exchanged (from heating steam to oil) in the heater widely varies. The heat transfer area remaining 'same, the heat transfer quantity can be varied by controlling the Log Mean Temperature Difference (LMTD).

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The Log Mean Temperature Difference is a function of saturation temperature of heating steam in this case, since, the oil temperature range required is constant. The steam saturation temperature could be varied by throttling the steam pressure at the heater inlet by a control valve in the steam line. A temperature controlling instruments monitor continuously the oil temperature at the heater outlet and controls the opening of the fuel oil temperature control valve in the heating steam line. As the oil temperature shoots up at low oil flows the valve is commanded to close and at failing oil temperature to open up more. The oil viscosity at the gun shall be well below 20 CST. The oil sample shall be tested weekly or bi-monthly, check for its Temperature-Viscosity characteristics and set the temperature and other monitoring instruments at suitable levels. 6.8 Steam Condensate Removal The heating steam looses its latent heat to the oil and turns into condensate. Continuous removal of the formed condensate from the heater steam side is essential for effective utilization of heat transfer area. Each heater is provided with steam trap station for this purpose. The steam trap is of inverted bucket type design which could handle higher loads with least steam loss and work effectively with large back pressure. Each trap station is provided with isolating valves, bypass valve, vent or inspection valve and check valve. The condensate is piped upto a near by drain. Refer to supplier's manual for principle of operation and trap discharge characteristics.

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7.

FUEL OIL SYSTEM BOILER FRONT EQUIPMENT 7.1 Normally the oil preparation equipment like pumps, and strainers are shop assembled on fabricated bases and transshipped as assemblies. The fittings coming on the operating floor are supplied loose and get installed at site. 7.2 The main trip valve flow meters, and required instruments and initiating devices are arranged at the main operating floor. The burner trip valve stations are located nearer to individual burners at the respective floors. The scheme of fuel oil system clearly shows the various equipment coming at the boiler front with piping details. 7.3 After the operating floor fittings the piping of each fluid medium goes below the main operating floor, branches into two legs and forms a "U" shape distribution header to reach all the four corners of the furnace. At each corner, riser pipes are branched off, from where tapping for each oil burner are taken at different levels. 7.4 The burner fittings are arranged closer to the respective burners. The piping between the oil gun and the burner trip valves and the piping between burner valves and the corner risers or down pipes are limited to the barest minimum considering the following: a) Minimum oil cold legs. b) Minimum header pressure dips while cutting in oil burners. c) Oil reaching the gun in shortest time. d) Minimum condensate legs. 7.5 The oil lines are provided with vent valves at the top of corner risers for air removal during initial charging. The oil header layout is such that all piping slope down towards a common point where drain valves are provided. In the steam lines steam traps are provided to remove condensate to have dry steam for atomization. Atomisation steam lines are legged with HFO line for tracings purpose.

END

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