Beruflich Dokumente
Kultur Dokumente
1.Procedure for Checking, draining and putting back into operation of the
boiler gauge glass:
Responsibility : Operator
Prior to check the gauge glass the control room Panel engineer shall be informed
about the activity.
The firing floor operator shall wear all PPE ( Face shield and hand gloves) .
Isolate the gauge glass from water side by closing the isolation valves.
Isolate the gauge glass from steam side by closing the isolation valves.
Open the drain valve slowly and observe water level drop in the gauge glass.
Flush the gauge glass and drain by crack opening of steam side isolating valve for
two to three minutes then close the steam side isolating valve.
Slowly open water side and steam side valves to take the gauge glass into
operation and confirm back for water level.
Report back to control room Panel engineer for the activity completion.
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Responsibility : Operator
Prior to check the furnace and collecting the coal sample from feeder the control
room panel engineer will be informed about the activity.
The control room Pannel engineer shall maintain the furnace draft between 3 to
5 mmwc and permit the activity.
The operator shall wear all PPE (Face shield, hand gloves) and open the furnace
peephole for confirming the negative draft.
When there is no backfiring is observed, the operator shall check the furnace
condition through peephole.
For collecting the coal sample the operator shall ensure the above conditions then
collect coal from the feeder mouth.
When the above activities are completed inform the control room panel engineer
for normalization of furnace pressure.
Control room Pannel engineer shall reduce the furnace draft to normal value.
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Prior to conducting the hydraulic test for the boiler ensure that all safety valves
are gagged.
Keep open the drum air vents, main line air vents.
Ensure that the main steam stop valve is closed and open the drain between stop
valve and range valve.
Ensure that gauge glasses, drum level transmitters and Yarway level indicator are
isolated.
Ensure that all pressure parts are properly illuminated for facilitating the
inspection.
Start filling the boiler with cold water from the line provided at the economizer
inlet header.
Once the boiler is filled with water the water from vents can be observed.
Close all vents when the boiler pressure reaches 3.0 kg/cm2 and no air bubble
from vents.
Establish the feed water flow to the minimum so that the pressure raise in the
boiler shall be 1kg/cm2/minute. To achieve this the boiler Spray control valve can
be adjusted suitably.
Raise the boiler pressure to 1.5 times of maximum drum working pressure slowly
and steadily.
Slowly drop the pressure to drum normal working pressure with Main line vent
Thoroughly
inspect
the
boiler
pressure
parts
i.e
furnace,
superheaters,
Once the inspection is completed inform the leakages if any to the engineer incharge.
Once the pressure drops to < 10 kg/cm2 stop the boiler feed water pump.
Once the pressure drops to 3.0 kg/cm2 open the drum, main line vents, bed
superheater drains.
Keep the drum water level to normal working level to make the boiler for start
up.
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Collect coal sample twice a shift and send the composite sample to Central Lab
once a day during the early shift to measure GCV and total moisture.
Collect Fly Ash sample at Economiser, AIR preheater,ESPS twice a shift send the
composite sample to Central Lab once a day during the early shift to measure the
unburnt carbon.
Monitor the quality parameters against the following targets on monthly average
basis.
less than 6 %
above 85%
Collect Feed water, drum water, drum steam, and main steam samples once a
shift and send them to Central Lab. Monitor their quality parameters against the
below mentioned targets and give blow down, if the drum water quality is beyond
the target.
pH
Conductivity Silica
( mhos)
(ppm)
---------------------------------------------------
Feed Water
7.2 to 9.2
<2
<0.05
Drum Water
7.5 to 10.5
<200
<5.00
<5
<0.05
Main Steam
<2
<0.05
7.5 to 9.5
Ensure that minimum five bed temperatures are between 650 950 deg.C.
Ensure that the oxygen level in the flue gas is maintained between 3 5 % in
stable load conditions above 65% MCR for efficient operation when the bed
condition is healthy.
Check both the drum gauge glasses level once a shift and blow down once in
each shift.
Cross check and ensure that the control panel readings and the Yarway
level, Gauge glass level and transmitter level indicator are same at least
once a shift.
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5.EMERGENCY OPERATIONS
Responsibility : Operator
Inform to the shift in-charge and other boiler operators, if any
tube failure occurs and drum level is not maintaining and carry
out the following activities :
Draw steam from other boilers, if required, and reduce the load on TGs
accordingly.
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: 2.36 MM
: 0.85 MM
: 20
Particle density
: 2000 Kg/M3
Bulk density
Chemical composition
: Alumina
Silica
Fusion temperature
: 1400 Deg C
: 19.89 MT
45% to 35%
55% to 65%
Charcoal
Size
: 15-25 MM Lumps
Calorific value
: 6600 Kcal/Kg
: 440 Kgs
Diesel
: 50-150 Ltrs
Bed material to be filled and level of defluidised bed should be 300 MM of WC.
And first compartment to 225 MM of WC for reduction of charcoal and diesel
consumption.
Fill the water and keep the drum level 30-40%.Irrescpective of drum level 3040% take water into drum through economiser initial fill up line and drain
excess quantity to avoid any starvation of economiser if yet all economiser is
in emptied before light up by any mistake.
Check for dry fuel(0-6 MM) is available in bunker and gates below bunker are
open and fuel is available at feeder inlet.
A fixed quantity of dry charcoal (400 Kgs i.e 20 Kg.per M3 area of bed)is
spread uniformly over the start up compartment.
Start the LD oil pump and maintain the oil pressure between 6.0 8.0
kg/cm.sq.
Keep the oil burners in position and flush out the diesel and atomising PA air
lines.
Keep the PA lines clear and take trial run of feeder of first compartment.
Initally the top bed temperature raise and at the time of mixing temperature
drops and bottom temperature raises at the time of mixing.
it is not possible to
access how much charcoal is burnt out.It is advised to cool throughly and
drain the bed material and do fresh light up.
When the bed temperatures reaches 450-600 Deg C start the drag chain coal
feeder.
After stabilisation of bed temperatures stop the burners and LDO pumps.
Close all air vents when the drum pressure reaches between 2 to 3 kg/cm.sq.
Ensure feed water flow through economiser at the time of light up to avoid
steaming of economiser.
Open Pilot valve of the Stop valve when the steam pressure reaches 60 - 70
kg/cm.sq. and temperature reaches between 400 to 450 deg.C.
Open Stop valve when the steam pressure reaches 65 - 75 kg/cm.sq. and
temperature reaches between 400 to 450 deg.C. and close the Pilot valve.
Open
Charge the ESP fields and start the ash handling system.
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6.COMPARTMENTAL TRANSFER
Responsibility :
Now open the compartment (FD)air damper of the adjacent compartment which
is to be activated.
Allow heat transfer from the Hot bed to cold bed until the bed temperature of
operating bed drops to 750 Deg C.
Follow the process until the new compartment reaches 600 DEG C.
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7. COMPARTMENT SLUMPING
Responsibility :
Bring down the fuel rate to minimum and switch of the feeder.
When Fludising air through a compartment is cut off the other compartments air
will increase.
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In case of power failure shut off inlet dampers of FD fan and ID fan.
In case of Boiler stoppage.Close the boiler stop valve and maintain drum level.
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Reduce the fuel feeding rate and slowly empty before switching off feeders.
Open the manual doors at the drag chain feeders to kill the vaccum created by
PA fan to avoid carry over of coal by gravity.
Open air vent to reduce the steam pressure if steam is not drawn out.
If it is not necessary to enter the boiler for maintenance slow rate of pressure
and temperature decay is desirable. Switch of fans when bed has cooled down to
500 DEG C.
After bed temperature reaches 100 DEG C open boiler blown down valve and
drain water if the boiler water temperature reaches only 90 DEG C. ( To be done
only incase to attend any maintenance jobs on pressure part side).
In case to attend fludising nozzles or distrubuter plate jobs drain bed material.
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If the boiler is required for shut for short period (Minimum 2 Hours) only.
Close the main steam stop valve and keep the vents in closed condition to
sustain steam pressure and temperature.
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Open the air vent Ensure FD damper and PA damper for open condition.
Gradually open ID and FD fan dampers to maintain air flow D.P of 30 MM and
plenum chamber 10 MM.
Increase the speed of fuel feeders and watch the bed temperatures.
As the bed temperatures increases slowly increase the air flow and fuel feed rate
as per load requirement.
If the bed temperature is below 600 DEG C throw charcoal and raise the
temperature.
If th bed temperature falls below 300 DEG C cool the bed and start the boiler
following normal startup from cold procedure.
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For single element control drum level is directly taken and feed control valve
regulates according to it.
Up to 30% of boiler load drum level to be controlled by single element and above
30% by three element control.
b. Combustion control
Purpose is to ensure air flow into the furnance is proportional to the total amount
of fuel entering the furnace at any instant.
Air flow control to be taken in auto when all compartments are in service
atleast once.
Observe for alarms when air flow reaches maximum and minimum valves.
Main steam pressure and bed temperatures are considered for fuel flow
control.
Out of two bed temperatures average is considered and erratic signal( like
bed temperature less than 600 Deg c, Open circuit of thermocouple and
temperature difference of more than 50 deg C)are not considered.
The fuel feeder trips if bed temperature reaches high 950 Deg C and starts
when temperature drops 750 Deg C.
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Bed temperatures can be reduced upto 700 Deg C and can be increased upto 900
Deg C based on demand.
Further load can be reduced by reducing fluidising air flow not to the extent of
defluidisation of bed.
In Such above cases air flow through PA lines should never be reduced.
Ingress of foreign material to be removed this may lead line choke which is
indicated by Drop in Bed temperatures for the same load and by PA line DP
switches.
Continous blown down (CBD)to be kept constant after fine tunning. Only
Intermedite Blow down (IBD) to be operated depending upon Lab (Conductivity
,silica & TDS levels)report.
Safety valves to be inspected at the drip pan for any passing of valves as passing
may lead to damage of safety valve seat.
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ID fan drive end and non drive bearing temperatures should be below 115 Deg C.
PA fan drive end and non drive bearing temperatures should be below 115 Deg C.
PA should be in operation.
FD fan drive end and non drive bearing temperatures should be below 115 Deg C.
Feed pump drive and non drive temperatures should be below 115 Deg C.
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14. TRIPPINGS
Source of Tripping
Alarm
Trip Value
33%
77%
22%
88%
Tripping Victim
FD Bearing Temp
Winding Temp
PA Trips
Furnace draught
90 Deg C
110 Deg C
-
115 Deg C
135 Deg C
+24.5 MMWC
FD fan
FD fan
FD fan
FD fan
PA Bearing Temp
Winding Temp
ID Trips
90 Deg C
110 Deg C
-
115 Deg C
135 Deg C
-
PA fan
PA fan
PA fan
ID Bearing Temp
Winding Temp
Boiler drum level Low
High
90 Deg C
110 Deg C
-
115 Deg C
135 Deg C
22%
88%
ID fan
ID fan
ID fan
ID fan
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115 Deg C
135 Deg C
1600 MMWC
30 %
FD fan trip
Closes
Closes
ID fan
ID fan
FD fan
Feed
Feed
Feed
Feed
pump
pump
pump
pump
Fuel Feeder
Fuel Feeder
Fuel Feeder
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