1 If One F.D.

Fan Trips: -
1. Airflow drops.
2. Furnace Draft high on –Ve side.
3. Disturbance to combustion.
4. Disturbance to water level in drum.
2 If One I.D. Fan Trips: -
1. Trips one F.D., one P.A & lower coal mills.
2. Furnace Draft high on +Ve side.
3. Disturbance to combustion.
4. Disturbance to water level in drum.
5. Drop in main steam pr. & temp.
Action :-
1. Stabilize furnace draft.
2. Stabilize boiler drum level.
3. Cut in oil burner.
4. Reduce load on generator.
5. Load working F.D. & I.D. Fan as required.
6. Check wind box pr.(L & R )
7. Load running coal mill to permissive value of P.A. flow/pr.
8. Maintain main steam temp. In case it drops, watch turbine differentials.
3 One P.A. Trips
1. P.A. pr. drops, hence lower coal mills trip out to maintain P.A. pr.
2. Steam pr. & temp starts dropping.
3. Drum level drops.
Action:-
1. Reduce generator load.
2. Cut in oil gun to stabilize flame.
3. Load running coal mill to permissive value of P.A. flow/pr.
4. Watch turbine differentials
5. Stabilize boiler steam pr. by adjusting B.T.
4 Both P.A. Trips
1. All mills trip.
2. Boiler trips on’ Loss of all fuel or flame failure.’ if it is on coal firing.
 If boiler trips on furnace pr. high, immediately check buck –stays &
their pins of all the three elevations. Meanwhile boiler can be lighted
up after purge complete. Coal cycle to be cut in only after ensuring
that furnace buck-stays are normal.

5 Flue Gas Temp Low

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 1. At low load & FO firing, SCAPH is charged& there drains are
functioning normal. Check air temp. before AH which must be at least
70 0C
2. At high load, HPHs & LPHs are charged & FW temp is not less than
specified.
3. Check for no eco. Tube leakage.
4. See that AH seal leakages are within permissible values- compute from
O2 & CO2 values before & after AH.
5. Air flow is normal.
6. See that water washing nozzles are not dripping water in the AH.
6 Furnace Out Let Temp. High ( before rolling)
Cause:-
1. To protect RH where there is no steam flow till turbine is rolled &
loaded, furnace out let temp. is to be maintained at less than 520 0C
Action :-
1. Check & reduce firing rate.
2. Check that diff. pressure between oil to air or oil to steam is not
low(keep 1.0 kg / cm2)
3. Check air flow through auxi air damper ( min 30 % of boiler load)
7 Scanner Air Pressure Low
For effective cooling of scanner min 120 mm over furnace pressure is
required to be maintained for scanner cooling air.
8 Slag In Water Wall

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 Cause:-
Slag accumulation on water wall continues during coal firing. Abnormal
operating conditions accumulate deposits. Change of coal properties, improper
air distribution between corners, too fine or too coarse cola, low to excessive
air, excessive –VE burner tilt, high firing rate caused by low feed water
temp., improper fuel air distribution etc. are conditions which can accelerate
slagging.
Plant response
1. High superheat & reheat temp. calling for excess spray or low burner
tilt.
2. Metal temp. of superheaters & reheaters increases.
3. Boiler outlet flue gas temp. goes up.
Action:-
1. Commence FWS blowing
2. Check FW temp. If heaters are out of service bring them into service
or reduce load to contain SH/RH
3. Increase air flow to get O2 in flue gas to @ 4 %
4. Check opening of fuel air dampers of working C/Ms. Depending on
volatilities, a higher opening may be required.
5. Reduce loading on top C/Ms. Or stop it if possible.
6. Check BT for unequal tilt or upward tilt can cause SH / high slagging.
7. Coal fineness should be 80 % through E 200 ( If not adjust classifier)
8. Check un brunt carbon in bottom ash.
9. Check hot air temp. from AH is not excessive.
10. Check PA flows through each corner. Unbalanced PA flow due to
deformed nozzles / pipe chock up can cause faulty firing & slagging.
9 Slag In SH
Slag or ash accumulation in SH cause low SH temp.& high boiler exit flue gas
temp.
10 Flame failure
Possible cause:-
1. Sudden closure of aux. ,fuel air dampers to burner nozzles.
2. Too low/high wind box pressure causing unstable combustion.
3. WW tube failure( Jet extinguishes flame)
4. BT –ve extreme due to air failure to power cylinders.
11 Air Flow High
Plant response:-
1. O2 in flue gas high
2. High SH/RS temp.
12 Air Flow Low

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 Plant response:-
1. O2 in flue gas low
2. Low SH/RS temp.
3. Unstable combustion/ boiler pressure start falling.
13 High Furnace Pressure
Possible cause:-
1. One ID tripped or mal operation of control vanes of ID/FD/PA or
closing of damper.
2. Unstable flame furnace flame condition .Sudden starting of C/M.Low
wind box pressure ( Under normal FD fans loading condition)improper
air distribution at elevations)
3. Unequal BT tilt at corners. Or BT in extreme up or down.( Check BT at
all corners is equal Adjust between +10 to-10 & check control air
pressure of BT.
4. Fouling of AH or AH tripped.
5. Furnace water seal broken. ESP or flue gas path man opened (High
suction reading after EP on one side may indicate less gas flow in that
side.)(Check furnace seal, water flow through seal trough overflow.
Furnace hydraulic seal may get broken by sudden slag fall. Reestablish
seal.
6. WW tube rapture/ leakage. (Stop the boiler)
14 Low Furnace Pressure
Possible cause:-
1. ID fan AUTO control fail.
2. ID fan vane control fail causing vanes wide open.
3. Decrease in air input or tripping of FD fan.
4. Sudden tripping of C/M
15 Drum Level Low
Possible cause:-
1. Mal-operation of Feed AUTO control or feed regulator or scoop AUTO
2. Tripping of one BFP & s/by did not pick up.
3. Sudden reduction of load.
4. Sudden increase of firing. Purging of C/M
5. Tube rapture.( Check water flow & compare with previous feeding rate
& steam flow. High feed flow indicates tube failure.
6. Inadvertent opening of low point drain valves
16 Drum Level High
High drum level ,beyond the visible range of GG is a potential source of water
carry over& can cause serious & instantaneous damage to turbines, SHs, main
steam lines, turbine CVs. It is also a possible source of salt deposition in
turbine blades.
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 Possible cause:-
1. Sudden increase in load resulting in drum pressure drop.
2. Sudden decrease in firing rate e.g. tripping of running C/M.
3. BFP scoop tube position suddenly increase.( Check diff. pressure
across feed CV & maintain 5 kg/cm2 by adjusting scoop tube position.
Action:-
1. Open EBD, main steam line drains between boiler main steam stop valve
& turbine CVs.
17 Drum Level Tripping
For U # 3,4,5 high & low drum level tripping is from two transmitters.
Another two transmitters are provided for feed control.
In the event of sudden development of steam/ water leakage in any of the
transmitters, it will sense false level. If this transmitter happens to be that
on which level being control then if leakage is on steam side it will sense high
level& actual level will be brought down on AUTO. Other transmitters which
is on this tapping point from the drum will also sense high level. Hence some
transmitters will show high level & some low. Boiler will not trip either on high
level or low level in such case.
18 Flame Failure At An Elevation
Possible cause:-
1. Sudden decrease of mill feeder speed to min.
2. Too high or too low wind box pressure causing unstable combustion.
( Check that sy. Air wind box dampers are modulating to maintain @ 80
mm. wind box to furnace diff. pressure )
3. WW tube failure
4. BT mechanism –ve extreme to air failure to power cylinder
5. Rapid load changes without adjusting air flow leading to improper
combustion.
19 WW Tube Leakage
Possible cause:-
1. Starved WWs due to very low drum level and / or( Compare FW flow &
steam flow to assess the magnitude of tube leakage.
2. Sustained flam impingement on WWs tubes and /or
3. Blocked tube, scalling of tube resulting in over heating of tube metal,
pitting , corrosion of tube and/ or
4. Soot blower steam impingement and/ or
5. Circulation affected due to opening of low point drain.
( (i) Check ECO. hopper for water leakage steam noise
(ii) Over loading of ID fan.
(iii) As the load is reduced due to suspected tube leakage, try to
locate the burst tube. This can be best done during oil firing.)
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20 RH/SH/ECO Tube Leakage
Possible cause:-
1. Sustained high metal temp. due to WW slagging or forcing boiler at
the time of hot restart and/or
2. Erosion on tubes due to high excess air, high ash content in coal,
disclosed tubes, soot blowing and /or
3. Blocked tubes causing over heating and /or
4. Salt deposition due to high water level in drum, poor quality of water
during hydraulic test. (ECO tube can fail due to over heating if
concentration of Fe, Cu is more in FW. Steaming in ECO occurs causing
salt deposition & harming the tube.)
5. Inadequate flow due to open SH/RH drain.
Plant response:-
1. Hissing noise, noticeable hours before other symptoms.
2. Unexplained drop of flue gas temp. in the affected region
3. Over loading of ID fans / increased draft losses
4. Higher FW consumption
5. SH/RH temp. drop
6. High SH/RH metal temp. due possible ECO. Tube leakage.
7. Drop in flue gas temp. after eco. Zone.
8. Noise in eco. Zone.
9. Ash solidification in eco. Hoppers
10. Water leakage from eco. Hoppers.
21 Low SH/RH temp.
Possible cause:-
1. Low RH temp.
2. Inadequate air flow.( Increase if necessary)
3. High spray
4. Low BT
5. To high FW temp.
Plant response:-
1. Turbine expansion may go to –ve
Action :-
2. Initiate FWS blowing.
3. C/O to top mills.
22 High RH/SH temp.

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 Possible cause:-
1. Furnace slagging
2. Top C/Ms on low loads
3. High BT
4. Excess air high
5. Low FW temp.(Bring in heaters).FW diff pressure should be at least 5
atg.
6. Sudden increase in firing rate leading to spurt in boiler pressure
7. Inadequate spray.
23 Boiler Conductivity High
Too high conductivity leads to scale formation in tubes if sustained over a
period of time. Dropping of PH, increased conductivity, decreased phosphate,
presence of chloride may indicate condenser tube leakage.
Increase phosphate dozing to maintain PH
24 FW PH Low
FW PH to be maintained at not less than 8.0 by dozing ammonia,along with ….
To keep the regeneration system corrosion free.
Specific reason :-
Condenser tube leakage leading to acid components depressing PH at normal
dosing rate
Possible Response:-
1. Cu. Pick up in heaters
2. High phosphate consumption in drum.
25 Steam Impure
Possible cause:-
1. High silica in steam.
2. Phosphate carry over.
Plant response:-
1. Solids carry over in steam lead to deposits on Tuebine blade- increase
of first stage pressure gradually reduction in turbine out put.
Action:-
1. Increase blow down on boiler.
2. Disruption of water flow to seals & existing water getting evaporated.
3. Inadequate water flow without overflow
4. High furnace pressure/mild explosion.
Plant response:-
1. Furnace draft fluctuation
2. ID fan get over loaded
3. Combustion gets disturbed.

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 BOILER MALFUCTION
Sr.No. INDEX Page
Nos.
1 If One F.D. Fan Trips 1
2 If One I.D. Fan Trips 1
3 One P.A. Trips 1
4 Both P.A. Trips 1
5 Flue Gas Temp Low 2
6 Furnace Out Let Temp. High ( before rolling) 2
7 Scanner Air Pressure Low 2
8 Slag In Water Wall 3
9 Slag In SH 3
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10 Flame failure 3
11 Air Flow High 4
12 Air Flow Low 4
13-a High Furnace Pressure 4
13-b Low Furnace Pressure 4
14 Drum Level Low 4
15 Drum Level High 5
16 Flame Failure At An Elevation 5
17 WW Tube Leakage 5
18 RH/SH/ECO Tube Leakage 6
19 Low SH/RH temp 6
20 High RH/SH temp. 7
21 Boiler Conductivity High 7
22 FW PH Low 7
23 Steam Impure 7
24
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