Boiler Operation TTPS

TUTICORIN THERMAL POWER STATION
200
4
OPERATING INSTRUCTION MANUAL

UNITS I, II & III
CONTENTS
Sl.No.
CHAPTERS
PAGE NOS.
1.
BOILER
2.
FEED WATER SYSTEM
3.
FUEL OIL FIRING SYSTEM
14
4.
AIR PRE HEATER SYSTEM
23
5.
INDUCED DRAFT FAN SYSTEM
27
6.
FORCED DRAFT FAN SYSTEM
36
7.
AUXILIARY STEAM SYSTEM
47
8.
SCANNER AIR FAN SYSTEM
50
9.
SEAL AIR FAN SYSTEM
53
10.
PRIMARY AIR FAN SYSTEM
55
11.
COAL PULVERISER SYSTEM
61
12.
COAL BURNER SYSTEM
68
13.
SH / RH ATTEMPERATION SYSTEM
73
14.
DUST CONTROL SCHEME
76
15.
SOOT BLOWER SCHEME
81
16.
ASH WET DISPOSAL SYSTEM
83
17.
STEAM CIRCUIT SYSTEM
89
18.
STEAM GENERATION
95
19.
COLD / WARM START UP ACTIVITIES
103
20.
HOT START UP
126
BOILER
INTRODUCTION :
The Boilers of 210 MW Units in TTPS are of conventional Single Drum,
Natural Circulation, Radiant, Dry Bottom, Balanced Draft and Re Heat Type. The
Steaming capacity of the Boiler is 700 T / Hr., designed for full Load Oil Firing or
Coal Firing, depending upon the availability of Fuel. During Startup, when the
Furnace will be comparatively cold, Light Oil (High Speed Diesel Oil) will be used
and can be changed over to Heavy Oil Firing and subsequently to Coal Firing as
the Furnace temperature and Steam flow through the Boiler increases. The heat
released in the Furnace is received by the Water / Steam / Air to the maximum
extent to have a Boiler Efficiency of the order of 86 %. The Boiler consists of the
Furnace, Drum, Down Comers, Water Wall, Super Heaters, Re Heaters,
Economiser, Air Pre Heaters, Bottom Ash Hopper and the connected auxiliary
equipments for injecting Coal / Oil to the Furnace and for extracting the
combustion products.
The Natural Circulation in the Boiler Water Walls is based on the Thermo
Siphon principles. As the Heat input to the Furnace increases, the water
temperature near the surface of the tube increases and reaches saturation
temperature. At this point a change from liquid to vapour occurs locally. But since
bulk of the water does not reach Saturation temperature, the steam bubbles collapse
giving up their Latent Heat to raise the temperature of the bubbles do not collapse.
This condition is known as the Nucleate Boiling. The Circulation system in this
Boiler is designed to ensure the Nucleate Boiling for all anticipated operating
conditions. One more design criterion is the acceptable percentage steam by
volume or the corresponding percentage Steam By Weight (SBW) through out the
fluid flow path. The SBW is the circulation number which is the ratio of the
quantity of the mixture flowing through the circuit to the quantity of steam
produced in the circuit, which will be normally around 6 to 8 .
The circulation is achieved by the density difference between the column of
water in the Down Comer and the column of water and steam mixture in the
Furnace Walls.
TECHNICAL SPECIFICATIONS :
1. TYPE :
Tangentially fired, Balanced draught, Natural Circulation, Radiant

Reheat Type, Dry Bottom with Direct Fired Pulverised Coal with Bowl Mill or
with Fuel Oil.
2. FUEL :
a. Bituminous :
Designed Coal
Worst Coal
Fixed Carbon
Volatile Matter
Moisture
Ash
Grindability
HHV
33 %
28.5 %
15 %
23.5 %
45 HGI
5000 Kcal / Kg.
40.5 %
33 %
7.5 %
19 %
55 HGI
5960 Kcal / Kg
b. Fuel Oil : (IS 1593 )

Carbon
Hydrogen
Sulphur
Others
GCV
85.5 %
11.05 %
2.5 %
0.5 %
10,200 Kcal / Kg.
c. Warm up and Ignitor Oil :

HSD Oil to the Specification IS 1460 / 1974
3. FURNACE :
Width 13.868 Metre.

Depth 10.592 Metre.
Volume 5210 M3
Type Fusion Welded Panels
4. SUPER HEATERS :
Type
a) Stage I
b) Stage II
c) Stage III
LTSH
Platen S.H
Final S.H
Heating Surface in M2
6360
1006
1037
5. RE HEATER :
Type
Pendent
Total Heating Surface

2700 M2
Control
Burner Tilt.
6. ECONOMISER :
Type
Total Heating Surface
No. of Stages
5690 M2
Continuous Finned
One
7. AIR PRE HEATER :
Type
Vertical Tri-Sector Regenerative

Rotary Air Pre Heater 27 VI 72
No. Off
2 per Boiler
Heating Surface
19100 M2 (each).
8. FUEL BURNING EQUIPMENT :
a. Burners
b. Coal Burners
:
:
c. Oil Burners
d. Ignitors
Tilting Tangential Burner.

24 Nos. Off / Boiler (located in the Corners of the
Furnace).
12 Nos. Off / Boiler (located in the Corners of the
Furnace).
12 Nos.
9. MILLS :
a.
b.
c.
d.
Type
No. Off
System
Basic Capacity
e. Motor
:
:
:
:
:
BOILER AUXILIARIES
A. FANS :
XRP 763 Bowl Mills.

6 per Boiler.
Pressurised Primary Air System.
33.8 T / Hr. for Coal with 55 HGI to 70 % through
200 mesh at maximum moisture 10 %
320 KW, 990 rpm, 6.6 KV
Sl.
Duty
No.
1.
F.D
2.
P.A
3.
I.D
Type
Axial
Reaction
API 20 / 11
Radial
ND FV 20 b
Axial
Impulse
AN 25 e 6
Medium Design
Motor
No. off /
Quantity Pressure Temp.
Boiler
KW rpm
0
M3 / Sec. mmWCL
C
2
150
495
40
1100 1480
2
67.5
940
40
900
1480
220
420
140
1700
990
B. SOOT BLOWERS :
Sl.No.
1.
2.
3.
Zone
Type
Furnace
Water Wall Soot

Blower
Platerns
Convection LRSB
Zone Re Heaters
Air Pre Heater
Swivelling
Quantity /
Boiler
56
Medium
Steam
20
Steam
Steam
Make
Dresser
Type
1759 WA
1749 WA
1749 WA
1538 VX
Set
Pressure
ksc (g)
158.2
161
162.4
141.5
Reliving
Capacity
T / Hr.
159
193
195
87.0
1739 WD
1739 WD
1775 WA
1785 WA
1785 WA
1785 WA
144.5
143.8
33.0
33.4
33.8
34.1
87.0
86.0
100.0
130.3
131.6
133.0
1705 RWD
30.6
115
C. SAFETY VALVES :
Sl.
No.
Location
1.
Drum
2.
Super Heater
(Electromatic
Valve)
3.
Re Heater (CRH)
4.
Re Heater (HRH)
Relief
FEED WATER SYSTEM
Purpose of this system is to Feed Water of specified quality to the Boiler and
its related parts to the required level at the time of filling the Boiler with Boiler
Feed Pump before Unit light up or Hydraulic test.
FEED WATER SYSTEM DESCRIPTION :
The Feed water system consists of the following:
i)
De mineralised water storage tank (DMWST)
ii)
De mineralised water make up pump (DMWMP)
iii)
Condensate storage tank (CST)
iv)
Hot well make up pump (HWMP)
v)
Main Condensate Pump (MCP )
Boiler feeding before Unit light up may be classified as,

1) INITIAL BOILER FEEDING TO THE REQUIRED NORMAL LEVEL OF DRUM :
This includes filling of water to the full level of Water Wall, Economiser and
to the normal level of Drum. This is for the purpose of Unit light up.
2) FILLING ALL PARTS OF BOILER :
This includes filling of water to the full level of Water Wall, Economiser,
Drum, Super Heaters and Main Steam Piping up to MSSV. This is for the purpose
of Boiler Hydraulic Test.
In both the above cases, filling is done by Boiler Feed Pump after providing
required chemicals (i.e Hydrazine and Ammonia ) in the Deaerator.
Regular feeding of water to Hot Well of the Turbine Condenser (i.e. Make
up Water) is done with Hot Well Make Up Pump, while Unit is in service.
FLOW PATH OF FEED WATER SYSTEM :
The flow path of Feed Water system starts from DM Water Storage Tank
(DMWST) and travels as follows.
i)
DM water at DMWST is pumped to CST to the required level with DM
Water Make up Pump.
ii)
DM Water from CST pumped to Hot Well to the required level through Hot
Well Make up Pump.
iii)
From Hot Well DM water is pumped to Deaerator using MC Pump.
iv)
The Chemically Treated Water at Deaerator is pumped to the following

through Boiler Feed Pump.
a) Economiser and then to Drum.
b) Water wall ring header and then to drum through water wall tubes.
c) SHH drain header and then to all SH headers and then to drum and
MS piping system up to MSSV.
RELEVANT INFORMATIONS REGARDING BOILER FILLING :

1) VOLUME DETAILS OF BOILER SYSTEM
(in M3) :
-----------------------------------------------------Sl.No.
Location
Total Volume to be
Volume to filled
Volume filled for unit
for Hydraulic
Light up
Test.
- - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1.
Drum
37.20
11.53
37.20
2.
Water Wall
126.30
126.30
126.30
3.
Super heaters
97.18
-97.18
4.
Re-heaters
48.10
--5.
Economiser
25.17
25.17
25.17
6.
MS piping
12.05
-12.05
------------------------------------------------------Total
346.00
163.00
297.90
------------------------------------------------------2) TECHNICAL DETAILS OF PUMPS AND TANKS :
i)
Pumps :
a) De Mineralised Water Make Up Pump (DMWMP) :

Quantity
Make
HP
RPM
Capacity
b) Boiler Feed Pump :
:
:
:
:
:
4 Nos. for Unit I, II & III.

BEACON
15
1440
40 M3 / Hr.
Make
Type
Quantity
Delivery head
Temp. of Fluid
Motor Capacity
:
:
:
:
:
:
BHEL / Hydrabad
200 KHI
7330 L / Min.
1830 MLC.
164.2 0C
4000 KW
c) Hot well Make Up Pump (HWMP) :

Quantity
2Nos. per Unit (i.e. 6 Nos. for Units I, II & III).
PUMP
CAPACITY OF PUMP
HEAD
CAPACITY
SPEED
:
:
:
:
100 T / HR.
30 MWC.
15 KW
1480 RPM
MOTOR
MAKE
KW
RPM
AMPS
PHASE
VOLTAGE
FREQUENCY
ii)
:
:
:
:
:
:
:
UNIT I & II
UNIT III
NGEF
15
1460
28
3
415
50 Hz
KIRLOSKAR
18.5
1470
32
3
415
50 Hz
Tanks :
a) Demineralised Water Storage Tank (DMWST) :

Quantity
Capacity
Diameter
Height
:
:
:
:
1No./ Unit
500 M3 (each tank)
9000 mm
8250 mm
b) Condensate Storage Tank (CST) :

Quantity
Capacity
Diameter
Height
:
:
:
:
1No. / Unit
350 M3
7.5 M
8.5 M
c) Quality of water from DM Plant to CST :
Conductivity
pH
Silica
:
:
:
0.3 mho / cm
6.5 7.0
Not traceable.
FEED WATER SYSTEM OPERATING PROCEDURE :

I)
DRUM FILLING FOR UNIT LIGHT UP :
a) Pre checks and preparatory steps :

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
No Line Clear is pending.

Hydra step (Drum level indication) is available.
Drum air vents, Economiser air vents and Super Heater air vents (except SH
start up air vents) are open.
E-2 Valve kept Open.
Close all WW drains and Eco drain valves in WWDH and close its inlet
Isolation Valve and master drain to IBD FT close also the Isolation Valve to
SHH filling line.
ERV Isolation Valve Open.
Safety valves in Drum, CRH, HRH and MS lines are ready.
Phosphate dozing Isolation Valve at 52 M Open.
CBD line drain is made through to IBD Flash Tank. (CBD Control Valve
may be opened only after Unit light up)
EBD valves may be opened once and after checking its performance, those
valves may be closed fully.
All instruments are ready.
MSSVs Closed.
10th Header Isolation Valve to Soot Blowers Close.
Man Holes, Inspection Doors and Peep Holes Close.
All Soot Blowers are in retracted condition.
16. FW System :
Isolate main Isolation Valve from FW line to Attemperation Headers.
Isolation Valves of Feed Control Valves (both FCV-2 & FCV-1 / 7) are kept
Open.
FCV-2 (1No.) and FCV-1 / 7 (2Nos.) Control Valves are in closed condition.
E-2 (Eco. Inlet Isolation Valve) valve Open.
Economiser Recirculation Valves Open.
17. All sampling line valves of Steam and Water open.
b) Drum Filling activities :

1. Fill up Deaerator up to Normal Level.
2. Doze with Ammonia and Hydrazine at Deaerator.

3. Start Boiler Feed Pump keeping its RC Valve Open and its Discharge Valve
Close till required value of pH and Hydrazine (Approx. 9 pH & 10 15 ppm
respectively) in DM water at Deaerator is attained.
4. Fill the Boiler slowly through FCV-2 for Normal Level in the Drum.
II. DRUM & SHS FILLING FOR HYDRAULIC TEST :
a) Pre checks and preparatory Steps :
1.
2.
3.
4.
No Line Clear is pending

All air vents (SH, Eco and Drum) at 52 M Open.
SH start up air vents (L&R) Close.
ERV Isolation Valve Close.
(Boiler operator should select ERV in manual or OFF mode).
5. Sampling line of CBD, Saturated Steam and Main Steam at 52M area are to be
Closed.
6. Phosphate dozing Isolation Valves at Drum Level Close.
7. MSSV L&R Close.
8. 10th header Soot Blowers Main Isolation Valve Close.
9. Economiser inlet Isolation Valve E-2 Open.
10.FW sampling Isolation Valve near E-2 Valve Close.
11.Feed Control Valves (FCV-2 & FCV-1 / 7 and its Isolation Valves) Ready.
Ensure closure of Feed Limb Drain Valve.
12. CBD valves at 18 M Close.
13.Main Isolation Valve to SH & RH Attemperation lines from Feed Water line
Close.
14.Economiser RC Valves Close.
15.SHH Drain Valves (12Nos.) at 18 M level should be kept Closed, its (manual)
master Drain Valve IBD to be Closed.
16.If the Hydraulic Test pressure is to be exceeded the pressure set values of Safety
Valves, then all the Safety Valves are to be gagged (by Boiler Maintenance).
17.All the Water Wall Drains & Main Header Valve (12 + 2) at Boiler 0M Level
(to IBD flash tank) must be kept Close condition during Hydraulic Test.
(i)
Drum & SHs Filling activities :
1. Fill Deaerator up to Normal Level.

2. Doze Chemicals Hydrazine and Ammonia at Deaerator.
3. Start the Boiler Feed Pump by keeping Discharge Valve Close and
RC Valve Open.
4. After ensuring the Chemical Values (pH 9 , N 2H4 10 -15 ppm), Start feeding
the Boiler through FCV-2.
5. After ensuring Free Flow of Water in the Drum Air Vents, Economiser Air Vents
and Super Heater Air Vents, Close them one by one.
6. Raise the Boiler Pressure slowly to 135 ksc and keep it for 5 Minutes.
7. After 5 Minutes, slowly reduce the Pressure to 70 ksc for inspecting the Boiler.
8. After completion of Hydraulic Test Drum Pressure may be gradually lowered to
about 5 ksc suitably after stopping Boiler Feed Pump.
9. Boiler Line Up for Light Up After Hydraulic Test :
a) Open all the air vents (SH, Eco. & Drum) at 2ksc.
b) Open SHH drains and Master valve to IBD for draining the Super Heaters.
c) Bring the drum level to normal value by opening EBD valves.
d) Open all the sampling line valves at Economiser and drum floor (CBD,SH&SS)
e) Inform Boiler Maintenance crew to release the Safety Valves gagging, if any.
f) Open ERV Isolation Valve.
g) Open Phosphate Dozing Isolation Valve at Drum Level.
h) Open Economiser RC Valves.
i) Open Start Up Vent Hand Valves.
Note : One Number Boiler Fill Pump is available at D.M Plant for Unit I, II & III
and its Specifications are as below :
PUMP :
Make
Rated Capacity
Shut off Head
Speed
Pump Efficiency
Power Input to the Pump
:
:
:
:
:
:
SAM TURBO INDUSTRIES LTD.,

200 M3 / Hr.
200 M.
1500 rpm.
74 %
160 KW.
:
:
:
:
:
:
:
Crompton Greaves
3 Induction Motor.
415 10 Volt.
1490 rpm.
260 A.
160 KW.
95.3 %
MOTOR :
Make
Type
Voltage
Speed
Current
Rated Capacity
Efficiency
There are provisions for filling the Deaerator and Boiler (through bottom
Water Wall Drains and Super Heater Drains) for Units I, II & III by using Boiler
Fill Pump. Boiler Fill Pump LT Breaker is available at Unit III Heat Exchanger
Switch Gear Room.
FUEL OIL FIRING SYSTEM
The main objective of this system is for lighting up the boiler and flame
support to main fuel up to and below 120MW.
SYSTEM DESCRIPTION :
1) HIGH SPEED DIESEL OIL SYSTEM :
HSD firing is normally carried out only during cold light up periods. It is
also advisable to use HSD till Furnace temperature is increased to a limit above
which HFO can be easily & freely fired. It will take at least one hour for the above
temperature rise and hence, HFO change over is being carried out only after one
hour of Boiler lighting up. During this period, only one pair of Guns in AB
elevation is to be cut in to service. It is the routine practice to cut in AB 1 to 3
Guns for the first hour and AB 2 & 4 Guns are cut in additions in the next
hour, so that warming up of the Boiler will be uniform and slow.
HSD contains minimum Sulphur contents (almost 0.5%) and HFO contains
almost 1 to 3%, hence it will be better to cut in SCAPH before lighting up the
Boiler to avoid cold end corrosion of APHs.
HSD is being transported from IOC at Nellai through Oil Tankers. Oil is
transferred to HSD Storage Tank of capacity 1176 KL through 2x100 % duty HSD
Oil Decanting Pumps. Each Pump can deliver 50 M3 / Hr. oil.
HSD Pumps are Screw Pumps. There are 2 x 100 % duty HSD Pumps to
deliver HSD to one stage. There are two Strainers at the suction side of the Pumps.
Any strainer can be used for any Pumps. Pump discharge pressure is being
controlled by a pneumatic RC valve at Pumps discharge. In the firing floor HSD
line is provided with a Trip Valve and a flow Control Valve. Bypass Valve to flow
Control Valve is also provided for the purpose of manual operation in case of
failure of pneumatic control of PCV.
The Controlled Oil is then allowed to go through all the Guns in AB
elevation through Hydra motor valve and NRV.
Since this HSD is costlier than HFO, the duration of HSD firing is restricted
to about one hour only.
2) HEAVY FURNACE OIL SYSTEM :
HFO is brought to TTPS either through roads or by rails. There are 2x100%
duty Transfer Pumps at oil and Decanting Pump House to transfer the receipt HFO
to HFO Tanks at TTPS.
There are 2 Nos. HFO Tanks of 13,598 KL capacity each. As the hot oil
circulation is being done continuously, the HFO Tank temperature is maintaining
around 80 0C so as to restrict the firing of oil in the Oil Tank itself, it is the routine
practice in TTPS to cut out the HFO heating only if the Tank temperature exceeds
85 0C and HFO heating is cut in to service if the HFO Tank temperature has fallen
down below 75 0C.
There are three numbers of oil temperature gauges at local in each HFO
Tank at 120 o apart.
There are Two Nos. of drains in each HFO Tank (provided 120 o apart) so
that the water is being let out periodically. Usually this draining is being carried
out once a week.
Auxiliary PRDS steam is utilized for the following purposes at FOPH and
decanting pump house.
a) For steam coil heating inside the HFO tank.
b) Steam coil heating in the bottom of HFO tank but at the Normal, Take off
point of HFO to the Common Suction Header to the Pumps.
c) HFO Heaters.
d) HFO Tankers heating while decanting the LSHS (Low Sulphur High Stock oil).
Apart from that, electrical space heaters at various locations in HFO Pump
suction lines, FOPH lines, HFO lines after Pumps and HFO return lines are
provided to keep up the temperature so that easy flow of HFO may be ensured.
Each Tank receiver oil from Decanting Pump House at its top. Isolation
Valve is provided to completely isolate the receipt of oil from Decanting Pump
House. Similarly each Unit RC lines are also connected at the top of the HFO
Tank.
The oil delivery from HFO Tank to Pump is taken at two levels in HFO
Tank. The normal source level is somewhat at higher elevation when compared to
that of emergency source delivery point. The normal source of delivery line
contains steam heating provision where as the emergency lines do not.
Two numbers of normal and emergency take off points connect two numbers
of HFO receipt line. Normally one number receipt line is made through to all
Units HFO Pumps suction.
The construction of HFO Strainers and HFO Pumps are just like that of HSD
Pump except the following :
a) One LDO line is connected well before the Strainers of the HFO scheme so as
to release Strainers choke up in case of LSHs handiling. This LDO Isolation
Valve is being normally kept closed during HFO handling.
b) Pumps
Numbers
Discharge
Pr. (ksc)
Capacity
LPH
HSD
4 (Stage I & II )
22.5
205
HFO
6 (Stage I & II)
22.5
1140
c)
HFO Tank
LDO Tank
Capacity :
13598 KL
Capacity :
1176 KL
Height
15.33 M
Height
11.6 M
Dia
35 M
Dia
12 M
Vertical Tank
Vertical Tank
c) Steam Heaters are available in HFO system to ensure easy flow and for having
better atomization.
e) RC at Burner location is available in case of HFO system.
f) Fine Filters are available at 18 M Level.
III.
OPERATION :
A)
HSD LINE : LINE-UP AND CHARGING :

1)
HSD Tank :
a) Isolation Valve to Pumps from the Tank Open
b) Isolation Valves of RC Valves at HSD Tank Open
c) Tank Vent Open
2)
Pump Side :
a) One Strainer is in service, the other one is standby.
b) Suction valves of both the Pumps are open.
c) Discharge valves of both the Pumps open
d) Isolation Valves of Pneumatic Control Valve (RC valve) Fully Open.
Its Bypass Valve Fully closed.
e) Pumps are primed up.
f) Strainers are also primed up.
3)
18 Metre Side :
a) Trip valve is made through.
b) PCV is made through. Ensure the closure of PCV Bypass Valve.
c) Atomizing air pressure is adequate.
d) All LMS (Local Maintenance Switches) in AB elevation are in
Remote position.
e) All limit switches of AB elevation HSD lines and air atomizing lines
are being made through.
f) Ensure the closure of all HMVS.
NOTE:
For starting any HSD Pump, Tank side and FOPH side clearances
only are essential. The 18 M side LINE-UPS should be
followed up
by the 18 M Operator during Pre-Light up checks.
Priming the Strainers :

1. Open the Strainer Vent (Say LHS)
2. Slightly open the Suction Valve of the LHS Strainer.
3. Close the Strainer Vent, only if HSD oil alone is coming out of the Vent.
4. Then open full the Suction and Discharge Valve of the LHS Strainer.
5. Similarly the RHS Strainers may also be made ready. But keep any one
Strainer in service at a time.
Priming the Pumps :

1. Prime the strainers as mentioned above.
2. Open suction valve of pump full.
3. Open discharge valve of pump full.
4. Just rotate the pump by hand for some time.
5. Similarly prime the other pump also.
NOTE :
1. Since the pumps are Screw Pumps both the Suction and Discharge Valves of
both the Pumps are to be kept in full open condition.
2. The Strainer different pressure is always to be lower than 0.5 ksc. If it exceeds
the limit, bring the other Strainer in service and isolate the former one.
Operation of the Pump :
1. Start any HSD pump (Say A)
2. Ensure the healthy running of the pump, just as
a) No vibration
b) No abnormal noise
c) No leaks
d) Discharge pressure normal
e) Strainer DP within limits
3. FOPH Operator informs Boiler Operator about the starting and normalcy of
the HSD Pump.
4. Boiler Operator is getting clearance from 18 M Operator also.
5. Boiler Operator is doing the Purging operation.
6. Boiler Operator selects the Light Oil Firing Selection
7. Boiler Operator opens the LOTV.
8. AB elevation Light Oil header pressure is being raised to about 12 to 15 ksc
by suitably operating PCV.
9. AB-1 & 3 Guns are cut-in
AB-1 Gun will prove first
AB-3 Gun will prove next
During this period, the Light Oil pressure will lower due to the consumption
of oil by Guns. Hence Boiler Operator will keep up the elevation Light Oil
header pressure by properly operating the Light Oil PCV.
10.Boiler Operator cuts in the Light Oil Guns of AB-2 & 4 after an hour.
11.Boiler Operator cuts in any two Guns in CD Elevation (HFO Guns) and then
only cuts out of AB Guns (LDO firing) while changing over to HFO.
B)
OPERATION HFO SYSTEM :
PRE START CHECKS IN HFO SYSTEM :
1. HFO Tank Oil level Normal

2. HFO Tank level indicator Working
3. HFO Tank temperature indicators Working
4. HFO Tank drains Close
5. HFO Tank RC lines and Decanting Isolation Valves Open
6. Electrical Space Heaters at various locations ON
7. Both the Strainers have been primed up.
8. Both the Pumps have been primed up.
9. RC Valves Isolation Valve Open.
Its Bypass Valve Close.
10.HFO Heaters Steam side isolated.
11.HFO Heaters Isolation Valves to cells Close.
12.HFO Heaters Isolation Valves from cells to concerned Unit Close.
13.Steam Traps in condensate lines Close.
Its bypass valve Open.
14.Steam is available from PRDS.
STARTING OF THE PUMP :
1. Start the Pump.

2. Ensure it normally.
3. Open the oil vent at cell (Heater)
4. Slightly open the cell Inlet Valve and charge the Heater cell at slower rate.
5. After confirming the proper venting out, close the oil vent.
6. Fully open Suction and Discharge Valves of the concerned cell (but slowly)
7. Similarly other cell is also brought into service.

8. Charging of steam to HFO Heaters.
a) Proper care should be taken to charge the steam side only if oil is already
charged with the concerned cell.
b) Slightly open the steam Bypass Valve.
c) After 10 Minutes warming up, bring the Steam Traps into service in the
steam condensate line and close the Bypass Valves of concerned Steam
Traps.
d) Charge steam side slowly, F.O. temperature at Heater outlet should be
maintained at 130 0C for HFO and 115 0C for LSHS.
e) Auto operation of Steam Control Valve may be tried with and if it is OK,
the C/P valve may be closed fully.
PRE CHECKS BY 18 M OPERATOR :
Pre Checks :
1) Short RC Valve Full Open
2) Strainers Fully Isolated & Its Vents Open
3) Trip Valve is made through
4) Long RC Valve is made through
5) HFO Control Valve is made through Its Bypass Valve is closed.
6) AB, CD & EF Elevations Isolation Valves both at inlet and outlet Open.
7) All limit switches of healthy HFO Guns Open full.
8) All HFO HMVS closed.
9) All scavenge HMVS closed.
10) All LMS Remote.
11) Atomizing steam is available.
CHARGING HFO AT 18 M LEVEL :
1)
2)
3)
4)
5)
Open any one Strainers inlet valve slightly.

Wait till proper priming.
Close the Vent fully.
Open both Suction and Discharge Valves of Strainer Full.
Similarly charge the other Strainer also and then keep only one Strainer in
service.
6) Since short RC Valve is in Full Open condition, oil will be circulating through
short RC Valve.
7) Open long RC Valve.
8) Open TV (Trip valve)

9) Open PCV and Throttle short RC Valve.
10) Now HFO pressure at Burner Header may be maintained around 12 ksc to
15 ksc. HFO temperature may pickup to 110 0C to 120 0C within 5 to 10
Minutes.
11) Select HFO firing selection in case of HSD firing in AB Elevation.
12) HFO long RC Valve will be closed on Auto only after the first Gun
establishment.
13) Regulate the Heavy Oil Header pressure either on Auto or in Manual
mode while cutting in and cutting out the HFO Guns.
14) If the warm up period is over in the Boiler, cut in any one pairs Guns in CD
Elevation Guns.
15) If CD Guns (HFO) are OK, cut out AB Guns (LDO firing).
16) Wait for 5 Minutes.
17) Select HFO firing in AB Elevation Guns.
18) Cut-in all the four Guns in AB Elevation one pair after the other (HFO
firing)
19) CD Guns may be cut out after cutting in the first one pair of HFO Guns in
AB Elevations.
20) All the four Guns (HFO) in AB Elevation may be kept in service
continuously till 120MW.
21) APH Soot Blowers may be operated continuously from the light up till oil
support is with drawn.
GENERAL:
Whenever unit load reduces below 130 MW, cut-in HFO Guns for stability in
any elevation where it is required.
During a Planned Shutdown, cut-in Oil Guns at / above 120 MW and cut out
all Mills after emptying the same. Trip Turbine by keeping one or two Oil
Elevation Guns with < 20 MW.
HYDROMETER VALVE
RETURN OIL
FSSS
PERMISSIVE
AIR
PR. LOW TRIP
PS
SCANNING
VALVE
FSD
PS
OIL
GUN
HOSE
LO
TANK
1000 T
AIR
PCV 12
SERVICE
AIR
PCV 8
FLOW METER
STRAINER
STRAINER
LO PUMPS
175 L/m
23.3 Kg/Cm2
LO
PCV 10
LOTV
FSSS PERMISIVE
PS
OTHER
ELEVATIONS
IGNITOR OIL CXT.

IOTV
AB ETC IGNITOR
PRV 11
STRAINER
RETURN OIL LINE

FO
TANK 1
18M LEVEL
FOPH
OM LEVEL
12500T
PCV 6
RC
RETURN OIL
UNIT I
OIL HEATING STATION

FORV
INTER
CONNECTION WITH
OTHER UNITS
STRAINER
OTHER UNITS
HO PUMPS
1100 L/Min
22 Kg/Cm2
TEMP.
STEAM TRAP
OTHER
ELEVATION
FLOW
METER
HOTV
STRAINER
FCV 3
AB Etc
FROM PRDS
PCV 7
TCV 7
FROM
PRDS
FO
TANK 2
12500 T
INLET
VALVE
NON PR. CONTROL

PCV 15
TO ATMOS.
HYD. MOTOR VALVE

AB ETC, HEAVY OIL
FSSS CONTROL
STEAM
HOSE
SCAVANGE
VALVE
OIL GUN
LIGHT OIL & HEAVY OIL FLOW

DIAGRAM
TYPICAL UNIT I
OIL HEATING STATION

S-39
FROM FUEL OIL
PUMP HOUSE
S-39
STEAM FROM PRDS
TCV-7
TO DRAIN
S-44
FO-38
FO-36
FO-36
FO-43
S-36
FO-37
HOTV
FO-37
TO BURNERS
S-36
FO-38
PCV-6
FO-37
FO-37
FO-17
FO-48
FO-36
FO-36
FORV
FO-43
FO-17
FO-57
FUEL OIL
RETURN
TO CONDENSATE HEADER
AIR PRE HEATER SYSTEM

The main objective of the system is to recover and utilize waste heat from
flue gas. Air Pre Heater is a rotating element, which absorbs waste heat from Flue
Gas and transfers this heat to incoming Cold Air by means of continuously rotating
heat transfer elements.
The Air-Pre Heater absorbs waste heat and transfers to incoming cold air by
means of rotating heat transfer elements of specially formed metal plates.
Thousands of these high efficiency elements are spaced and completely arranged
within twelve sector shaped compartments of a radially divided cylindrical shell
called the rotor. The housing surrounding the rotor is provided with duct
connections at both ends and is adequately sealed by radial and circumferential
sealing members forming an air passage through one half of the pre heater and a
gas passage through the other.
As the rotor slowly revolves the mass of elements alternate through the gas
and air passage, heat is absorbed by the element surfaces passing through the hot
gas stream; then, as these same surfaces are carried through the air-stream, they
release the stored up heat thus greatly increasing the temperature of the incoming
combustion or process air.
(a) HEATING ELEMENTS :
This is a compact arrangement of formed metal sheets contained in the rotor

in two or more layers. The basketed element in the cold end where the air is
admitted and flue gases are discharged can be removed through an access door in
the APH housing without disturbing the sealing members.
(b) ROTOR BEARING :
The complete Rotor is supported by a Thrust Bearing and the load is

transmitted to the bearing by a Trunion bolted to the lower end of Rotor Post. To
guide the upper end of Rotor, a Guide Trunion is bolted to the face of the Rotor
Post. The position of this Trunion is maintained by a Radial Guide Bearing
assembly.
(c) OIL CIRCULATION SYSTEM :
This system is designed to supply the Support and Guide Bearings with a
bath of continuously cleaned oil at the proper viscosity. Circulation of the oil is by
means of a motor driven pump through an external filtering system.
(d) ROTOR DRIVE UNIT :
The driving force for turning the rotor is applied at its periphery. A pin rack
mounted on the rotor shell is engaged by a pinion attached to the low speed shaft
of a power driven speed reducer or gear motor.
(e) ROTOR SEALS :
Seals are provided at both ends of air pre heater to minimize leakage
between the air side and gas side of the pre heater. The hot and cold end radial
seals are attached to each diaphragm of rotor and are set at specified clearance
from the sector plates which separate the air and gas streams.
The seals provided at rotor post are set to operate with minimum clearance
with respect to horizontal sealing surface of center section.
Bypass seals provide sealing between the periphery of the rotor and sealing
surface of the connecting plate and preheating housing.
Axial seals are provided vertically in the rotor shell in line with radial seals.
(f)
CLEANING DEVICE :
It consists of an electric motor coupled to a gear driven crank mechanism

which oscillates the swivel header carrying the nozzle pipes. The cleaning medium
is conveyed through the swivel header and respective nozzle pipe to the nozzle at
the end.
TECHNICAL DATA :
Heater Size :
27 V I ( T ) 72
1. ROTOR DRIVE: Motor

Speed Reducer
Oil capacity
Coupling
:
:
:
TEFC 11 KW 1500rpm 3 415V 50Hz

Class F Insulation.
5APC, APCO 110:1
50 Lt.
11.5 FCV fluid coupling.
2. AUXILIARY DRIVE :
Air motor
:
Coupling
:
Solenoid valve
:
Pressure switch
:
Rotor Support Bearing:
Guide Bearing
:
Chicaco Pheumatic air motor RSM 400 (APCO)

124 A Bibby.
BSP AVOCON 230V.
SOR NPT.
Spherical Roller Thrust. SKF 294/500.
Spherical Roller Bearing 23060.
3. OIL CIRCULATION SYSTEM:

For Support Bearing Motor
Pump
Coupling
For Guide Bearing Motor
Pump
Coupling
:
:
:
:
:
:
TEFC 0.75KW 1500rpm 415V 3 50Hz

HYPO 3 SP 15 Lit/Min.
Lovejoy L095.
0.55KW 1000 rpm 414V 3 50 Hz.
HYPO 3 SP 15 Lit/Min.
Lovejoy L095.
TEFC 0.18KW 1500rpm 415V 3 50Hz
:
:
:
Allroyd or Radicon.
Lovejoy L095
1200 kg / Hr / Device at 17.6 ksc.
4. CLEANING DEVICE :
Motor
Reducer
Coupling
Steam consumption
PROCEDURE :
The operating procedure is as follows :
PRECHECKS :
1) Confirming no Line Clearance pending on the system equipments.

2) Pre-checks for all the system equipments should be carried out such as:
a.
b.
c.
d.
Checking of oil levels.

Conditions of couplings.
Availability of air for air motor.
Availability of Auxiliary cooling water.
OPERATION :
1. Start Guide Bearing LOP A1.

2. Ensure its normalcy.
3. Start Guide Bearing LOP A2 and stop Guide Bearing LOP A1.
4. Ensure the normalcy of Guide Bearing LOP A2.
5. Keep Guide Bearing LOP A2 in service.
6. Similarly check the standby conditions of Guide and Support Bearing LOPs and
keep any one LOP of Guide Bearing and Support Bearing LOP in service.
7. Start air motor first in case of lighting up of the Unit after a Major Overhaul or
any work attended inside Air-Pre Heater.
8. Start main A.C. APH motor, Air motor will stop on Auto. Watch the no load
current.
9. Ensure normalcy of APH main motor and air motors standby condition. Then
keep main motor in service.
10.APH shall be stopped while making the Unit for Shutdown, when the FG
temperature outlet comes below 120 0C.
11.After stopping APH main drive, the Guide Bearing and Support Bearing and
Support Bearing LOPs shall be stopped 2 to 3 Hrs after the stopping of APH.
EMERGENCIES DURING OPERATION :
I.
APH Rotor Stopped : Annunciation at window appears when anyone APH

motor got tripped. Look for air motor starting or otherwise reduce the Unit
load immediately and look for the remedy.
II.
Fire in APH : Incase of fire in APH, reduce the unit load and look for fire
quenching by external agencies or by means of APH fire pump.
III.
Flue gas O/L Temperature at APHs : If there is a vast difference between

two APHs O/L temperature for example more than 15 to 20 0 then look for
the APH seals damage. In that case isolate that APH or reduce Unit load for
remedial measures.
INDUCED DRAFT FAN SYSTEM

Induced Draft Fan is provided in a Boiler to suck the Flue Gas resulting
from the combustion of the fuel inside the furnace and expel the same into the
atmosphere through the Chimney.
As the name implies, the Induced Draft Fan induces the flow of Flue Gas
along the two passes of the Boiler, by providing a gradually increasing negative
pressure from the Furnace the first pass, followed by the heat recovery equipments,
Viz, RH, SH, Eco. and APH arranged in the intermediate and second pass and
finally along the ESP. The Flue Gas is then handled by the ID fan, pressurized and
finally sent out through the Chimney.
The main purpose of inducing this flow of the Flue Gas at a rated speed over
the various heat recovery equipments is to recover the enormous heat carried away
by the Flue Gas, which would otherwise be wasted, resulting in lesser Boiler
Efficiency. The heat in the Flue Gas is transferred to the steam in SH and RH, to
water in the Economiser and to the Primary and Secondary Air in the APH. The
Flue Gas leaves the APH at about 147 0C and enters the ESP for ash removal. As
the ash removal is very effective when the temperature of Flue Gas passing over
the ESP fields is around 130 0C, the Flue Gas temperature at APH outlet should
never fall below 135 0C.
Another important function of the ID Fan is Purging. Whenever a Boiler is
to be lighted up after a Shutdown or a Tripping, the Furnace should be evacuated
of any combustible remnant. For this purpose one set of ID Fan and FD Fan is
brought into service and the Furnace is purged for 5 Minutes with > 30% Air Flow.
During normal operation, the ID Fans are loaded such as to maintain a Furnace
pressure of 5 to 10 mmWCL. But during any emergency, the pressure may
fluctuate both on the positive and negative sides. Whenever the Furnace pressure
becomes Very High, it may result in the Explosion of the Boiler, while Very Low
Furnace pressure may result in the implosion (buckling) of the Boiler. Hence the
operator must take enough care to maintain proper pressure inside the Furnace.
For this purpose, alarm is provided in the control desk to indicate Furnace pressure
high at +50mmWCL and low at 50 mmWCL. Further protection tripping of the
Unit is also provided at Furnace pressures of 150 mmWCL and + 150 mmWCL.
CONSTRUCTIONAL DETAILS :
The Fan consists of the following Sub Assemblies :
1) Suction Chamber.
2) Inlet Vane Control.
3) Impeller.
4) Outlet Guide Assembly.
5) Diffuser.
6) Bearings.
7) Flexible Coupling.
1) SUCTION CHAMBER :
The Suction Chamber is of welded sheet steel construction and is split
horizontally for easy assembly and dismantling. A man hole is provided in the
Suction Chamber for checking up the Inlet of the Fan.
2) INLET VANE CONTROL :
The Axial Inlet Vane Control Assembly of the Fan consists of a number of
Aerofoil Inlet Vanes fixed to individual shafts which are connected by means of
Angular Joints to a Central Ring. The Ring is guided by a set of Roller and Spring
Assemblies. A Control Lever is connected to the Ring which can be operated by
an electric servo motor or a Pneumatic Power Cylinder. The Inlet Vane Control
Assembly is split to facilitate handling and dismantling.
3) IMPELLER :
The Impeller body is welded sheet steel construction, with welded on, non
profiled solid blades. The Impeller is dynamically balanced. It is bolted to the
flange welded on to the hollow shaft. The Impeller casing is of undivided type but
the conical connection piece connected to the casing is split horizontally such that
the top half can be removed for removal of the Impeller. A peep hole is provided
in the casing for checking the wear on Impeller. The Impeller is supported in
between the bearings.
4) OUTLET GUIDE ASSEMBLY :
The outlet guides are fixed in between the core of the diffuser and the
casing. These guide vanes serve to direct the flow axially and to stabilise the drift
flow caused in the Impeller. The Outlet blades for fans handling dust laden gases
are of removable type from outside. During operation of the fan itself these blades
can be replaced one by one.
5) DIFFUSER :
Diffuser of the fan is of welded sheet steel construction with a core inside.
The core of the diffuser houses the inner bearing which is supported by all the
outlet blades. The core of the diffuser is provided with a man hole with access
from diffuser casing so that the bearing can be checked even during the operation
of the fan. For fans handling Hot Gases the diffuser cores are insulated inside.
The lubrication pipes as well as the thermometer for the inner bearing are brought
outside through the core for easy access.
6) BEARINGS :
The Bearings are self aligning roller type. The flanged bearing on the
impeller side is the fixed bearing and the outer bearing is the expansion bearing.
Both bearings are grease lubricated and the lubrication point is available on
diffuser casing for inner bearing. A grease quantity control ring is provided in each
bearing to discharge the surplus amount of grease. For controlling the Bearing
Temperature a contact Tele Thermometer is provided in the bearing. The
contacts are to be set to 80 0C for signaling and to 90 0C for stopping the main
Motor.
The Cooling pipe for cooling the inner bearing is provided for fans handling
gases above 70 0C.
7) FLEXIBLE COUPLING :
Coupling between the motor and fan is flexible pin type with rubber bush
inserts.
TECHNICAL DATAS OF ID FANS :
Number of Fans / Unit
Type
:
Capacity
Total Head
Speed
Fan Drive coupling
Medium Handled
Temperature of medium
Specific weight of medium
Motor Rating
:
2
Axial / Impulse Type AN 25 e6
:
220 M3 / Sec.
:
430 mmWCL.
:
980 rpm
:
Pin Type Flexible Coupling
:
Flue gas
:
150 0C
:
0.807 Kg / M3
:
1700 KW
OPERATION DETAILS :
PRE-START CHECKS :
Whenever the ID Fan is to be started, the following checks have to be

carried out by the Local Operator and the Control Board Operator.
a) Checks by Local Operator :
i)
Ensure that all the manholes are closed.
ii)
Ensure that water has been filled in the seal trough, Bottom Ash Hopper
and water is filled up in the mixing boxes of all ash hoppers.
iii) Check oil pressure and flow to the motor bearings.

iv) Check the availability of pressure and temperature gauges.
v)
Ensure the full opening of all the gas dampers other than the suction and
discharge dampers of the two ID fans.
vi) Ensure local push buttom is in released position.

vii) Ensure that APHs are running normal.
b) Checks by Control Board Operator :
i)
Ensure that there is no work permit pending in the ID fans, ESP or in the
furnace and APH.
ii)
Check Lub Oil permissive is available.
iii) Ensure that Fan protections and interlocks have been checked and found
O.K. (This is normally done when the Fan is being started after a long
Shutdown / Overhaul)
iv) Check the Remote operation of the Suction and Discharge Dampers and
also the IGV.
v)
Ensure electrical supply from 6.6KV Switch Gear. Also ensure that all
related relays are in reset condition.
Start Permission for ID Fans (Say IDFA) :

i)
Suction Dampers (GD-22, 23, 24 & 25 for Unit I & II ; GD-220 & 221
for Unit III ) closed.
ii)
Discharge Dampers (GD-12 &13 for Unit I & II ; GD- 204 & 205 for
UnitIII ) closed.
iii) Control Vane minimum.

iv) APH (Corresponding to the fan) is running.
v)
Lub Oil pressure adequate (> 3.5 ksc)
STARTING PROCEDURE :
After the completion of the pre-start checks and after ensuring the
availability of all permissive, ID Fan is started from remote as follows :
i)
ID Fan motor is switched ON. The starting current, acceleration time

and No load current are observed and ensured normal.
ii)
The suction and discharge damper (GD-22, 23 & 13 in case of ID fan A

and GD-24, 25 & 12 in case of ID fan B for Units I & II ; GD-220 &
204 in case of ID fan A and GD-221 &205 in case of ID fan B for
Unit III ) are opened in auto. The complete opening of the same is
ensured from Local Operator / Control Desk.
iii) Ensure the opening of the ID Fan Stator Cooling Water Valve.
iv) Load the fan gradually so as to maintain a furnace pressure of 5 to
10 mmWCL.
Post Start Checks (by Local Operator) :
i)
Ensure normal performance of motor.
ii)
Ensure full opening of the Suction & Discharge Dampers.
iii) Check smooth loading and normal running of Fan.

iv) Checks Lube Oil pressure and temperature for normalcy.
Once the Fan operation is found normal, one FD Fan is started as per the
procedure and purging is carried out with > 30 % Air Flow.
The second ID Fan is normally brought into service as and when the Unit is
synchronized. One ID Fan is enough to maintain the Furnace pressure within the
normal limit of 5 to 10 mmWCL when Oil Guns are in service in two elevations
and two milling systems are in service. When further loading of the Furnace is
required, the second ID Fan is started as per the same procedure as that of the first
Fan. Once both the ID Fans are brought into service, the loading of both the Fans
are matched and put on Auto.
SHUTDOWN PROCEDURE:
i)
Reduce Unit load gradually by cutting out the milling systems one by
one.
ii)
Introduce oil support at appropriate time and appropriate elevation.
iii) When the load reduction is gradual, the Furnace pressure master control
takes care of the Furnace pressure automatically. But if there is large
variation, the master control is thrown to Manual mode due to the high
deviation between the set pressure and actual pressure. In such case, the
Operator takes the master on Manual and reduces the loading of the ID
Fans and normalizes the Furnace pressure.
iv) At < 20 MW load, the Unit is tripped by actuating Turbine Trip. This in
turn actuates the MFT (Master Fuel Trip) and trips the Boiler. All Boiler
side equipments trip, leaving the following in service.
-
Both ID Fans.
Both FD Fans.
Both APHs with their LOPs.
AC Scanner Air Fan
PA Fan LOPs.
v)If the Boiler is to be Boxed Up, the MSSVs at Boiler end are closed after
the Baring Gear starting. Both the ID Fans and FD Fans are stopped after
purging the Boiler followed by a Boiler trip. To stop the ID Fans.
- Fan is unloaded by reducing the load gradually.
- Once the Control Vane is minimum, the Fan is switched OFF.
- The Suction and Discharge Dampers close on Auto. Complete
closure of the same is ensured from the Local Operator / from the
Control Desk.
- Ensure the closing of ID Fan Stator Cooling Water Valve.
If the Boiler Maintenance personnel require the cooling of Furnace / Boiler
passes / ESP fields for taking up maintenance work, one set of ID Fan and FD Fan
is kept in service as long as required by them and then switched OFF.
EMERGENCIES :
In a normal running Unit, an emergency is created if one or both the ID

Fans trip suddenly. The possible causes for the sudden tripping of an ID Fan are :
i)
Motor Protection Trip (Thermal Over Load, Earth Fault etc.)
ii)
Supply failure to the Feeding Bus.
iii) Lube Oil pressure low ( < 1.5 ksc for 120 Sec).
iv) Motor Bearing Temperature > 80 0C (70 0C Annunciation )
v)
Fan Bearing Temperature > 90 0C (80 0C Annunciation )
a) When One ID Fan Trips :

- Corresponding FD fan trips.
- Bottom Mills trip leaving top three mills (in service)
- Suction & discharge dampers close.
- Furnace pressure becomes positive.
- MS pressure and temperature drop.
- Secondary air flow and wind box DP fall drastically.
Operator action :
- Cut in Oil Guns for flame stability.
- Reduce the load on the existing Mills so as to maintain Furnace pressure.
If required, cut out one of the Mills.
- Stabilize Furnace Draft by loading the running ID Fan fully.
- Load / Unload the working FD Fan so as to maintain proper Air Flow,
Wind Box DP as well as Furnace pressure.
- Maintain steam temperature by adjusting Burner Tilt and Sprays.
- Ensure proper flame condition in the Oil elevations from Local Operator.
- Find out the cause of tripping from Local Operator / maintenance
personnel get it rectified by concerned agency and restart the Fan at the
earliest and normalize the Unit.
b) When Both ID Fans Trip :
- Unit Trips with Both ID Fans OFF as first up.
FLUE GAS CIRCUIT

ID FAN-A
GD7
GD22
GD4
GD2
APH-A
WIND BOX
GD13
GD11
GD9 ESP-A GD23
GD5A
PLTN
FURNACE
SUPER
FINAL
CON
SH
SH
RH
CHIMNEY
ECO
HEATER
GD5B
ID FAN-B
ESP-B
GD6
GD-1
WIND BOX
GD25
GD3
GD12
APH-B
GD10
GD8
GD26
AD 15
AD 17
AD 20A
UNIT III FLUE GAS CIRCUIT

PA FAN A
AD 20
AD 34
AD 155
FROM ECO
TO MILL F
GD 192
APH A
AD 40
GD 194
ESP A
GD 198
AD 3
AD 6
FD FAN A
GD 199
ESP B
GD 206
GD 220
GD 207
ID FAN A
GD 204
GD 202
AD 22
AD 28
AD 8
GD 196
TO WIND
BOX (LEFT)
SCAPH A
HOT
TO MILL B
TO MILL D
TO WIND
BOX (RIGHT)
SCAPH B
AD 39
AD 7
TO MILL E
GD 193
FROM ECO
AD 27
APH B
AD 9
AD 45
AD 33
CHIMNEY
AD 5
COLD
AIR
TO MILL A
AIR
BUS
BUS
TO MILL C
GD 222
AD 1
AD 4
FD FAN B
GD 200
GD 195
AD 2
AD 21A
GD 201
AD 156
GD 223
GD 197
ESP C
ESP D
GD 221
PA FAN B
FILTER
SEAL AIR FAN A
AD 16
FROM
ATMOS
SCANNER AIR FAN A-C

S.A.FAN D-C
V DAMPER
TO SCANNERS
TO MILLS
SEAL AIR FAN B
FILTER
IGNITOR AIR FAN A

V DAMPER
I.A.FAN B
SEAL AIR FAN C
GD 205
ID FAN B
GD 209
AD 21
AD 18
GD 203
GD 208
TO IGNITORS
FORCED DRAFT FAN SYSTEM

The Forced Draft Fan system serves the purpose of supplying Atmospheric
Air to the Furnace for complete combustion of the fuel and also to protect and cool
the Scanners heads and non operating Burner heads.
The Forced Draft Fans (F.D.Fans) are the rotating machine with bladed
impellers which maintain a continuous flow of air. It sucked air from the
atmosphere and forcing it into the Boiler Furnace via Wind Box. The air supplied
by F.D. Fans is known as Secondary Air. The Forced Draft Fan system comprises
of the following main component :
A) Forced Draft Fans ((FD Fans);
B) Ducts and Wind box;
C ) Dampers
A) FORCED DRAFT FANS :
There are 2 Nos. of Forced Draft Fans per Boiler and located at Ground
Floor. The Technical Datas of the FD Fans incorporated in both the stages are
provided below:
---------------------------------------------------------------------------------------------------Sl.No.
PARTICULARS
FAN DATA
---------------------------------------------------------------------------------------------------1.
Fan Type & Size
-Axial Reactio Type API20/ 11
2.
Fan Orientation
-Horizontal
3.
Medium Handled
-Atmospheric Air
4.
Location
-Ground Level
5.
No. of Fans / Boiler
-Two
6.
Fan Design Rating
i. Capacity
-150 M3 / Sec
ii. Total Head Developed
-485 mm WCL
iii. Temperature of medium
-40 0C
iv. Specific Weight of medium
-1.089 Kg / M3
v. Speed
-1480 rpm
7.
Fan Reserve
i. Flow
-29.3 %
ii. Pressure
-44.8 %
8.
Fan Drive Coupling
-Coupling with Intermediate
Shaft.
9.
10.
11.
Drive Motor
i. Manufacturer
ii. Frame Size
iii. Rating
iv. Voltage
v. Frequency
vi. Phase
vii. Speed
Fan Weight
Lubricating Equipment
i. Fan (Forced Lub Oil system)
ii.
12.
Motor (Forced Lub Oil system)
Type of Fan Regulation
---------
BHEL Hardwar
AC 142 36 H4 A
1100 KW
6.6 KV
50 Hz
3
1480 rpm
7000 Kg
--
70 LPM
M/s. Metal Weld - Drg.
0-56-910-00116
5 LPM
Tecalenut
Pitch Control
---
FD FANS CONSTRUCTION DETAILS :.

The Forced Draft Fan consists of the following components.
1. Inlet bends.
2. Fan Housing.
3. Impeller with blades & Setting Mechanism.
4. Guide Wheel Casing with Guide Vanes & Diffuser.
The Fan Housing and Guide Wheel casing are of Two Part Design.
Inlet Bends and Diffuser are of single part design are welded structure,
Reinforced by Flanges and rips and supported by Bearing Pedestal on the
foundation. The Inlet Bend is executed as Inlet Nozzle at its Impeller end. To
direct the flow, Guide Vanes are located in the Guide Wheel Casing. They connect
the Hosing Core and the Jacketing.
The Unit is driven from the Suction side. In the core of the inlet bend, the
shaft is accommodated in a special design Bearing Housing. The Impeller is
mounted in overhung position on the Shaft. The critical speed of the latter is well
above the operating speed.
The centrifugal and setting forces of the blades are taken up by the blade
bearings. The blade shafts are placed in combined radial and axial antifriction
bearings which are well sealed off to the outside.
The part of the setting mechanism being inside the Diffuser core is
accessible through mounting holes.
BEARINGS :
The rotor is accommodated in cylindrical roller bearings. In addition, an

inclined ball bearing at the drive side absorbs the axial thrust.
Lubrication and cooling of these bearings is assured by a combined oil level
and circulating lubrication system. The bearings are vented through the lube oil
return line and the oil reservoir. The vent hood (for the bearings ) is mounted on
top of the oil reservoir.
For controlling the bearing temperature, there are contact tele
thermometers which must be connected to signaling instruments by the customer.
Incorporated Bearings :
Impeller Side
1 Cylindrical roller bearing NU 230 C3
Coupling Side
1 Cylindrical roller bearing NU 230 C3

2 Inclined ball bearing 7230 B. UA
BLADE ADJUSTING DEVICE :
An Oil Hydraulic servo motor flanged to the impeller and rotating with it
adjusts the blades during operation. This results in a closed flux of force between
adjusting forces and oil pressure, so that no forces are released to the outside
(bearings, housing, foundation). The servo motor consists of piston, cylinder, and
control devices.
During adjustment of the blades, the translational movement of the servo
motor piston is turned into rotation via the adjusting levers of the pivoted blade
shafts so that the blades can be set at different angles.
The restoring moments of the blades are produced by the rotating blades.
They are counter balanced by the oil pressure in the servo motor.
Weights at the blade shafts partly compensate the restoring moment. These
weights produce a moment opposed to the restoring moment of the blades so that
the adjusting devices are relieved.
The Oil Hydraulic servo motor can be connected to any control or
regulating system. It can also be adjusted by hand. The movement of the non
rotating control slide in the servo motor to initiate the blade adjustment requires
only small forces of a few Kilo Pounds.
The control slide is Hydraulically centered.

practically preventing friction and wear.
It moves on a liquid film
The blade adjustment operates according to the follow up control

principle.
A regulating system arranged outside causes the actuating movement of the
non rotating control slide via rods (Actuator). Each movement of the control
slide is followed up by the actuating piston and, via the Actuating Disc, by the
blades.
Have the regulating system rated in such a way that there are no constant
movements and counter movements around a set load point of the fan.
Poorly damped regulating systems constantly cause minor regulating
movements in the blade adjustment. These are of dis-advantage for the life of the
blade bearings and are to be avoided.
The control oil conveyed by the oil unit reaches the control slide with a
constant pressure set between 8 and 12 ata.
If the Governor moves the control slide to the left, the right control edge
opens the admission to Chamber 2. The pressure oil flows into this chamber and
moves the adjusting piston to the left until the control edges are in line again.
Simultaneously, the control oil out of chamber 1 flow via the control slide into
the return duct to the oil reservoir. Analogously the same happens if the Governor
moves the control slide to the right. The left control edge of the control slide will
then open the admission to chamber 1 and the oil pressure moves the adjusting
piston to the right until a state of equilibrium has been regained.
The adjusting disc is firmly connected to the adjusting piston. If transfers
the movements and counter movements of the adjusting piston via slide pads and
levers as rotating movement to the blade shafts.
The Hydraulic adjusting device and the oil unit form one system. If the oil
supply is interrupted the then set blade position will stay. The adjustment will not
be damaged. The adjusting impulse will however have to be interlocked via the
control oil pressure.
OPERATING PROCEDURE :
The operation procedures for various operating conditions of FD Fan system

are grouped as follows:
1) Pre start up checks
2) Start up First FD Fan
Second FD Fan
3) Check up during normal running
4) Tripping Procedures
5) Alarms & Tripping conditions One FD Fan Trip
Both FD Fans Trip
6) Other Operations.
1) Pre-Start Up Checks :
1. Get confirmation that all Welding Permit / L.C. issued on F.D. Fans and Air
Flow System have been returned and cancelled.
2. Any one ID Fan is running.
3. Check Inlet Guide Vane (AD-1 / AD-2) at minimum position.
4. Check that the Outlet Damper AD-3 for Fan A and AD-4 for Fan B is
closed.
5. Get confirmation that the Air Dampers before and after Air Pre Heater (AD5 & 7 for Fan - A and AD-6 and AD-8 for Fan-B) are open.
6. Check that the local push button is released.
7. Check pressure and temperature gauges are ready.
8. Ensure that the following permissive are available.
(a) Lub Oil pressure more than 3.5 ksc.
(b) Control Oil pressure more than 5 ksc.
9. Check that no man hole is open and repair useable is going on clearance
from local operator to start the Fan from U.C.B.
2) (a). Start Up of First FD Fan :
After ensuring that the final permissive available for starting the FD Fan can
be started both at local through LPB or from UCB
Start the FD Fan by pressing the start button and see that the ammeter
reaches the starting current. Let the current reduces to no load reading
within 8 to 10 Seconds.
Ensure the opening AD-3 or AD-4 on Auto (or) Local opened it.
Open IGV gradually and see that the discharge pressure and Secondary Air
Flow indicators show increase in their readings. Establish slightly more air
flow than the minimum Air Flow required for Purging (i.e 240 T / Hr 30%
of MCR). Suitable loading of ID Fan should be done to keep up the Furnace
Draft.
Purging :
Purging is nothing but the scavenging of the Boiler with the minimum air to
avoid accumulation of unburned fuel and explosion possibilities, which has to be
necessarily be carried out before every light up and after a Boiler trip out. Purging
is started after ensuring that the following permissive are available and carried out
for 5 Minutes.
Permissive for Purging are:
1) Any one ID / FD set is in service with > 30 % Air Flow
2) Drum Level Normal
3) No Boiler Trip Persists
4) Burner Tilt Horizontal
5) No Mills Running
6) No Feeder Running
7) LOTV Close
8) HOTV Close
9) All HMVS Close
10) All Scanners No Flame
11) All HAGs Close
12) Both PA Fans Stop.
(b). While Starting Second FD Fan :
Normally for lighting up in the cold condition one set of ID / FD Fans is

sufficient. However, before going for synchronizing the second set of ID / FD
Fans are to be brought in service. To cut in the second FD Fan the following
procedure is to be adopted.
Check the following permissive are available :
1. Both ID Fans running
2. IGV Minimum
3. Discharge Damper closed
4. Local Push Button released.
5. Check that there is any reverse rotation in the second FD Fan due to Back
pressure of the Secondary Air. If no reverse rotation, start the second FD
Fan from UCB. If not the same to be started at Local after arresting the
reverse rotation mechanically.
6. Check for direction of rotation and abnormal noise.
7. Observe the starting current, time taken to drop to no load current.
8. Ensure the opening of Discharge Damper on Auto or opened it Manual.
9. Open the IGV gradually and adjust both IGVS in such a way that they are
equally loaded.
10.Check for Motor and Fan Bearings for vibration and temperature and
record periodically.
3) Checks During Running :
Check for any abnormal noise
Check for lubrication for bearings. Get it lubricated at regular intervals by
Maintenance Staff.
Check the Fan bearings for vibration and temperature.
Check the motor bearings for vibration and temperature and take hourly
readings.
If any abnormality is noticed, inform the concerned Maintenance Staff
4) Stopping Procedures :
While stopping the FD Fans when the Unit is in tripped condition, the
following procedure is to be adopted.
Reduce the IGV loading gradually for one Fan and see that the Air Flow
drops.
If required load the other FD Fan to maintain the required Air Flow.
Reduce the IGV to minimum and stop the Fan
Ensure the Closure of Discharge Damper on Auto (or) Close it Local.
Similarly, the same procedure is to be adopted to stop the second FD Fan
also. After stopping the HT Breakers to be racked out and DC kept OFF if not
required to be brought back into service immediately. Whenever operating FD
Fans & ID Fans are to be adjusted either Manual or on Auto.
5) Alarms & Tripping conditions One FD Fan Trip
Both FD Fans Trip
1. When One ID Fan trips, the corresponding FD Fan will trip. (Tripping of
One FD Fan leads to tripping of Mills leaving top 3 Mills ).
2. When Both ID Fan Trips, Both the FD Fans will Trip which leads to Unit
Trip.
3.
(a) Bearing Temperature Very High at 80 0C (Annunciation 70 0C ) for
Motor.
(b) Bearing Temperature Very High at 90 0C (Annunciation 80 0C ) for
Fan.
When one FD fan trips, the Secondary Air Flow, Wind Box to Furnace DP,
Furnace pressure etc. go down and become insufficient and thus creating
emergency. In that case, the following procedure to be adopted.
Increase the loading of the other FD Fan in service to the maximum
permitted level.
Maintain the Furnace pressure by adjusting ID Fan loading.
Adjust the SADC control at control desk so as to maintain the Furnace to
Wind Box DP.
Bring the IGV of the tripped FD fan to the minimum position.
Check with on which protection the Fan has tripped and what annunciation
has appeared on the Panel.
Check with Switch Gear operator which relay has acted.
On findings from the above it is to be intimated to the concerned
Maintenance Staff.
When both FD Fans trip, the Unit gets tripped if in service. When Fans
alone are running, tripping of both FD Fans lead to highly negative pressure in the
Furnace which can be corrected by suitably adjusting the ID Fans loading.
6) Single FD Fan Operation :

For a single FD Fan with reduced Unit loading :
Gradually reduce the Unit load by cutting out the Mills one by one. Cut in HFO
Oil Guns for Flame stability.
Maintain a Unit load permissible for a maximum loading of One FD Fan.
Minimize the IGV loading of the Fan to be stopped.
Stop the FD Fan
Load the other FD Fan to the maximum possible level limited by load current.
Adjust the Unit load with respect to the available Air Flow.
Issue L.C. for the FD Fan if required.
7) Other Operations :
L.C. Issue :
Stop the FD Fan as per the procedure discussed above.
Inform the Switch Gear Operator to rack out the HT Breaker and to keep D.C
OFF and get conformed.
Ensure that the Local Push Button latch has been put ON.
Issue the Line Clear.
TRIAL RUN :
While starting a FD Fan after completion of Line Clearance / Over Hauling the
procedure to be adopted is as follows.
Check all the protections with Breaker in Test position.

See that the bearing temperature Gauge of Motor is properly fixed.
Ensure the free rotation of shaft of the motor in the de coupled condition.
Ensure the HT Breaker racked in and D.C kept ON.
Start the Motor at local by pressing the Local Push Buttons.
Observe the starting current and time taken to come down to no load current.
Also check for direction of rotation.
Observe for any current hunting in the Ammeter at UCB.
Check for any abnormal noise or vibration.
Check the temperature readings.
After running for a required time, the Motor can be stopped and clearance
given for coupling of Fan.
For a Trial Run in the Coupled Condition :
Ensure that all other systems in a Unit are available with all Clearances.
APHS and ID Fans are maintaining the Furnace Pressure.
Check for FD Fans permissive.
Control Oil pressure adequate.
IGV Minimum.
ID Fans Running.
Discharge Damper Close.
L.O pressure Adequate
Ensure that the HT Breaker is racked in and DC kept ON.
Ensure that the bearing temperature Gauge is fixed in their position.
Start FD Fan at local.
Check for any abnormal noise and vibration at no load.
If normal Fan to be loaded gradually and trial run conditions to be observed at
various loadings.
Check all the available parameters at various loadings
Ensuring the normal performances, the Fan to be stopped after reducing the
IGV to minimum and to be kept ready for service.
Generally whenever a disturbance is experienced in the Secondary Air Flow
System it mainly affects the flame condition and Furnace Draft and thus creating a
total instability. Hence when such disturbances occur the parameter like Furnace
Draft, Wind Box to Furnace DP are to be immediately adjusted so that a perfect
flame condition is being maintained with or without the support of Oil Gun. This
can be achieved by adjusting ID Fan, FD Fan Vane Control and SADC Control
etc., and better Unit conditions can be established. It will be better to have oil
support at less than 120 MW.
SECONDARY AIR FLOW CIRCUIT

MAIN DRIVE
TO PA FAN - A
AIR MOTOR
STATION AIR
AD-155
FD FAN-A
AIR
AERO FOIL
AD8
PRE
AD-3
AD-6
HEATER - A
FROM ATMOSPHERE
AD-1
WIND BOX
AD-158
FURNACE
AD-5
AD10
WIND BOX
TO SCANNER AIR FANS
FD FAN-B
AD-159
AERO FOIL
AIR
AD9
AD-7
AD-4
FROM ATMOSPHERE
PRE
HEATER - B
AD-156
AID MOTOR
STATION
AIR FROM
COMPRESSOR
AD-2
MAIN DRIVE
TO PA FAN - B
AUXILIARY STEAM SYSTEM

This system provides steam at 15 ksc and 200 0C temperature for the
following purposes.
1. Deaerator Pegging / Heating.
2. HFO Heating.
3. HFO Atomising.
4. Main Ejectors, Starting Ejector and G.C 1 Ejector
5. Turbine Gland Sealing.
This Auxiliary Steam is tapped off from Main Steam lines. The pressure and
Temperature are suitably reduced by throttling and spraying water against the flow
of steam. This is called Pressure Reducing De Super Heating Station.
During start up till Boiler is capable of steam at required parameter of 15 ksc
and 200 0C this auxiliary requirement of steam is to be met from alternative source
from adjoining running Units
Self charging control valve of PRDS are 100% main and 100% Bypass
connected together and its inlet was connected with MSL-LHS & RHS lines and its
outlet was connected in the PRDS header and attemperation line also connected in
between header and self charging line inter connecting line adjoining units
operating control by Control Valve.
PROCEDURE :
a) Start Up Procedure From Neighbour Unit :
The opening of interconnection valve should be so gradual. The steam
drawing unit PRDS NRV Isolation Valve must be kept opened and the steam
supplying unit PRDS pressure control may be suitably operated.
PRDS header to various places is kept closed.
PRDS header drains kept in open condition.
Keep Steam drawing unit inter connection valve is in open condition.
Open the interconnection valve of steam supplying unit gradually till the line
header is fully charged to 15 ksc and 200 0C temperature.
b) START UP PROCEDURE FROM SELF :

After ensuring drum pressure is about 40 ksc, keep PRDS Header Line
Drains open for 15 minutes for warming up by crack opening V2 16 ..
Open MSSV L & R after ensuring the opening of the PRDS header line
drains and after completing the warming up operation, close all the PRDS
header line drains. Open V2 16 fully and charge PRDS header through
PCV.
c) SHUT DOWN PROCEDURE :
In case of Unit Shut Down, PRDS is isolated automatically if MSSV is
closed. Anyhow, BFP attemperation line is to be closed fully during such
occasions. PRDS drains must be closed after ensuring no pressure in the
Header.
In case of total supply failure, complete isolation of PRDS to Turbine is to
be done as quickly as possible to avoid rupturing of LPT diaphragms.
MAIN
STEAM
PRDS SYSTEM
SAFETY
VALVE
V2-16
(R)
(L)
TO EJECTOR
V2-17
V2-18
ATTEMPERATION
TO GLAND STEAM
HDR
PRDS-PCV
FROM FEED
PUMP
V2-19
TO
DEAERATOR
VALVES AT
13.5 MT
TO
OHS
TCV
TCV
BYPASS
DEAERATOR
DIVERSION
TO
IC
SCANNER AIR FAN SYSTEM

Scanners are provided to sense the flame in Boiler Furnace. The scanners
are very sensitive and precisive. Visible range scanners (Fire ball scanners and
discriminative scanners) are ensuring the combustion phenomenon in a Furnace.
In our Boiler we have two types of scanners namely.
1) Fire Ball Scanners 20 Nos. in AB, BC, CD, DE & EF Elevations and
2) Discriminating Scanners 12 Nos. in AB, CD & EF Elevation. Cooling Air
towards scanner heads is essential as radiation heat from the Furnace may heat
up and may damage it. Hence, Scanner Air Fans are provided.
There are two types of Scanner Air Fans (1) A.C Scanner Air Fan (2) D.C
Scanner Air Fan. A.C Scanner Air Fan is in operation during normal running of the
Boiler. D.C Scanner Air Fan starts on auto when the A.C supply fails.
Scanner Air Fan Filters is provided in the common suction line. So that pure
air is sent to Scanners to avoid erosion and dust deposits on the scanners one filter
is in service and the other one is stand by. If the DP across filter > 15 mm WCL,
the filter will be taken up for cleaning. Provision is given to change over the filters
and clean the filters without affecting the running condition of the Fan.
During initial starting of the A.C Scanner Air Fan when the FD Fan is not in
operation, the EAD (Emergency Air Damper) is to be opened Manually for taking
suction from atmosphere. As soon as the FD Fan is started the EAD is to be closed
and Scanner Air Fan takes suction from FD Fan discharge line.
The Scanner Air Fan develops a discharge pressure of 350 mmWCL. Auto
start of the stand by Scanner Air Fan will occur only when the running scanner fan
trips.
FAN TECHNICAL DATA :
SERVICE
TYPE
MAKE
MAKERS No.
ORIENTATION
MEDIUM HANDLED
No. OFF / BOILER
:
:
:
:
:
:
:
SCANNER (COOLING ) AIR

RADIAL BACK WARD CURVED
M/S. S.F. INDIA LTD.
HCBB 1 025 47
SIDE AXIAL INLET , VERTICAL OUTLET
ATMOSPHERIC AIR
1
FAN DESIGN RATING :
:
:
:
:
:
3450 M3 / HR.
200 MMWC
50 0C
1.014 KG / M3
2920 RPM
ON CAPACITY
ON TOTAL PRESSURE
:
:
20 %
18 %
FAN DRIVE COUPLING
FAN DIRECTLY MOUNTED ON TO MOTOR
:
:
:
NGEF / AMW 160 M

SQUIRREL CAGE / INDUCTION / TEFC
5.5 KW , 415 V A.C , 3 , 50 HZ
CAPACITY
TOTAL PRESSURE
MEDIUM TEMPERATURE
MEDIUM DENSITY
SPEED
FAN RESERVE :
SHAFT
DRIVE MOTOR :
MAKE / FRAME SIZE

TYPE
RATING
D.C SCANNER FAN DRIVE MOTOR :
MAKE / FRAME SIZE

RATING
:
:
KIRLOSKAR / TDC 180 / D

7.5 KW , 220 V D.C , 3 , 50 HZ
PROCEDURE :
Scanner Air Fans can be started only from UCB (Unit Control Board). Its
operation comes under Furnace Safe Guard Supervisory System (FSSS) control,
control switches and indicating lamps are provided in UCB at FSSS console.
Provisions are not made to start the Scanner Air Fans from local, in order to avoid
many unnecessary emergencies due to mal operation. It is a vital system without
scanners air fan system the unit should not run more than 10 Minutes.
a) STARTING :
Scanner Air Fans A.C and D.C can be started manually by depressing the
respective start push button in FSSS console. Normally A.C Scanner Air Fan
started initially when Boiler light up activities is started. It develops a discharge
pressure of 350 mm WCL. Auto start to standby Scanner Air Fan will occur only
when the running Scanner Air Fan trips.
b) STOPPING :
AC / DC Scanner Air Fans can be stopped manually by depressing the
respective push button in FSSS console.
Normally Scanner Air Fans are stopped when the RH metal temperature
dropped down to about 40 0C after a Boiler Trip out.
SEAL AIR FAN SYSTEM

As the Milling system is of the pressurised type, Seal Air supply is essential
at the bearings, Journals, Feeders and Mill discharge valves in order to avoid
entering of coal dust and damaging the precision components.
There are three Seal Air Fans in this system. One will be in service and
others are standby. It can supply necessary seal air to the pressurized pulverizing
system. These Fans get the air intake from Primary Air Fan cold air duct at the
pressure of 800 mm WCL. These fans are having 2 x 100 % duty filters at the
common inlet. Each filter is having its Isolation Dampers at both ends to isolate
any one filter for cleaning purpose. One filter will be in service and other is
standby. Each fan is having separate Inlet Dampers and Outlet Dampers. This
axial type fans, having the capacity of boosting pressure of 508 mmWCL and
driven by motor each of 37 KW at 2850 rpm. Three separate intakes are taken
from Seal Air Fan discharge at boost up pressure of 1000 mmWCL, to Mill
Bearings, Mill Discharge Gates and Mill Feeders. Each in takes are having
Isolation Dampers for maintenance purpose.
FAN TECHNICAL DATA :
SERVICE
TYPE
MAKE
ORIENTATION
MEDIUM HANDLED
No. OFF / BOILER
:
:
:
:
:
:
SUPPLY OF SEAL AIR TO PULVERISERS

HCBB 040 75
M/S. S.F. INDIA LTD.
GROUND MOUNTEDDISCHARGE VERTICAL UPWARDS
AMBIENT AIR NORMALLY DUST LADEN

3
FAN DESIGN RATING :

CAPACITY
TOTAL PRESSURE
MEDIUM TEMPERATURE
MEDIUM DENSITY
SPEED
:
:
:
:
:
15300 M3 / HR.
680 mmWCL
50 0C
1.09 Kg / M3
2960 rpm
:
:
:
25 %
10 %
IMPELLER MOUNTED DIRECTLY ON
MOTOR
FAN RESERVE :
ON CAPACITY
ON TOTAL PRESSURE
FAN DRIVE COUPLING
SHAFT
DRIVE MOTOR :
MAKE / FRAME SIZE :
CROMPTON GREAVES / D 250 M
TYPE
:
SQUIRREL CAGE
RATING
:
60 HP , 415 V , 3 , 50 HZ
OPERATION PROCEDURE :
Seal Air Fans can be started either from Unit Control Board or from Local.
After starting the Fan , discharge damper is opened gradually and Seal Air pressure
is maintained 200 mm WCL above Primary Air Header pressure.
a) STARTING :
Seal Air Fan A/B can be started manually by pressing the respective start
push button in console.
b) STOPPING :
Seal Air Fan A/B can be stopped manually by pressing the respective push
button in console after stopping PA Fans.
c. ALARMS :
i.
Seal Air Fan filter Differential Pressure (DP) high alarm persists when the
DP goes over 55 mmWCL. So immediately the standby filter will be put
into service in parallel and the chocked filter will be isolated, cleaned and
kept as standby.
ii.
Seal Oil Air Fan discharge pressure low alarm persists when the pressure
reduces to 1000 mmWCL. The standby Seal Air Fan will be started
automatically.
iii.
Seal air to corresponding Mill DP low alarm persists when the DP reduces to
125 mmWCL and the corresponding Mill will be tripped.
PRIMARY AIR FAN SYSTEM

PRIMARY AIR FAN SYSTEM:
Two numbers of NDFV 20 b radial fans are used for supplying the required
Primary Air for transporting the pulverized coal from the Mills to the Furnace.
The quantity of Cold Primary Air at the outlet of the APH are controlled in
such a manner, that the flow to the Mills is maintained at 52 T / Hr and the coal air
temperature at the outlet of the Mills at about 80 0C. These Fans are of single
suction single stage centrifugal type in which FD Fan Discharge Air enters the
impeller axially and after passing through the impeller leaves radially. A large part
of the energy transferred to the air is converted into pressure energy as the air
passed through the Impeller. The spiral casing converts part of the kinetic energy
in the air to pressure energy. These Fans are driven by constant speed Squirrel
Cage Induction Motor. The output of the Fan is controlled by an inlet guide vane
damper assembly. Each Fan is provided with a shut off gate at the discharge duct.
The Fan and the motor shafts are coupled with pin type flexible coupling.
CONSTRUCTIONAL FEATURES OF PA FAN :
This is a single stage, single suction centrifugal fan. The Fan consists of the
following sub-assemblies :(i)
INLET VANE CONTROL :
An Inlet Guide Vane unit is arranged on the suction side. The Axial
Inlet Vane control assembly of the Fan consists of a number of aerofoil inlet vanes
fixed to individual shafts which are connected by means of angular joints to a
central ring. The ring is guided to the rotating position by a set of roller
assemblies. A control lever is connected to the ring which can be operated by an
electric servo-motor or a pneumatic power cylinder.
(ii)
ROTOR :
The Rotor consists of an Impeller and Shaft assembly mounted

overhung on a bearing assembly. Blades are welded on to a back-plate and
shrouded by a cover plate and impeller ring. The back-plate is having a welded
hub with taper bore. The Impeller is mounted on a Shaft with a taper fit and
locking-nut. The critical speed is maintained well above the operating speed. All
Rotors are statically as well as dynamically balanced at our works.
(iii)
HOUSING :
The box-section spiral casing is of two-part design. The casing is

provided with manholes for access. The entry to the casing is through a man hole.
The lower part of casing rests on is supporting brackets on the foundation.
(iv)
BEARINGS :
The Fan Rotor is placed in Cylindrical Roller Antifriction Bearings.

An Angular Contact Ball Bearing absorbs the axial thrust on the Impeller side. For
some cases two Angular Contact Ball Bearings were used in Tandem. An oil level
indicator is provided to check oil level. A ventilation hood at the bearing cover
ensures the ventilation. It serves also as oil filling branch. For indicating the
bearing temperature thermometers are provided in the bearing housing. For ID
Fans water cooling coils are provided. For large and high speed fans, depending
upon necessity, lubricating oil circulation system are provided to keep the bearing
temperatures within 90 0C.
(v)
FLEXIBLE COUPLING :
Coupling between the motor and fan is normally of flexible pin type
with rubber bush inserts.
(vi)
SHAFT SEAL :
A two part labyrinth seal, seals off the fan spiral casing at the shaft
passage.
Lub oil system for cooling and lubrication of fan bearing consists of one pair
of Pumps, Filters and Coolers, one each being standby. The system is fitted with
thermometers, pressure gauges and pressure switches. Lub oil system control
panel is located in the ESP from where the L.O. system can be operated in Remote.
Three pressure switches provided in the lub oil header before bearing are set at 3.5,
2.5 and 1.5 ksc. for alarm, auto change over and protection of the fan respectively.
TECHNICAL DETAILS OF PA FANS :
Number of Fan / Unit
Type
Capacity
Total Head Developed
Speed
Fan Drive Coupling
Medium Handled
Temperature of Medium
Specific Weight of Medium
Motor Rating
:
:
:
:
:
:
:
:
:
:
2
Single Suction Radial Type NDFV 20 b
67.5 m3 / Sec.
940 mmWC.
1480 RPM.
Pin Type Flexible Coupling.
Atmospheric Air
40 0C
1.089 kg / m3
900 KW
PRE-START CHECKS:
1. Ensure that there is no pending Work Permit in the PA Fans, Air Heater, PA
Ducts, Mills, Furnace and Flue Gas Ducts.
2. Ensure the man holes are closed.
3. Check that Air Pre Heater Inlet and Outlet Dampers are open.
4. APH, ID Fan & FD Fan are in service before taking any PA Fan into service.
5. Ensure that air circuit is made through atleast in one Mill to the Furnace, by
opening Cold Air Gate and Damper and the Mill Discharge Valves.
6. Check the oil level in the Lub Oil tank and bearing housing.
7. Ensure the cooling water flow through the cooler and bearing housing.
8. Check the availability of the instruments to measure the flow, pressure, and
temperature of the PA Fan and its lub oil system.
9. Check the opening & closing of the Suction / Discharge Dampers (AD-155,
AD-156, AD-17 & AD-18). Keep it closed before starting the PA Fan.
Ensure that the vane position is in minimum.
10.Ensure that the Local Push Button is in released position.
11.Check the operation of vane control from UCB.
12.By simulation checks confirm all the protections and interlock functions
properly. Especially when the PA Fan is started after long Shut Down, all
the protections must be checked.
PA FAN LUB OIL SYSTEM :
Line up and taking into service :
1. Ensure oil level in the tank. Level should be between the maximum and
minimum marks in the oil tank gauge glass.
2. Ensure the Suction and Discharge Valves of Lub Oil Pump are kept fully
opened.
3. Commission the Lub Oil Coolers and ensure water flow through it.
4. The Lub Oil Filters may be made through.
5. Check for full opening of the needle valve before bearing in Lub Oil line.
6. The Lub Oil Pump may be started from Manual or Auto from the Lub Oil
Pump Control Panel located in ESP Control Room. There is a selector switch
consisting of two positions 1. Manual 2. Auto.
7. Ensure the power supply and control supply to the control panel.
8. Ensure Local Push Buttons for the Pumps are released.
9. Ensure the pressure switches and temperature gauges are intact.
Start any one Lub Oil Pump manually from control panel putting the selector
switch in manual position and observe the Lub Oil pressure low annunciation in
the control panel gets reset. Check that there is no oil leak in the system.
After resetting the Lub Oil pressure low annunciation the selector switch
may be turned to Auto.
Now trip the running Lub Oil Pump and observe that standby pump starts on
Auto. The Lub Oil Pump starts on Auto when the Lub Oil pressure drops to
2.5ksc., annunciation will appear in the panel window. Thus any one of the Pumps
may be kept in service.
Ensure adequate oil flow to the bearing by seeing the return oil flow in the view
glass.
a) Normal working pressure of Lub Oil inlet is 3.5 ksc to 5.0 ksc.
b) Normal working pressure of Cooling Water inlet is 2.2 ksc.
c) Differential pressure across filter should be less than 0.3 ksc.,
normally the DP will be 0.1 ksc.
PA FAN START PERMISSIVE:
1. Primary Air Fan Suction / Discharge Dampers (AD-155, AD-156, AD-17 &
AD-18) closed.
2. Inlet Guide Vane at minimum.
3. Lub oil pressure to the Motor & Fan bearings adequate.
4. No master fuel trip relay is actuated.
5. PA Fan stopped condition is established.
6. PA Fan tripped indication should not exist.
7. All the Cold Air Dampers to the Mills should be less than 5 % open.
Note:
Before starting any PA fan select any one Seal Air Fan should be put into
service keeping Suction & Discharge Dampers in open condition.
POST START CHECKS:
1. Note the starting current of the motor.
2. Check the opening of the Suction / Discharge Damper on interlock or
open the Damper by switching ON from UCB control desk.
3. Immediately after the Suction / Discharge Damper is opened load the Fan
slightly by opening the inlet guide vane up to required P.A Header
Pressure.
4. Check the Fan and the motor for smooth running.
5. Check the bearings for proper lubrication, and monitor regularly the
bearing temperatures.
6. Maintain the PA header pressure at 800 mmWCL by suitable loading of
the PA Fan, for taking Mills into service.
PA FAN TRIP INTERLOCKS:
1. Motor drive end bearing temperature Very High 80 0C.

2. Motor non drive end bearing temperature Very High 80 0C
3. PA Fan drive en bearing temperature Very High 90 0C.

4. PA Fan non-drive end bearing temperature Very High 90 0C.
5. PA Fan running with Lub Oil pressure low (with time delay of 2 min) (1.5
ksc.)
6. If Boiler Master Fuel Trip relay acts both PA Fans will trip.
7. Electrical protection of motor.
a)
Instantaneous Over current
b)
Locked Rotor
c)
Thermal Over load.
d)
Phase Unbalance.
e)
Earth Fault.
INTERLOCK OPERATIONS :
1. When one PA Fan trips, the running Bottom Mills will trip, leaving Top three
Mills in service. .
2. When both PA Fans trip, all the Mills will trip on PA Header pressure very low,
less than 450 mmWCL.
3. When the Boiler trips, both PA Fans will trip on MFT protection.
4. When any one of the PA Fans trip, the Suction / Discharge Dampers will close
automatically.
5. The Suction / Discharge Dampers of both PA Fans will close, when both PA
Fans trip.
STOPPING PROCEDURE OF ONE PA FAN :
The following procedure may be carried out to stop any one PA Fan to attend
any breakdown maintenance.
1. Reduce the generation by keeping two Mills and oil guns in two elevations
in service.
2. The Oil Guns should be put into service when the Unit generation is reduced
to below 120 MW.
3. Maintain the SH and RH temperatures above 510 0C. So that the Turbine
Expansions are within the limit.
4. To maintain the SH and RH temperatures, close the SH and RH spray
valves.
5. After stopping all the Mills except two Mills and all the Guns in two
Elevations (AB and CD) got proven then stop the particular PA Fan.
6. Maintain the PA header pressure at 800 mmWCL by increasing the vane
control of the running PA Fan.
7. If it is unable to maintain the PA header pressure within the limits (around
550 to 600 mmWCL) then stop another Mill by running one Mill only.
8. The LOPs of the stopped PA Fan can be stopped after the Motor & Fan
bearing temperatures (DE and NDE) are reduced to below 40 0C.
PRIMARY AIR CIRCUIT
TO COLD PA BUS
PA FAN - A
AD 17
AIR
TO SEAL AIR FANS
AD 21
PRE
AD 21A
FROM FD FAN A
DISCHARGE
AD 155
HEATER - A
AD 15
AIR MOTOR
MAIN DRIVE
TO HOT PA BUS
STATION AIR
AD 19
AD 157
MAIN DRIVE
TO HOT PA BUS
AIR MOTOR
PA FAN - B
AIR
FROM FD FAN B
DISCHARGE
PRE
AD 20
AD 20A
AD 18
AD 156
HEATER - B
AD 16
TO COLD PA BUS
COAL PULVERISER SYSTEM

This system continuously supplies pulverised coal to the Boiler, over a wide
range of Boiler loads at the specified fineness.
The pulveriser system consists of
1. Coal bunkers
2. Raw Coal Feeders
3. Pulverisers
4. Coal pipes
COAL BUNKERS :
There are six numbers of Coal Bunkers for each Unit with an individual
storage capacity of 680 Tones. They are filled by either of the two Traveling
Trippers, through Conveyors 25A or 25 B. Raw Coal Bunkers normally have one
day storage for full load operation of their respective Units. The Coal Handling
Plant does the filling operation. A 36 chain operated coal valve is provided in the
Bunker Discharge pipe to the RC feeder
RAW COAL FEEDERS :
The Raw Coal Feeders are volumatric type is set to supply 33.8 Tonnes/Hr
of Coal to Pulveriser per Hr. while operating on a 415 V ; 3 phase ; 50 Hz Power
Supply.
COAL PULVERISERS :
Six numbers of Bowl Mills of the type XRP-763 is provided for each Unit.
The capacity of the pulveriser is 33.8 T / Hr. for a Primary Air supply of 52 T / Hr.
at 800 mmWCL.
The pulveriser consists of essentially a grinding chamber with a classifier
mounted above it. The grinding chamber has 3 No. of rolls placed 120 apart on a
rotating bowl, in which centrifugal force is utilized to move the coal delivered by
the Raw Coal Feeder, outward against the Grinding Ring (or Bull Ring). Rolls
revolving on journals that are attached to the Mill-Housing pulverise the coal
sufficiently to enable the air stream to pass through the pulveriser to pick it up.
Heavy springs acting through the journal saddles provide the necessary
pressure between the grinding surface and the coal. The rollers do not touch the
Grinding Rings, even when the pulveriser is empty. The tramp iron and foreign
material are discharged through a suitable spout.
The Air and Coal mixture passes upward in to the classifier with its deflector
blades where the direction of the flow is changed abruptly causing the coarser
particles to be returned to the bowl for further grinding. The fine particles
remaining in suspension leaves the classifier and pass through the coal piping to
the Coal nozzles. When the Mill is unloaded intentionally or due to a foreign
material or due to coal choking, Mill motor current low alarm is provided to
the operator. Each Bowl Mill supplies an entire Elevation of Coal nozzles, through
4 No. of Mill discharge valves. The Mill discharge valves are connected to coal
pipes, which deliver Coal + Air mixture to all the four corners of an Elevation.
PULVERISER DATA
TYPE OF PULVERISER
BOWL MILL WITH CLASSIFIER

(PRESSURISED)
SIZE
763 XRP
No. OF MILLS / BOILER
BASIC CAPACITY OF MILL
33.8 T / Hr. FOR A PULVERISED FUEL

FINENESS 70 % THROUGH 200
WITH A RAW COAL OF
GRINDABILITY
TOTAL
THAN
M / S. BHEL, HARDWAR.
MESH
INDEX 55 HGI AND A
MOISTURE OF NOT MORE
8 %.
MOTOR
320 KW , 6.6 KV, 1000 RPM (SYNCH.)
TYPE
AD 13168 H 6A
COUPLING
GEAR TYPE FLEXIBLE COUPLING

BETWEEN MILL & MOTOR
BEARINGS
ANTI FRICTION BEARINGS

MAIN VERTICAL SHAFT ASSEMBLY
JOURNAL SHAFT ASSEMBLY
WORM SHAFT ASSEMBLY
COOLING SYSTEM
OIL BATH IN MAIN MILL DRIVE &

GEAR HOUSING FOR
WORM GEAR,
WORM
LUBRICATING
WORM SHAFT,
SHAFT BEARINGS &
VERTICAL SHAFT BEARINGS. OIL
IS COOLED BY CIRCULATING
WATER INSIDE THE CUBE BUNDLES
IMMERSED IN THE OIL BATH.
No. OF COOLERS / MILL
COOLING WATER REQUIREMENT

FOR THE OIL COOLER
COOLING
KSC
12 M3 / HR. OF CLEAN, COLOUR

LESS & AMMONIA
CONTAMINATION FREE
WATER AT 32 0C & 3 TO 4
PRESSURE.
WAER SURFACES
OF
GRINDING ROLLS, BULL RING

SEGMENTS & LINERS MADE
HIGH QUALITY Ni HARD
( COMBOLLOY N ) CASTINGS.
COAL PIPES :
The coal pipes carry the coal + air mixture to all the four corners of the
Boiler Furnace from the Mills. Each coal pipe is connected to the respective Mill
discharge valve. The coal piping are connected at places by means of Grooved and
Sleeve type pipe couplings. These pipe couplings are specially designed to achieve
quick assembly and to automatically allow for contraction, expansion, and to some
extent translation of the coal pipes. Orifice plates are installed in the vertical run
of the coal piping leaving the pulveriser discharge valves, to compensate for unequal resistance to flow due to different length of piping to the Coal Nozzles.
COAL BUNKERS :
When filling the Bunker with coal, first close the Feeder inlet coal valve to
minimise the filling pressure on the Feeder to avoid compaction of the coal at the
Feeder inlet. This precaution is unnecessary if the Bunker is refilled while atleast
2.4 to 3 Meters. (8 10 Feet) of coal remain in it.
RAW COAL FEEDERS :
I) START UP AFTER A CLEAN SHUT DOWN :
1.
2.
3.
4.
5.
6.
7.
8.
Ensure all the Line Clear and Permission etc., in the pulveriser
system are cancelled.
Keep the corresponding mill in service with necessary FSSS
interlocks.
Open the Bunker Discharge Gate and Feeder Inlet Gate slowly.
Open the seal air connection butterfly valve.
Energise the Feeder controls at the power cabinet in the Relay
Panel Room adjacent to UCB and observe Feeder off green indication.
Open Cold Air Gate and Cold Air Damper to control Mill
Outlet Temperature.
Open Hot Air Gate.
Open Hot Air Damper and allow a Primary Air Flow of 52 T /
Hr in the Mill.
When the Mill O/L temperature of 75 0C is reached start the
9.
Feeder.
Maintain the Mill outlet temperature of 65 0C for high volatile

coals and 820C for low volatile coals by operating the Cold Air Damper.
11.
Slowly raise the Feeder speed as per the Boiler requirement
while maintaining 52 T / Hr of Primary Air at a Mill outlet temperature,
depending upon the Volatile Matter of the Coal.
10.
II) PROCEDURE FOR CLEAN SHUT DOWN :

1.
2.
R.C Feeder got tripped with no coal flow by closing the Bunker Gate and
Feeder Gate.
Close the Hot Air Damper, Hot Air Gate and Cold Air Damper.
III) NORMAL START UP PROCEDURE :

1.
Ensure all the Line Clear and Permission etc., in the pulveriser system
are cancelled.
2.
Keep the corresponding Mill in service with necessary FSSS
interlocks.
3.
Open the Bunker Discharge Gate and Feeder Inlet Gate slowly.
4.
Open the seal air connection butterfly valve.
5.
Energise the Feeder controls at the power cabinet in the Relay Panel
Room adjacent to UCB and observe Feeder off green indication.
6.
Open Cold Air Gate.
7.
Open Hot Air Gate.
8.
Open Hot Air Damper and allow a Primary Air Flow of 52 T / Hr in
the Mill.
9.
When the Mill O/L temperature of 75 0C is reached start the Feeder.
10.
Maintain the Mill outlet temperature of 65 0C for high volatile coals
and 820C for low volatile coals by operating the Cold Air Damper.
11.
Slowly raise the Feeder speed as per the Boiler requirement while
maintaining 52 T / Hr of Primary Air at a Mill outlet temperature,
depending upon the Volatile Matter of the Coal.
IV) NORMAL SHUT DOWN PROCEDURE :
1.
2.
3.
Slowly decrease the Feeder speed to minimum.

Maintain the Primary Air Flow of 52 T / Hr in the Mill for all the
Feeder speeds.
Stop form UCB.
MILL OPERATION :
Normal start up procedure :-
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Check that all Permission and Line Clear in the milling system are
cancelled. Check lubrication with reference to proper level and cleanliness
of lubricants.
Check sufficient Raw Coal in the Raw Coal Bunker.
Check for proper operation of Mill Discharges Valves, Hot Air Shut
Off Gate, Hot Air Damper and Cold Air Damper and Seal Air System.
Check that all Classifier Vanes are open to the same extent.
Check that no Boiler trip conditions exist.
Check sufficient ignition energy is available in the Furnace.
Check that all Mill Discharge Valves are in open condition.
Check that all Seal Air Valves to Mill are open and Seal Air supply
present at adequate pressure.
Check the cooling water line is open and cooling water supply present
at the Mill Oil Coolers.
Check that tramp Iron Spout Valve is open.
Check that Raw Coal Bunker Outlet Gate and / or Inlet Gate to Feeder
is /are open.
Check that Cold Air Gate is open.
Check that adequate Primary Air pressure is available in the Hot Air
Header (i.e), 800 mmWCL.
Ensure 6.6 KV supplies to the motor are available with necessary
protection and interlocks.
Start the Mill from the UCB, FSSS Panel.
After the Mill has been started, check up the return oil flow from the
upper bearing through the flow sight provided. This should be observed
within 8 to 15 Minutes after the Mill start up.
Raw Coal Feeder must be started only after the Mill has been started
and warmed up.
During the initial period and load picking up of the Mill check that
sufficient ignition energy is available in the Furnace till pulverised fuel
from each Mill attains self sustained condition.
Check all bearing and oil temperatures.
Check for Mill rejects, quantity and quality.
Check for any abnormal sound.
Check for any air or pulverized fuel leakage.
Check for Fuel fineness at routine intervals and adjust the classifier
vanes accordingly.
NORMAL SHUTDOWN PROCEDURE :
1.
2.
3.
Close the Mill Hot Air Damper and Hot Air Gate and open Cold Air
Damper to maintain 100 % Air Flow.
Continue feeding coal till the Mill outlet temperature reaches 50 0C then
stop the Feeder.
Run the Mill for another few minutes till it becomes empty and then shut
down the Mill.
4.
Cold Air Damper should be throttled to approximately 5 % open after the

Mill is stopped. A minimum Air Flow must be maintained through the
Mill at all times.
EMERGENCY SHUT DOWN PROCEDURE :
1.
2.
3.
4.
On loss of Furnace Ignition or another condition that requires a Mill

trip, the Mill Motor should be tripped immediately.
Stopping the Motor will trip the Feeder and closes the Hot Air Shut
Off Gate automatically.
An emergency trip subjects residual fuel in the Mills to conditions,
which may cause spontaneous combustion.
So the Mill should be restarted within a reasonable time.
START UP AFTER EMERGENCY SHUT DOWN :
After an emergency trip, the Mills that were in service will be hot and
contain a considerable amount of partially pulverised coal. The Hot Coal should
be removed from the Mills one by one by taking them in to service quickly. So the
following procedures are to be followed.
1.
2.
3.
4.
5.
6.
7.
8.
Purge the Unit.

Establish ignition energy in the Furnace for the Mill to be taken into
service.
Check that the Mill Discharge Valves are closed on all Mills not in
service.
This will prevent Hot Furnace Gases, which will be at higher than
normal pressure upon initial ignition of the coal, from surging down the
fuel piping in to the idle pulverisers.
Open Mill Discharge Valve on the Mill to be cleared.
Hot Air Shut Off Gate should remain closed. Open Cold Air Damper
and establish 100 % Air Flow through the Mill to transport the Coal.
Start the Mill and leave it on for several minutes to remove all the
Coal. Start the Feeder before Mill is empty. Then open the Hot Air Shut
Off Gate and modulate Hot Air Damper to bring the Mill to normal
operating temperature.
When required number of Mills is taken into service, the discharge
valves of standby Mills should be opened to allow the required minimum
Air Flow.
SHUT DOWN PROCEDURES FOR A MILL FIRE :
The two most common indications of a fire in the milling system are
A high or rapidly increasing Mill outlet temperature without other cause.
Paint peeling from the Mill and / or Fuel piping.
I.
If a mill system fire occurs, perform the following

a. Regardless of the fire location, do not shut down the Mill.
b. Close the Hot Air Damper fully and open Cold Air Damper to
maintain 100 % Air Flow.
c. Continue feeding coal at a high rate without over loading the Mill.
II.
Closing Hot Air Gate will frequently extinguish the fire, but if the Mill
temperature continues to rise
a. Cool the Mill by admitting water.
III.
After the Mill outlet temperature has dropped and all signs of fire are gone
a. Shut off the water being admitted to the system.
b. Stop the Feeder.
Run the Mill for several minutes to completely purge the system and to
reduce the possibility of an accumulation of water.
IV.
If it becomes obvious from peeling paint and change in colour that a fire
exists completely throughout the Mill and Fuel piping and the preceding
methods of comparing the Fire have been ineffective.
a. Clear all personnel from the area surrounding the Mill and its
associated Feeder and Fuel piping.
b. Shut Off the Feeder and allow the Mill to clear itself of Fuel.
c. Maintain a flow of Cold Air through the Mill until all evidence of
fire has disappeared and the Mill is Cold.
d. Shut Down and Isolate the Mill.
COAL BURNER SYSTEM

The Coal Burner system supplies the required heat flux to the Furnace
through the Wind Box compartments. The Wind Box distributes the pulverised
Coal and Air mixture uniformly in the Furnace.
The system consists of
Wind Box Assembly
Coal Burners
Burner Tilt Mechanism
Wind Box Secondary Air Dampers.
WIND BOX ASSEMBLY:
The Fuel Firing equipment consists of four Wind Box Assemblies located in
the Furnace Corners.
Each Wind Box Assembly is divided in its height into number of Sections or
Compartments. The Coal compartments (Fuel Air compartment) contain a Coal
nozzle. The top, bottom and intermediate compartments are used for admission of
Secondary Air (Intermediate Air compartments), Combustion Air (Secondary Air)
is admitted to the Intermediate Air compartments and each Fuel compartment
(around the Fuel Nozzle) through sets of louvre Dampers, each set of Dampers is
operated by a Damper Drive Cylinder located at the side of the Wind Box. The
drive cylinders at each elevation are operated either remote manually or
automatically by the Secondary Air Damper Control System in conjunction with
the Furnace Safeguard Supervisory System.
Some of the (Auxiliary) Intermediate Air Compartments between Coal
Nozzles contain a Retractable Oil Gun. Retractable High Energy Arc (HEA)
Ignitors are located adjacent to the Retractable Oil Guns. These Ignitors directly
light up the Oil Guns. Optical Flame Scanners are inserted in Flame Scanner
Guide Pipe Assemblies in the Auxiliary Air compartments. The Scanners sense the
visible light given off by the flame and then prove the flame.
COAL BURNERS:
In a tangentially fired Boiler, four tall Wind Box (combustion air boxes) are
arranged, one at each Corner of the Furnace. The Coal Burners or Coal Nozzle are
located at different levels or Elevations of the Wind Box. The number of Coal
Nozzle Elevations is equivalent to the number of Coal Mills. The same Elevation
of Coal Nozzles of 4 Corners is fed from a Single Mill.
The Coal Nozzles are sandwiched between Air Nozzles or Air
compartments. That is Air Nozzles are arranged between Coal Nozzles, as one
below the Bottom Coal Nozzle and one above the Top Coal Nozzle.
The Coal Fuel and Combustion Air streams from these nozzles or
compartments are directed tangential to an imaginary circle at the center of the
Furnace. This creates a turbulent vortex motion of the Fuel, Air and Hot Gases,
which promotes mixing, ignition energy availability, combustion efficiency.
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.
The Coal Nozzles Elevations are designated as A,B,C,D,E,F from Bottom to
Top. The Bottom End Air Bozzles as AA and the Top End Air Nozzles as FF.
The adjacent Coal Nozzles like AB, BC, CD, DE & EF from Bottom to Top
designate the Auxiliary Air Nozzles.
The four Furnace Corners are designed 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 the in between Auxiliary Air Nozzles. In this Boiler with
6 Mills or 6 Elevations Coal Nozzles, there are 12 Oil Guns arranged in
3 Elevations at Auxiliary Air Nozzles AB, CD & EF .
BURNER TILT MECHANISM :
The Air and Fuel Nozzles are vertically adjustable by means of movable
nozzle tips, which can be tilted upward or downward through a total angle of 60 o.
This movement is effected through connecting rods and tilting mechanism in
each Wind Box compartment, all of which are connected to a drive unit at each
corner operated by automatic control. Provision is given in UCB to know the
position of nozzle tips during operation. The tilt drive units in all four corners
operated in unison so that all nozzles have identical tilt positions.
WINDBOX DAMPERS :
The function of the Wind Box Dampers is to proportion the amount of

Secondary Air admitted to an Elevation of fuel compartments in relationship to the
air admitted to adjacent elevation of Auxiliary Air compartments.
Wind Box Compartment Damper positioning affects the air distribution as follows:
Opening up the FuelAirDampers or closing down the Auxiliary Air
Dampers increases the Air Flow around the Fuel Nozzle. Closing down the FuelAir Dampers and opening the Auxiliary Air Dampers decrease the Air Flow
directly around the fuel stream.
The Wind Box Compartment Dampers are operated by the Secondary Air
Damper Control system in conjunction with the Furnace Safeguard Supervisory
System. When an Automatic Control System provides modulation of the Auxiliary
Air Dampers as required maintaining a preset Wind Box to Furnace Differential
Pressure.
I ) WIND BOX :
1
After taking ID Fan and FD Fan into service maintain a 30 40 % of Total
Air Flow and purge the Furnace.
2
3
Open all the Elevations of Auxiliary and End Air Dampers to have a uniform
and thorough purging across the Furnace volume.
4
5
Maintain a Furnace to Wind Box Differential Pressure of 40 mmWCL for a
Boiler load up to 30 % by opening the Auxiliary Air Dampers.
6
7
Open the associated Oil Elevation Auxiliary Air Damper when Oil Guns are
taken in to service.
8
9
Open the Oil Elevation Air Dampers as a function of oil header pressure.
10
11
All the Coal-Air Dampers normally are closed, when the corresponding Coal
Mill is not in service.
12
13
Open the Coal Air Dampers after the associated Feeder is started and open
the Coal-Air Dampers as a function of Feeder speed.
14
For a Boiler load above 30 % , Furnace to Wind Box Differential Pressure
should be maintained at 100 mmWCL ,by operating Auxiliary Air Dampers
accordingly.
15
16
Total Air Flow should be increased for maintaining the Furnace to Wind Box
Differential Pressure when the firing rate is increased.
17
18
Keep the Bottom End Air Damper to a fixed pre-determined position, to
reduce unburned coal dust fall out.
19
When the Coal-Air Dampers are fully open, further Damper adjustments
should be made, if necessary , with the Auxiliary Air Dampers only.
20
21
Close the Coal-Air Dampers when the corresponding Coal Mill is stopped.
22
23
When changing Damper positioning an entire elevation should be treated
simultaneously (i.e.) Damper positioning at the same elevation should always be
identical in all Wind Boxes.
24
The Oil Elevation Dampers modulate as a function of oil header pressure
when put on Auto mode.
25
26
The Coal Elevation Dampers modulate as function of Feeder speed when put
on Auto mode.
27
28
The Auxiliary Air Dampers modulate as a function of Furnace to Wind Box
Differential Pressure according to the Boiler load, when put on Auto mode.
29
30
All the Auxiliary Air Dampers maintain their status quo upon a Boiler trip
and will open fully when both FD Fans are off, under Auto mode of operation.
31
II) BURNER TILT :
32
Ensure minimum instrument air pressure of 5 6 ksc for the Burner Tilt
mechanism.
33
34
Always have the tilt mechanism on Master Control, which tilts all the
Burners in all the corners.
35
36
Tilt the Burner either upwards or downwards so that the steam temperatures
are maintained at 540 0C for any combination of firing elevations.
37
38
Exercise it manually through full range, minimum once in a shift, to ease the
mechanism.
39
40
Set the RH Steam temperature at 540 0C for keeping the Burner Tilt master
on Auto mode.
III) COAL BURNERS :
Adjust the Wind Box to Furnace Differential Pressure to 30 40 mm WCL

up to a Boiler load of 30 % or at 100 mmWCL for a Boiler load above 30 %.
When the Coal Mill is started and Coal Burners are put into service, ensure
correct Primary Air header pressure (800 mm WCL) and Primary Air Flow to the
Mill (60 T / Hr).
Check for a stabilised flame at 300- 450mm away from the tips.
The design-firing rate per compartment (i.e.) 33.41 x 106 kcal / Hr while
firing high calorific value coal should not be exceeded.
During combination firing, let the loading at three adjacent tiers (coal + oil)
be less than design rate of the tiers.
Ensure no flame impingement and brushing on Water Walls.
Check with hand touch all coal pipes at Wind Box for possible plugging or
over heating. A cold pipe on a line in service is a good indication of plugging.
If plugging of coal pipe is confirmed, then the respective Mill has to be
stopped and Work Permit may be given to the Maintenance Staff for cleaning coal
pipe choking.
SH / RH ATTEMPERATION SYSTEM
The purpose of the SH / RH Attemperation system is to maintain the Boiler
outlet SH / RH Temperature well within the permissive limits.
The metal temperature at all sections in the Super Heater and Re-heater and
also in the Turbine should be maintained with in the permissible values.
Attemperation by Feed Water injection is used to limit the temperatures to steam at
Boiler outlet. The design margin in temperature control may get deviated and may
result in higher outlet temperature control due to slag formation in Water Wall,
high excess air, low feed water temperature, low load operations, and top tier Mills
in service. The cause has to be identified and action taken to keep the SH and RH
temperature at 540 0C, at Boiler outlet always.
Wall Blower operation and Burner Tilt adjustment are also made in addition
to adjust temperature control. Temperature control by feed water injection has to
be initiated as a final measure. For SH steam temperature control, the required
quantity of feed water is injected at the SH connection links between LTSH and
Platen SH through a nozzle. Normally spray type De-Super Heaters are provided
with renewable liners to protect the main Super Heater shell from erosion of spray
water and thermal shock. Since they are placed before Platen Super Heater, the
water particles entry to Turbine is remote.
For Re-Heater temperature control Burner tilting is carried out. Re-Heater
spray injection is carried out as a last resort at the Cold Re-Heat pipe before
entering the Re-Heater coils.
A Control Valve in an automatic control drive unit regulates the flow of
spray water quantity supplied to the De-Super Heaters for Main Steam and RH
steam temperature control of 100 % stand by Spray Control Valve is provided for
RH & SH temperature control. Both of the main and stand by Spray Control Valve
are provided with electrical Isolation Valve at the upstream side and hand valve at
the down stream end.
For SH / RH Attemperation system of the Boiler is of Direct Spray Type &
which consists of the following components.
1. Electrically operated main inlet block valve for both SH and RH Attemperator
Heaters.
2. Spray water limbs for SH Attemperation 4 Nos.
3. Spray water limbs for RH Attemperation 4 Nos.
4. Pneumatically operated Block Valve to RH Attemperation main inlet.
5. The Spray water required for the Attemperation taken from the Feed Water inlet
to the Boiler, through the electrically operated Attemperation Valve E 13 and
further distributed to SH / RH Attemperation through the electrically /
pneumatically operated Isolation Valves. Spray water enters through this limbs
to the Super Heater Header No:10th outlet, for SH temperature control and at the
CRH header for RH temperature control.
PROCEDURE :
SH TEMPERATURE CONTROL :
When the temperature is high, the following procedures are to be adopted :

1. Open the Main Inlet Electrical Valve (E 13 ).
2. Keep open all the Electrical and Manual Isolation Valves for both sides.
Gradually open the Pneumatically operated Control Valves till the SH
temperature is controlled. Normally SH Attemperation is being cut-in at about
60 MW while pressurizing the Boiler and cut out if Boiler load is less than
120MW while Shutting Down the Boiler. A minimum duration of five Minutes
is to be delayed to fee the exact nature of Attemperation. If the temperature is
stable, the system is to be put on auto.
RH CONTROL:
RH temperature control is done by means of Attemperation only after using

the Burner Tilt to the maximum level. Normally SH Attemperation is being cut in
at about 60 MW while pressurising the Boiler and cut out if Boiler load is less than
120 MW while Shutting Down the Boiler. RH Attemperation is given > 100 MW.
SH / RH ATTEMPERATION
SHH 11
RHH2
HRH
HRH
DESH
STEAM FOR
SHH 10
RHH1
SOOT BLOWING
S56
S30
S37
S33
S32
S55
DESH
S36
S27
S28
DESH
S54
S39
TO
DRAIN
S43
S29
CRH
INLET
S31
R44
R21
S49
R23
R29
R28
R16
R30
R24
FROM BFP
R45
R19
R25
E13
TO
DRAIN
DISCHARGE
R36
R17
R20
R22
R37
CRH
INLET
DUST CONTROL SCHEME

The Dust Control Scheme consists of the Electro Static Precipitators and
Mechanical Precipitators. In India the normal condition of Pollution is between 500 to
1000 mg / NM3, whereas in advanced countries such as USA, the value is as low as 70
mg / NM3. In our country also measures are being taken to control the Pollution to
150 to 300 mg / NM3 for Urban / Rural areas. The Electrostatic Precipitators place an
important roll in this respect which handles large quantities of Gases from which Solid
particles are to be removed. The various types of Dust Control Equipments and the
Particles Separating Efficiencies are as follows.
1.
2.
3.
4.
Cone Cyclones
Electrostatic Precipitators
Scrubbers
Fabric Filters
:
:
:
:
85 %
99 %
99.7 %
99.9 %
ELECTROSTATIC PRECIPITATOR :
The Technical Superiority of Electrostatic Precipitator lies in low pressure drop,
High Efficiency for small particle size and relatively easy removal of the collected
particles.
The four different steps are,
1.
2.
3.
4.
Ionisation of Gases and Charging of dust particles.

Migration of the particles to be collected.
Deposition of Charged Particles on the Collecting Surface.
Dislodging of Particles from the collecting surface.
The Electrostatic Precipitators essentially consists of two sets of Electrodes one

in the form of wire called Discharging or Emitting Electrodes and the other said called
Collecting Electrodes in the form of Pipes. The Emitting Electrodes are placed in the
midway of two plates and are connected usually to Negative Polarity of High Voltage
D.C source of the order of 25 to 70 KV. The Collecting Electrodes are connected to
the Positive Polarity of the source and Grounded. The High Electric Field in the
vicinity of the Emitting Electrodes creates Corona Discharge Ionising the Gas
Molecules. The Dust Particles entrained in the case acquire Negative Charge and
Experience a force which drives them towards the Collecting Electrodes where they
get deposited. The Collected Material is dislodged by knocking the Electrodes by a
process called Rapping.
MAJOR PARTS OF ELECTROSTATIC PRECIPITATOR :
The major parts of the Electrostatic Precipitator are,

1. Casing.
2. Hopper.
3. Gas distribution Scanner.
4. Collecting System.
5. Emitting System.
6. Rapping Mechanism for Collecting System.
7. Rapping Mechanism for Emitting System.
PRINCIPLE OF OPERATION :
A.C Input is applied to the Main Transformer through the load windings of the
two Transducers. The Control Windings are connected in series and the Control
Current is provided by a Thyristor Bridge Circuit. The Thyristor Bridge is driven by a
pulses generated by an Electronic Pulse Generator which in turn is controllable by
Electronic Control System. Basically transducer is employed as a variable impedance
device which controls the input applied to the Main Transformer. If the Main A.C is
applied, with Zero Excitation to the Transducer Control winding, the Transducer
impedance will be high compared to the reflect load impedance on the Primary of the
Main Transformer and the HV Output from the set will be low. As the Control Current
is gradually increased, the impedance of the Transducer falls, thus enabling application
of increased A.C Voltage to the Main Transformer. Control Current to the Transducer
is in turn under the Control of a Thyristor Bridge. The Controller Output regulates the
conduction angle of the Silicon Control Rectifier (SCR) Bridge via the driver
regulating the set output.
Note : The Electrostatic Precipitator need not be cut in to service while the Boiler is
under Oil Firing.
TECHNICAL DATA
DESIGN CONDITIONS :
a)
Gas Flow Rate
12,96,000 M3 / Hr.
b)
Temperature
140 0C
c)
Dust Consentration
33 gm / M3
d)
Pressure at the inlet of ESP
- 200 mm WCL
e)
No. of Fields in Series

in each Gas Path
5 Nos.
f)
Guaranteed Collection Efficiency
98.5 %
g)
Pressure Drop across the

Electrostatic Precipitator
15 mm WCL
h)
Treatment Time
13.68 Seconds.
i)
Velocity of Gas at
Electrode Zone
1.053 M / Sec.
39 Nos.
351 (9 Plates in each

Row)
:
:
:
:
5616
9M
400 mm
109.44 M2 / M3 / Sec.
:
:
Spiral Coil Conical Ends.

2.5 mm
:
:
:
:
:
36
1368
21888
7879 M
125 mm
A. COLLECTING ELECTRODE :
a)
b)
c)
d)
e)
f)
No. of rows / Collecting

Electrode per Field
No. of Collecting Electrode
Plates per Field
Total No. of Collecting Plates
per Boiler
Nominal Height of Collecting Plate
Nominal Length of Collecting Plate
Specific Collecting Area
A. EMITTING ELECTRODE :
a)
b)
c)
d)
e)
f)
g)
Type
Size
No. of Electrodes in the Frame
forming in one Row
No. of Electrodes in each Field
Total No. of Electrodes per Boiler
Total Length of Electrode per Field
Plate / Wire Spacing
B. RAPPERS FOR COLLECTING ELECTRODES :
a) No. and Type of Rappers :

b) Rapper Size
c) Frequency of Rap
:
:
d) Drive
One drop Hammer per Row of

Collecting Electrode having a
Collecting Surface of 64.8 M2
4.9 Kg.
1st Field 12 Raps / Hr.
2nd Field 10 Raps / Hr.
3rd Field 8 Raps / Hr.
4th Field 4 Raps / Hr.
5th Field 2 Raps / Hr.
Geared Electric Motor.
C. RAPPERS OF EMITTING ELECTRODE :
a) No. and Type of Rappers
b) Rapper Size
c) Frequency of Rap
d) Drive
:
:
:
Approximately one drop

hammer for two Row of
Electrode.
3.0 Kg.
10 Raps / Hr.
Geared Electric Motor.
D. HOPPERS :
a)
b)
c)
d)
Type
No. of Hoppers
Capacity
Heating
e) Baffling Arrangement
:
:
:
:
:
Pyramidal
40 (2 / Field )
8 Hours Storage.
Electrical Heating Provided to
the Bottom of the Hopper.
2 Sets of Reflector Plates for
each of the Hopper underneath
the Collecting Plate to prevent
gas sneakage.
E. RECTIFIER :
a) Rating
b) No. of Rectifiers
c) Type
:
:
:
d) Location
70 KV (peak) / 800 mA (mean)

20
Silicon Diode, Full Wave
Bridge Connection.
On the Top of the Precipitator.
F. MOTORS :
Rapping Motor of Emitting or Collecting Electrode Motor

a. Quantity
b. Rating
:
:
20 Nos. for each.

Geared Motor, 0.5 / 0.33 HP,
1.1 rpm at 3 415 V 50 c / s
G. HEATING ELEMENTS :
a. For 40 Hoppers, Hopper Heaters

at 6 KW / Hopper
:
b. For Shaft Insulators
1. For 16 Insulators at 1 KW :
2. For 64 Nos. of Support
Insulators at 1 KW
:
240 KW
16 KW
64 KW
SOOT BLOWER SCHEME

Whenever Fossil Fuels are burnt they have a combustion residue broadly known
as Ash. The fouling of the Unit by Fly Ash assumes several forms:
a. Fused Ash or Slag Deposits can occur on Water Walls and other surfaces
exposed to high gas Temperature.
b. Sintered Ash, Deposits and Convection surface, though the Temperature of
the gas in the area is far less than the Ash softening Temperature.
c. Fly Ash: In the Cooler parts powder Fly Ash deposits. These cause
Corrosion due to the acidic nature.
d. Fuel Oil Ash : The Main constituents of the oil which cause troubles of the
Suplhate of Alkalis and Vanadium Pent oxides. These components have low
melting temperature to form a tough coating on the tubes.
The effects of the deposits are:
a. Reduction in Heat Transfer as the Ash Deposits act as an Insulator.
b. Accumulation of Deposits on the Tube banks may block the Flue Gas
path and hence increase the Draft Loss in Flue Gas Flow.
c. Ash Deposits cause Corrosion of the Tubes due to the corrosive
components of Ash.
d. Build up of Slag Accumulation near Burner Mouth may affect the
Combustion / Distribution of Fuel in the Furnace.
The soot blowers used in various locations of the Boiler are:
a. Water Wall Soot Blower
b. Long Retractable Soot Bower
c. Air Pre Heater Soot Blower
a) WATER WALL SOOT BLOWER :
These are used for cleaning the Furnace Water walls. There are 56 Nos. of Water
Wall Soot Blowers per Boiler. The operating Steam pressure / Temperature of
W.W.S.B are 15 ksc / 250 0C to 350 0C.
b) LONG RETRACTABLE SOOT BLOWER :
These Blowers are normally employed for cleaning the Super Heater, Re
Heater Zones of the Boiler, where the Flue Gas temperature would be more than 980
0
C. There are 20 Nos. L.R.S.B per Boiler. The operating Steam Pressure / Temperature
of L.R.S.B are 18 ksc / 250 0C to 350 0C.
c) AIR PRE HEATER SOOT BLOWER :

These Soot Blowers are used for cleaning the Air Pre Heater Heating Elements.
There are two numbers of Soot Blowers per Boiler. The Operating Steam Pressure /
Temperature of Air Pre Heater Soot Blower are 12 ksc / 250 0C to 350 0C.
1. Keep four Drain Valves Open.
2. Steam Inlet Valve at 52 M from 10th Header slightly opened for Warming up.
3. After Warming Up (Steam Temperature 250 0C) Close all the Four Drain
Valves.
4. Open the Steam Inlet valve to the required pressure ( 18 ksc for LRSB
operation, 15 ksc for Water Wall Soot Blower Operation, 12 ksc for Air Pre
Heater Soot Blower Operation )
5. After completing the Blower Operation close the Steam Inlet Valve at 52 M.
ASH WET DISPOSAL SYSTEM

Indian Coals are generally of high ash content by its nature. Almost 45 to 50%
ash is to be extracted from Boiler at various points, and handled by Ash Handling
System.
About 150 Tonnes of coal is being fed to each boiler in MTPS per every hour
for the full generation of electricity and hence 6500 to 6800 Tonnes of ash are to be
handled every day in total.
The exact location of generation of ash is at the Furnace . Normally 10 to 20%
of ash which is heavier fall down to Bottom Ash hoppers. Water jets are provided in
Bottom Ash Hoppers so that accumulation of ash particles in the Furnace area was
avoided.
The Seal Trough is provided at bottom of the Furnace, which is giving,
allowance for Boiler Expansion at the bottom portion of the First Pass as the entire
Boiler is hanging from top. The Seal Trough is continuously filled up by ACW water
and is overflowing into the Bottom Ash Hopper. The seal plate is immersing into the
seal water in the Seal Trough and hence furnace sealing is possible always.
The temperature of ash falling bottom ash is cooled first by water stored in the
Bottom Ash Hopper and then it immerses in to the Bottom Ash Hopper water and
settled.
The settled ash is carried upwards by moving scraper plates to Clinker Grinder
where the ash is being crushed to powder and discharged to the slant draining channel.
The ash slurry thus formed forcibly carried away by the jet of water and
transported to ash slurry sump through ash trenches. Nozzles are fitted at the sides of
trenches for providing water jets.
The balance of 80 to 90 % of ash carried along with flue gas, as ash weight is
feeble. Hence this ash is called as Fly Ash. Among this 6 % of ash is being collected
in Economizer Hoppers and 3 % of ash is being collected in APH Hoppers.
The above ash is collected in the mixing chambers of concerned Hoppers where
sufficient water from HP water system is being mixed to form ash slurry. The ash
slurry is sent to the ash slurry sump through ash trenches.
The balance quantity of fly ash is separated at ESP fields and collected in the
ESP Hoppers located at down side of fields. There are 48 Nos of ESP Hoppers for
each Unit. The Fly Ash so collected is sent to mixing chambers at its bottom and ash
slurry is formed. Ash in all the Hoppers above the mixing chambers is collected by
water jet.
The ash slurry from BAH Economizer Hoppers, APH Hoppers, ESP Hoppers
and Chimney Hoppers are sent to ash slurry sump by gravity and by forcing through
water jets.
Diversion sluice gates just before ash slurry sumps are provided to divert ash
slurry into any ash slurry sumps in particular stage. Normally unit basis drawl of ash
slurry is being carried out.
LP line water make up is provided at ash slurry sump for clearing deposits in
the grate and diluting purpose. HP line water make up through water jets near the
suction line of ash slurry pumps is provided to clear the ash choke up, diluting ash
slurry and to pickup slurry sump level speedily if necessary.
Great provision is made in the sump to restrict the flow of larger size ash blocks
into the suction of ash slurry pumps.
Each stage Ash Handling Pump House has two numbers of Ash Slurry Sumps
and each Sump is being connected with two streams of Ash Disposal System. So each
stage has four streams of Ash Disposal System are called A,B,C,D streams.
Each stream has three number of Ash Slurry Pumps connected in series and the
suction line of first pump is connected with Ash Slurry Sump through two suction
valves. One is electrically operated Isolation and the other is Manual Isolation Valve.
The suction line sucks the ash slurry from Ash Slurry Sump and sent to Ash
Slurry Pump No. 1 (say A1 for A stream) where the discharge pressure is 4.5 ksc.
The pressurised ash slurry goes to the suction of next pump (say A2) and the ash slurry
pressure is raised to 9.0 ksc. The discharge from second pump is sent to the suction of
third pump and the final discharge pressure of ash slurry is around 13.5ksc.
In the discharge side there is a discharge valve (Manual). In the down stream
side of the discharge valve the following valves are being connected.
1) One number ash slurry drain valve which is connected to common header drain
pipe. Similarly every stream discharge lines drains are connected to this drain
header. This drain header runs over to ash slurry sumps. Stop valves are also
provided at ends of drain header over the sump.
2) Flushing line from Flushing Water Pump is also connected at the down stream
side of ash slurry pump discharge valve through NRV.
The LP water and HP water are supplied to the system through LP and HP water
pumps respectively. Flushing of ash slurry discharge line being done after stopping
the ash slurry pump to avoid ash slurry choking in the discharge line. For this purpose
two numbers of Flushing Pumps are provided for each stage. Water sealing is provided
for ash slurry pump glands by means of Seal Water Pumps.
For all the above water pumps water is fed from Ash Water Tank. Auxiliary
cooling water return line from the individual unit normally feeds the corresponding
Units Ash Water Tank. Over Head Tank water make up can also be made if in the
case of any emergency of low water level in ash water tank. No isolation provision is
made in the ACW return line and the entire water is to be collected in the Ash Water
Tank.
PROCEDURE :
OPERATING INSTRUCTIONS :
PRE CHECKS
1) Ensure the opening of following valves
All ESP hopper valves
All Economizer hopper valves
All APH hopper valves
Chimney hopper valves
Mixing chamber isolation valves at various location
ACW line to seal trough
ACW line to BAH nozzles
HP line to BAH nozzles
Clinker grinders seal valve
LP valves to ash slurry sumps
Seal water line valves to ash slurry pumps
All feed gates in BAH
Nozzles at various location made through
2) Ash water tank is filled up.
3) OHT line isolation valve to seal water pumps is opened and start one seal
water pump per each unit and opened its delivery valve.
4) Open the suction valves of one number HP Water pump and one number of LP
Water pump in each Unit.
Crack open the discharge valve of HP / LP water pump (to be started).
Start HP water pump and then open its discharge valve full gradually.
Similarly start LP water pump also.
5) Ensure that seal water is available for ash slurry pumps by opening the
individual valves.
6) Ensure the filling up of
Seal trough
BAH
AH mixing chute chambers of ash hoppers at various locations.
7) Start both the clinker Grinders and check for the correct direction of rotation.
8) Start both the scrapper feeders.
9) Open all the four feed gates at the Bottom ash hoppers.
Note : Starting of scrapper feeder, clinker grinder and opening of feed gates are
to be done just before the starting of the very first mill.
10) Ensure all nozzles at various locations are working all right.
11) If required manual isolation valves in HP or LP lines may be opened to dilute
the ash slurry where it tends to block the drain channel.
12) STARTING OF ASH SLURRY PUMPS
Ash slurry pumps discharge valve should be in closed condition.
Ash slurry discharge drain valve is to be kept in full closure position.
Ash slurry discharge flushing valve also be closed fully.
Manual isolation suction valve to ash slurry pump is in OPEN condition.
Rack in the Breakers of THREE ash slurry pumps in that particular
stream.
Release the local push button.
Reset the flags in the panel.
Open the inlet electrical valve.
Ensure the avilability of seal water to both the pumps.
Start the first pump.

Then start the second pump.
Open the delivery valve gradually to full open.
Start the third pump.
In case of any blockage at the suction line of the pump the running pump
may not consume normal load current. This is the correct indication of nonloading of pump. Hence to release the blockage the LP/HP water spray in the ash
slurry sumps is opened. Normally LP water make up is being opened for the
dilution and ash slurry sump level make up.
STOPPING OF ASH DISPOSAL SYSTEM.
1.
2.
3.
4.
5.
6.
Ensure the Tripping / Shutdown of the Unit.

Close the Feed Gates.
Stop Scrapper Feeders.
Stop Clinker Grinders.
Continue BAH filling and Seal Trough filling till ID Fans run.
Continue rapping of all ESP fields may be tried one field after the other and all
hoppers may be emptied quickly. If required, manual rapping of ESP fields
may be carried out.
7. Ensure no ash slurry is fed from BAH, Economiser Hoppers, Air Pre Heater
Hoppers and ESP Hoppers.
8. Diversion sluice gates may be properly closed or opened just before Ash
Slurry Sumps of the particular stage so that concerned Units Ash Slurry
make up to sump is diverted the next Unit sump.
9. LP water line may be kept open to Ash Slurry Sump so as to maintain the
Ash Slurry Sump level till pumps are stopped.
10. Normally Ash Slurry Pumps are kept in service till ash slurry is diluted to the
maximum extent.
11. Gradually close delivery valves of HP and LP Water Pumps, and then stop the
Pumps.
12. Gradually close the delivery vale of Ash Slurry Pumps and stop both Pumps.
Close the suction Butterfly valve of the Ash Slurry Pumps.
13. Open the drain valve at down stream side of the Ash Slurry Pumps discharge
valve and divert disposal line ash slurry into the next Units Ash Slurry
Sump.
14. Close the drain valve in the Ash Slurry Pump discharge valves down stream
side, if ash slurry draining is over
15. a) Open slightly the discharge valve (almost 20 %) of the Flushing Water
Pump of concerned Unit. (Suction valve should be in full open
condition)
b) Ensure Breaker for Flushing Pump is in service position.
c) Release the Local Push Button.
d) Reset the relay flags.
e) Keep Flushing end Isolation Valve slight open (2 to 3 turn), Start the
Flushing Water Pump and then open the discharge valve gradually. (The
pressure around 13.5 ksc).
16. Ensure the closure of Ash Slurry Pumps Discharge Valve and Ash Slurry Drain
Valve.
17. Gradually open the Isolation Valve in the flushing water line that connects the
ash disposal line in which ash slurry is completely drained.
Note :
If the disposal line ash slurry is not completely drained after the stopping of the
pumps, then water content in the ash slurry inside the higher level disposal line
may pass into Ash Slurry Sump, due to its gravity and passing in the discharge
valve. But ash content in the discharge line will stay in the pipe itself, which may
cause choking of the pipes. Hence it is the routine practice to drain the slurry
immediately after stopping of the pump, the flushing operation is followed.
If it is required to back wash the Ash Slurry Pumps the same also can done by
keeping its suction valves open and admitting flushing water through the Pumps
Discharge Valve. During this operation slightly opening of Discharge Valve only is
enough.
18. Flushing operation is normally being carried out for about 20 Minutes.
19. The close FW Isolation Valve and then stop Flushing Water Pump after closing
its Discharge Valve.
20. Close the delivery valve of seal water line and stop the Seal Water Pump.
IMPORTANT NOTE :
Never start ASH SLURRY PUMPS if
Ash Slurry Sump level is inadequate
No sealing is given to Pumps
Adequate dilution of Ash Slurry is available.
Never stop the Ash Slurry Pumps before closing the discharge valve.
Never leave Ash Slurry in the ash disposal line.
STEAM CIRCUIT SYSTEM

This system deals with the Flow Scheme of Steam from the Drum to High
Pressure Turbine via Super Heaters and that of the Flow Scheme of High Pressure
Turbine to Intermediate Pressure Turbine via Re Heaters and from IPT to LPT.
Feed water is supplied to the Boiler Drum (Steam Drum) from the Economiser
outlet. The waterside is connected with the Furnace Bottom Water Wall headers
through Down Comers.
The Front and Rear Water Wall Bottom Headers feed the Front and Rear
Furnace Wall Tubes. The Furnace side walls are supplied by the two side wall bottom
headers. All the bottom headers are connected together to form a ring.
The water in the Furnace walls, front and rear water walls absorbs heat. Due to
the density difference between the hot water in the water wall and the Drum, water
circulates naturally. The resultant mixture of water and steam is collected in the outlet
headers and discharged into the steam drum through a series of riser tubes. In the
Steam Drum separation of water and steam takes places. The Boiler water mixes with
the incoming water. The dry saturated steam is led into the Super Heater connecting
tubes.
Passing through the various stages of Super Heaters, the steam is super heated
to the design temperature, keeping the pressure constant. This process of increasing
the temperature of steam above its saturation temperature is called as Super heating.
Super heated steam is very essential for power generation due to the following
advantages.
1)
2)
3)
4)
It reduces the specific steam consumption.

It reduces the condensation losses in pipes.
It eliminates the erosion of the turbine blades in the last stages.
The efficiency of the steam power plant is higher with the use of super heated
steam.
STEAM DRUM INTERNALS :

The steam drum serves the following three main purposes.
1) To provide necessary space for separation of steam from a mixture of steam &
water.
2) To house the equipment needed for purification of steam after separation from
water.
3) To provide a water storage for preventing the starvation of tubes.
Wet steam entering the drum from the riser tubes and furnace walls is collected
in a compartment called separating chamber. From here the steam is led through two
rows of Turbo-separators consisting a primary stage and secondary stage.
From the secondary stage of Turbo separators the steam flows uniformly and
with relatively low velocity upward to the series of screen dryers, extending in layers
across the length of the Drum. These screens perform the final stage of separation.
The fitting and alignment of Drum internals are very important for its efficient
performance.
SUPER HEATER:
The details of 4 basic sections of Super Heater is as follows:
SL.NO.
SECTION
LOCATION
1.
PLATEN
Directly above the Furnace in front of

the Furnace arch.
2.
PENDANT
Behind the screen tubes.
3.
HORIZONTAL
Rear vertical gas pass above the

Economiser.
4.
Steam Cooled
Wall & Roof.
Side, front and rear walls and roof of

The vertical gas pass.
STEAM FLOW :
Saturated, dry steam from the steam drum flows as follows:
1) Steam cooled wall roof tubes.
2) Steam cooled side wall tubes.
3) Extended steam cooled side wall tubes.
4) Front steam cooled wall tubes.
5) Steam cooled root and rear wall tubes.
6) Super Heater rear horizontal assemblies.

7) Super Heater De-Super Heaters.
8) Platen Super Heater.
9) Pendant Super Heater.
The approximate temperature and pressure of super heated steam at various
sections (Header) are given below.
Super Heater
Header No.
SHH-1
SHH-2
SHH-3
Temperature
in oC
341
345
350
SHH-4
SHH-5
SHH-6
SHH-7
SHH-8
SHH-9
SHH-10
355
360
370
380
400
430
Pressure
in ksc
146.5 Steam cooled roof tubes-I pass
146.0
---do
--- II pass
145.5 Steam cooled side wall tubes
(L&R)
145.0
---do
-----144.5 Steam cooled side wall tubes.
144.0
143.5
143.0
142.5 Super heater horizontal (Lower)
142.5 Super heater horizontal (Upper)
De-Super Heaters
SHH-11
SHH-12
SHH-13
SHH-14
427
515
530
540
142.0
141.5
141.0
140.0
Platen super heater inlet

Platen super heater outlet
Pendant super heater inlet
Pedant super heater outlet
Final
super
heater
Super heated steam from the pendant super heater outlet header goes to the
H.P.Turbine via main steam lines.
After passing through the high pressure stages of Turbine, steam is returned to
the Re-Heater via Cold Re-Heat lines. The Re-Heat De-Super Heaters are located in
the Cold Re Heat header. Re-Heat steam flow through the unit is as follows.
1) Front Pedant Re-Heater.
2) Rear Pendant Re-Heater.
After being re-heated to the required temperature the re-heated steam is returned
to the low pressure section of the turbine via the HOT REHEAT LINE.
The main purpose of re-heating is to increase the dryness fraction of steam
passing through the later stages of turbine.
Additionally by the use of re-heat cycle,

1) The specific steam consumption decreases.
2) Thermal efficiency increases marginally and this depends upon the ratio of re-heat
pressure to original pressure of steam.
The table below provides information about the advantage of reheat cycle.
Super heated to 600 0C
Super heated & reheat to 600 0C
160 bar
350 bar
160 bar
350 bar
------------------------------------------------------Efficiency % 45.3
46.8
46.8
48.5
------------------------------------------------------Dryness
77.2
70.8
95.4
87.1
at exit
-----------------------------------------------------From the above table it is clear that the moisture content of the steam at the exit
of turbine is very less and this avoids the danger of erosion of turbine blades, and also
increases the nozzle and blade efficiency.
DE SUPER HEATERS :
De-super heaters are provided in the super heater connecting links between
SHH 10 and SHH 11 and the cold reheat header to permit reduction of steam
temperature and to maintain the required temperature values.
The spray water is taken from boiler feed water, and it should be chemically
pure, in order to prevent chemical deposition in the Super Heater & Re Heater and
carry over of solids to the Turbine.
Two spray type de-super heaters are installed in the connecting links between
the rear horizontal outlet header and the platen inlet header.
Two spray type de-super heaters are installed in the cold reheat header.
PROTECTION & CONTROL :
As long as there is fire in the furnace, adequate protection must be provided for
super heater and Re-heater elements. Especially during startup and shutdown there
will be no steam flow through the turbine and adequate flow through super heaters is
assured by means of drains and vents in the headers, links and main steam piping.
Re-heater header drains & vents provide means to boil off residual water in the
re-heater elements during initial firing of the boiler.
During all startups, care must be taken not to overheat the super heater or Reheater elements. The firing rate must be controlled and exit gas temperature must be
below 540 0C.
Safety valves are also provided in the main steam lines and HRH / CRH lines to
expel out maximum quantity of steam while Boiler pressure exceeds the
predetermined design value.
An Electrometric Relief Valve (ERV) also provided in the main steam line
which has the setting below the minimum Super heaters safety valves setting. This
valve can also be operated manually at any pressure.
The 14Nos. of safety valve set pressure details are given below.
---- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sl.
Safety Valve
Set Pressure
Reviving
No
Location
in ksc (g)
Capacity
(in T/Hr)
----------------------------------------------------1
Drum LHS-B1
158.2
159.0
2
,,
RHS-B2
161.0
193.0
3
,,
RHS-B13
162.4
195.0
----------------------------------------------------4
MSL RHS S 1
143.8
86.0
5
MSL RHS S 53
144.5
87.0
6
MSL ERV
141.3
87.0
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7
CRH LHS
33.0
100.0
8
CRH LHS
33.4
130.3
9
CRH RHS
33.8
131.6
10
CRH RHS
34.1
133.0
----------------------------------------------------11
HRH LHS
30.6
115.0
----------------------------------------------------12
Soot blower Line
38.0
-----------------------------------------------------13
PRDS Line
18.0
-----------------------------------------------------14
CBD expansion tank
7.8
-- -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MAIN PARAMETERS :
1) Steam generation
2) Feed water supply
3) Drum steam pressure
4) Main steam temperature
:
:
:
:
700 T / Hr.
715 T / Hr.
147 to 150 ksc
540 0C
5) Main steam flow pressure

6) Reheater steam flow
7) Reheater steam inlet pressure (CRH)
8) Reheater steam inlet temperature(CRH)
9) Reheater steam outlet pressure (HRH)
10) Reheater steam outlet temperature (HRH)
:
:
:
:
:
:
137 ksc
580 T / Hr.
26 ksc
332 0C
24.5 ksc
540 0C
STEAM QUALITY :
-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pressure in ksc
--------------------------------------------< 40 ksc
40 to 100
100 and above
------------------------------------------------------Sodium mg /Kg < 60
< 15
< 10
Na
- - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Silica mg /Kg
--< 25
< 20
Si02
-----------------------------------------------------Conductivity
-------< 40 50 s/cm
PROCEDURE :
The horizontal super heater sections and steam cooled walls are completely
drained by opening the super heater header drains and Eco., Drum & SH vents before
lighting up. Super heater header drains are closed at a drum pressure of 5 to 7 ksc.
Close Eco., Drum & SH air vents when they begin to steam.
1) SH start up vents are opened immediately after lighting up and closed after
synchronization.
SH start up vents are closed if HP / LP Bypass system is brought into service.
The above vents are again opened during Turbine rolling as HP / LP Bypass station is
closed.
STEAM GENERATION
A Boiler services the purpose of generating steam at a required Pressure and
Temperature (137 ksc & 540 0C in case of a 210 MW Unit) which is utilised in driving
the Turbine for Electrical Energy Generation in Generator.
The steam generator used in a 210 MW unit is described as follow
a) NATURAL CIRCULATION :
The flow of water from the drum through the down corners followed by the
rising of water in the water walls and the rising of the steam up to the drum all occur
naturally and no external pumping is carried out. The natural circulation takes place
due to the density difference between the steam and water in the water wall tubes as
the operating pressure (137 KSC) is well below the critical pressure.
b) BALANCED DRAUGHT :
A combination of both forced draught and induced draught fans are used, there
by maintaining a furnace pressure of 5 to 10 mm WCL inside the furnace.
c) WATER COOLED FURNACE:
The furnace walls are made up of water wall tubes, which serves dual purpose
of steam generation as well as cooling the furnace.
d) TANGENTIAL CORNER FIRED:
The fuel (both oil and coal) is injected into the furnace from the corners and the
nozzles are so designed as to direct the fuel tangential to the imaginary fire ball, thus
giving a swiveling action to the fire ball, resulting in effective heat transfer.
e) DRY BOTTOM:
The maximum furnace temperature is well below the ash fusion temperature
and hence the ash from the furnace falls as dry ash.
In addition to the above definitions, the boiler used in a 210 MW is of two pass,
single drum, radiant superheat and reheat type with regenerative air pre-heater.
PROCEDURE :
1) COLD START UP :
Ensure no line clears are pending.

Check lubricant level in auxiliaries.
Charge cooling water for auxiliaries.
Ensure instrument air availability.
Ensure service air availability.
Ensure, from local operator, that all air vents (Drum, economiser, SH &
Drum) open.
Ensure that both economiser R/C valves are open.
Ensure SHH drains are open.
Line up flue gas path.
Line up secondary air path & PA path.
Ensure HT & LT supply are available to all equipments.
Fill the boiler drum up to normal level with Boiler Water having pH 9
and Hydrazine (N2H4) 12 ppm.
Ensure that seal through and BAH are filled with water.
Check and ensure that all man holes and peep holes doors are closed.
Ensure all fly ash hoppers are sealed to air ingress.
Charge aux. PRDS from neighboring unit by opening the manual
interconnection valve.
Charge HFO atomizing steam header, using PRDS steam taken from
neighbouring unit.
Start LDO pump.
Start HFO pump and put on re-circulation using short RC value, so as to
raise the temperature of HFO.
Start AC scanner air fan. Ensure that EAD is open, from local operator.
Start APHs GB and SB LOPs. This is usually done by local operator.
Both sets of LOPs are started and ensured that they develop adequate
pressure. Finally one set is kept in service.
Start APHS. Check if the air motors come into service by tripping the
electrical motors. Then keep the main drives in service.
Start ID fan.(Any one). Maintain draft of 10 mm wc.
Start FD fan. (Usually corresponding to the ID). And load it to maintain
an airflow of 30% MCR. Accordingly, load ID fan so as to maintains furnace
pressure at 10 mm WCL. Open the SADC Auxiliary air dampers wide

enough to facilitate propose purging of boiler. Confirm the closure of EAD.
Ensure that all Light Oil and Heavy Oil Hydro motor Valves and all
HAGs closed.. Both HOTV and LOTV are closed. Both PA fans are off and
all feeders are off. Also ensure that all scanners sense no flame and that there
is no Boiler trip. This will provide Purge permissive.
Start purge and evacuate the boiler, for any left out fuel, for five minutes.
Open LOTV and LO flow control valve.
Select light diesel oil in AB elevation.
Make burner tilt horizontal.
Ensure from local operator that the local maintenance switches of all the
four corners are put on remote, manual isolation valves are open for both oil
and atomising air in all four corners.
Light up the boiler by cutting in oil guns in corners 1 & 3 of AB
elevation with LDO pressure of 10 KSC. (On giving a start command, the
HEA igniter rod of corner 1 advances, followed by the opening of atomising,
air nozzle valve. The ignitor then starts operating and simultaneously the oil
nozzle valve opens and atomised oil is sprayed into the furnace, which ignites
and the flame is sensed by the discriminating scanners. The ignitor sparks for
10 seconds and then retracts automatically. After 15 seconds from the initial
command to the 1 & 3 corners pair, the above said sequence begin in corner 3.
The whole sequence is completed in 90 seconds and flame is established in
corners 1 & 3.Open the Start up Vents. The SADC oil dampers are opened out
and WB DP is maintained at around 40 to 50 mm wc. As coal burners are not
in service in the adjacent elevations, the oil guns come into service in pair
mode only. For ensuring uniform heating of the water walls and uniform
expansion of the boiler, the second pair of guns corners 2 & 4 are taken into
service and corners 1 & 3 are cut out. This process is repeated at regular
intervals.
Open CBD Control valve by half turn.
The steam parameters start raising very slowly. The air vents are closed
at about 2 KSC pressure, after ensuring free flow of stream through them. As
the SH start up vents are kept open, flow is established, thus resulting in
raising of steam parameters. Close SHH drains if Drum pressure 7 KSC.
Inform ESP operator to switch on the rapping motor,. Shaft & Support
Insulators and Hopper Heaters.
Ensure that the HFO temperature after the discharge strainer has reached
0
120 C. Open HFO long R/C valve and HOTV and put HFO is long ReCirculation so that the HFO Burner header temperature also raises to 1200C.
Ensure that the cold end average temperature has raised to about 90 C
(Average of the sum of the flue gas temp at APH O/L and secondary air
temperature at APH I / L). Only then HFO can be introduced into the furnace,
in order to avoid cold end corrosion.
Cut in HFO guns in CD elevation at corners 1 & 3. Ensure proper flame

from local operator.
Cut out the LDO guns in AB elevation from service totally.
Select HFO in AB elevation.
Cut out HFO guns in CD elevation.
The steam parameters are raised gradually. The oil guns may be cut in or
cut out as per requirement in both the elevations.
Keep the firing rate such as to limit the furnace outlet temperature to 540
C, to avoid RH starving, until adequate flow is established in RH coils. This
care is taken until HPLP bypass is taken into service.
Open CBD Control valve up to 1 or one and half turns if necessary to
control Silica value.
The MSSV valves are opened gradually at boiler end.. Even before this,
the Turbine operator ensures the opening of the MSL drains to avoid
hammering.
At about 20 KSC, SH steam sample is checked for purity. If the ammonia
value is less than 1 PPM, the steam can be used for PRDS.
At about 40 KSC, charging of self PRDS is done after proper warming up
of the lines. The line drains are kept open till free flow of steam and only then
closed to avoid hammering.
Once HP / LP bypass is being charged, throttle the SH start up vents and
finally close them completely.
Increase steam parameters by increasing the no. of oil guns and the oil
pressure (now the furnace temperature can be raised above 540 C as flow has
been established in the RH Coils) so that the required steam pressure &
temperature for turbine rolling is achieved. ( 35 KSC & 350 C).
While the turbine rolling is under progress, line up the primary Air path.
Start PA fans LOPs and put the other set on auto.
Start Seal air fan and open its Discharge Damper.
Start PA Fan (Usually the one corresponding to the ID and FD in service).
Load PA fan so as to maintain 800 mmwc pressure in the Hot PA header.
Ensure from the SWGR operator that the HT breakers are racked in and
DC switched on for all the pulverizers. Also ensure that all the concerned
relays are reset so that the mill can be started as and when required.
Unit is synchronized with grid and load raised to 10 MW and soaked for
half an hour.
Start mill A open HAG & HAD and raise the temperature. ( HPT over all
Expansion is to be 18 mm )
Start feeder A and load it gradually so as to reach 30 MW load in 50
minutes and soaked for half an hour.
ESP operator is informed to switch on all the fields in ESP.
Start second ID fan in the mean time.
Start second FD fan and match the loading.

Start second PA fan Load both PAs equally.
Furnace pressure control may be put on auto after normalizing the
furnace draft.
Start mill B and feeder B as per procedure after half an hour soaking at 30
MW.
Raise unit load up to 70 MW. ( HPT over all Expansion is to be 20 mm )
Line up SH & RH spray lines by opening the main inlet valves and the
individual isolation valves.
Soak the turbine at 70 MW for half an hour.
Start mill and feeder C and raise unit load to 120 MW, provided Turbine
operator has given clearance. ( HPT over all Expansion is to be 22 mm )
Cut out the CD elevation oil guns after starting the third pulverizer.
Start mill and feeder D and load it gradually. ( HPT over all Expansion is
to be 24 mm )
Cut out the AB elevation oil guns also.
Start mill and feeder E and raise the unit load up to 180 MW. ( HPT over
all Expansion is to be 26 mm )
After the charging of HP heaters by AE/Turbine, unit load can be raised
to 210 MW.
The pressurization of boiler (from cold state) to full load must be done in
a duration of 4 and half hours right from synchronization to avoid unnecessary
problems with Turbine differential expansions.
2) HOT RESTART:
Normally the casing metal temperature of HPT is more than 350 C in case of HOT
start.
Open SH drains and air vents if the pressure has reduced considerably
although this will cause further pressure reduction.
If the re-start is immediately done after a tripping, the drains and vents
should not be opened.
Purge the boiler as per procedure.
Cut in HFO guns in CD elevation (in case of immediate hot start) or LDO
guns in AB elevation (in case of delayed hot start). The decision can be made
depending upon the flue gas temperature at APH O/L. Then change over to
HFO guns in CD elevation and cut out LDO guns in AB elevation. Cut in
HFO guns in AB elevation if required.
Start mill D and feeder D and raise the steam parameters such that the
steam temperature is 50 C higher than the HPT casing temperature.
Turbine rolling is done through IPT by the Turbine operator.
Unit is synchronized with Grid.
Start Mill and Feeder C.
Start Mill and Feeder B.

Cut out AB elevation guns, if in service.
Start Mill and Feeder A.
Cut out CD Elevation Oil Guns.
Start Mill and Feeder E.
The loading of the Boiler is done gradually so that the unit load is raised to 210 MW is
50 to 55 Minutes time.
The starting of the fans and other auxiliaries is done in same way as cold start up.
3)
BOILER SHUT DOWN:
Note: 1) If the Boiler is to be Shut Down for a long period like overhauling, the
Bunkers have to be emptied. Hence the feeding to the Bunkers is stopped well in
advance after maintaining the Bunker levels such that the Mills can trip in the
following sequence.
ii) If the Shut Down is for a short duration, the Feeders can alone be emptied by
closing the Bunker Gates, if required by MP maintenance.
Gradually reduce Boiler load and hence the Unit load. The drop in the
saturated steam should not exceed 83 0C per Hour.
Cut out the top most Feeder ( E & F as the case may be ). Admit the
Cold air to the Mill for a while to cool the Mill. Trip the Mill if the Mills O /
L temperature is around 50 0C.
Cut out Feeder A and Mill A as per procedure. Close main SH / RH
Attemperation Valve to avoid abrupt drop of MS & HRH temperature.
Cut in Oil Guns in CD Elevation. ( If the temperature drop is drastic due
to problem in spray lines, EF Elevation Guns may be cut into service).
Cut out Feeder B and Mill B.
Cut out Feeder C and Mill C.
Finally cut out Feeder D and Mill D.
The Unit is now on Oil Guns alone. Usually the Unit is Tripped using
Turbine Trip switch.
MFT is actuated. The Oil Guns Trip. PA Fans and Seal Air Fan Trip. All
Oil Trip Valves close.
4)
ID Fans, FD Fans, APHsA&B main drives with a set of GB & SB

LOPs, AC Scanner Air Fan and PA Fan LOPs alone are in service in the
Boiler side.
BOXING UP THE BOILER (to facilitate Hot restart after a short duration)
Stop both IDs and both FDs as per procedure.

Close MSV at Boiler end, only after starting Turbine Barring Gear motor.
APHs are kept in service till the Flue gas temperature drops to about
0
120 C at APH O/L.
AC Scanner Fan is also kept in service till the Furnace cools
considerably. Ensure the opening of EAD from Local Operator.
PA Fan LOPs can be switched off after sufficient cooling of PA Fan
Bearings (< 40 0C.)
Blow Downs should be given in Platen and Rear Water Walls Drain
Valves at Boiler 0 M when the Boiler Drum Pressure falling to 25 ksc. for 5
Minutes each.
If the steam pressure drops to 10 ksc and below, SHH drains may be
opened out. At 2 ksc, the air vents (Drum, Eco & RH) may be opened out.
5) DRAINING OF BOILER IN CASE OF LONG SHUT DOWN.
Once the steam pressure is killed completely, the Boiler is drained by

opening the low point drains to atmosphere through IBD Flash Tank.
If cooling of the Furnace is required as in case of overhauling works or

tube puncture works, one set of ID and FD Fans are kept in service for a time
period as required by the maintenance personnel.
Normally all the Boiler side drains are opened out after the tripping of the
Unit for long Shut Downs to avoid trapping of water resulting from
condensation of the steam, which may cause hammering while charging
during start up. The opening of the drains is also ensured during the pre-start
checks for light-up.
6)
ROUTINE OPERATIONS
Operate APH Soot Blowing in all the three Shifts by drawing steam from
10 Header.
Operate WWSB twice a Week.
Charge CBD Expander if CBDs Silica value drops below 0.2 PPM.
Cut out CBD Expander and raise CBD valve opening whenever Silica
value raises above 0.4 PPM.
th
Always try to minimize attemperation of the SH & RH. Control

temperatures using Burner Tilt to the maximum extent possible and only then
introduce sprays.
Scavenge all the Oil Guns once in every Shift.
Arrange for cleaning of the One Elevation Oil Guns by BM staff once in
a Shift.
In case of Emergencies, swiftly cut in Oil Guns in the proper Elevation so
as to support the existing Mill and also for flame stability.
Whenever a Mill change over is effected, follow proper Shut Down
procedure for stopping the Feeder and Mill.
During normal operation keep a close watch of the following parameters.
a) Furnace pressure
b) SH steam pressure
c) SH & HRH steam temperatures.
d) SADC position.
e) Furnace to Wind Boxes DP.
f) Excess O2 in APH inlet Flue Gas
g) CO in Flue Gas at ID Fan outlet.
h) Colour of Chimney Flue Gas and BAH Slurry (reported by ESP operator).
i) Rejection of Mills (reported by MP personnel).
j) Mill outlet temperature.
k) To ensure once in a day the Combustibles in Fly Ash is below 1.5 % and
Bottom Ash is below 8 %
The main duty of a boiler operator is to maintain these parameters within normal
limits.
COLD / WARM START UP ACTIVITIES

FOR UNITS I, II & III
LINE UP FOR SEAL OIL SYSTEM
Sl.
Description
No.
1. All LCs in Seal Oil system equipments and
lines are returned.
Action
Check
2.
AC, DC Seal Oil pumps suction valves SO-5

and SO-8
Open
3.
AC, DC Seal Oil pumps discharge valves

SO-7 and SO-10
Close
4.
Seal Oil Pump Recirculation valve SO-11
Open
5.
Seal Oil cooler Bypass valve SO-13
Open
5.a
Seal Oil coolers inlet / outlet valves.
Close
6.
Hydraulic seal tank drain valve SO-34
Close
Remarks
7.
Hydraulic seal tank float by pass valve SO-33 Close
8.
L.O return header siphon drain valve SO-39
Close
9.
Hydraulic seal tank line drain valve SO-35
Close
10. POR By pass valve SO-43
Open
11.
Open
DPR By pass valve SO-23
12. Damper tank by pass valve SO-63
Open
13. Damper tank drain to L.O return header

SO-61
Close
14. Exciter End Seal Oil return line siphon drain

valve SO-26
Close
15. Turbine end seal oil return line drain valve

SO-35
16. Hydraulic seal tank vent SO-31
Close
17. Damper tank vent SO-62
Open
18. Hydraulic seal tank gas line valves SO-28 &

SO-29
Open
Open
19. Damper tank over flow to Hydraulic seal tank Open

SO-27
20. Seal Oil Cooler inlet / outlet valves (A.B)
SO-12 / SO-14 and SO-81 / SO-83
Open
21. Seal Oil filter inlet / outlet valve (A.B) SO-15 Close
/ SO-17 and SO-16 / SO-18
22. DPR and POR inlet valve SO-20
Open
23. Feed back line of POR SO-41
Open
24. Feed back line of DPR SO-38
Open
Normally one cooler

will be in service if
conditions warrant
the stand by cooler
may also be kept in
service.
25. Gas pressure line of DPR SO-37
Open
26. Damper tank inlet and outlet valves SO-24

and SO-64
Open
27. DPR inlet / outlet valves SO-21 / SO-22
Close
28. POR inlet / outlet valves SO-42 / SO-40
Close
29. Oil levels in Bearings of AC / DC SO Pumps
Check
30. Availability of Bearing C.W supply.
Check
Unit III only.
31. Supply for AC / DC seal oil pumps
Establish
AC SOP 415 Volts

N/E supply DC SOP
220 V DCSWG.
Also check control
supply & panel
supply.
Sl.
Description
No.
1. Discharge valve of AC / DC seal oil pumps
SO-7 SO-10.
Action
Remarks
Close
2.
Start AC seal oil pump from local
Observe
the
performa
nce of
the pump
3.
Discharge valve of AC seal oil pump SO-7
Open
Watch load current of
gradually AC seal oil pump
and then
keep it
full open.
4.
Recirculation valve SO-11
Throttle
Open
5.
DC seal oil pump discharge valve SO-10
Open
To maintain load
current of SOP about
18-20 A
fully
6.
Seal Oil filters inlet / outlet valves SO-15 / 17 Open

and SO-16 / 18
Open gradually.
Charge by air
releasing.
7.
D.P across the filter
Check
Check should be
below 0.5 ksc.
8.
POR inlet / outlet valve SO-42 / SO-40
Open
gradually
9.
POR inlet / outlet valve SO-42 / SO-40
Full
Open
10. DPR inlet / outlet valve SO-21 / SO-22
11.
Damper tank level
Open
Check D.P 0.6 to 0.8
gradually ksc
and keep
it full
open
Check
Conform any
overflow to Hydraulic
Seal Tank.
12. Hydraulic Seal tank level
Check
13. S.O flow through Hydrogen side drain line
Check
14. Damper tank vent SO-62
Close
After free flow of oil.
15. Recirculation valve SO-11
Throttle
Watch SOP load

current and maintain
around.
16. Charge S.O coolers (A, B) on oil side SO12 / SO-81 and SO-14 / SO-83
Open
17. Cooling water to SO coolers.
Admit
18. Induction level indicators (ILI) valves of

Hydraulic seal tank SO-72, SO-73, SO-74
and SO-75
Open
Watch the C.W flow

through vent. Check
any oil traces.
19. Pressure gauge impulse valves after filters,

before and after DPR.
Open
20. Auto Selector switch of AC / DC seal oil

pump.
Switched
ON.
Place it
in locked
position
21. Seal Oil Pump header pressure
Bring it
to 5 ksc.
22. DC seal oil pump
Observe
for auto
start.
Bring it
to normal
pr.12 ksc
24. DC Seal Oil Pump
Stop
25. Starting oil pump / M.O pump
In
service
26. Injector outlet valve SO-4
Open
27. Injector inlet valve SO-1
Throttle
28. Injector oil valve SO-2
Open
Bring it
to 6.5 ksc
30. AC seal oil pump
Observe
for auto
start
Bring it
to normal
pressure
12 ksc.
32. AC seal oil pump
Stop
So header pressure to
be maintained around
12 ksc.
Seal oil system is in service with injector and AC / DC Seal Oil Pumps on
AUTO stand by.
LINE UP FOR GAS SYSTEM

Sl.
Description
No.
1. Seal oil system.
Action
Inservice
2.
Seal oil pumps Auto starting
Check up
3.
Hydrogen and Carbon-di-Oxide cylinder
Kept in
position
4.
Inlet valve of Hydrogen Generating Plant H 1 Close
5.
Hydrogen gas manifold isolating valves H 2

to H 6.
Close
6.
H2 gas manifold to gas filling valve H 7
Close
7.
Gas analyzer isolating valve H 11
Close
8.
Filter and Regulator isolating valve in
Close
Remarks
Hydrogen control panel H 22

9.
Pressure gauge valves to atmosphere H 26

and H 28
Close
10. Drain valve to atmosphere H 17
Close
11.
Open
Drier inlet valves H 31, H 33
12. Drier outlet valves H 30, H 32
Open
13. Casing filling up valve H 18
Open
14. A 2 valve in filling line common to H 2 inlet

to casing and drier outlet
Open
15. Drier isolating valve H 15, H 16
Open
16. Air discharge valve H 10
Open
17. Carbon di Oxide gas manifold discharge

valve C 10
Close
18. Carbon di Oxide gas pressure gauge valve Open

C1
19. Carbon di Oxide gas filling to casing
valve C 11
Open
20. Carbon di Oxide gas cylinder valves C 2

to C 8
Open
Carbon di Oxide
admitted
21. Pressure of Carbon di Oxide gas admitted Adjust to Read from GPG 1
3 ksc
pressure gauge
22. Collect samples
Analyse
23. Percentage of Carbon di Oxide gas in air
Check up 90% at 0.2 ksc
Purging of Air by Carbon di Oxide Gas Completed
FILLING WITH HYDROGEN :

Sl.
Description
No.
1. Hydrogen discharge valve H 10
Action
Remarks
Close
2.
Carbon di Oxide cylinder valve C 2 to C8 Close

and CPG-1 valve C 1
3.
Carbon di Oxide discharge valve C 10
Open
4.
Hydrogen cylinder valves & H 2 to H 6 and

shut off valve H 7
Open
5.
Portable gas analyzer
Select
the scale
of H2 in
CO2
Check up
purity &
pressure
6.
Hydrogen in Carbon di Oxide
Close
Purity 97 % pressure
0.5 ksc
7.
Carbon di Oxide in discharge valve C 10
Build up
to 3.5 ksc
8.
Pressure of Hydrogen in Generator
Open
9.
Gas valve H 22 and H 24
Open
10. Induction liquid indicator inlet and outlet

valves L 2 and L 3
Open
11.
Open
Drier isolating valves H 15 and H 16
Gas analyzer in
service
Bring any one drier

into service by
opening either H 30
and H 31 or H 32 and
H 33
Now, Hydrogen system is in service

PURGING OF HYDROGEN BY CARBON DI OXIDE FOR GENERATOR
IN LONG SHUT DOWN
Sl.
Description
No.
1. Hydrogen cylinder valve H 2 and H 6 and
shut off valve H 7
Action
Remarks
Close
2.
Gas valve H 22 and H 24
Close
3.
Carbon di Oxide pressure gauge valve C1 Open

and cylinder valve C 2 to C 3
Carbon di Oxide
is admitted
4.
Hydrogen discharge valve H10
Open
Hydrogen pressure
reduced to 0.2 ksc
5.
Portable gas analyser
Connect
- ed to
generator
vent
6.
Concentration of Carbon di Oxide in

Hydrogen
Check up
purity &
pressure
Purging of Hydrogen by Carbon di Oxide completed.
PURGING OF CARBON DI OXIDE BY AIR

Sl.
No.
Description
Action
Remarks
1.
Hydrogen discharge valve H 10
Close
2.
Cylinder Carbon di Oxide valves C 2 to C 8 Close
3.
Carbon di Oxide discharge valve C10
Open
4.
Air inlet valve A 1 and H 9
Open
5.
Potable gas analyser
Select the
2%
scale of
Carbon di
Oxide in Air.
Purging of Carbon di Oxide by air completed.
BOILER LIGHTING UP & PRESSURISING

Sl.
Description
No.
1. Auxiliary Cooling
Water Pumps
2. Instrument air
compressor
3. Service air compressor
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
T.G set
C.W Pump to condenser
Bottom Ash Hopper &
Sealing trough
Drum level
All peep holes & man
holes in boiler
Soot blower (Wall
blowers, long retract
and APH soot blower)
Soot blower PRS valve
pneumatic valve and
isolation valves
Isolation valve to
impulse safety valve
Both Air Pre Heaters
A/B
Both ID fans A / B
Both FD fans A / B
15. Burner tilt operation

16. Oil Guns, Ignitors and
spark plug
17. Fire fighting
equipments
18. Ignitor fan & AC
Scanner air fan
19. DC Scanner air fan
Action
Remarks
3 Nos. in Service
2 Nos. in Service
2 Nos. in service
on barring gear
3 Nos. in service
Filled up
with header
pressure 7.5 ksc.
with header
pressure 7.5ksc.
Check up over
flow
Normal
Closed
Check that all blowers are
retracted
Closed
Opened
In Service
In Service
In Service
Check and placed in 0
position (50 %)
Cleaned and made ready for
operation
Check for availability
In Service
Check fuses, Supply switch to
be kept ON
Lined up
20. Ignitor oil system for

AB, CD, EF elevations
21. Warm up oil system for Lined up
AB elevation
22. Chemical dosing system Lined up
Phosphate Hydrazine
dosing
If SCAPH avails
charge (Unit III)
23. Boiler drum vents

(L&R) , Eco. Vents (L&
R), Super Heater Vents
24. Super Heater drains
25. Main Steam line drains
(MSL)
26. Re Heater vents
27. Start up vents hand
valves
28. Start up vent electrical
valve (L&R )
29. CBD hand operated
valve
30. CBD regulating valve
31. EBD hand operated
valve and Electrical
valve
32. Super Heater
attemperation (E 13)
valves and Re Heater
attemperation valves
33. FCV-1, FCV-2 and
FCV-3
34. Hand operated valves
for FCV-2 for Unit I &
II and Electrical valves
for Unit IIII
35. HSD and HO system
36. HSD and HO pumps
A/B
Opened
37. Economiser
Recirculation valves
(2 Nos.)
Open
Opened
Fully Opened
Closed Condition
Opened
Opened by 5 turns
Opened
At 18 M & 52 M
Closed
Closed
At 18 M
Fully closed
Closed
Kept opened
Lined up
In Service
Select the Stand

by pump for Auto
Start.
BOILER LIGHTING UP
38. Purge ready Condition
39. Purge ready Indication
40. Purge complete
Indication
41. Ignitor trip valve and
Warm Up oil trip valve
42. Warm Up oil firming
for AB elevation
43. AB elevation Ignitors
Check
Available in FSSS console.
Push to purge is depressed
After 5 minutes purge
complete indication will come
in FSSS console.
Open
Selected in FSSS console
Cut in
Check flame
44. AB Worm Up oil guns 1 Cut in one pair of guns into

& 3 or 2 & 4
service.
45. Flame of the oil Guns
Check
46. Start up vent 514 & 516 Open

47. CBD Regulating valve Opened by one turn
48. Drum level control
If due to swelling the drum
level raises control through
EBD. If level starts dropping
start one BFP and raise the
level through FCV -2
49. Eco. and Drum vents
Charged after free flow of
and Super Heater vents steam at 2 ksc.
50. Super Heater drains
Close whether the pressure
rises to 5 to 7 ksc.
51. AB elevation guns
Cut in all the four guns
( Warm Up oil )
52. Charging of PRDS
From other Unit and charge
H.O heating station also
53. Heating oil system AB, Lined up
CD & EF oil elevation
54. Steam atomizing system Lined up
55. H.O temperature
Temp. reaches more than
1100C at 18 M
56. Wind Box temperature Check for 150 0C
57. AB elevation W.U guns Cut out
58. H.O firing selection
Selected ASSS console
59. H.O Guns (AB)
Cut in and flame checked of
locally
60. H.O Guns (CD)
Cut in
61. Charging of PRDS from If the boiler pressure is more

self boiler
than 35 to 50 ksc. PRDS can
be charged from self
62. Generator Seal oil
In service
system Stator water &
H2 gas system
63. Hydrogen gas coolers
Check
locally ( 18 M )
The same has to
be changed over
to other pair after
30 min.
If the flame is
smoky adjust the
oil pr. or wind box
to furnace D.P.
At 18 M.
52 M
18 M
Vacuum pulling &

Gland packing to
be carried out
V2 31 (L&R) Unit
I & II
V2 7 (L&R) Unit
III slightly open
for warming up
charged with ACW

system
COLD AND WARM START UP

LINE UP OF HP AND LP BY PASS SYSTEM CHARGING
Sl.
Description
No.
1. Supply to HP & LP by pass
oil pump
2. Oil pump of HP & LP by
pass station
3. Pressure oil to HP / LP by
pass valves and injection
valves
4. ESV, IV
5. ES 20, ES 21, CRH, NRV
by pass valves
6. Vacuum in condenser
7.
MC 39 & 57 (Unit I & II)

MC 49 & 50 (Unit III) of
steam through device
8. Evacuation valves CA 21 &
22
9. CRH & HRH chain to flash
tank
10. LP by pass injection hand
valves
11. Control supply for HP & LP
by pass valves and injection
valves switched on
12. LP by pass valves ( LBP-1
& LBP-2)
Action
Remarks
Establish
service
Check for Auto Starting of

pumps.
Admitted
Close
Close
> 540 mm of
Hg
Open
Open
Open
Atmospheric drain valves

closed.
Open
Check
Open steam
purity less
than 1 ppm
Open
13. LP by pass injection valves

(LBPE1 & LBPE2)
14. HP by pass valves (BP 1 & Open
BP 2)
15. HRH pressure should not by Observe
more than 6 ksc for Hot
Start HRH pressure < 1 ksc
for cold & warm start
16. HP by pass injection hand
Close
10 % and then fully opened.
about 20 %
Close for cold & warm start
valve
Throttle open by about 2 to 3

turns fro hot start to control the
temp. of the HP by pass.
17. Start up vents S 14 & S 16

18. CRH & HRH drains
Close
Close
WARMING UP THE TURBINE FOR ROLLING

Sl.
Description
No.
1. Barring gear in service
2. Condenser vacuum
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Main steam stop valve

V2 31 (Unit I & II)
V2 7 (Unit III )
HP / LP by pass in service
Main steam temp. should be

50 0C more than that of the
HP turbine metal temp.
ESV & IV (L & R), V2 6, V2
7 & V2 8 (L & R ) (Unit
I&II)
V2 8, V2 9 & V2 10 (L & R)
(Unit III)
CRH, HRH drains to flash
tank
CRH loop drains to flash
tank
Drains between ESVs and
MSVs
MSL drains to atmosphere
HP transfer pipe drains Hand
valves 4 Nos. and
Electrical valve DW 40
(Unit I & II )
IP transfer pipe drains Hand
valve 4 Nos. and electrical
valve - DW 40 (Unit I & II)
HP casing & IP casing drains
CRH (L&R), HRH (L&R),
1st stage drains & LP by pass
(L&R) drains
Extraction line drains LPHs
Action
Remarks
Check
Check > 600
mm Hg.
Opened
Check
Observe
Close
Open
Open
Open
20 % Open
Open
Open
Open
(DW38,DW 4)
(Unit I&II)
Open
The hot reheat pr. is < 1 ksc

in case of cold and warm
start and about 6 ksc for hot
start.
before NRV (2, 3 & 4)

15. HPHs after NRV drains
16. LPHs after NRV drains DW
22, 23 & 24 hand valves
17. Starting oil pump
18. Speed Control gear position
19. ESV, IV Left & Right hand
arrest
20. 86 T4 relay
(DW 38 )
(Unit I & II)
Open DW 39
Unit I & II
DW 40 (Unit I
& II) Open
In service
Check Zero
Check
Reset
21. TLR
Reset
22. Speeder gear position turned

to anti clock wise position
and the position to be
brought to 8.5 mm
23. ESV to be opened 20 mm
and IV 5 mm
Open
gradually
24. V2 7, V2 8 (Unit I & II )

V2 9 & V2 10 (Unit III) both
valves
25. Watch the temp. pick up in
HP and IP transfer pipes
26. Rotor Eccentricity to be
noted by local dial gauge
Opened 80 %
27. HP & IP transfer pipe temp.

pick up becomes saturated in
the recorder
Observe
Open
gradually
Observe the
recorder
Check
86 G1, G2 & G3 are to be

reset.
Observe the primary oil pr.
and back up protection
Observe EGPV charging.
Hot Re Heat pr. is < 1 ksc in

the case of cold and warm
start and is about 6 ksc in the
case of Hot start.
The valve should be less

than 0.07 mm on barring
gear.
Now Turbine is ready for rolling.
ROLLING OF T.G SET (COLD / WARM START)

H.P. ADMISSION
Sl.
Description
No.
1. Start up vents in Super
Heaters S 14 & S 16
2. Both HP By pass valves
3. Evacuation valve CA 21 &
CA 22
4. Both LP By pass valves
5.
6.
7.
8.
9.
Valves V2 7 & V2 8 (Unit I &

II)
V2 9 & V2 10 ( Unit III )
Valves V2 6 (Unit I & II)
V2 8 (Unit III) for tight
closure
Speed control gear to be
brought to zero
ESV & IV hand arresters to
be opened full
Speed control gear to be
brought to 13.5 mm
10. By pass valves of MSV

V2 7 & V2 8 (Unit I & II)
V2 9 & V2 10 (Unit III)
Action
Open partially
Remarks
To maintain steam pr.
Close
Close
Close
Close after Re Heat pr.

comes to zero.
Close
Check
Close the valve manually

to ensure full closure of
the valves.
Check
Open
Rotate gradually
anticlockwise
direction
Partially open
Check both ESV & IV

and all control v alves
open full and CVSM full
open.
The steam quantity is
sufficient for rolling the
set.
TURBINE ROLLING
11.
The TG set starts rolling and Check

the speed picks up gradually.
When the speed exceeds 5
rpm Barring gear gets
disengaged and the Barring
gear motor stops on Auto.
12. Speed of TG set rotor to be
Open speed
a) If the Barring gear

disengages and the
Barring gear motor is on
continuous run Stop it
immediately.
b) If the speed does not
pick up TG set rotor
comes to stand still again
put the TG set on Barring
gear and proceed for
rolling again.
Check that all control
increased gradually to 500

rpm by opening valves
V2 7 & V2 8 (Unit I & II)
V2 9 & V2 10 (Unit III)
control gear
further by one or
two turns
13. Observe T.G set for its

smooth running
Check
14. Turbine MSV By pass valves

V2 7 & V2 8 (Unit I & II)
V2 9 & V2 10 (Unit III)
15. Turbine MSV By pass valves
V2 7 & V2 8 (Unit I & II)
V2 9 & V2 10 (Unit III)
Close and
observe
valves are in full open by

adjusting speed control
gear. Ensure full arc
admission always at lower
speed.
T.G set for rubbing noise
and ensure smooth
running of the Turbine.
Shaft should not come to
rest.
Open and raise

the speed to 500
rpm.
FLANGE AND STUD HEATING SYSTEM FOR HPT

To be given during 500 rpm on Turbine Rolling
Sl.
Description
No.
1. AS 16 steam admission valve to
flange and stud heating scheme
2. AS 51 drain of steam header
3. AS 30, 31, 32, 33, 34 and AS 35
drain from flange and stud heating
jackets
4. AS 18 flange heating valve
5.
6.
7.
Action
Remarks
Open
Open
Open
Crack
open
AS 19 stud heating valve
Crack
open
AS 50 isolating valve (Electrically Open
operated)
partially
AS 40 drain of flange and stud
Open
heating system
partially
Always kept open.

Open to maintain 1.5 ksc
pressure.
pressure
Observe vacuum. If vacuum
drops slightly charge the
header.
FLANGE AND STUD HEATING SYSTEM FOR IPT

If needed to be given during 500 rpm on Turbine Rolling
Sl.
Description
No.
1. AS 17 steam admission valve to
flange and stud heating scheme
2. AS 52 drain of steam header
3. AS 36, 37, 38, and AS 39 drain
from flange and stud heating
jackets
4. AS 20 flange heating valve
5.
AS 21 stud heating valve
6.
AS 50 isolating valve
(Electrically operated)
AS 41 drain of flange and stud
heating system
7.
TURBINE SPEED AT 500 RPM

Sl.
Description
No.
Action
Remarks
Open
Open
Open
Crack
open
Crack
open
Open
partially
Open
partially
Always kept open.

pressure.
pressure
Observe vacuum. If vacuum
drops slightly charge the
header.
SOAK FOR 5 TO 10 MINUTES

Action
Remarks
1.
Observe Bearing oil temp.
Admit cooling
water to oil coolers
2.
By pass valves
V2 7 & V2 8 (Unit I & II)
V2 9 & V2 10 (Unit III)
Turbine speed at 1200 rpm
Gradually open and

raise the speed to
1200 rpm
Soak for 20 minutes Observe bearing
vibration pedestals.
Full open
Full arc admission
desirable.
Line up and admit
Watch expansion
3.
4.
5.
6.
Control valve servo motor

position
Flange and stud heating of
HP casing and also for HP
casing if required
Stator Water Primary
system
7.
Stator Water Secondary

system
8. Main Steam stop valves by
pass valves
V2 7 & V2 8 (Unit I & II)
V2 9 & V2 10 (Unit III)
9. Main Steam stop valves at
3000 rpm
a) V2 6 (Unit I & II)
V2 8 (Unit III)
b) V2 7 & V2 8 (Unit I &
II)
V2 9 & V2 10 (Unit III)
10. Main oil pump discharge pr.
picks up to 20 ksc at 2850
rpm and MOP takes over
from SOP
11. Discharge valve of SOP
OL6
12. Starting oil pump
To be brought into
service
To be maintained around
42 0C from 500 rpm to
3000 rpm and also on
load.
Rates of speed raise 50
rpm per minute.
Flow meters to be
brought to service
position.
To be brought into
service
Open such that
Turbine speed
increases and
attains 3000 rpm
Full open
Full open
Observe
Governing oil pr.

constant.
Stop
Cut in second oil
elevation
13. Disc. valve at SOP OL 6
Open
SOP stand by
14. Bearing oil temperature
Observe
To be maintained around
42 0C
15. Oil temperature after the oil Maintain around
Adjust the cooling water
0
coolers
42 C
to the cooler accordingly.
SYNCHRONISING AND INITIAL LOAD PICKING UP
Sl.
No.
Description
Close gradually
Action
Remarks
1.
Turbine speed 2950 rpm and

governor taken control
Check
2.
Turbine stop valves

V2 6 (L&R) (Unit I&II)
V2 8 (L & R) (Unit III)
Gradually
open full
3.
V2 7 & V2 8 (L & R) (Unit I & II)

Close
V2 9 & V2 10 (L & R) (Unit III)
Lub oil temperature, Journal bearing Check
temp., Thrust bearing temperature
instruments and recorder
Inform OD / Switch yard and close Close
isolators 29 A and 29 B
4.
5.
6.
Inform 6.6 kv switch gear operator

to switch ON field flashing supply
7.
8.
AVR control selection switch

position
Field breaker push button
9.
Synchronising switch
10.
Match the voltage by AVR control
11.
Match the Speed / Frequency of the

T.G set by the speeder gear
Inform Boiler Operator, Turbine
Operator, Synchronise the T.G set
by the Generator MOCB. Close the
generator MOCB when the check
synchronizing lamp glows
Load on the T.G set to be picked up
by speeder gear to about 5 to 10
MW
12.
13.
14.
Stator Water Secondary Pump
15.
H2 gas cooler Booster Pump

common outlet valve
Excitation Transformers Cooling
16.
HPT and IPT control

valves throttle and the
speed is maintained.
Observe and correct if
there is any speed
variation by speeder gear
from UCB / Local.
For normality.
Conformation to be
obtained from OD /
Switch yard for proper
closing.
Switch ON Confirmationto be
obtained from 6.6 kv
operator
Auto /
Manual
Press to
Generator terminal
close
voltage will built up to 14
with in 20 sec.
Turned
Manual position, observe
clockwise the Bus and Generation
voltage
Raise /
Frequency of Grid & T.G
Lower
set
Raise /
Observe check
Lower
synchronism lamp
Close
Synchro scope rotation in
clockwise direction
slowly while
synchronizing.
Pick up
load
Switched
ON
Fully open
Switched
1) Start up vent to be
closed by Boiler
confirmation.
2) All drains to flash tank
& MSL drains to
atmosphere to be closed
17.
Fans
Field flashing supply
ON
Switch
OFF
Confirm from 6.6 kv

operator.
The set is synchronized. Check up vibration, expansion and other parameters.
LOADING THE TG SET UP TO FULL LOAD (210 MW)

Sl.
Description
No.
1. Initial Load
Action
5 to 10 MW
2.
Soak the set
3.
Steam
parameters
4.
Load on the TG Increase to 30

set
MW in a period
of 10 minutes
Soak the TG set About 20 to 30
minutes
Load on the TG Increase the
set.
Load to 70 MW
in a period of 30
minutes.
5.
6.
10 MW for 10
minutes
Observe
7.
Unit Auxiliary
Transformers
Cut in.
8.
Drip Pump
Cut in.
9.
Load on the TG Increase the

Set.
Load to 90 MW..
10. Boiler Feed

Pump.
Start Second
Boiler Feed
pump.
11. H.P.Heaters
Charge.
Remarks
Preforably two heavy oil elevations in
service
Watch expansions vibrations and other
parameters
Main Steam Pressure 30 ksc & Temp.
350 0C ; Temp. before IPT 320 0C
Thermal Expansion- 10 mm from front
pedestal
Prepare PA fans, Seal Air Fans & Mills
Cut in First Mill. Watch steam

parameters
Main Steam Pressure-65 ksc &
Temperature430bOC
Temperature before IPT- 420 OC
Thermal Expansion-20 mm.
After getting confirmation from OD /
6.6 kv cut in Unit Auxiliary
Transformers
Drips drains to condensers were to be
cut out & Drip drains were diverted to
Dearator.
Cut in Second Mill and pick up load.
Remove One Oil Elevation.Main Steam
Pressure-105 ksc, Temperature-490 OC
& Temperature before IPT-490 OC
Thermal Expansion- 22 mm
Kept in Re-circulation. If needed load
the pump & maintain Boiler Drum
Level. The third Boiler Feed Pump to
be kept as Reserve.
Through FW-1 & FW-2 (Unit-I to III )
Water side.
12. Load on the TG Increase the

Set.
Load to 150
MW.
13. H.P.Heaters
Steam side.
14. Load the TG
Set.
Warming up.
15. H.P.Heaters
Steam side.
Charge
Increase the
Load to 180
MW.
V2-92, & V2-93-Open and V2-94-Close

(Unit I & II ) & Coil drains-Close,
Shell drain-Partially Open & Extraction
drain- Open
Cut in Third Mill and pick up load.
Main Steam Pressure-125 ksc,
Temperature-520 OC & Temperature
before IPT-520 OC. And Thermal
Expansion-24 mm
Shell drain & Extraction drain close
ES-3,4 &5- Partially open.
Cut in Fourth Mill and pick up load.
Main Steam Pressure-130 ksc,
Temperature-530 OC & Temperature
before IPT-530 OC. And Thermal
Expansion-26 mm
ES-3,4 &5- Open Fully. Drip drain to
Deaerator-Open & Air Valve to
condenser- Open. Watch Vacuum drop.
Decrease Heavy Oil header Pressure.
HOT START UP
Sl.
Description
No.
1. Lubricating oil system /
Governing oil system
2. T.G set rotor either on Barring
gear / Counting down
3.
Auxiliary Cooling Water
Action
In service
Check
In service
4.
Cooling water system
In service
5.
Condensate Pump
In service
6.
Boiler Feed Pump
In service
7.
Service Air Compressor &

Instrument Air Compressor
Diff. Expansion of Rotors
Vacuum
In service
8.
9.
10. Drum level normal ID and FD

ignitor Fan and Scanner Fan
11. CRI (ESV & IV & stop valves)
closed resets
12. Purge ready- push to purgepurge completed
13. Ignitors in AB, CD & EF
elevation
14. Hand valves before B.D valve
15. CRH and HRH drains to Flash
Tank
16. SH attemperation pneumatic
valves and E13 valve
17. AB elevation oil guns
3 pump out of 4
pumps in service with
Tower fans.
3 pump out of 4
pumps in service.
Two out of three
pumps in service
One out of three to be
kept in service
Two out of 3 kept in
service.
With in limits
More than 540
mm of Hg
In service
Check
Check
Boiler trip-oil
elevation trip coal
feeder drip resets.
Cut into service

Open
Open
Closed
Cut in
18. Open LP by pass valves initially Check

by 5 %
19. MC 39 & MC 57 to be kept
opened MC 49 and MC 50 for
3rd Unit
20. Put LP by pass injection valves
on Auto to maintain LP by pass
down stream temp. with 125 0C
(If not maintain manually)
Remarks
Check flame in the

furnace.
The pressure in the Re
Heater circuit is
reduced to 1 ksc.
Check
Check
The hand valves in the

injection lines from
MC Pump discharge
(L & R) are already
open.
21. Open HP by pass pressure

valves (L&R) by 5 %
Observe
22. ES 18 & ES 19 will close for 60

sec. and then open
MC 39 & MC 57 (Unit I & II)
MC 49 & MC 50 (Unit III)
23. CA 21 & CA 22 will open on
Auto. If not open manually
24. CRH & HRH drains to falsh
tank
Check
25.
26.
27.
28.
29.
30.
31.
Check
Close after about

10 min. or
opening HP by
pass valves
Maintain the down stream temp. Check
of HP by pass with in 360 0C by
HP by pass injection valves on
Auto or on manually
CD elevation and EF elevation
Bring into service
oil guns
one after other
Atomising steam pressure
Check for 9 ksc.
HP and LP by pass pressure
Open suitably to
valves
maintain M.S
pressure with in
100 ksc and Re
Heater pressure
below 6 ksc.
HP Transfer pipe drains DW 16, Open
17, 18 & 19 (Hand valves) and
DW 41 (Electrical valves) and
IP Transfer pipe drains DW 33,
34, 35 & 36 (Hand valves) and
DW 37 (Electrical valves)
Curtis stage drain and HP and
Open
LP cylinder drains
ESVs and IVs
Lock manually
with Hand wheel
in closed
condition
32. HRH steam pressure
Watch the HP casing

temp. which should
not fall abruptly.
Maintain at 6 ksc
by suitably
adjusting HP and
LP by pass
If exceeds 360 0C HP
by pass will get
closed.
In case the main

Steam pr. raises by
closing HP by pass the
same has to be
controlled by firing
rate.
33. Bring the speeder gear position
to zero and then open the
speeder gear to 8 mm
34. ESV (L&R) and IV (L&R)
35. V2 7 & V2 8 (L&R) (Unit I & II)

and V2 9 & V2 10 (L&R) (Unit
III)
Resetting the
Turbine
Open manually by
20 mm for ESVs
and 5 to 10 mm
for IVs by the
Hand arrestors
Open by 2 to 3
turns
So that the turbine

does not roll by steam.
Allow for the Transfer

pipes get warmed up
as shown by the temp.
of the Transfer pipe
till the temp. show
arising tendency.
TURBINE IS READY FOR ROLLING

36. a) Bring the speeder gear
to zero
b) Load limiter is in fully
open condition
37. Mechanical locking of
ESVs & IVs
38. Rise the pressure of HRH
to 6 ksc
39. Open the speeder gear
gradually
40. Barring gear Motor
disengages and cuts off
automatically when the
speed is more than 3.5
rpm
41. Bring the speed to 1000
rpm
Check
Check
Release fully
Close suitably the LP by pass The T.G set may
valves (and open HP by pass roll and if it rolls
valves if required)
continue, roll the
machine
Move anticlockwise slowly, Watch forth
till such a time the speed
opening of IVs &
picks up then close HP
ESVs and then
bypass valves
CVs
Check
If not switch off
manually
Rolling through IPT. HPT

control valves are not open
42. LPHs extraction valves

Es 12, ES 13 & ES 14
Open
43. LPH drips to condenser

44. Stator Water Primary
Open
In service
Watch over
expansion,
bearing temp. and
vibration.
Open ES 6 for
Deaerator
pressure
Check the specific
system
45. Lub oil coolers
Cut in suitably to maintain

the lub oil temp. with in 45
0
C
46. a) V2 7 & V2 8 (L&R)

(UnitI&II)
V2 9 & V2 10 (L&R)
(Unit III)
b) V2 6 (L&R) (Unit I &
II)
V2 8 (L & R) (Unit III)
47. Close the 230 KV
isolators
48. V2 7 & V2 8 closes (Unit
I & II )
V2 9 & V2 10 closes
(Unit
III)
49. Field flashing module
Open partially
50. Raise the speed to 3000

rpm pass through the
critical speeds smoothly
Gradually open the speeder

gear suitably anticlockwise
so that the speed rise is
smooth while crossing
critical speeds
Charge 3 to 4 lub oil coolers
to limit the lub oil temp. with
in 45 0C
Select voltage control on
Auto close field breaker and
pick up voltages to rated
value viz 15.75 kv
51. Lub oil coolers

52. Excite the Generator
Resistivity for
normal value
>500
Soak the Turbine
at 1000 rpm for
10 min.
Open fully
Confirm the closing of the
same from OD / Switch Yard
Check
Switch on
To be switched on
by OD / 6.6 KV
Check vibration &
bearing temp.
SYNCHRONISE
53. Synchronise
Adjust the Generator

voltage and T.G speed
and synchronize pick up
load to 10 MW
Switch off the field flashing

module. Close CA 21 & CA
22. Close all drains to Flash
Tank MSL drains to
atmosphere.
54. All drains to flash
tank and MSL
drains
55. Stator Water
secondary system
56. Hydrogen Coolers
Booster Pump
common O/L valve
57. LP by pass
Fully close
Put into service
Fully open
Close fully immediately

after synchronizing close
the LP by pass spray
control valves if not
close on Auto
58. Pick up the load to The CVSM position
about 30 to 40 MW should be more than 140
mm
59. Closing of HP by
Start closing of HP by
pass
pass valves. Watching
the HRH pressure which
should not fall below 6
ksc
60. CA 21 & CA 22
61. MC 39 & MC 57Unit I & II
MC 49 & MC 50 Unit III
62. Load can be picked
up by suitably
cutting in
additional mills
one by one
After fully closing the HP by

pass valve close the HP by
pass spray control valves,
BD valve & Hand valves
before BD valve if not
closing on Auto.
Close fully
Close fully watching the
exhaust hood temp.
should be below 50 0C
By varying Speeder Gear Depending up on the Boiler
control
parameters and Turbine
parameters
LOADING THE T.G SET UP TO FULL LOAD 210 MW

Sl.
Description
Action
Remarks
No.
1. Initial load
5 to 10 MW
2.
T.G set on soak
3.
Steam parameter
4.
All Drains to
Flash Tank &
MSL Drains to
atmosphere.
Differential
Expansion
Close
Metal Temp.
difference
between inner
and outer casing
of HPT.
Load on the TG
Set
Maintain
5.
6.
7.
8.
Soak the TG Set

for about 20 30
minutes.
9. Steam
Parameters.
10. Load on the TG
Set
50 MW for 10
Minutes
Check & observe
Maintain within
limits
- 0.6 to + 4.00 mm ( HP )
- 1.5 to +3.00 mm ( IP )
-2.5 to + 4.5 mm ( LP )
Within 35 0C
Increase to 30
Prepare Seal Air Fans, PA Fans and
MW in a period of Mills for put into service
10 minutes
Observe
Observe
Increase to 70
MW
11. Drip Pump

Cut in
12. Boiler Feed Pump Cut in 2nd pump
13. HP Heaters water Charged
side
14. Pick up load to 90 Increase the load
MW
15. UAT A & B
Preferably two Heavy Oil elevation

in service.
Watch expansions, vibrations and
other parameters.
Pressure 30 ksc ; Temperature
before HPT 350 0C ; Temperature
before IPT 320 0C ; Thermal
expansion at front pedestal 10 mm
Cut in one more Heavy Oil elevation
and increase the Oil pr. if needed
Cut into service
Cut in First Mill. Charge ESP fields.

M. S.Pressure 65 ksc
M.S. Temp. 430 0C
Temp. before IV 420 0C
Thermal Expansion 20 mm
Cut out Drip drains to Condenser.
Put into RC.
Through & opened by FW 1 & 2 and
V2 92 & 93 and close V2 94.
Modules of V2 92 & 93 should be
switched off in 6.6 kv control room.
Cut in Second mill & pick up load
and remove one oil elevation.
MS Pr. 105 ksc. ;
MS temp. 490 0C
Temp. before IV 490 0C ;
Thermal expansion 22 mm
Tie breakers from C1 & C2.
nd
16. 2 Boiler Feed

Pump
17. Pick up the load
gradually to 150
MW.
18. HP Heater steam
side
19. HP Heater steam
side

gradually to 180
MW
21. Flange & Stud of
HPT & IPT
22. Starting Ejector

gradually to 210
MW
24. Maintain the Full

Load
Start & Load

Increase the load
Tripped on Auto.
According to drum level
Cut in Third mill

M.S temp - 510 0C ; M.S pr.110
ksc; Thermal expansion 24 mm
Warming up
Partially open ES 3, 4 & 5 and HD
22, 23 & 24
Charge
Open ES 3, 4 & 5 and HD 22, 23
&24. Open air valve. Open ES 7
and cut out ES 6 and maintain
Deaerator pressure & open HD 31 &
air valve CA 8
Increase the load
Cut in Fourth mill
MS temp. 530 0C ; MS pr.120ksc
Thermal expansion 26 mm ;
Decrease Heavy Oil Header pr. and
cut out one oil elevation.
Cut out AS 40, 18, Watch vacuum drop if vacuum drops
19 & AS 16
charge flange and stud of HPT &
(HPT) Then, cut IPT
out AS 41,
20,21& AS 17
(IPT) & AS 50
Cut out CA 5 and Maintain PRDS pressure around 15
then gradually cut to 16 ksc and watch vacuum drop.
out AS 4
If vacuum drops increase main
ejector pr. around 10 ksc.
Increase the load
Cut in Fifth mill after conforming
flame stability cut out all oil
elevations and cut out MC 39 & 57
(Unit I & II) MC 49 & 50 (Unit III)
after confirming LPT Exhaust Hood
temperature < 50 0C ; Thermal
Expansion 28 mm.
Watch
MS temp 540 0C ; MS pr.- 135 ksc
and watch all parameters.

Boiler Operation TTPS

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Boiler Operation TTPS

Hochgeladen von

Copyright:

Verfügbare Formate

TUTICORIN THERMAL POWER STATION

OPERATING INSTRUCTION MANUAL

FEED WATER SYSTEM

FUEL OIL FIRING SYSTEM

AIR PRE HEATER SYSTEM

INDUCED DRAFT FAN SYSTEM

FORCED DRAFT FAN SYSTEM

AUXILIARY STEAM SYSTEM

SCANNER AIR FAN SYSTEM

SEAL AIR FAN SYSTEM

PRIMARY AIR FAN SYSTEM

COAL PULVERISER SYSTEM

COAL BURNER SYSTEM

DUST CONTROL SCHEME

SOOT BLOWER SCHEME

ASH WET DISPOSAL SYSTEM

STEAM CIRCUIT SYSTEM

COLD / WARM START UP ACTIVITIES

Tangentially fired, Balanced draught, Natural Circulation, Radiant

b. Fuel Oil : (IS 1593 )

c. Warm up and Ignitor Oil :

Width 13.868 Metre.

Total Heating Surface

Total Heating Surface

7. AIR PRE HEATER :

Vertical Tri-Sector Regenerative

8. FUEL BURNING EQUIPMENT :

Tilting Tangential Burner.

XRP 763 Bowl Mills.

Water Wall Soot

FEED WATER SYSTEM

De mineralised water storage tank (DMWST)

De mineralised water make up pump (DMWMP)

Condensate storage tank (CST)

Hot well make up pump (HWMP)

Main Condensate Pump (MCP )

Boiler feeding before Unit light up may be classified as,

From Hot Well DM water is pumped to Deaerator using MC Pump.

The Chemically Treated Water at Deaerator is pumped to the following

RELEVANT INFORMATIONS REGARDING BOILER FILLING :

a) De Mineralised Water Make Up Pump (DMWMP) :

b) Boiler Feed Pump :

4 Nos. for Unit I, II & III.

c) Hot well Make Up Pump (HWMP) :

2Nos. per Unit (i.e. 6 Nos. for Units I, II & III).

a) Demineralised Water Storage Tank (DMWST) :

b) Condensate Storage Tank (CST) :

c) Quality of water from DM Plant to CST :

FEED WATER SYSTEM OPERATING PROCEDURE :

DRUM FILLING FOR UNIT LIGHT UP :

a) Pre checks and preparatory steps :

No Line Clear is pending.

b) Drum Filling activities :

2. Doze with Ammonia and Hydrazine at Deaerator.

No Line Clear is pending

Drum & SHs Filling activities :

1. Fill Deaerator up to Normal Level.

SAM TURBO INDUSTRIES LTD.,

FUEL OIL FIRING SYSTEM

2) HEAVY FURNACE OIL SYSTEM :

6 (Stage I & II)

HSD LINE : LINE-UP AND CHARGING :

Priming the Strainers :

Priming the Pumps :