1

OPERATING MANNUAL

FOR

STEAM GENERATION PLANT

NATIONAL FERTILIZERS LIMITED

PANIPAT
 2
INDEX
ITEM
Page
1. Introduction 1
2. Brief of description of the process 1
3. Equipment specification and design operating datas 7
VU-40 Boiler
Package Boilers

4. Unit operating procedure 30

Normal Start up (Boiler cold) 30
Preparation 30
Filling of Boiler with water 32
Lighting off. 32
Normal operation-Unit load charges 36
Normal shutdown to hot stand by 38
Hot restart 39
Emergency Procedure. 42
Normal Shutdown to cold

5. Liquidation of typical emergency in Boiler 46

Sign and causes of emergency Action.
6. Operating Procedure of 54
Mills 54
Soot Blower 57
ID & FD fans 59
Air Preheater 61
Ash handling system 65
7. Interlocks 72
8. Specification 94
Coal 94
Fuel Oil 94
Polish Water 94
Feed Water 95
Steam 95

9. Diagram
 3
STEAM GENERATION PLANT

1.1 INTRODUCTION
The Steam Generation Plant comprises of three identical pulverized coal fired boilers
with oil support, having a maximum continuous rating (MCR) of 150 T/Hr steam at a
pressure of Kgs/cm2g and 4950C. The normal rate of steam generation (NCR) is
84T/Hr. The boilers are tangentially fired, balanced draught, Natural circulation,
radiant dry bottom and provided with bow mills.

1.2 MAJOR EQUIPMENT:

i) Bowl Bills- 3 Nos per boller.
ii) Fuel firing system
iii) Furnance Ash hopper
iv) Furnance chamber
v) Forced draft fan
vi) Induced draft fan
vii) Regenerative type of Air-heater
viii) Steam/air pre-heater
ix) Economiser
x) Electrostatic Precipitation for fly ash
xi) Water drum, steam drum and boiler, tubes
xii) Steam desuperheater and super-heater
A common chimney is provided for final disposal of flue gases for all the
three boilers.

DESCRIPTION OF THE PROCESS

1.3 FEED WATER

Boiler feed water at a temperature of 131 0C and a pressure of 141Kg/cm2g is
pumped from the Deaerator by boiler feed water pumps AGA-701AB. This feed water
passes through a synthesis economizer and goes to boiler house at a temp of 200 0C. It
boiler house it is distributed to each boiler through an 8” individual feed water line.

1.4 FUEL AND ASH:

Coal is pulverized in the bowl mill and used as feed for the boilers under normal
operation. Ash which is formed as a result of burning of coal is collected in the bottom
ash hopper/fly ash hoppers is disposed off through the ash disposal system. Flue gases
are discharged out through the chimneys.

1.5 I.D. FAN & F.D. FAN:

Motor driven FD fan ID fan provide a draft for the furnance

 4
FD fan supplies the combustion air to the furnance after heating the air in tee
regenerative type air pre-heater. The flue gases are finally disposed off by the ID fan to
the atmosphere via chimney.

1.6 STEAM SUPPLY AND DISTRIBUTION:

Super heated steam at 105 Kg/cm2g and 4950C is produced in boiler. A part of this
steam is let down to a pressure of 3 Kgs/cm 2g in a de-superheater for use in fuel oil
unloading system.
Rest of high pressure steam is carried to Ammonia Plant where steam from Ammonia
Plant steam superheaters ABA-701 at 103Kg/cm2 and 4950C is also mixed with it and
the entire superheater steam is distributed as under:-

1. Synth compressor turbine 175.O T

2. N2 Compressor turbine 80.O T
3. O2 Compressor turbine 25.O T
4. Air Compressor turbine 58.O T
Exhaust steam from Air Compressor, Oxygen compressor turbines and condensing
turbines of synthesis is compressor is condensed in respective surface condensers and
the condensate, thus obtained is sent to the DM/Plant for treatment for re-use as boiler
feed water.

The extraction steam from back pressure turbines of synthesis compressor and N 2
compressor meets the entire demand for the process plants, utilities and off site area at
various pressure levels of 65,40,9 and 3 Kg/cm 2g. The requirement of steam at
different pressures for various plants are given below:

Sr. Plant Steam Pre. & Qty. Source

No. temp.
1. Ammonia 65kg/cm2 430oC 60.0 N2 Compressor
2. Urea 40 Kg/cm2/370 80.0 Syn. Compressor
o
C
3. NH3 Compressor 40 Kg/cm2 70.0 Syn. Compressor
4. Ammonia 9 Kg/cm2/230 oC 15.0 NH3 Compressor
5. De-aerator 3Kg/cm2/187 oC 20.0 Ammonia
6. FO Storage Tank 3Kg/cm2/187 oC 8.0 NH3 Plant
7.
Boiler FO day 3Kg/cm2/187 oC 0.1 -do-
Tank
 5

8. LPG Vaporizer 3 Kg/cm2/187oC 0.1 Ammonia

9. Caustic Soda -do- 0.2 ----do----
10. Caustic soda -do- 0.7 ----do----
Unloading
11. Miscellaneous -do- 3.0 ----do----

1.7 STEAM FOR FURNACE OIL UNLOADING

Apart from the steam required for various plants, steam at a pressure of 3 Kg/cm 2g is
also required for fuel oil unloading facilities. The requirement may fluctuate from O
T/hr to 21.7T/hr depending on the ambient conditions, quantity and quality of oil being
unloaded.

1.8 START UP FACILITIES:

i) During start up, the boilers use HSDO upto 10% of the normal load, then fuel oil
upto 30% and coal above 30% of the normal load suitable. Firing facilities are
provided for each boiler.

ii) One electric motor driven feed water pump is provided in Ammonia Plant to
pump boiler feed water to the boiler until enough steam is generated and the
turbo feed pump is put into operation.

B.F. WATER AND STEAM CIRCUIT

Feed water coming from NH3 Plant after dosing required amount of hydrazine
(N2H4) and ammonium hydroxide (NH4OH) enters the economizer inlet heater via feed water
common heads and feed line control valve.

The economizer is located in the second pass of the boiler above the air heater.
Each section is composed of a number of parallel tube circuits arranged in horizontal rows.
All tube circuits originate from inlet heads and discharge into onlet header. The feed water
flow is upward through the economiser that is in counter flow to the hot flue gases. Most
efficient heat transfer is thereby accomplished. Any chance of steam generation with in the
economizer is eliminated by the upwater flow.

Feed water is supplied to the Steam drum from economizer outlet header. After
side of the steam drum is connected with the furnance bottom ring header through boiler bank
tubes. Lower water drum and two 406 mm OD down comers.
 6

The furnace front wall tubes slope forward to form the roof of the furnance and routed in such
a way that the super heater penetrations is possible. The furnance front roof tubes are
expanded to the steam drum.

The rear water wall tubes slope forward to form the furnance rear arch. Half of the rear wall
tubes are joining the lower drum and remaining tubes form furnance screen tubes and are
connected to the upper part of the furnance to permit passage of the flue gas with uniform
velocity.

Both side walls are crowned with side outlet header. The side wall outlet headers
are connected with steam drum by a system of riser tubes.

The water in the furnance wall absorbs heat. The resulting steam water mixture is discharged
into steam drum directly from front and rear whereas the steam water mixture from side walls
are collected by the outlet headers and discharged in the steam drum by means of a system of
steam risers. Those discharged steam from the riser tubes and furnance wall is collected in
the chamber formed by the vertical buffle panels in the drum. Here the primary separation of
steam water is made. Most of water drops down after impact and passes around the ends of
the panels to mix with the incoming feed water.

A portion of the water is tapped off through the perforated continuous blow down pipe
at this point of high solid concentration. The steam and some water are released over the top
ends of the panels and cascades into the main part of the drum. From here, wet steam rises
and passes through the primary screen where much of the water is removed. Then the steam
enters the screen dryer, consisting of several layers of screens, where the last entertained
moisture is removed. This water is returned to the water side of the drum through the drain
pipes. Dry steam leaves the drum through the top outlet nozzles. Dry steam after separation
from the drum enters into the primary or platon super heater where it is super-heated to about
390oC to 460oC by both radiant and convection heat of the furnance. Steam from platon
super heater enters to the final super heat via desuperheater where required amount of water
is injected in it to monitor the final superheater inlet temperature. In final superheater, steam
is further superheated to 495oC +- 50oC by conversion heat of flue gas. Then, this superheated
steam at 495oC +- 5oC and 105 Kg/cm2 is supplied to NH3 Plant through SX common header
for further use.
 7
FUELS COMBUSTION :

Each boiler is designed for steaming with two mills supported with FO guns.
Pulverized cool is supplied to the furnance at the four corners of the boiler in three elevations
A.B and C. Each mill suppliers PF coal in all the four corners of one elevation only. There
are two types of FO guns in between elevation AB and BC in all the four corners of the
boilers. As such, there are 12 Nos. of pulverized cool burners and 8 Nos of FO guns. There
is provision to burn HSD in lower tyre FO guns as and when required.

The coal from unloading bay comes to the raw coal bunkers passing through crusher
houses conveyed by a system of conveyer belts. Coal coming from raw coal bunkers comes
to raw cola feeder and then supplied to the mill Quantity of coal supplied to the mill is
controlled by changing the speed of raw coal feeder. This coal is crushed in between bowl
and bull ring segments of mill. Hot air is introduced to mill, which is coming from RHS and
LHS wind boxes of the boiler. There is provision to supply cold air to maintain the
temperature of coal dust and air mixture from 70oC to 90oC. This coal dust and air mixture is
passing via classifier vanes and exhauster of the mills, supplied to all the four corners of the
boiler furnance through distributor. Size of the coal dust is 200 m of 70% passing Regulating
of the fireness of grinding is done by changing the angle of the vanes of classifier of the mill.

In order to ensure safety against explosion hazards are provided peepholes in furnace
and explosion diaphragms in flue gas path at different placed on flue gas ducts after Air Pre-
heater.

This cola dust and air mixture burns in the furnace with the support of fuel oil. Adequate
quantity of secondary air supplied to the furnace to boost up ignitions by both side wind
boxes, regulated by aux.air dampers in each corner. Heat liberated due to combustion of fuel
in furnace is absorbed by water walls for steaming inside tube water and remaining heat goes
with flue gas for further use. This flue gas heat is used in superheaters to superheat steam
temperature in bank tubes and economizer for further heating up water temperature in air pre-
heatet to raise the temperature of air coming from FD fans.

70 to 80% of the ash particles are driven out with flue gas and remaining are collected
in bottom ash hoppers. More than 99% of ash particles are liberated in electro-static
precipitators from flue gas. This flue gas, temp, about 140 oC goes to chimney through 2 Nos.
of ID fans, and then to atmosphere. The ashes of bottom ash hoppers and electrostatic
precipitators hoppers transferred to the ash ponds, out side of factory by ashing system
equipment.
 8

BASIC COMBUSTION REACTIONS

Carbon, Hydrogen and Sulphur in the fuel, Combine with oxygen in the air to form
CO2, H2O vapours and SO2 and releasing heat as follows:-

--- C+O2  CO2+8014 K.cals/Kg of Carbon

--- 2C+O2  2CO+2430 K cals/Kg of Carbon
--- 2H2+O2  2H2O+28922K cals/Kg of Hydrogen
--- S+O2  SO2+2224 K.cals/kg of Sulphur

If excess air is used for combustion, Sulphur trioxide(SO2) may also be formed
as combustion product.

TURN DOWN RATIO:

The relationship between the maximum and minimum fuel input without heating
excess air level is called’ Turn down Ration’ For example a burner whose maximum input is
250,000K cals and minimum rate is 50,000K, cals has a turn down ration of 5 to 1.
 9

EQUIPMENT SPECIFICATION AND DESIGN OPERATING DATE

DATE SHEET

Boilers Type: Tangentially Fired, Balanced Drought, Natural Circulation, Radiant

dry Bottom with Direct fired Pulverised coal with Bowl Mills.

Boiler Designation:- TT 19/20Vu-40 54/25, 45/20, 20/67

Furnace:- 5766mm with Depth 6070mm Volume 858 m3 Type

Fusion welded Radiant dry bottom

Superheater:- Platen Heating surface 378 m3

Spaced Final ------do-------- 635m3

Economiser:- Type Total heating No. of stages

Continuous Surface in m2 One
Finned 1425

Air Heater:- Type H S in m2 No. of Block

Regenerative 20-5-VIR-62 4582 One

Burning Element Burners-Tilting Taugential burners:-

Capacity No. of/Boiler Location

Coal Burners 2.2 Te/Hr 12 Corners of

Fuel oil Burner 3.2 Te/Hr. 48 furnace
Mills
Type System Capacity Motor
XRS- Suction 145 Te/Hr 280 KW for Coal 51 grindability 75%
603 Type through a 200 mesh
Exhauster

Type Speed Drive

2974 V-25 990 R.P.M Driven by Radial Paddle type exhauster to suit the
Motor mill
 10

Fans

Fan Type No. DESIGN CONDITION Motor Control

Gf/Blr KW RPM
F.D. NDF 2 29 3 383 40 oC 135 145 Inlet Vane
186 m3/Sec Kg/m2
I.D NDE 2 41 290 135 oC 145 740 Inlet Vane
246 m3/Sec Kg/m2

Soot Blower

Type Qty/Blr Medium

Furnace Wall Blowers 24 SH Steam
Rw SE
Platens Long Retractable 6 SH Steam
Convection Zone Model T-30 Make IE

Safety Valves

Location Make No. off Relieving Size Set Pressure

&Type Per Blr Capacity
Drum Dresser 1 118.8 2” 120 4 Kg/cm2
1738-WA Te/Hr.
Dresser 1 2” 123 9 Kg/cm2
1738-WA
Super- Dresser 1 29 7 2” 109 2 Kg/cm2
heater 1728-WD Te/Hr

Pipe Line

Main Steam Feed Water

Size 273X32 219X20
No. off/Boiler One One
 11
PREDICTED PERFORMANCE
Evaporation Te/Hr 100% MCR
Te/Hr 150
o
Feed Water temperature C 200
o
Feed Water Temperature C
o
Leaning Economiser C 254

STEAM TEMPERATURE
o
Drum C 320
o
Super Heater outlet C 495

STEAM PRESSURE
Drum design atg 121.0
Operating atg 113.4
Super heater outlet atg 105.0

PRESSURE DROP
Economiser atg 0.5
Final super heater atg 8.4

FLUE GAS TEMPERATURE

o
Leaving furnace C 1052
o
Entering super heater C 1052
o
Entering Economiser C 497
o
Entering air heater C 327
o
Leaning air heater corrected C 142

PRESSURE DROP FLUE GAS

Furnace mmwc 4
Super heater & boiler mmwc 21
Economiser mmwc 20
Duets, bends, dengers etc. mmwc 20
Air Heater mmwc 105
Static head mmwc 20
Electrostatic precipitator mmwx 20
Total mmwc 210

PRESSURE DROP AIR SIDE

Wind box mmwc 110
Air heater air side mmwc 82
Air ducts mmwc 30
Steam coil & venturi mmwc 15
Total mmwc
 12

HEAT LOSS
Dry gas % 4.45
H2O in air & H2 in fuel % 5.29
Carbon % 2.00
Radiation % 0.32
Unaccounted & manufacturing
Margin % 0.50
Total % 13.56
Efficiency % 86.44
Excess air leaving %
Economizer % 25
Coal % Bituminous
Coal
Fixed carbon % 30.0
Volatile matter % 24.5
Moisture % 6.5
Ash % 39.0
Hydrogen % 3.05
Grindability Hardgroore 50
High heating valve Kcal/Kg 4271
Lower heating valve Kcal/Kg 4100
Size of mill mm 20

PERFORMANCE

Total coal fired Te/Hr 24.38

Number of mills operating Two
Coal/ mill Te/Hr 12.19
Maximum mill capacity Te/Hr 14.50
Air flow through mill Kg/hr per mill 25855
0
Temp of air/fuel mixture after C 77
classifier
0
Temp. of air at inlet to mill C 149
0
Temp. of tempering air C 40
0
Hot air temp. available C 288
Total tempering air to mills Kg/hr 27345
Total hot air to mills Kg/hr 24365
 13

Sl. Description Quantity Quantity Capacity Full load RPM

N. /Per Blr per current/voltage
Project
1. H.T.Motors 3 9 280 KW 3.3. KV 990
Mill Motors
1. L.T. Motors 2 6 150 KW 415V/258A 990
F.D.Fan Motor
2. I.D. Fan motor 2 6 160 KW 415V/275A 990
3. Light oil pump motor - 2 5.5 KW 415V110A 1460
4. Fuel Oil pump Motor - 2 15 KW 415V/275A 1460
5. Igniter fan motor 1 3 2.2KW 415V/4.65A 2850
6. Scanner fan Motor 1 3 2.2KW 415V/5,65A 2850
7. Raw Coal feeder 3 9 2.2/
motor
3.7 KW 415V/7.6A 950
8. Air heater drive 1 3 3.7KW 415V/6.86A 1480
motor
9. Rapping mechanism 6 18 0.25KW 415V 1390
for collecting
10 Rapping mechanism 6 18 0.25KW 415V 1390
. for discharge
11 HP dosing pump 6 2 1.5KW 415V/3.2A 2900
motor
12 Mixing tank motor 2 0.75KW 415V 1440
13 Long retractable soot 6 18 0.37KW 415V/1.36 1500
blower traverse
Rotary 6 18 0.45KW 415V/0.44 1500
14 Wall blower 24 72 0.56KW 415V/0.8 1500
Transverse
Rotary 24 72 0.05KW 415V/1.26 1500
15 Air heater blower 1 3 0.18KW 415V
.
16 Ash 3 3 250KW 3300V/55.0 1488
. water pump
Valve Drivers
 14

S.No. Description Quantity/per Quantity Capacity Full load RPM

Blr per current/Voltage
project
1. Main Steam 1 3 2.2 KW 415V 1430
stop V/V
250/250/550
2. Start up 1 3 0.55KW 415V 1430
valve
65/250/550
3. Soot blower 1 3 0.12KW 415V 1430
drain valve
4. Soot blower 1 3 0.18KW 415V 1430
main valve
40/250/55
5. Feed stop 1 3 2.2 KW 415V 1400
valve
6. Air heater 1 3 0.75KW 415V 1400
soot blower
stop valve
7. By pass 1 3 0.12KW 415V 1400
valve for
main
steam stop
valve
 15

Economiser Final Superheater Platen

continuous (Pendant superheater
finned Convective) (Panel type)
steam-less Pendant
Radiant
52 33 18 No. of superheater assembly

16 66 54 No. of coils(tubes)/blr
5 4 No. of loops
Counter Parallel Parallel Flow type
Staggered Inline Inline Arrangement
44.5X4.5 44.5 44.5 Tube size out side dia in mm
SA-210Gr SA-213T11 SA- Material of construction
A1 SA-213T22 209T1BS3059
P2S2 620 SA-
213T22
(4.5) (44.5X4.6) Material thickness(mm)
(5) (44.5X4.5)
(44X5)
124 96 96 Longitudinal mm

Spacing Inlet header

78 Alternatively 304.8 Transverse mm
139.7X165.1
1 - - No. off
219.1 X 323.9+32 219.1X28 Size mm
28
SA-106Gr SA 335 P12 SA-106Gr B Material
B
1 1 12 No. off```
header
Outlet

219.1 X 28 323.9X36 329.9X32 Size mm

SA-106Gr SA 335 P12 SA 330 P12 Material
B

1 (each) 1 12 No. off

Steam Line
Main

tubes
Transfer

212.1X20 273X32 108X10 Size mm

SA-106 SA-335 P12 SA-106 Gr2B SA-106 G2B
GrB
 16

METALURGY COMPONENT

Metal Carbon Siliea Mang Phos Sulphu Chro Molibd

Grade C Si anese phoru r S mium enum
Mn sP Cr MO
1 SA 209 TI Min 0.10 0.10 0.30 0.44
Ma 0.15 0.50 0.80 0.045 0.045 0.65
x
2 SA213 TII Min 0.50 0.30 1.00 0.44
Ma 0.12 1.00 0.60 0.03 0.03 1.50 0.65
x
3 SA-213T22 Min 0.30 0.030 1.90 0.87
Ma 0.12 0.50 0.60 0.030 0.03 2.60 1.13
x
4 SA-335 P12 0.13 0.32 0.47 0.019 0.022 0.96 0.54
5 SA-106 0.20 0.26 0.70 0.013 0.014 Nitro Copp Nic Tin
G2B gen er-Cu keL Sn
0.008 Nl
7
6 BS 3059 0.10 0.10 0.40 0.040 0.040 0.70 0.45 0.25 0.30 0.0
P2S2 620 To To To To To 30
0.15 0.35 0.70 1.10 0.65
7 Grinding 3.0 2.0 0.75 4.0
Roll to
5.0
8 Bullring 2.0 7.5 to Nil 5.0
segment, to 9.5 to
Periphery 8.0 6.0
liner
 ELECTRASTATIC PRECIPITATOR
17

1 DESIGN CONDITION :

i) Gas flow rate 68 M3/Sec.

ii) Temp. of flue gas at the inlet of precipitation 150oC.
iii) Dust concentration 3.61 gm/sec.
iv) Pressure at the inlet of precipitator 160 mm WC.
v) Type of precipitator 2 FAA-3x36-6560-2.
vi) No. of precipitator 1.
vii) No of parallel gas pans per bottle 2.
viii No. of fields in series in each gas pan 3.
)
ix) Guaranteed collection efficiency for design 98.5 %.
condition
x) Pressure drop across the precipitator for design 15 mmwc.
condition
xi) Velocity of gas at electrode zone on total area 0.87m/sec.
xii) Treatment time 12.41 sec.

2 COLLECTION ELECTRODES

I) No. of rows of collecting electrodes per field 27.

ii) No. of collecting electrodes per field ( Nine 243 (9x27).
plates are arranged in each row)
iii) Total no. of collecting plates per boiler 1458 (6x243).
iv) Nominal height of collecting plates 6 Mtrs
Total no. length
v) Nominal of electrodes per boiler
of collecting plates 5616.mm.
400
Total length
vi) Specific of electrodes
collecting area per field 5391.36
99.10 m8m.
/4/sec.
vii) Plate wiring spacing 125mm.
3 EMITTING ELECTRODES
4 RAPPERS FOR COLLECTION ELECTRODES

i)
I) No. ond type of rapper
Type One drop ofSpiral
hammer
withper rowtype
hook of
collecting electrodes
ends rowing a
ii) Size collecting surface of 43.2m2
Dia. 2.5mm.
ii)
iii) Weight of hammerin the frame forming one
No. of electrodes 4 9row
Kg. 36.
iii)
iv) Frequency of rapin each field
No. of electrode Varying from 6 rpm/hr at the inlet
936.
field to 1 rap/hr at the exit field. The
frequency of rapping at intermediate
field can be adjusted between 6 and
1/hr according to requirement during
commissioning.
 18
iv) Drive Geared electric motor controlled by
synchronous programmer.
v) Location On the side of the casing.

5.
v) RAPPERS FOR EMITTING ELECTRODES
Baffling arrangement 2 sets of deflector plates for each
happer underneath the collecting
i) No. and type of rappers Approximately
plates to preventonegasdrop hammer for
leakage.
two rows of electrodes.
ii)
7. Rapper size
GAS DISTRIBUTION SYSTEM 3.0 Kgs.
iii) Frequency of rap 10 raps/hr.
iv)
i) Driveand quality
Type Geared motor
Perforated controlled
plate 2 sets by
ii) Location synchronous
Inlet programmer.
of precipitator.
8v) Location
RECTIFIER On the side panel of conny.
i) Rating 60 KV, 600 VA.
6.
ii) HAPPERS
Number 3 ( one for two field ).
iii) Type Silicon diode, full wave bridge
i) Type By ramididical.
connection.
ii)
iv) No. of happers
Location 6 (one peron
Mounted field).
top of precipitator.
iii) Capacity 8 hr storage.
9iv) Heating
RECTIFIER CONTROL PANEL Electrical heating provided for the
bottom of happers
i) Type of control Transducer
ii) Number 3.
iii) Location E P control room.

10 AUXILIERY CONTROL PANEL

i) Number 2 (one per pass).

ii) Equipment control Geared motor of rapping mechanism
heating elements, insulation houring
and shaft insulator.
iii) Location E P control room.

11 MOTOR

i) Rapping of electrode 6+6.

ii) Rating Gear motor 33KW/1.1 Rpm at 3 ph,
415 V, 50 c/s.
iii) Location On the side panels of casing.

12 HEATING ELEMENT

iv)
i) Control
Hoppers Thermostatically controlled for
For 6 hoppers @6KW=36KW.
ii) Shaft insulation For 6 insulators @ 1 KW=6 W
iii) Support insulation in the insulators For 24 insulators @ 1 KW=24 KW
houring
 19
hoppers and support insulation.

TECHNICAL DATA

1 HEAVY FUEL OIL

a) Used for Stabilizing coal floma and low

load carrying.
b) Flash point 66 oC.
c) Kinematic viscosity at 50 oC max m 120 centi strokes
d) Sulphur total by weight 4 %.
e) A P I gravity 12 SP gravity 1.986 at 15 oC.
f) Gross heating value 10270 K coal/Kg.

2 LIGHT OIL

a) Used for Cold start up of boiler warm up

guns and igniters.
b) Flash point 38 oC.
c) Kinematic viscosity at 38 oC 2 to 7.5 centi strokes.
d) Carbon residue rams bottom by weight max m 0.20 %.
e) Sulphur total by weight 1.0 %.
f) A P I gravity 35 SP gravity 0.85 at 15 oC.
g) Gross heating value 10720 K coal/Kg.

3 IGNITERS GUN

a) Application Start up and coal flame stabilizing.

b) Type 6 inches Eddy plate oil side
igniters, light oil, air atomized.
c) No. off 8 (4 per elevation).
d) Heated at Elevation AB/BC.
 20

e) Capacity each 0.5 millions Kcal/hr (2 million Btu/hr).

f) Oil firing rate 50 Kg/hr/igniter.
g) Oil pressure at control cabinet 12.5 to 14.0 Kg/cm2g
h) Atomizing air quantity Service air, moisture free.
i) Atomizing air consumption 14.5 Nm3/hr/igniter while in service.
1.6 Nm2/hr/igniter while in service.
j) Atomizing air pressure at the control 5.5 to 7.0 Kg/cm2g.
cabinet
k) Combustion air quantity 560 Nm2/hr/igniter.
l) Combustion air pressure at ignitor/ box 75 mm WC.

4 LIGHT OIL GUNS

i) Application Cold start up warming up of boiler.

ii) Type Tilting tangential air atomized internal
mix.
iii) No. off 4.
iv) Location at Elevation AB at the corner wind boxes.
v) Capacity 10% of boiler MCR total.
vi) Turn-down 3:1.
vii) Oil firing rate 280 Kg/cm2g.
viii) Oil pressure at gun 3.9Kg/cm2g.
Ix) Atomizing air quantity Service air water free.
x) Atomizing air consumption 60 Nm2/hr/gun on normal scavenging
operation.
100Nm3/hr/gun on gun scavenging.
 21

xi) Atomising air pressure at the gun 4.90kg/cm2g

xii) Differential pressure between oil & air
1.00 kg/cm2 air pressure to be
more than oil pressure.
xiii) Atomising nozzle assembly designation Mixing platon 41A spray plate-
60N41

HEAVY FUEL OIL GUNS

Application Stabilizing coal flame low load

carrying hot start-up
Type Tilting tangential steam atomized
internal mix
No. off 8 (4 per elevation)
Located at Elevations AB and BC at the corner
wind boxed
Capacity 15% of boiler MCR per elevation
maxm 30% of boiler MCR total in
two elevation
Turn down 4:1
Oil firing rate 435 Kg/hr/gun
Oil Pressure at the gun 7.75 kg/cm2g
Oil leiseasity at the gun 16 to 28 centistoke
Steam consumption 70 kg/hr/gun during normal
operation 115 kg/hr/gun during gun
scavaning
Steam pressure at the gun 8.75 kg/cm2/g
Defferial pressure betn oil & steam 1.00 kg/cm2/g steampressure to be
more than oil pressure
Atomizer nozzle assembly designation Mixing plate N44 SH spray plate
60 N44

Above said figures and designa value corresponding to normal operating conditions
 22

HEAVY OIL HEATERS

1. Type U-Tube, hair pin type, oil on the

shell side, condensing type
2. No. off 2 (Including one stand-by)
3. Heater area each 20 m2
4. Oil flow rate 900 kg/he (9.0 MT/hr)
5. Oil temperature range 40oC to 115oC
6. Steam pressure 10.0 kg/cm2
7. Design pressure 24.0 kg/cm2 g oil side,
16.0 kg/cm2g Steam side
 23

Sr. Item Description Nos.off Supplier make Type/Size particulars Remakrs

No for
.
1. HEAVY OIL 2 John Heiner Multiscrew, position
PUMP Bornomann o Co displacement with
West German built in relief valve
165 Ltrs/min at 150 C
at, discharge pressure
22 kg/cm2g 1450 rpm
2 LIGHT OIL 2 -do- Multiscrew, positive
PUMP displacement with
built in relief valve
65 ltrs/min at 1.50
CST and discharge
pressure 22.00
kg/cm2g 2920 rpm
3 MOTOR DOE 2 Bharat Bijlee Horizontal foot
HEAVY OIL mounted squirrel
PUMP cage flave proof
motor KW-15, rpm-
1460, volts-415
4. MOTOR FOR 2 Kirloskar Horizontal foot in
HEAVY OIL mounted squirrel
PUMP cage flame proof
motor KW-5 5, rpm-
3000, volts-415
 24

MILLS

1) Type of Pulverisation Bowl mill with classifier & exhauster

2) Size 603 X RS suction type
3) No. of Mills 3 Nos./ Boiler
4) Capacity 198 T/Hr.55 hardgrove index, 70% Thro
200 mesh 20mm raw each size

5) Motor 280 KW combined mill and exhauster

6) Coupling Gear type coupling both sides of
mill(Motor-mill & mill-exhauster)
7) Cooling System Oil both in main mill drive gear housing
for lubrication worm geer and bearing
oil is cooled by circulating water inside
the tube bundles immersed in oil bath 4
to 4.5cm2/hr cooling water required per
mill at 36oC
8) Wear Surfaces Grinding roll, bull ring segments and
liner are made of high quality N1 hard
costing
9) Feeders Rotary feeders, Independent feeders
10) Capacity 5 to 30 t/hours
11) Speed 2.67 to 16.00 rpm
12) Drive Positively infinitely variable speed unit
with flange mounted motor

VARIATOR OF RAW COAL FEEDER

VC-Speed variation control

1) VC 3.7 KW
2) Variation ratio 6:1
3) Speed change operation Lower control
4) Drive motor 3.7 KW,3 phage, Induction motor flange
type directly mounted
 25

5) Nominal reduction rates

of signal gear on motor 1:2
side
6) Nominal reduction ration
of single gear on out-put 1:30
side
7) Techno-Generator Including techo motor direcly mounted
on the VC body
8) Safety coupling Connected to VC out-put shaft and
designed to slip if excess torque is
forced on the out-pu shaft
9) Special air breather Provided on the VC
 26

TYPE VU BOILERS

DATA OF ID & FD FANS

S.No. Particulars FD Fan ID Fan

1. Type NDFY 186 NDFY 246
2. Fan Orientation Style 01 left Style 01 left up
bottom 55o to wards view from
vertical view drive end
from drive end
3 Medium handled Atmosphere air Flanges
4. Non of fans/bir 2 2
5. Fan designating
i) Capacity M3/Sec. 29.3 41
ii) Total head developed 383 290
mmwc
iii) Temperature of medica 40 -
oC
iv) Sp. Wt of medium 1.128 0.882
v) Speed rpm 990 740
7 Drive coupling Pin type Pin type
8. Drive motor supplier Siemens
i) Frame size 400 M 400 M
ii) Rating KW 150 160
iii) Voltage KV 415 415
iv) Frequency cps 50 50
v) Phase 3 3
9. Fan weight in kg 6888 9696
10. Type of fan regulation Inlet guide vane Inlet guide vane
11. Bearing NU332C3 NU332C3
12. Thrust bearing 7234 BVA 7234 BVA
13. Coupling side N234C3 N234C3
 27

ALARM AND TRIP SETTING

S. No. Tag No. Service Setting
1 PS-27.4 Mill differ press. high 270 mm WG
2 PS-27.5 Mill differ press. low 35 mm WG
3 PS-27.6 Mill differ press. High interlock 280 mm WG
4 PS-49.4 Mill temp. high 900 C
5 TIA-58.2 Mill oil bath temp. high 800 C
6 TS-66.4 Mill motor WDG temp.high 760 C
(Winding)
7 TRA-52.2 Mill bearing temp.high 840 C
8 PS-4.5 Air flow low 2.5 M3 / Sec
9 PS-4.6 Air flow V low 0.0 M3 / Sec
10 PS-4.8 Air flow normal interlock 10.0 M3 / Sec
11 PS-13.4 Furnace PR V HIGH inter MFR Trip +40.0 mm WG
12 PS-13.5 Furnace PR high +15 mm H2O
13 PS-13.6 Furnace PR low -25 mm H2O
14 PS-13.8 Furnace PR normal interlock -5 mm H2O
15 TRA-63.3 Metal Temp. high 5700 C
16 PS-7.4 Feed water PR low 108 kg/cm2
17 PS-41.4 Main inlet steam temp.high 5050 C
18 PS-5.4 Drum level high +100 mm H2O
19 PS-5.5 Drum level low -100 mm H2O
20 LS-10.1 Drum level V low TRIP -200 mm H2O
21 PS-10.4 Shoot blower steam PR low 8 kk/Cm2
22 PS-90.4 Aux Steam PR low 8 kg/Cm2
23 PS-94.5 Cooling water PR low 2.0 kg/Cm2
24 PS-95.4 F.O. Pump disch PR low 8 kg/Cm2
25 TICA-93.1 F.O. heating Unit temp. high 1200 C

S. No. Tag No. Service Setting

26 PS-91.3 Inset air PR low 1.0 kg/Cm2
27 PS-92.3 Compressed air PR low 5.5 kg/Cm2
28 PS-BAH-102-A BFP Discharge PR high 145 kg/Cm2
29 PS-BAL-102-A BFP Discharge PR low 120 kg/Cm2
30 TS-70.2 A Air heater bearing high 900 C
31 TS-70.2 B Air heater bearing high 600 C

LUBRICATION CHART
S.No. Lubrication Chart Type of Lube Oil Quantity in Liters
 28
1 257/40 500
Mill gear box
2 Mill exh. Bearing 533 2
3 Mill Roller 533 11-12
4 ID Fan 317 15
5 FD Fan 317 15
6 Ash water pump bearing housing 317 2
(both sides)
7 Air heater gear box 533 30
8 Clinker grinder gear box 533 15
9 Clinker grinder fluid coupling 314 4-5
10 Soot blower gear box 317 1
11 Phosphate dosing pump 553 20-25
12 Air heater bearing (top/bottom) c-100 10-15
13 Rapping motors 553 5-7
14 MSSV (MCV) 317 5-7
15 MSSV by pass (MCV) 317 2-4
16 Start up vent (MOV) 317 4-6
17 RCF GEAR BOX 533 15-20
18 Lr Soot blowers 317 2
19 LDO unloading
WESTER pumpWORK 317 1

PACKAGE BOILER

DETAILED SPECIFICATION SHEET

1 Shell Diameter (ID) 3800 mm plain 1010 mm

2 Combustion Tube Dia plain/corrugated Corrugated 1000/1100 mm
2 Nos.
3 Distance over Tube Plates 7304 mm
4 No. of plain Tubes (63.5 mm OD) 45
5 No. of Stay Tubes (63.5 mm OD) 39
6 Thickness of Plain Tubes 95 W.G
7 Hearing surface (Water Side) 663 M2
8 Thickness of Stay Tube 9.5 mm
9 Water Storage (Capacity) (up to storage 40,950 ur
level)
10 Steam Holding Capacity 10.7 M3

11. POWER REQUIRED EACH

 29
Feed Pumps
2 Nos.
Capacity 33.32 M3 Lts
Motor HP/Kw 50/37
Head 18.29 kg/cm2
R.P.M. 3000
Oil Pump 2 Nos.
Capacity 3000
Head 30 kg/cm2
R.P.M. 1500
FD Fan 2 Nos.
Capacity 12000 NM3/Hrs
Pressure 515 MM/wg
Motor HP/kw 50/37
R.P.M. 1500

WESTER WORK HORIZENTAL SMOKE TUBE

PACKAGED BOILER

MAJOR SPECIFICATIONS

1. Boiler No.W-482, year of Make1980,model WPO-240,

boiler operating pressure-15 kg/cm2
2. Construction : Class – 1
FE – 2 Nos.
PJ BurnersWelgrass -651
3. Recommended : CO2 -13 %
Max Flue gas temp. – 2300C
4. Evaporation Capacity: -20 te/hrs
5. Safety Valve set Pressure - 1 post 15.3 kg/cm2
22 –post 15.5 kg/cm2

6. Max. Fuel Consumption : 1576 kg/hrs

TDR – 5:1
7. Electric Power Requirement voltage – 415 cycles-50/5/3 PH
4 wire system -160 KW
8. Feed water line from left water service tank to pump -4” NB Dia
9. Main steam stop V/V 7”
(Blow down V/V 21/2 “ Dia)
10. Drain line WLC drain 1” Dia
(G Glass drain 3/8’ BSP
 30
11. Safety V/V drain ¾” BSP
(Safety V/V EX- 6”NB)
12. Boiler flue gas opening 1320 mm
13. Recommended vest chimney – dia 1420

UNIT OPERATING PROCEDURE

NORMAL START-UP (Boiler Cold)

To ensure a maximum safety during cold start-up, it is recommended that a high air
flow of at least 30% MCR be used in order to produce an air-rich furnace atmosphere. This
precludes the possibility of accumulations of explosives mixtures in the events of poor or
delayed ignition after field in introduced to the furnace. It is recommended that this high air
flow be maintained during the lighting off and ward up period until the boiler is on the line
and reaches a load where additional air is required to maintain the design operating excess air.
During start-ups, lighting off is done with igniters and warm-up oil guns with light oil firing.
It is recommended that during starts-ups initial firing be done by means of oil guns in the
lower burner. When burning the unit up to pressure and temperature, saturated steam
temperature rises, should be limited to 55oC per hour.

During all start-ups the firing rate must be controlled to keep the maximum
temperature of gases leaving the furnace below 497oC. Flue gas temperature probes should
be used near the lower bends of first gas touched superheater elements so that the furnace
outlet gas temperature can be measured frequently or recorded continuously.

The following steps outline the procedure for bringing cold boiler up to working
pressure & temperature. It is assumed that boiler has been boiled out and prepared for
operation. The boiler should be filled up with treated feed water. The water level in steam
drum should be at normal operating level.
 31
PREPARATIONS

1. INSPECT THE BOILER PRIOR TO STARTING CHECK: -

- All foreign materials has been removed from pressure part.

- All personnel clear.
- All access door closed.
- Starting equipment and interlock cleared.

- Retractable soot blower elements removed from gas side.

- Individual fuel valves at burner closed.
- All boiler fitting & valves in proper order.

2. SEE THAT FOLLOWING VALVES ARE CLOSED.

- Feed water regulating valves (closed and on manual control)

- All blow down & drain valves on boiler and water walls.
- Boiler and super heater on filling valves.
- Soot blower master steam supply valves.
- Main steam line stop valves.
- Desuperheater control valves & by pass line valves.

3. OPEN THE

- Drum vents
- Water gauge glass valves (Locked open)
- Superheater header drains and vents and main steam line drain
- All instrument and control connections to the boiler
- Including valves on both side of desuperheater control valves.

NOTE: -Close all superheater drains when headers are free of water except the
superheater outlet header drain which remains open.

4. CHECK:
 32
- Following equipments for adequate lubrication, cooling water flow and ready
for service.
- Air heater and drive (if rotary air heater is provide)
- Fans and drive
- Boiler feed pump and drive
- Slag removing systems
- All servo/Pneumatic drive for valve and dampers.

5. RECHECK ITEMS SUCH AS

- Oil guns properly inserted and coupled.

- All oil guns and igniter piping ready for service

- All manual valves open.
- All control valves closed.

6. It is presumed that pulverized equipment has been checked for proper functioning
and ready for service recheck.

1)Exhausters discharge valve open.

2)Hot air glass closes, Hot air dampers closed.
3)Raw coal gate is open and coal is available to feeders.
4)All classifiers vane setting identical
7. It is presumed that all the soot blowing equipment has been checked for proper
operation and system is in the startup condition.

8. It is presumed that wind boxes have been checked for proper damper positioning,
burner is in horizontal position etc.

9. Make sure sealing and aspirating air is available.

10. Put all automatic control equipment on manual control and see that all control
equipment is ready for service. Manually operate all sequential trips and see that the
emergency fuel trips function property.

FILLING OF BOILER WITH WATER:- Before start filling up open all the vent valves on
economizer, boiler drums platen and final superheater. It is also possible to fill the
 33
economizer simultaneously through drain valves or through the main feed line. The boiler is
filled up to top of drum.

LIGHTING: -

i) Starts ID and FD Fan. (Included draft-ID)

(Forced draft-FD)
ii) Start ignitor air fan.
iii) Adjust the fan and wind box dampers to permit purge air flow of atleast 30% of
total air flow and a furnace draft of approximately 4mm.
iv) When the fans are started, the secondary air damper control should adjust the
auxillary air dampers to obtain approximately 40mm water column of wind box of furnace
differential pressure. Check that all other purge permissive are satisfied.
v) Start igniters.

vi) Visually check the flame is proven. Then start the one warn up gun.
vii) Close the drum vents when the drum pressure reached 2 Kg/cm2 (gauge)
viii) The firing rate can be increased gradually keeping the furnace exit gas
temperature below 497oC
ix) While the unit is heating up make frequent checks of boiler expansion
movements, special attention should be given to expansion of lower part of boiler.
x) As drum pressure increases, progressively throttle the final superheater outlet
header drain and other start-up vents and drain used (main steam line drain), Sufficient
steam flow must be maintained at all times to assure clearing the superheater elements
of condensates by means of starting to atmosphere valve. Increase the tiring rate as
necessary without exceeding the furnace exit gas temperature limitation (497 oC) Do
not close the start up drain completely until steam flow through the main steam line is
established.
xi) As load demands the firing rate has to be increased or decreased by taking or
cutting in heavy oil or coal at any one elevation.

xii) It is necessary that during start up initial firing be done by means of the warm
up oil guns which are rated to give 15% of boiler MCR, at which point the
load carrying heavy oil guns can be placed in service or oene mill can operate
continuously at minimum rati g
xiii) To prepare a mill for service, proceed as follows:

- Check to see that all the classifier vanes setting are identical
- Check coal supply and open the coal gates to mill feeder.
- Fully open the exhauster discharge valve. Make sure that tampering air damper
has freedom movement.
- Hot air gates closed. Hot air control dampers closed.
 34

xiv) Before placing the mill in service, check the associated burner windbox
dampers.
xv) Start the mill, open the hot air gate. Operate without coal to warm up the mill
with hot air to required temperature make sure that warm up oil guns to must
in stable condition. When ready to fire coal, start the mill feed at minimum
rating. It the ignition of pulverized coal does not take place, immediately
stops the feeder.
xvi) When the mill is not empty (in emergency fuel trip case) when other mills are
loaded,.

the furnace draft must be raised sufficiently to prevent- getting aq pressure in the furnace and
thus blowing hot furnace gases back into idle mill and coal pipings. The exhauster discharge
valves of other mill (idle mills) shall be closed

xvii) If the coal ignition of coal in furnace not occurs within 5 seconds, stop the
feeder of purge the furnace, cause for failing to lighting of load may be due
to-
- too much secondary air.
- Too lean a coal primary mixture.
- Loss of warm up oil gun flame.

xviii) When the ignition of coal has become stable on preparation, cut the fuel rate
to minimum. Watch the fire:-
xix) Main coal/Air temperature leaning the pulveriser, regulate hot air damper
manually to hold between 74 to 80oC for high volatile coal and 80 to 85oC for
low volatile coal at outlet of pulveriser.

The lamp should not exceed 90oC. If it should 90oC, the hot air gate must
closed. Check the pulveriser oil temperature of turn on the water to oil cooler
when temperature approaches 65oC at any time.

Note: Pulveriser start up will cause a sudden and sharp increase of steam pressure. This
will level out rapidly as load is increased.

xx) Place the second pulveriser in same way when feeder rating of first pulveriser
has reached approx 80% of maximum.
 35
The warm up guns of ignitors must remain in service until the feeder rating of
each of two pulverisers exceeds 50% of maximum or otherwise during single
mill operating conditions.

xxi) The boiler inter locks and secondary air damper controls or the operator
should close the auxiliary air dampers serving compartments adjacent to coal
nozzles which are out of service when the boiler reaches 301. of full load and
increases the windbox to furnace differential pressure to approximately 100
MMWC.

xxii) It is essential that air flow to the furnace is sufficient for the firing rate at all
times Automatic control is normally preferred for maintaining such a
balanced condition. The O2 measuring devices which are often tried in with
the air flow control should be checked periodically to assure continuous and
dependable operation.

xxiii) Place the desuperheater spray control and combustion control on ‘Auto’ when
firing conditions are stable and temperature & pressure controls set point
have been reached before refers to control equipment.

xxiv) Adjust the feed water supply to boiler as necessary to maintain normal water
level. Feed water control should be placed on automatic as soon as possible
& practicable when continuous feed water flow is established.

xxv) If the setting of safety in drum and superheater has not been checked
previously this should be done prior to going on the line.
 36

NORMAL OPERATION- UNIT LOAD CHANGES:-

During normal operation, with the unit on the line, changes in pulveriser loading and/or
the number of pulverisers in service may be required to accommodate unit load changes. A
wide range of load control can be achieved with the pulverisers on automatic.

a) Decreasing load:-
If the unit load decreased to a point when the feeder rating off the pulverisers in
service is reduced below 50% of maximum, stabilization fuel oil firing should be
introduced and if so desired one pulveriser be taken out of service and the load on the
other pulveriser increases
.

To remove the pulveriser from service proceed as follows:

- Start stabilization oils guns.

- Gradually reduce the feeder rating of the selected pulveriser to minimum.
 37
- When the feeder rating is at minimum (approx 25%) close the hot air shut off
gate.
- Allow the pulveriser to run for at least two minutes to in sure that it is
completely empty, then stop the pulveriser.

If the unit load is reduced to a point where no pulveriser are required, auxiliary support
oil guns can be used to carry the boiler load.

NOTE:- Auxiliary supporting fuel should be used at any time and under any condition
in which in the operators judgment, stabilization of ignition is necessary.

INCREASING LOAD:- If after a load decrease, where one pulveriser has been taken
out of service, the unit load should increase to a point where the feeder rating of the
pulverized in service exceeds 80% of maximum, the second pulveriser could be placed in
service as follows:

i) Start the pulveriser

ii) Open the hot air shut off gate and bring the pulveriser to operating temperature.

iii) Start the pulveriser feeder, the feeder control should be on “Manual” at minimum
feeder rating.
iv) When the pulveriser is grinding and coal ignition has been established, gradually
increase the feeder rating until the pulveriser loading equals that of the other
pulverisers in service. Then place the pulverisers on auto control.
v) The auxiliary supporting fuel may be taken out of service when furnace conditions
have established and both the pulverisers are in service each with a feeder rating of
at least 50%
 38

NORMAL SHUT DOWN TO HOT STAND BY

It is assumed that the boiler will be shut down for a relatively short period of time
and existing pressure and temperature conditions will be substantially maintained.
A procedure similar to normal shutdown except the following:-

1. Do not reduce the drum pressure in the line with unit load reduction. The rate of
pressure drop should be much smaller than the rate followed by during normal shut down.
When the desired pressure at which boiler is to be held is reached after the boiler is off the
line. The boiler may be bottled up by dosing all desuperheater drains and vents.

2. It is not necessary to close the feeder inlet gates and to run the spouts and feeders. As
each pulveriser is taken out of service, close the hot air shut down off gate. Stop the
feeder when the coal air temperature drops to 45 oC. Run the pulveriser until empty
and stop the pulveriser.

3. After all fires are out, keep the fans in service for at least five minutes (at 30% air
flow) to purge the unit close all gas duct, secondary air duct and wind box dampers
after the fans are shut down.
 39

Caution: It oils has been fired and it is knower suspected that combustible particles
deposits are present in air heater, the air heater has inlet temperature must be reduced to 180
o
C before shutting down the F.D. fans, I.F fans.

4. Keep the water level insight in gauge glass. As the unit cools and the water shrinks
make up should be added intermittently to prevent water from dropping out of sight
in gauge glass.

The operator should observe the gauge glass periodically so that he is always aware of the
actual drum level and can take appropriate action to reestablish water level when the unit
is being restarted.

HOT RESTART

Assuming the boiler has been down for a comparatively short period of time and
considerable drum pressure was maintained by the following procedure should be used in
restarting the Unit.

1. Make a general inspection of boiler and check the all-necessary points.

2. Start the fans as per produce of normal start up.
3. Open wide all superheater drains to allow draining superheater headers/or
elements. After draining close all drains and vents except the outlet header
drain. Keep this start up drain wide open. Open the desuperheater isolation
valve with control v/v in close position.
4. Initiate a furnace purge and normal light off sequence of ignitors and warm-
up oil guns. The rate of firing and duration of warming period depends
entirely on the boiler pressure and temperature. Care must be taken to
control the firing rate with in the superheater limit and within the pressure
and temperature limits required by the process. The working period should
be long enough to allow complete boiling out of superheater.
5. Establish he firing conditions to maintain the maximum furnace exit gas
temperatures without exceeding it.

EMERGENCY PROCEDURES:- Emergency shut down procedure due to

 40
1. Master fuel trip.
2. Low Water level
3. High water level]

1. MASTER FUEL TRIP:-

Under conditions requiring a master fuel trip through normal interlocks or operators
action(manual trip), all fuel should be tripped instantaneously. If coal was being
fired the pulverisers should be tripped immediately. Tripping the pulverisers will
automatically trip the feeders and close the hit air shut off gates.

If oil was being fired, the oil and ignitor trip valves and individual nozzle shut off
should be closed immediately.

Following steps to be taken immediately:-

a) Maintain the unit airflow at pre-trip value for at least 5 minutes to purge the system. If
a hot restart is anticipated the airflow may be gradually reduced to light-off air flow
(30% of full load air flow) during the purge period.

b) If oil guns were in service when the fuel trip occurred, check to ensure that all
individual nozzles shut off valves are closed. Oil guns should be retracted, removed,
cleaned and reinstalled to be ready for restart of the Unit.

c) If all auxiliary power sources are lost during a

trip, upon restoration of power, start the fans and purge the furnace for five minutes.

d) Pulverisers were in service when the fuel trip

occurred, all pulverisers containing coal should be cleaned off coal successively as
soon as possible. Each pulveriser should be unloaded in following manner:-

- Close the exhauster discharge valves on pulverisers that contain coal. This will
prevent hot furnace gases from being carried back into these pulverisers.

- Establish the required ignition energy for the pulveriser to be started.

 41
- Start the pulveriser and allow it to clear itself of coal.

- If the pulveriser will attained in service, start its feeder when the pulveriser
amps begin to fall off. When the feeder is started, open the hot air shut off gate
and bring the pulveriser upto normal operating temperature.

- If the pulveriser will not be retained in service, stop the pulveriser after it is
completely cleared of coal. The exhauster discharge valve should remain open
to allow a flow of coming air through the empty pulveriser.

LOW WATER LEVELS:

If the water level falls out of sight in water gauge, due to failure of feed water
supply or neglect of operator, except in the case of momentary fluctuations that night
occur with extraordinary changes in load, appropriate action should be taken at once to
trip the fuel. Any decision to continue to operate, even if only for a short time at a
reduced rating would have to be made by someone in authority who is thoroughly
familiar with the circumstances that lead to emergency and positively certain that the
water level can be restored immediately without damaging the boiler.

In absence of such a decision:-

a) Trip all fuel immediately,

b) Shut off all steam being discharged from the unit.
c) Maintain a high air flow at first to heat the cooling process.
d) If pressure parts damage is suspected, reduce the steam pressure gradually byt
opening the superheater start up drains. Open the drum vents when the pressure
drops below 2 Kg/cm2 (gauge). As the boiler cools reduce the air flow. Shut
down the air heaters and fans as soon as the unit is cool enough for a man to
enter. Drain the boiler when drum metal temperature is 90 oC following normal
draining procedure. Determine the cause of low water and examine the boiler
for the effects of possible overheating such as leaks and distortion of pressure
parts.
e) Repair any leak etc.

f) Hydrostatically test the boiler at working pressure before putting the unit back in
service.

HIGH WATER LEVEL:

 42
Abnormally high water level should be avoided as it may lead to carry over and even
priming. If the water level rises above the recommended normal operating range proceed as
follows:

a) Reduce the water level immediately by throttling the feed supply and opening
waterwall system drain valves.

b) Reduce the steaming rate, if necessary, and place feed water control on manual. If
priming should occur, as indicated by rapid fluctuations in outlet steam temperature,
Proceed as follows-

- Reduce the steaming rate.

- If water level is abnormally high reduce the level.
- Investigate the water condition (alkanity & solids)
- Investigate the condition of drum internals as soon as an opportunity is afforded

GENERAL:

- During the failure of direct water gauge, the boiler can be left in operation only
when the remote water gauges is in perfect condition. Repair of the direct water gauges must
be carried out as quickly as possible i.e. within 24 Hrs. The remote water gauge must be
observed with greater attention prolonged operation with one disconnected water gauge is not
permissible.

- In the case the safety valves blow up because of exceeding the maximum of
design pressure, it is necessary to bring down the pressure by reducing the firing
increasing the feeding and steam extraction and blowing down the boiler.

- In case of maximum temperature of outlet superheated steam is exceeded even

under full injection of desuperheater or if maximum permissible temperature
after the individual superheater is exceeding it is necessary to limit the firing and
to check up the feed water temperature.

- In case the quality of feed water of boiler water gets worse which might cause
dangerous pollution or damage to the tube walls it is necessary to reduce the
boiler output or to shut down the same if the condition does not improve.

- In case of unusual phenomenon the cases of which can’t be investigated &

removed during boiler operation the boiler must be shut down.
 43
The boiler must be shut down immediately in cases:

a) Water level in indicator continuously drops even after blowing & closure of
steam supply.
b) Failure of both water gauges
c) Failure of feed pumps.
d) Defect in feed piping.
e) Occurrence of cracking of leakage to such extent that it is not possible to
maintain the minimum level in the boiler even at increased feeding or that
might induce explosion or endanger the personnel.
f) Explosion furnace which had damaged the brick-work or pressure parts.

g) Fuel burning on the heat recovery areas accompanied by abnormal rise of

temperature of leaving there gases.
h) Deformation of pressure parts which might cause explosion and endanger the
personnel.
i) In all cases where there is danger of accident or occurrence of defect at long
time operation, e.g. at impermissible rise of superheated steam temperature.
j) Reliable operation of boiler cannot be ensured because of conditions like bad
visibility fire and danger of explosion.
Shutting down of boiler and reduction of its output in most of failures is
secured by automatic interlocking of the boiler.
 44

NORMAL SHUTDOWN TO COLD

The following procedure for normal shutdown are based on the assumption that the
unit is operating at full load on automatic control and that if is the intention to reduce the
pressure to zero & cool the boiler completely.

i) Gradually reduce the load on the unit, reduce the firing rate in line with the
decreasing steam flow. Allow the pressure to drop with the reduction in load to
accelerate cooling. Reduce the steam temperature at the rate prescribed.

Steam temperature control may be left on automatic until the point is reached
where better control can be obtained on manual.

ii) When the feeder rating on pulverisers is reduced to below50% put the fuel oil
gun in service. Place the pulveriser supplying the upper coal elevation on manual control
Gradually reduce the feeder rating. When minimum rating is reached close the hot air shut
off gate. Stop the feeder when the coal air temperature has dropped to 45 oC. It is advisable
to close the coal shut off gates above the feeder and run the spouts and feeders empty before
stopping the feeder. Keep the pulveriser running for about 2 minutes or until it is completely
empty. Then stop the pulveriser.

iii) As pulveriser are taken out of service, the secondary air damper control system
should close the associated wind box dampers and throttle other dampers as required to
compensate for the reduction in firing rate.
 45

iv) Take the second pulveriser out of service when the feeder rating on this
pulveriser reaches 40%

v) Operate all soot blowers.

vi) Reduce the airflow in line with fuel reduction until 30% of maximum air
flow is reached. Do not reduce the air flow below this rating until all fires are
out and the unit is off the line. To avoid firing instability during this period of
high relative air flow, the auxiliary air dampers at all elevations should open and
reduce the wind box to furnace differential pressure to its lower setting.

vii) Check the expansion equipment of the unit as load is being reduced.

viii) After the last pulveriser has been shut down, remove the fuel oil guns and the

ignitors from the service shut off cooling water to pulverisers. All fires should be
removed when the unit is off the line.
ix) Immediately after the boiler is off the line, open wide the superheater outlet
vents and drains. Open other drains in the superheater system as required for
further pressure reduction.
x) Close desuperheater-isolating valves.

xi) If during the shut down period, it

will not be necessary to enter the unit, a slow rate of pressure and temperature
decay may be desirable. This can be established as follows:

a) Purge the unit by running the induced draft and forced draft fans for at least five
minutes (30% air flow) after the fires are extinguished.

b) Reduce the airflow through the unit to a minimum; Keep the fans in service until
the unit has cooled to the desired temperature.

c) Keep the water level near normal in the gauge glass and make up as required.

d) Open the drum vents when the unit pressure has decayed to 2 Kg/cm2/gauge.

xii) It is desirable to accelerate the cooling process in order to permit entry into the
unit for maintenance proceed as follows:
 46
a) Purge the unit by running the induced draft and forced draft fans for at least five
minutes (at a minimum of 30% air flow after the fires are extinguished.
b) Continue running the fans to cool the unit at the desired rate.
c) Maintain the water level near normal in the gauge glass.
d) Open the drum vents when unit pressure has been reduced to 2Kg/cm2g.

xiii) If the boiler is to be emptied, the boiler water temperature should be reduced at
least 95oC before draining.

LIQUIDATION OF TYPICAL EMERGENCY

Boiler must be immediately Shut-Down

1. When the water level in the drum falls down below 10 to 200mm and level cannot be
seen in gauge glass while closing the steam VIV of G.I.G

2. When water level rises beyond visible level in the gauge glass.

3. When there is a break in the heating surfaces and impossible to maintain proper water
level.
4. When all gauge glasses fails.
5. When drum pressure rises beyond 124 atm (If safety valves had not opened and pressure
could not be reduced)
6. When boiler frame beams gets red hot and there is danger that livings will fall.
7. When soot and fuel particles start to burn in the boiler gas flues.
8. When there are cracks, break in pipes leaks in welding joints riveted joints in main
elements of the boiler (drum, header and piping) main steam pipeline.The boiler must be
shut down in all emergency cases that required shutting down boiler.

DIRECTION AND LIQUIDATION OF TYPICAL EMERGENCY IN BOILER

1. Full of partial load-off on compressors

 47
(By NH3 Plant)
A) Sign of load off on boilers
I) Sharp increase of steam pressure in boiler drum and steam pipe line (Right to
tripping of safety valves)
II) Additional rise of steam temp.
III) Falls in steam consumption
IV) Rapid rise in water level in boiler drum

B) ACTION OF BOILER HOUSE PERSONNEL

I) Reduce fuel supply to the boiler furnace to maintain boiler furnace and
readjusted adequate furnace droughts.

II) Control boiler feed water to maintain normal level]

III) Close/adjust/injection to de-superheater

2. ELECTRICAL SUPPLY TO BOILER AUXILIARY LOST

A) I) All the electrical motors of auxiliaries equipments will stop except those of
D.C supply equipments( D.C. supply equipments can be operate)
II) Flame in furnace dies
III) Boiler steam pressure drops.
IV) Steam consumption drops
V) Feed water pressure dropped for short term voltage dip, personal should not
interfere in their performance on dis continuation of auxiliary supply then
action to be taken (If interlock fails)
B) ACTION:

I) Electrical motors are switched off and shut the dampers of FD fans, hot air
line to mill, and partially ID fans, so as not to over load during further
starting up.
II) Close injection to de-superheater.
III) Drive manually APH motor.
IV) Take out partially scanner guns of all the corners.
V) Close manually main steam line valves to check further reduction of steam
or. Of B/r.
 48
VI) To follow boiler box-up operations.

C) DAMAGE IN HEATING SURFACE TUBE IN BOILER

i) Sharp noise of steam jet in furnace can heard.
ii) Difference in reading of steam and water flow, meters (Sharp increase of
feed water consumption)
iii) Rapped drop in water level to drum and steam pressure in boiler.
iv) Positive pressure in the furnace.
v) Steam and gaseous coming out of feed holes and cracks in boiler linings
etc.

B) ACTION WHEN WATER WALL PIPE DAMAGE (BROKEN)

i) Charge over the head to on other boilers.

ii)Shut down the furnace stop RCFs, mirls, fuel oil to furnace. FD fans and
leave ID fans in service until the main mass of steam and flows of furnace
removed.
iii) Stop feeding the boiler with water.
4. SIGN OF BREAK IN WATER WALL OR SUPER HEATER PIPE:

i) Sound of issuing system in the are of the furnace or SH.

ii) Unsteady combustion in furnance
iii) Difference in readings of steam flow meters and water flow metes.
The water issuing out of the water wall and steam from super heater tubes can
damage the neighboring tubes in short time. Hence damage and increasing time
eliminated by immediate shutdown.

5. A) SIGN OF DAMAGE IN ECONOMISER TUBES

i) Difference in readings of steam flow meters and water flow meters.

ii) Noise in the area of economizer.
iii) Drop in flue gas temp. out-let to economizer and air pre heater(APH)
iv) Positive pressure in the furnace(furnace dropt disturbance)
vi) Water leakage from economizer APH ash hopper to be water check.
Water issuing out of damage part in short time can damage neighboring pipes
increasing the size of damage and time required its elimination.
 49
B) ACTION OF BOILER HOUSE PERSONNEL

Immediate information should reach to chief of shift of boiler house and get the
instruction from him. In case, it is necessary to continue running the boiler, only
permissible in small leakages.

i) Carefully watch the water level in boiler and feed liner pressure. If
feed line pressure dropping and large difference in flow of water meter and steam flow
meter, then demand to start stand by feed pump.

ii) If water level is dropping even intersity the feeding and gets lower the mark and
signal a water escaped from the drum. If protection fails, shut down the boiler and stop
feeding. I.D fan is left in service till steam and gas flues are removed.

iii) Open super heat blow down and after 15-20 minutes, close the superheater blow
down.

6. ESCAPEMENT OF WATER IN THEBOILER:

A) REASONS

i) Lowered level gauge glasses are out of order.

ii) Water level instrument supply fails or defective instrument, impulse line
condensate escapement problems etc.
iii) Pressure in feed line gets low.
iv) Regulating valves in feed lien are out of order
v) Draining valves are leaking or passing heavily.
vi) Water wall piping or economizer pipings are damaged.
vii) Uncareful control from the side of operation.

B) SIGN OF WATER ESCAPMENT

If water level gets down the limit level then (a) water level low (b) water level very
low (boiler trip) (c) water level dangerously low indications will appear. Boiler will trip
in interlock if it is in service.

C) ACTION OF THE PERSONNEL

i) Make sure that water escapement took place, compare the water level
instruments reading at control room instruments and level gauge glasses.
ii) Compare the readings of steam and water flow meters.
iii) Quickly check the boiler drum gauge glasses.
iv) If there is no level in gauge glass.
 50
a) blow down the drains of G/G. (b) The close valve can kept open water valve,
and if after that water does not appear. The emergently shut down the boiler and
stop feeding (c) Open superheater blow down for 10-15 minutes and then close
it.

7. OVER FEEDING THE BOILER WITH WATER

REASONS: Over feeding the boiler with water taken place if

i) Uncareful control of the boiler feeding.

ii) Water level gauge glasses and control room instruments are out of order.
iii) Regulating valve of feed line is erratic functioning.
iv) Foaming and forcing of the boiler when increasing the phosphate valve.

If water goes to the steam line then it is dangerous to steam line and steam driven
compressors and turbine.

SIGN OF OVER FEEDINGS

i) Water level gauges goes beyond permissible limits

ii) Drop in SH steam temp.

ACTION OF BOILER PERSONALS

i) Quickly compare the readings of water level instruments in control room.

ii) Check up the temperature of super heated steam temperature at outlet of platon
and final super heaters.
iii) Check-up the gauge glasses of drums by blowing down drains and sea level in
Eye-Hye Gauge glass also,.
If checking proves over feeding these emergency shut down the boiler according
to emergency shut down instructions and inform to Ammonia Plant and shift in
charge boiler house.

8. INFLAMATION UNBRUNT CARRIED AWAY FUEL IN GAS FUELS OF

THE BOILER:

REASONS:- Incomplete burning of fuel will cause formation of shoot (during

Combustion of fuel oil) and carried away unburnt particles (cool dust) causes
 51
deposits of dry easy to in flame components in gas fuels of boilers ,wants
economizers, an air heater elements and ducts ,

Deposits of carried away combustibles may catch fire under definite conditions and
causes serious damage to boiler and elements.

SIGN OF INFLAMATION OF CARRIED AWAY FUELS

I) Sharp increase of exhaust flue gasses temperature of the boiler.

II)Flame and smoke coming out of boiler parts and black smoke from chimney
III) Rise in temp. of furnace.
IV) Heating up of causing exhaust flue gas ducts.
In case of rapid increase of temperature of flue gasacus by instruments and
visible inspection at site necessary.

a) Immediately urgently shut-down the boiler as per instruction with complete

stoppage of both FD fans ID fans.

b) Close completely the gas and air dampers.

c) Open the valves to supply steam through Fuel oil burners and fill the gas flue
with steam.

The droughts left and air supply to inflamed placed contribute burning and will
damage the equipments.

9. EXINCTION OF FLAME AND SUDDEN DIE OUT IN THE FURNACE

1. Extintiction of the flame in the furnance take place.

a) un even supply of coal dust to furnace. May be due to starting/stoppage of Raw
coal feeders, restriction of coal due to foreign material and mills problems.
b) Load of the boiler gets lower the limit ensuring steady ignition of coal dust
c) If air to the furec is increased sharply. ( If large air leaks-in)
d) If there is repturce in water wall pipes.
e) Oil support in the furnace cut-off

2. Extinction of flame and its subsequent firing up with oil burner with out
preliminary ventilation of furnace and with uninterrupted coal dust supply may
cause to explosion in the furnace chamber. It is practically important wran
burning coal with high volatile contents.
 52
3. If the flame dies out in he furnace and protection is switch on position (timing 5
seconds) protection gives out on impulse to shut-down the boiler.
4. If the protection failed. If form to shit-In charge and ammonia plant personnel to
unload compressors to desired to maintain steam pressure quantity.
a) Stop immediately fuel to furnace, switched off coal feeders, mills, oil
b) Take out boiler from steam common header
c) Interlock the furnace 5-10 seconds.
d) Boiler control charge over from auto to remote control.
e) If the explosion takes place in the furnace and gas flow makes round the
furnace check the condition of the furnace cl when its condition found O.K.
then close man holes and explosion doors that have got opened during
explosion. After that fire up the, then start pulverisers and charge over to coal
dust keeping oil support in service.

It should be kept in mind that, when fire dies out in furnace, sharp drop of water level
takes place but do not force feeding the boiler as water level may increase beyond limit
when the flame fires up again.

10. INCREASE IN SUPER HEATER STEAM TEMPERATURE AT SUPER HEATER

OUTLET

REASONS:-
1) Disturbance in regime of furnace
2) Increase in air excess in furnace
3) Unsatisfactory performance of spray injection control valve.
4) Furnace chamber got stagged
5) Decrease in differential pressure in the drum and after the super heater during low
steam load.
6) When spry line valves, nozzle etc. got checked or valves seat may get alom-
damaged. Then adequate quantity of spray water could not be supplied.
7) Sharp increase in amount of saturated stream from the boiler, taken for auxiliary
steam and soot blowing etc.
8) Drop in temperature of feed water.
 53
ACTION:-
IF INCREASE IN SH STEAM TEMP.
I) Operation care should be adopted after finding out the reason in disturbance of ragime
and corresponding operation will be done in particular case.
2. a) One should take care on injections regulation, differential temperature before and
after the injection, as well as steam temperature before injection.
b) If possible feed water temp. manage to be increased to normal value.
3. If steam temperature before injection gets above 460 oC (above normal) pay
attention to the burning in furnace and staging of water wall pipings.
4. Increase in temperature is dangerous to compressors turbine and super heater pipes.
Hence do every efforts to decrease SH temp to normal parameters. Change over
mills from top tyre to bottom tyres, reduce of mills and adjust secondary air
dampers for good quality of combustion in furnace. Accordingly inform to shift
Engineer.
5. Increase the quantity of injection water to steam
6. Do soot blowing of water walls and SH zones if necessary.

7. If above measures do not effect to decrease the SH Steam temp and reaches to
515oC and above and keeps during 3 to 5 minutes and continue to rise. The boiler
should be emergently stopped as per instructions.

8. INCRASE IN PRESSURE AT SUPER HEATER OUTLET

REASON:- Increase in super heater steam pressure

I) Partial loading of compressors

II) Fall steam loads off from Ammonia Plant
III) Wrong performance of fuel regulation to boiler furnace
IV) Uncontrollable of coal flow from Rek and coal dust from mill to furnace

ACTION:-

1. Find out the reason for increase of pressure of steams and act accordingly.
2. Cut out raw coal feeders and remaining also if necessary.
 54
3. Vent steam thro 710 valve to control pressure but practice to venting of steam
should be avoided so for as possible, due to reason of saving of raw materials and
cost.
4. To check the coal dust system and cut it out if necessary.
5. Check the fuel oil regulation system
6. If we are unable to control increasing of pressure and safety devices (drums & SH
safety VIV3 & venting system of SH Steam) fails to operate to control pre. Then
emergently shut down boiler.

OPERATION OF MILLS

PRINCIPLES

The coal-enters to the center of the revolving bow Centrifugal force causes the material
to travel toward the outer perimeter of the bowl where it comes between the grinding ring in
the revolving bow and the mills. The mills, which are spring loaded, impart the pressure
necessary for grinding. The partially pulverised material continuous up over the edge of the
bowl.

Air enters the mill housing below the bowl, in directed upward part the bowl passes
through the classifier vanes at the top of the iner cone. The air picks up P.F. and heavier
particles striking against the deflectors return the bowl and get crushed. Lighter particles
through classifier vanes is sucked by exhauster fan and goes to burner through distributor
pipes.

Any tramps iron or difficult to grind foreign material in the feed is carried over the top
of the bowl where it drops out through the air stream to the lower part of the mill housing.
Pivoted scrapers attached to the bowl hub sweep the tramp iron into rejecting sport.

Mill type-603 XRS-X-Capacity 26.8 T (Moro) 33KV Motor KW amps Fineness 70%
through 200 mesh screen.
 55

MILL OPERATION
CHECKINGS:

1. Get sure that the maintenance work on mill-exhauster Coal feeder or any of its motors
are not going on and work permits if any has been surrendered by the respective department
viz B/M, P/M & I/M.

2. Make sure that power is available in mill motor and coal feeder motor.

3. Make sure that interlock system of hot air gate mill feeder is O.K.

4. Make sure that feeder control-Hot air control & exhauster control drives are O.K.

5. Make sure about lubrication in mill gear housing and Roller journals housing PIV
gear housing and exhauster bearing etc.

6. Make sure about cooling water flow through mill gear housing oil cooler.
7. Make sure that adequate supporting flame is there in the furnace.

STARTING:-

Make sure that inset air supply is assured.

1. Start the mill, starting amps, and time. No load amps.

2. Check for any unusual behaviors if Viz., unusual vibration sound of any bearing parts
or any bill body.
3. Take care about furnace draft-Dr. level etc.
4. Open exhauster gate, vent will close.
5. Open hot air gate
6. Let mill temp. to go at about 65oC.
7. Establish adequate air flow through mill to lift the cola in the furnace.
8. Start the coal feeder.
9. Mill loading to be increased gradually by keeping watch on furnace draft-ST.
pressure and steam temperature mill temperature, mill amps. etc.
10. Normalise the mill loading by keeping watch on the mill motor amps.
11. Keep a continuous watch on milling equipments to run it smoothly.
Shut down (a) Establish oil support in the mill Group to be cut out.
b) Gradually reduce mill amps, feeder amps, mill temperature St. pressure, steam
temperature, furnace draft etc.
C. At no load stop coal feeder.
D. At no load of mill shut hot air gate and exhauster isolation gate.
 56

4. Keep watch on mill temperature to be below 60oC, stop mill.

Emergency shut down. If fire is lost or for any other kanor tourbles mill can be tripped
on full load. Automatically hot air gate and feeder motor will be tripped. Take care
before the mill started again to avoid any over loading.
MILL TROUBLES:-

1. Mill temperature high: Increase temperature air and decrease hot air. Also increase
coal feeding watch on mill amps.

2. Mill fire: Feed coal to the maximum extent possible by keeping watch on mill amps.
Open coal air damper now and reduce hot air. The fire should decrease or lost
otherwise shut down the mill and isolate the mechanically. Charge foam extinguishers
through manhole inside. Let the mill get cooled gradually.

3. High motor amps: Reduce coal loading. Observe for any unusual sound, vibration
for any foreign material and check rejection gate to be clear.

4. Mill puffing: Due to low air flow maintain minimum air flow to get required coal
air velocity.

5. Poor grindability: Due to warm out roller parts in bull ring, ring housing. Reducing
mill loading.
6. Excess rejection: Due to minimum air through the mill deracted capacity of the mill.

MILL INTERLOCKS:

1. There is an interlock system for protection of the mill groups and associated boiler.
a) If FD fan gets tripped the mill group trips.
b) If mill trips then coal feeder trips.
c) If hot air gate gets closed then coal feeder trips.
e) Either exhauster isolating gate or exhauster vent valve will open or close
alternative.

CHECKING DURING OPERATION:-

1. Check the bearing temperature and vibration.

 57
2. Check the recirculation oil flow.
3. Check the water flow and temperature.
4. Check/operate the rejection gate and remove the rejection time to time.
5. Constant water on normal sound, vibration of the running mill.
6. Check the roller oil level.
7. Watch on classifier temperature.
 58

SOOT BLOWER AND SOOT BLOWING SYSTEM

Steam at pressure of 113 Kg/cm2 (g) is tapped from Platen Super heater outlet header
(SHH2) for the purpose of Soot Blowing. The Pressure is reduced to 30 Kg/cm 2 (g) by
means of pressure reducing valves. The set pressure for safety v/v is 36 Kg/cm 2 (g). It is
capable of discharging the full capacity of the soot blowing steam. The pressure after
reduction valve is further reduced to operating pressure of individual Blower by adjusting at
the Soot Blower’s valve head.

During starting of soot blowing cycle, drain valves are to be opened widely and main
inlet valves are to be gradually opened. All the condensate are to be completely drained &
warmed. The drain valves are to be closed and the soot blowing operation is to be started.
Only one blower operates at a time. The sequence of operating of blower which is
predetermined is controlled by the soot blower control panel. After the soot blowing cycle is
completed the main inlet valves are to be cleaned and drain valves are to be kept open.

Medium of flow - Superheater steam

Before reduction - 116 Kg/Cm2 (g) at 440oC
After reduction - 40 Kg/cm2 (g) at 380oC
No. of long Retractable - 6
Soot blowers
No. of wall blowers - 24
No. of air heat blower - 1

LONG SOOT BLOWER IMPORTANCE INSTRUCTIONS FOR OPERATIONS

1. Do not operate with wet steam

2. DO not operate the same blower in quick Succession Minimum one hour period.
3. Take care to avoid extending the lance in to the boiler without bloning medium.
Subjecting the lance to temperature in excess of 550oC
4. Do not operate the soot blower without blowing medium during boiler operation.
5. DO not put the blower in to manual operation when the steam line in “ON”
6. Check lubricating oil level frequently.
7. Do not attempt maintenance work when power and/or blowing medium are “ON”
8. Observe all safety practice in use.
 59
9. Do not operate the soot blower with excessive steam leakage through pecking.
10. The hand cranks provided for emergency operation should be removed after their use
on the blower.

Blower No. Type Recommended set Pressure Kg/cm2(g)

25.26 T-30MKIE 11
27 to 30 T-30 NKIE 9
1 to 24 RWSE 10.5

WALL BLOWER

INSTRUCTIONS:-

1. Do not operate the wall deslagger with wet steam.

2. Donot operate the blowers adjacent to burner at loads less than 60% MCR.
3. Check nozzle position an alignment with respect to water wall after each shut-down of
the boiler.
4. When adjusting limit switches, switch off the power to the unit to avoid any injuries.
5. Before operating the blower made sure the drain holes in the motor frames point
downwards and are open.
6. Check lubricating oil level frequently.
 60

I.D & F.D. FANS

CHECK LIST FOR DO’S

1. Check for lubricant in bearing housing.

2. Check tightness of foundation bolts and other bot fixing impeller, bearing and
motor.
3. Check for operation of inlet guide vane unit. All the blades should be in correct
position.
4. Check for cored bearing clearance(Tube done by mechanical engg. deptt. in case
any work in done on bearing.
5. Ensure correct alignment of coupling
6. Ensure no foreign matter left inside the fan casing.(In case job was attended inside
the casing)
7. Check impeller clearances (To be done by mechanical engg. deptt.)
8. Check for correct direction of rotation of the fan, check the emergency off’ switch
for correct functioning.

II) START UP AND NOMRAL RUNNING

1. Close the inlet guide vanes of fan.

2. Close dampers at suction and delivery.
3. Check up for starting current and normal running current of motor viz-a-viz the
manufacturing specification.
4. Check for vibration and temperature of bearing.
5. Check for the lubrication of bearing housing and inlet guide vanes etc.
6. Check for the abnormal noise in the fan if any.
7. Check up the wire mesh provided forwards the suction side of FD fan and arrange
for the cleaning of the same periodically.
8. In case any abnormality in bearing temperature/motor temperature is noticed record
it properly and inform the shift in charge.
9. In case any leakages are noticed from oil seals or level indicator, inform the shift in
charge to get the same attended.
 61

10. Before starting of the fan make sure that the man holes of the fan, drain cover are
closed. No water traces should be there in the FD fan duct.
11. In case of ID fan any erosion notice in the inlet duct or caring should be properly
recorded and informed to the concerned supervisor for necessary action,.
12. Keep the inlet guide vanes and it’s actuating level clean and free from accumulation
of ash for smooth operation.

DONTS:-

1. Do not run the fan if any abnormality is observed during running.

2. Do not open inlet guide vanes and dampers under the motor correct reaches to
normal operating value.
3. Do not operate two fans(Especially) FD fans at low load.
4. Do not mix oil of different quality or lubricants from different supplier.
5. Do not run the fan if any foreign matter is left inside the casing.
6. Do not run the fan when heavy vibration are present. Allowable maximum
vibration valve is 120 microns single amplitude.

CHECK LIST:-

Date:-
Time:-
Atmosphere temperature(oC)
Temperature of medium(oC)
Temperature of radial by coupling side(oC)
Temperature of radial being impeller siade (oC)
Temperature of axial by (oC)
Inlet cane angle in % (Control room)
Inlet none openium in degree(oC)
Pr. Developed by fan (mmwc)
Motor current (%)
Flow
Vibration amplitude at the bearing in micron (m)
 62

AIR PREHEATER

The regenerative type of air heater absorbs waste heat from flare gas, then transfers to
incoming cold air by means of continuously rotating heat transfer elements of specially
formed metal plates. Thousands of these high efficiency elements are speed and completely
arranged with twelve sector shaped compartment of gradually divided cylindrical shell called
the rotor. The housing surrounding the motor 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 preheater and a gas passage through the other.

As the motor slowly revolves the mass of elements alternatively through the gas and air
passage, heat is absorbed by the element surfaces raising through the hot gas stream, then as
these same surfaces are carried through the air stream, then release the stored up
heat…….thus greatly increasing the temperature of the incoming combustion process air.

The complete rotor is supported by a thrust bearing(spherical rotor bearing. To guide

the upper end of the rotor, a guide tornion is bolted to the face of the rotor post. The position
of this trunnion is maintained by a radial guide bearing assembly. The bearing is water
cooled.

The oil level of the support bearing is to be maintained such that the rolling elements of
the bearing are submerged in the oil.

An auxiliary drive through an oil turbine is provided to keep the air heater running in
case of failure of motor. The air passes through solenoid operated valve.

The air heater is provided with soot blowing arrangement at the bottom part of the
rotor towards the flue path.

Water washing arrangement through nozzle is provided for cleaning during shut down.
 63

WORKING PRINCIPLE OF AN ELECTROSTATIC PRECIPITATOR

The precipitator essentially consists of two sets of electrodes viz collecting electrodes
and emitting(discharge) electrodes. The collecting electrode is made up of steal sheets,
pressed or rolled to a special profile. The emitting electrode is a thin wire, wound to a helical
form. These two electrodes are arranged in alternative rows. A unidirectional high voltage
from a rectifier is applied between these two electrodes, connecting its negative polarity to
the emitting electrodes and the positive polarity to the collecting electrodes, which are
earthed.

The dust laden flue gas from boiler passes between rows of collecting and discharge
electrodes. The gas molecules which are normally neutral ionized due to the presence of
high electric field. The positive charges of the ions created travel toward the discharge
electrodes and the negative charges (ions and electrons) towards the collecting electrodes. On
the way to the collecting electrodes, the negative charges get attached to the dust particles.
Thus the dust particles are electrically charged. In the presence of high electric field, between
the emitting and collecting electrodes the charged dust particles experience a force which
causes particles to more towards the collecting electrodes and finally get deposited on them.
A minor portion of dust particles which have acquired positive charges get deposited on the
emitting electrodes also. Periodically these particles are dislodged from the electrodes by”
rapping” the electrodes. The particles then fall into the ash hoppers at the bottom which is
cleared by the fly ash disposal system.

During the operation of precipitator, the applied voltage is reduced by potential drop
across the deposited dust layer on the collecting electrodes due to corona current flowing
through it. This results in reduction of working voltage which consequently reduces the
collection efficiency. In order to limit the build up of dusts on the collection electrode, the
layers are periodically dislodged by rapping mechanisms. The collection rate is high in the
first field have to be rapped at frequent internals, those in second and subsequent field at
progressively longer intervals. The operation of rapping mechanisms of different field at
correct frequencies is controlled by programmers in the auxiliary control panel.

The highest possible voltage for optimum collection efficiency is controlled by an

automatic voltage controller in the main control panel of the rectifier. The application of
highest possible voltage initials random flash over between the electrodes. Too high a flash
over ( spark) rate will not hnlp result in reduction of useful power and interruption
 64

of precipitation process but will also cause rapture of emitting electrode, due to electrical
erosion. A recommended flash over rate for optimum performance is found to be in the range
of 5 to 10 flash over per minute.

A fraction of the dust also gets deposited on the emitting wires, resulting in the
enlargement of the effective size of the wire which would inform suppress irrigation of gases
recovery for charging the dust particles. The effect is maintained by periodically dislodging
the dust particles by separate rapping mechanisms.

The performance of a precipitator is also closely related to even distribution of gas over
the cross section of the field. In order to minimize the re-entrainment of collected dust a gas
distribution system is provided in the inlet.

IMPORTANT INSTRUCTIONS ABOUT EPS

DO’S

1. MECHANICAL PARTS:-

1) Check up draining of ash from the hoppers at least once a shift of duration not
exceeding 8 hours.

Ensure that ash flows freely and the heaters and associated thermostats are
functioning properly.

2) RAPPERS:-

Ensure that the drives of the rapping mechanism of the bolts collecting and
discharge electrodes operate as details in the operation and maintenance manual.
Failure or improper operation of the rappers will lead to wastable and pool
performance of the precipitator. Check up the oil level in the geared motor.

3) INTERLOCKIN SYSTEMS:-

Ensure that the interlocks and keys provided are positioned properly for the
safety of the equipments and operating personnel.

ELECTRICAL PARTS:-

1) Record the readings (KV milliamps) on the rectifier panel at least once a shift.
 65
2) Adjust the power input from each rectifier control such that the optimum voltage
and current are maintained at “low spark rate not exceeding 5 sparks per minute
on average. Operation at high spark rate will lead to lowering the life of the
emitting electrodes by electrical erosion and consequent snapping.

3) Check up the operation of heating elements for hoppers, insulator housing

Etc. from the readings or the meters on the auxiliary control panels. Failure of
heating elements shall be immediately attended.
4) Ensure that all the controls meters and indicating devices on the control panels
of transformer-rectifier sets are in proper working condition. Any damage must
be set right by replacement.

The cause of failure of any field of the precipitator like snapping of wire, control
not working properly etc. must be reported to the engineer in charge of the
precipitator for timely action to set right and replaced the damaged components.

DONTS:-

1. Do not try to operate the rectier set at higher voltage and current when there is
excessive sparking.

2. Do not allow the hopper to get field up with ash. This may lead to eventual
shorting of the high voltage system and rendering the filed ineffective.

3. Do not energize any electrical field without the drive for the associated rapping
device functioning properly.

4. Do not fail to record faults or abnormal operations of the precipitator during shift
and bring it to the notice of the concerned engineer.

5. Do not fail to observe the general safety regulation pertaining to the high voltage
equipment.
 66

ASH HANDING SYSTEM

A. BRIEF DESCRIPTION OF THE SYSTEM

The complete ash handing system broadly consists of the following:-

1. Bottom Ash System.

2. Fly Ash System
3. Ash Slurry System
4. Ash Water, Service Water and Clarified Water System
5. Compressed Air and Fluidizer System

The complete bottom ash system shall be manually operated from the bottom ash local
control panel, one (1) No. to be provided for each Boiler Unit. However, the complete
fly ash system for all the three Units will be controlled from a common. Fly control
Panel.
1. BOTTOM ASH SYSTEM

The bottom ash resulting from the combustion of coal in the boiler furnace of each unit
will be collected in the respective water impounded self-supporting hopper. Once in a
cycle of eight (8) hours, the feed gate below each bottom ash hopper will be opened by
means of a 4-way manually operated valve. The ash together with stored water will be
discharged into a clinker grinder, where the larger ash lump will be ground and the
resulting ash slurry will conveyed through pipeline to disposal area via Hydraulic Jet
Pump located under respective clinker grinder.

2. FLY ASH SYSTEM:-

The fly ash system of all the three boiler Unit comprised two simultaneously of
working independent and parallel fly ash stream, namely,’ Stream-A’ and ‘Stream-B’
both of which will be provided with three (3) Nos. branch lines. One branch line
from each of three boiler unit will be connected to Stream-A while the other branch
line from each unit will be connected to Stream-B. Grouping of fly ash hopper outlet
of each boiler unit for connecting to one of the two branch lines will be done as
follows:-
i) Brach line to “Stream-A” Two ( 2 ) Nos. Economiser Hopper and three (3)
Nos. E.P. Hoppers are indicated in Single Line Flow Diagram.

ii) Branch line to ‘Stream-B” Two ( Nos.) Air Heater Hoppers and three (3 )
Nos. E.P. Hopper are indicated in single Line flow Diagram. Below each
fly ash hopper there will be an electro pneumatically operated ash
extraction valve and at the end of a branch line there will be an air-intake
check valve.
 67

The operation of the both fly ash conveying stream are identical. Two hydraulic
exhauster (one working and the other stand-by) is provided at the heard of each
stream. Once in a cycle of eight (8) hours shift, high pressure water supply will be
made to the hydraulic exhauster which will in turn crate necessary vacuum to establish
an air flow in the fly ash conveying pipe line. After the air flow is established, the ash
extraction valve below one hopper to the branch (with header valve open) will be
opened and ash will be discharge into the fly ash conveying air steam). The air and fly
ash mixture gets mixed with water in the exhauster and the resulting ash slurry (mixed
up with air) will be discharge in to the air separator. Air (from the ash slurry) will be
vented out in the air separator and ash slurry ( free of air) will be discharged directly
to the disposal. I are due to gravity head.

3. ASH SLURRY DISPOSAL SYSTEM:-

Ash slurry disposal system comprises two ( 2 Nos) disposal pipes one of which will be
working and the other will remain as standby. The system will be such that either
bottom ash of any boiler unit or fly ash system can be operated at a time through the
same disposal pipe line. Once in a cycle of 8 hours, bottom ash cleaning of the boilers
will be carried out one after another followed by the fly ash cleaning of all boilers.
Electro-pneumatic operated butterfly valves will be provided for isolating each
individual bottom ash and fly ash disposal lines from the main disposal pipe. A
universal cross over will be provided between the disposal lines so that the slurry can
be transported into disposal area by any of the liens.

4. ASH WATER, SERVICE WATER AND CLARIFED WATER SYSTEM

Three (3) Nos. ( 2Nos. working and 1 No. stand by ) high pressure ash water pumps
will be used for supply of water at required pressure to hydraulic exhauster, jet pump,
bottom ash hopper jetting nozzles.

Continuous supply of service water at required pressure shall be tapped from the
purchaser’s service water header to meet the requirement of bottom ash hopper, seal
through make-up and bottom ash hopper window spraying. For gland flushing of
clinker grinder during bottom ash cleaning, filtered water at specified pressure will also
be tapped from purchaser’s filtered water header.
 68

5. COPMPRESSED AIR & FLUIDIZER AIR SYSTEM

Compressed air in small quantity will be required for the control and actuation of
various equipment in ash handling system. This requirement will be met from
purchaser’s plant air supply header.

Two (2) Nos air blowers ( each 100% capacity, one working and one stand by)
have been provided in the ash handling system to supply fluidizing air to all fly
ash hopper, the air blower will maintain and air flow through the fluidizing pads
mounted on the respective hopper.

B. CONTROLS & INDICATIONS FROM CONTROL PANLES

1. BOTTOM ASH SYSTEM

One bottom ash local control panel shall be supplied for each of the boilers.
Each of the local panels will have the following:-

i) Start, stop, reverse push buttons for the clinker grinder motor.
ii) Indication lamps for above.
iii) Indication lamps for water line M.O. valve.
iv) Seal water line solenoid valve open/close-PB & II
v) B.A. cleaning over-PB:
vi) Indication lamps for slurry line solenoid operated valve in addition
necessary relays, fuses, space heater and mimic diagram.

2. FLY ASH SYSTEM

The following controls, indications and instruments will by provided for each of
Steam-A and Steam-B of fly as conveying system:-

i) System start/stop push buttons (P.B.)

ii) Sequence start PB with indication lamp (IL)
iii) Auto-jog Manual selector switch.
iv) ‘Jog’ – push button;
v) Header and hopper selector switches and indication lamps for all hopper
and header valves;
 69

vi) Water pressure normal –IL

vii) Air pressure normal-IL,
viii) Hopper empty-IL,
ix) Vacuum breaker open-IL,
x) Ash conveying line vacuum- Gauge and Recorder
xi) Annunciator windows.

In addition to the above, the following items of control and indications

will be provided on the panel to cater for the requirement of entire ash handling
plant operation:-

i) Ash water pumps- control switch/PB,IL and ammeters

ii) Fly ash anp bottom ash unit selector switch
iii) Unit- Shut down selector switches
iv) M.O. valve in exhauster water line-open, close and stop P3 and IL
v) Slurry line butterfly valve-open/close-PB & IL
vi) B.A. system slurry line isolating valve (common for 3 bottom ash Units)
open/close-PB & IL
vii) Motor operated water line valve for jet pump open, close and stop-PB &
IL
viii) Bottom ash slurry line butterfly valve, open/close-PB & IL
ix) Blower start/stop (for two blowers)-PB & IL
x) Bottom ash ON IL:
xi) Bottom ash Over-IL
xii) Bottom ash hopper designating (1,2 & 3)-IL
xiii) Annuciation Accept’ “Test and reset –PB;
xiv) Annuciation windows;
Compressed Air pressure gauge
xv) Ash water pressure indicator

C. PRINCIPLES FOR OPERATION

a) BOTTOM ASH SYSTEM

Prior to commencing bottom lash cleaning operation through local control

panel the following operations are required to be carried out from fly ash control
panel:-

1. Starting of ash water pumps

 70

2. The B.A. system slurry line isolating valve opened.

3. The selector switch for B.A. hopper units and fly ash system to be set to
the desired position to fix up the unit from whcich bottom ash cleaning is
to be started.
4. The slurry line butterfly valve for corresponding unit to be opened.
5. The M.O. water line valve for the corresponding unit to be opened.

After above operations are carried out necessary indication lamps on both the fly ash
and local control panels will be glowing and the following operations are to be
performed from the local control panel:

i) The seal water line solenoid valve to be opened.

iii) Clinker grinder to be started

Now the bottom ash cleaning is started by opening the feed gate through the 4-way
manually operated air line valve. In case the clinker grinder motor trips during ash
cleaning due to jamming of clinker, the grinder motor can be ‘Inched’ in reverse
direction from local control panel to remove jamming.

After the ash clearing for any B.A. hopper is over the following operations are to
be performed to stop ash cleaning.

1. The feed Gate to be closed.

2. Clinker Grinder to be stopped.
3. The ‘B.A.’ Cleaning Over’ PB to be pressed to give indication in the fly ash
control panel.

As soon as the operator of the fly ash control panel receive the indication of
‘B.A.’ Cleaning Over’ for that particular boiler, the M.O. water line valve and
sulrry line valve for that unit will be closed and ‘B.A. Unit Selector Switch’ will
be set by the next desired position. The ash cleaning for the next bottom ash
hopper will be carried out following the same sequence of operation as stated
above.

b) FLY ASH SYSTEM

First it is checked from the Control Panel Indication that bottom ash system is not
operation.

The necessary push buttons on the control panel is pressed to open the motor
operated water line valve in the exhauster water supply line and the solenoid
 71

operate valve in air separator slurry discharge line. The system start PB is to be
pressed.

IT may be noted that in the branch line of each boiler unit only one hopper valve
will operate at a time and corresponding branch header valve will remain open
during that period while the other branch header valves of the same stream will
remain closed.

Any one of the branch isolation valves (i.e. branch header valves) for each stream of
fly ash conveying header will remain open during fly ash clearing. Provision for
manual operation for hopper and header valves from control panel by means of
selector switches shall be incorporated in the system. It may be noted that both the
stream of fly ash system for each boiler shall operate simultaneously to keep the
slurry discharge lines full.

The fly ash system operation can be either AUTOMATIC SEQUEMETAIAL OR

REMOVE MANUAL

1. AUTOMATIC SEQUENTIAL OPERATION:-

When necessary to start the sequential system ‘sequence start’ push button is
pressed and step switch will rotate to the first position, opening the first hopper
valve and corresponding branch valve.

With hopper is emptied of ash, the vacuum drops to the empty hopper valve to
close the first vacuum switch(VS-I). Through necessary time delay relay (0-15)
secs. Approximately) sequence switch will index to the next position to open the
next hopper extraction valve in sequence and closed the first hopper extraction
valve.

If during the operation, the ash is discharged into the conveyor pipe line at too fast
rate, the vacuum rises above the normal conveying vacuum which causes vacuum
(VS-3) mounted on the fly ash line to operate to close the hopper extraction valve.
When overload condition is removed, VS-3 will reset to reopen the extraction valve
and ash conveying will continue.

In the event of “Plugged Hopper” condition i.e., when the ash arches over the
hopper outlet and does not flow, a vacuum switch (VS-2- operates through –a- time
delay (0-5 minutes approx) to energize necessary relays to give “Plugged Hopper”
alarm. After this alarm is annunciated the “Auto-Jog-Manual’
 72

switch is to be manually indexed to ‘Jog position. Now the system can be kept
hold for visual inspection or manual clearing of the plugged Hopper. On the other
hand if the ‘Jog’ push bottom is pressed in this condition, the step switch will step
to the next position. The operation selector switc h is then again put back to ‘Auto’
position and the step switch automatically continues to sequence thereafter.

When all the hopper of one unit is cleared the step switch will step to the next unit
by passing, if necessary, any shut down unit, guided by the ‘Unit Shutdown
Selector Switch’. Then the branch header valve and corresponding hopper valve in
sequence for the next running unit will be opened after closing of the earlier branch
header valve and hopper valve.

When the hoppers of all the remaining units are cleared in sequence, the step
switch will reset itself for next manual starting.

During the fly ash clearing operation one air blower will deliver fluidizing air
through the fluidizing pads for two hoppers (one from each stream) from which ash
is being discharged to the conveying pipe line.

2. REMOTE MANUAL OPERATION:

For remote manual operation of hoppers, first the “Auto-Jog-Manual Selector

Switch” is set at “Manual’ position.

Now the branch selection shall be done by “Header Selector Switch” and individual
hopper cleaning shall be carried out by setting “ Hopper Selector Switch” to
selected positions.

Vacuum switches VS-2 &3 shall be interlocked with manual clearing in the same
manner as described above for automatic sequential operation, and vacuum switch
VS-1 gives the empty hopper indication lighting an Amber Lamp “Hopper Selector
Switch” is to be to the next selected position thereby closing the early operating
valve and opening the selected hopper valve.

It shall be possible to carry cut this operation for all the fly ash hoppers at random.

The fluidizing blower and the solenoids in the fluidizing air pipe line shall be
interlocked with the fly ash system operation as described in automatic operation.
 73

D. SYSTEM INTERLOCKS:

1. INTERLOCKS BETWEEN BOTTOM ASH SYSTEM AND FLY ASH SYSTEM

AND BETWEEN BOTTOM ASH SYSTEMS OF DIFFERENT BOILER UNITS.

i) An interlocks shall be provided between Bottom ash slurry line isolating valve and
fly ash slurry line valve so that one valve cannot be opened till ht other valve is closed.

ii) While cleaning bottom ash system of any of the boiler units depending on the
position of the “Bottom Ash Unit and Fly Ash Selector Switch”, it is ensured that
cleaning of other BA Units and fly ash system cannot be carried out simultaneously.

2. BOTTOM ASH SYSTEM INTERLOCKS

i) The water line motor operated valve before jet pump cannot be opened unless the
respective slurry line butterfly valve is kept open.

ii) The motor operated valve will close immediately whenever the butterfly valve in
slurry line closes.

iii) The slurry line butterfly valve can be closed only if the respective waterline motor
operated valve is kept closed.

iv) Clinker grinder motor cannot be started unless the following requirements are
met:
a) Required water pressure available at the jet pump inlet, sensed via a pressure
switch PSW3.
b) Required water pressure available at the clinker grinder gland seal sensed via
a per pressure switch PSW4.

In the event of water pressure at the jet pump inlet and the clinker grinder
gland seal fall below pre-set valves the running grinder motor shall trip.

3. FLY ASH SYSTEM INTERLOCKS

i) Four (4) Nos pressure switches shall be provided in water line between
Hydraulic exhauster and the motor operated water line valve.

a) Out of these four, two (2) pressure switches (PSW1) shall be interlocked with
the vacuum breaker such that if adequate water pressure is not there the vacuum
 74
breaker cannot be closed to start fly ash cleaning. If the water pressure falls during
operation, the vacuum breaker will thereby stopping the fly ash cleaning operation.

b) Other pressure switches (PSW2) shall be inter locked with the fly ash system
such that if adequate water press is not there fly ash cleaning cannot be started and
conversely the system stops automatically when pressure drops below the preset valve.

ii) Two (2) Nos. air pressure switches PSA (one for each stream of fly ash)
connected to the compressed air line shall be so interlocked with the fly ash
system that the fly ash system cannot be started unless there is sufficient air
pressure. The fly ash clearing shall stop when the air pressure fails below set
pressure.
iii) Ash extraction valve shall open in sequence such that the ash hopper valve
nearest to the air intake valve shall/open first for each branch.
iv) Ash clearing will start from the economizer Hopper branch and end in E.P.
Hopper breach for stream A for stream B, the ash clearing will start from the Air
Heater Hopper branch and end in E.P. Hopper branch.
v) As the extraction valve of each of the hopper having fluidizing pads opens, its
respective fluidizer air valve shall also open to inject fluidizer air to the pads.
vi) The water line motor operated valve before exhauster cannot be opened unless
the fly ash slurry line butterfly valve is kept open.
vii) The motor operated valve will close immediately whenever the slurry line
butterfly valve closes.
viii) The slurry line butterfly valve can be closed only if the motor operated valve is
kept close.

E. ANNUNCIATION SYSTEM

a) BOTTOM ASH SYSTEM

Annunciation will be provided on the B A. Local Control Panel for tripping of
clinker grinder motor.

There will be an “Accept” push bottom in the Local Control Panel.

c) FLY ASH SYSTEM

1. This system shall have audio-visual alarming arrangement by means of

flashing of lamps along with sounding of a booter. There shall be accept,
reset and test buttons.

2. The Annunciation System shall remain effective even when the fly ash
system is operated manually.
 75
3. Individual annunciation windows with various engravings shall be provided
for the conditions as given in the ‘Annunciation List’ enclosed herewith.

BURNER CONTROL SYSTEM

1. GENERAL

This boiler is provided with 8 Nos. of oil burners, 4 Nos. of oil guns to fire light or
heavy oil in EL ‘AB’ and 4 Nos. of oil guns to fire heavy oil in EL’BC’. The light oil is used
for cold start-up and heavy oil for flame stabilization and load carrying upto 30% of the
boiler MCR. The light oil/burners can be put into operation after starting the corresponding
ignitors and proving ignitor flame.

2. BURNER CONTROL:

Oil burner system consists of the following field equipment. These are controlled from
the burner control panel located in the unit control room. The equipment send necessary feed
back and flame present signals to the control panel.

1. Ignitor oil trip valve 1 No.

2. Light oil trip valve 1 No.
3. Heavy oil trip valve 1 No.
4. Ignitor trip valves 8 Nos.
5. Burner trip valves 8 Nos.
6. Burner atomizing valves 8 Nos.
7. Burner scavenge valves 8 Nos.
8. Ignitor control boxes 8 Nos.
9. Flame scan head assemblies 8 Nos.

Ignitor oil, light oil and heavy oil trip valves can be individually operated from the
control panel. Ignitor trip valves/Burner trip valves and Burner scavenge valve can be
operated in pairs from the control panel.

Heavy oil manual valve, light oil manual valve, atomizing steam manual valve and atomizing
air manual valve before eadh burner in EL’AB’ have to be operated manually as per fuel
selected in the control panel.

Burner control panel consists of 3 sections: one for common equipment. AC and DC supply
changeover system and annunciation system: second for control of individual burner
equipment in EL’AB’ and annunciation system; third for control of individual burner
equipment in EL’BC’ and annunciation system.
 76

II) BURNER CONTROL PANEL CONSISTS OF THE FOLLOWING COMMANDING

EQUIPMENT:

A SWITCHES & PUSH BUTTONS

1. AC Supply ON-OFF switch (S1)

2. DC Supply ON-OFF switch (S2)
3. AC Supply selector switch (S3)
4. Burners emergency trip push button (PB10, PB 11)
5. IOTV close luminous push button (PB1)
6. IOTV close luminous push button (PB2)
7. IOTV close luminous push button (PB3)
8. LOTV close luminous push button (PB4)
9. HOTV close luminous push button (PB5)
10. HOTV close luminous push button (PB6)
11. Alarm accept luminous push button (PB7)
12. Alarm test luminous push button (PB8)
13. Fault reset luminous push button (PB9)
14. Ignitor 1 & 3 pair stop push button (13PB1)
15. Ignitor 2 & 4 pair stop push button (24PB1)
16. Ignitor 5 & 7 pair stop push button (57PB1)
17. Ignitor 6 & 8 pair stop push button (68PB1)
18. Ignitor 1 & 3 pair start push button (13PB2)
19. Ignitor 2 & 4 pair start push button (24PB2)
20. Ignitor 5 & 7 pair start push button (57PB2)
21. Ignitor 6 & 8 pair start push button (68PB2)
22. Burner 1 & 3 pair stop luminous push (13PB3)
button
23. Burner 2 & 4 pair stop luminous push (24PB3)
button
24. Burner 5 & 7 pair stop luminous push (57PB3)
button
25. Burner 6 & 8 pair stop luminous push (68PB3)
button
26. Burner 1 & 3 pair start luminous push (13PB4)
button
27. Burner 2 & 4 pair start luminous push (24PB4)
button
 77
28. Burner 5 & 7 pair start luminous push (57PB4)
button
29. Burner 6 & 8 pair start luminous push (68PB4)
button
30. Burner 1 & 3 scavenge ON push button (13PB5)
31. Burner 2 & 4 scavenge ON push button (24PB5)
32. Burner 5 & 7 scavenge ON push button (57PB5)
33. Burner 1 & 3 scavenge ON push button (68PB5)
34. Burner 1 & 3 L.O. firing selection (13PB6)
luminous push button
35. Burner 2 & 4 L.O. firing selection (24PB6)
luminous push button
36. Burner 1 & 3 L.O. firing selection (13PB7)
luminous push button
37. Burner 1 & 3 L.O. firing selection (24PB7)
luminous push button

B. INDICATING LAMPS:

1. RED LAMPS TO INDICATE:

a. AC-1 supply ‘ON’ indication (1ACL)

b. AC-2 supply ‘ON’ indication (2ACL)
c. AC-1 supply ‘ON’ indication (1DCL)
d. AC-1 supply ‘ON’ indication (2DCL)
e. Panel-1 heater ‘ON’ indication (HL)
f. Panel-2 heater ‘ON’ indication (HL2)
g. Panel-3 heater ‘ON’ indication (HL3)
h. Master fuel relay ‘ON’ indication (L2)
i. Ignitor fan ‘ON’ indication (L3)
j. Scanner fan ‘ON’ indication (L4)
k. Gun-1 in firing position indication (1L1)
l. Gun-2 in firing position indication (2L1)
m. Gun-3 in firing position indication (3L1)
n. Gun-4 in firing position indication (4L1)
o. Gun-5 in firing position indication (5L1)
p. Gun-6 in firing position indication (6L1)
q. Gun-7 in firing position indication (7L1)
r. Gun-8 in firing position indication (8L1)
 78

2. GREEN LAMPS TO INDICATE :

a. All ITVs closed indication (L1)

b. Compressed air pressure ‘OK’ indication (L5)
c. L.O.pressure ‘OK’ indication (L6)
d. H.O.pressure ‘OK’ indication (L7)
e. Elevation load more than 30% MCR indication (L8)
f. H.O. temperature ‘OK’ indication (L9)

3. WHITE LAMPS TO INDICATE

a. Burner pair 1&3 scavenge complete indication (13 L1)

b. Burner pair 2&4 scavenge complete indication (24L1)
c. Burner pair 5&7scavenge complete indication (57L1)
d. Burner pair 6&8 scavenge complete indication (68L1)

4. ANNUNCIATION WINDOWN TO INDICATE;

1 Elevation ‘AB’ flame failure (1FL)

2 Elevation ‘BC’ flame failure (2FL)
3 Heavy Oil Pressure low (3FL)
4 Light Oil Pressure low (4FL)
5. Heavy oil temperature low (5FL)
6 L.O./Air differential pressure low (6FL)
7 H.O./Steam differential pressure low (7FL)
8. Compressed air pressure low (8FL)
9 Ignitor oil pressure low (9FL)
10. Ignitor 1/3 failed (13FL)
11 Ignitor 2/4 failed (24FL0
12 Ignitor 5/7 failed (57FL)
13 Ignitor 6/8 failed (68FL)
14 Scanner -2 failed (1FL1)
15 Scanner –2 failed (2FL1)
16 Scanner –3 failed (2FL1)
17 Scanner –4 failed (2FL1)
18 Scanner –5 failed (2FL1)
19 Scanner –6 failed (2FL1)
20 Scanner –7failed (2FL1)
 79
21 Scanner –8 failed (2FL1)
22 Burner-1 auto trip (1FL1)
23 Burner-2 auto trip (2FL1)
24 Burner-3 auto trip (3FL1)
25 Burner-4 auto trip (4FL1)
26 Burner-5 auto trip (5FL1)
27 Burner-6 auto trip (6FL1)
28 Burner-7 auto trip (7FL1)
29 Burner-8 auto trip (8FL1)

III TESTING THE INITIAL CONDITION:

1) Select ACI supply by supply selection switch (S3), Switch ‘ON’ AC & DC
supply system switches (S1,S2). Availability of supply will be indicated by the
burning of red lamps (1ACL, 1DCL).

2) Completion of boiler purge and ‘No boiler trip’ condition is indicated by the
burning of green lamp (L2)

3) Running condition of ignitor fan is indicated by the burning of red lamp (L3)

4) Running condition of scanner fan is indicated by the burning of red lamp (L4)

5) Heavy oil (H.O.) temperature OK is indicated by the burning of green lamp (L7)

6) Closed condition of all ignitor trip valves is indicated by the burning of green
lamp (LI)

7) Compressed air pressure ‘OK’ is indicated by the burning of green lamp L5.

8) Light oil pressure ‘OK’ is indicated by the burning of green lamp L6.

9) H.O. Pressure ‘OK’ is indicated by the burning of green lamp L7.

10) Check-up whether the annunciation system and other operation indicating lamps
are functioning alright by pressing the system test push button PB8.

IV STARTING & TRIPPING CONDITIONS FOR ALL THE TRIP VALVES.

A. IGNITOR OIL TRIP VALVE:

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1. The following conditions should be satisfied to open the ignitor oil trip valve IOTV.

a) Boiler master fuel relau energized (MFR)

b) Compressed air pressure ‘OK’ (set at 4.5 kg/cm2)
c) Light oil pressure ‘OK’ (Set at 12.5 kg/cm2)
d) All ignitor trip valve closed.
e) Ignitor fan running
f) IORV open push button in pressed position.

2. Any one of the following condition should be present to trip/close IOTV.

a) Emergency trip push button in pressed position.

b) Boiler MFR is de-energised
c) Ignitor oil pressure low for more than 2 secs and any ITV open (Set at 9.1 kg/cm2
d) Compressed air pressed ‘low (Set at 4 Kg/cm2)
e) Ignitor fan tripped
f) IOTV close push button is pressed position.

B. LIGHT OIL TRIP VALVE.

3. The following conditions should be satisfied to open LOTV

a) Boiler MFR energized.

b) Light oil pressure ‘OK’ (Set 12.5kg/cm2)
c) All burner trip valves in elevation ‘AB’ in closed position or all burner L.O.
manual valves closed.
d) LOTV open push button in pressed position.

4. Any one of the following conditions in pressed position:

a) Emergency trip push button in pressed position

b) Boiler MFR de-energised.
c) DP of flight oil and atomizing air low for more than 2 secs. and eny any
elevation ‘AB’ burner trip valve not closed any any light oil manual valve not
closed.
d) LOTV closed push button in pressed position.
 81

A. HEAVY OIL TRIP VALVE:

5. The following conditions should satisfied to open HOTV.

a) Boiler MFR energized or heavy oil manual recirculatrion

valve in (HORCMV) open position.
b) Heavy oil pressure OK (set at kg/cm2)
c) Heavy oil temperature ‘OK’ (Set at oC)
d) All burner trip valves in elevation ‘AB’ closed/all H.O. manual valves in EL ‘AB’
closed and all burner trip valves in EL ‘BC’closed.
e) HOTV open push button in pressed position.

6. Any one of the following condition should be present to trip/close HOTV.

a) Boiler MFR is de-energised HORCMV is in closed position.

b) Emergency trip push button in pressed position and HORCMV
c) HO/Steam DP ‘low’ or HO pressure low for more than 2 secs. and any burner
trip valve not closed in EL ‘BC’ any burner trip valve in EL ‘AB’ not closed and
any burner H.O. manual valve in EL ‘AB’ not closed.
d) Heavy oil temperature low any burner trip valve not closed in EL ‘BC’ any
burner trip valve in EL ‘AB’ not closed and any burner H.O. manual valve in EL
‘AB’ not closed.
f) HOTV close push button is pressed position.

B. IGNITOR PAIR:

7. Ignitors at four corners of an elevation AB/BC start in pair(i.e. 1 & 3/2 & 4/5 & 7/6 &
if the following conditions are satisfied.
a) Ignitor oil trip valve is in open position.
b) Ignitor flame not proved.
c) ITV in closed position.
d) Ignitor pair start push button in pressed position.

8. Any one of the following conditions should be in present position:

a) MFR de-energised
b) Emergency trip push button in pressed position
c) Ignition time elapsed and flame not proved.
 82

d) LOTV closed .
e) Ignitor pair stop push button in pressed position and elevation load greater than
30% and both burner pair selected on HO and all four BTVs of the elevation open.

f) Ignitor pair stop push button in pressed position and corresponding scavenge trip
valves open and scavenge time elapsed or corresponding scavenge trip valves closed.

NOTE:-
1.) Ignitors should not be stopped while firing L.O. in EL ‘AB’ or HO
in EL ‘AB’/’BC’ when the elevation load is less than 30%

2.) For stopping ignitors under the above conditions, the corresponding burners shall be
stopped for normal shut down.

3.) When ignitor start command is initiated, corresponding ITV’s open and simultaneously
corresponding timer and ignition transformer are energized. Timer and ignition
transformer de-energise once the flame is proved within the pre-set time. If flame is not
proved within pre-set time, ignition transformer will de-energise and ITV will also
close.

4.) Diagonally opposite corner ignitor form a pair.

E. BURNER PAIR START :

9. The following conditions should be satisfied to start the burners in pair :

a) Boiler MFR energized.

b) L.O.firing selected in EL ‘AB’ and LO manual valve and atomizing air manual
valve of the pair selected for L O firing open and H O manual valve steam
atomizing manual valve of the pair selected for L.O firing closed.
OR

H.O.firing selected in EL ‘AB’ and HO manual valve and atomizing steam

manual valve of the pair selected for H O firing open and L O manual valve and
air atomizing manual valve of the pair selected for H.O firing closed.

NOTE:

For EL’BC’ corresponding pair of HO manual valve an atomizing steam manual

valves are to be ensured open manually since only HO firing
Is envisaged in EL’BC’.
 83

c) LOTV/HOTV open when LO or HO selected (For EL ‘AB’ only – For EL

‘BC’ HOTV open).
d) Associated ignitor in service.
e) Burner scavenge valve closed.
f) Burner gun in firing position.
g) Burner atomizing valve open.
h) Burner tilt horizontal or any RC feeder on.
i) HORCMV closed when HO selected.
j) Burner pair start push button in pressed position.

10. Any of the following conditions should be present to trip the burner pair:
a) Boiler MFR energized.
b) Emergency trip push button in pressed position.
c) LOTV/HOTV closed when LO/HO is fired (For EL ‘AB’ only – For EL
‘BC’ HOTV closed).
d) Associate ignitors not in service and less than 2 out of 4 scanner show
flame.
e) Associate ignitor not in service and EL load less than 30% and adjacent
less EL feeders not in service.

f) Burner scavenge valve not closed.

g) Burner atomizing valve closed.
h) Burner gun not in firing position.

i) Corresponding LO/HO manual valve closed or HO/LO manual valve not

closed when LO/HO firing selected ( for EL’AB’ only)

j) Corresponding atomizing air/steam manual valve closed or steam/air

manual valve not closed when LO/HO firing selected (for EL ‘AB’ only).

k) HO/LO selected when firing LO/HO ( for EL ‘AB’ only)

l) HO recirculation manual valve opened when firing HO in any burners.

m) Burner pair stop push button in pressed position.

NOTE:

1) When burner pair start push button is pressed, one of the two burners will start
and the second burner will start after a time delay of 15 secs.
 84
2) Burner pair start push button is common for two burner trip valves and burner
atomizing valves. When the push button is depressed, first the burner atomizing
valve will open and then the burner trip valve.
3) Burners in opposite corners from a pair.
4) If one of the ignitor fails, only the corresponding burner stopped.

F. SCAVENGE:

11. The following conditions should be satisfied to open burner scavenge valves in
pair:
a) Boiler MFR energised
b) Ignitor fan running.
c) Burner trip valves closed.
d) Burner trip valves closed.
e) Associate manual valves in atomosing air or steam line to burners open.
f) Associate burner atomizing valves closed.
g) Associate burner scavenge valves closed.
h) Associate burner guns in firing position.

V. OPEATION PROCEDURE:

A. SUPPLY CHANGEOVER SYSTEM:

Automatic supply change-over system is provided in the control panel for both AC &
DC supplies. Necessary interlocking systems and indicating lamps for this system are
incorporated in this panel.

B. SEQUENCE OF OPERATION:

1) Select position ‘ON in the AC & DC supply switches S1 & S2 and select
position AC1 in switch S3. The supply availability is indicated by the burning
of the red lamps.

2) Check up whether all initial conditions are OK as under section III.

3) Check-up whether all initial conditions required to open ignitor oil trip
valve (IOTV) are satisfied Press the LOTV open push button PB2 IOTV
solenoid energises through contacts of R2A (MFR energized), R3
(Ignitor fan ‘ON’) R5 ( compressed air pressure OK), PB1 (IOTV close
PB), PB2 (IOTV open
 85

R6 (L.O pressure OK) and R19 (All ITVs closed) and holes on through contacts
of R2A, R3, R5, PB1, R4), R4OA (IOTV open) and R8 (IO pressure OK) or
R19. The open condition of the valves is indicated by the glowing of the red
lamp L5.

5) After opening IOTV, check up where all initial conditions required for starting
the ignitors are satisfied. Press ignitor pair 1 & 3 start push button 13 PB1,
13R1 and 13T1 energise. Through contacts of 13R1 (ignitor start impulse),1R1
(ignitor flame not proved) and IR3 (no trip impulse available) ignition
transformer energises. At the same time through contacts of DP switch and
13R1 (line 275 and 272) ignitor trip valve open coil gets supply and starts
opening. When ignitor trip valve starts opening, limit switch ‘CLS’ changes over
and coil gets supply through 13R1 and CLS (line 269). When ITV completely
opens OLS changes over and if DP and flow are O.K. the relay IRI energises
indicating ignitor is on. Likewise ignitor 3 comes into service. Similarly any
ignitor pair can be put into service by pressing corresponding ignitor pair start
push button. If the ignitor flame proven condition does not come within the
preset time, 13 R2 energises which in turn energises trip relay 1R3. Now through
contract of 1R3 (line 270) and CLS ignitor trip valve close coil energises and
ITV starts closing. When it completely closed, limit switch CLS changes over
and relay 1R15 energises indicating ignitor trip valve closed condition.

5) Check-up whether all initial conditions required to open light oil trip valve
(LOTV) is OK. Press LOTV open push button PB4. LOTV solenoid energises
through contacts of R2A (MFR energized), PB3 (LOTV close PB), PB4 (LOTV
open PB), R6(L.O. pressure OK), 1R10 to 4R10 (BTVs closed in EL’AB’) or
1R12 to 4 R12 (LOMVs closed) and holds on through contacts of R2A, PB3
R17 (LOTV open) R41 and R14 (Air/oil DP OK) or R41 and 1R10 to
4R10/1R12 to 4R12 lamp PB4 glows indicating LOTV open condition.

6) Before starting the oil burner, the respective gun to be manually brought to the
advanced position and the oil gun should be properly purged.

Check-up whether the initial conditions required for opening the scavenge valves
are satisfied. Press the burner scavenge pair start push button (13 PN5).
Contacts R2B (MFR energized)13R5/3R9 burner not started/Burner scavenge
not complete),1R10 (BTV closed) and 13R8(Auto/Manual scavenge start
impulse) close or remain closed depending on the initial condition of the
contracts. At this point, the circuit branches out into two, one going to energise
the atomizing valve solenoid (BaV1) and the other going to energise the
scavenge valve solenoid (BSV1). The BAV1 energises through 13R5 (burner
pair not started) and 1R6
 86

(BTV not energized) after which the BSV is energized through 1R2 (associate ignitor
on), 1R13/1R14 (associate steam/air manual valve closed). 1R4(gun in firing position)
and 1R7 (BAV open). The scavenge and atomizing valve for Burner-3 also open
simultaneously in a similar fashion Steam/Compressed air is allowed through the oil
gun for the present time. Purge complete annunciation and lamp come on after
completion of the gun purge cycle To close the burner scavenge valve either the burner
pair start push button must be operated or the burner gun must be brought back
manually from the advanced position in case the burners are not to be put into service
immediately.

NOTE:

Burner gun should not be kept in advanced position for long time in the hot furnace
unless a cooling medium (steam/air) is available. Otherwise the burner tip will get
spoiled.

7) Select LO firing, by pressing 13PB6. Check up whether all initial condition required to
start the burner with light oil are satisfied. Press burner pair start push button 13PB3.
Burner atomizing valve solenoid energises through the contacts of R2B. 13R12A,
13R12, R17,R22, 13R5, 13R4 and 1R8. After this burner trip valve solenoid energises
thro’ R2B, 13R12A, 13R12, R17, R22, 13R5, 13R4, 13R6, 1R2, 1R4, 1R7, BSV1
CLS, 13R12, 1R11, 1R13, 1R12, 1R14. The light oil is atomized as long as L.O.
pressure is OK and burner is aided by ignitor flame. After a time delay Burner-3
comes into service. Lamp 13PB4 glows indicating Burner-1 and 3 are in service.

Similarly next pair of burners can be brought into service in EL’AB’

8) With 4 L.O. burners and 4 ignitors in service, steam (required for HO heating) shall be
admitted and the HO pumpoing and heating units shall be prepared for HO firing.
With the above, H.O. at boiler front will be available. Check-up the pressure and
temperature of H.O. be for HOTV.

Open the heavy oil re-circulation manual valve. Check up whether intial conditions
required to open HOTV are satisfied. Press HOTV open push button. HOTV open
solenoid energises through R2, PB5, PB6, R12, R9 abd 1R10 to 8R10. HOTV open
lamp PB6 glows. Allow the HO to circulate in the line till the temperature in the
temperature gauge before HOMRC valve (HOT) is observed at 100oC. Close the H.O.
manual recirculation valve.
 87

9) Check-up whether all initial required to start the burner in EL’BC’ are satisfied. Press
burner pair start push button (57PB8). Burner-5 atomising valve open and
subsequently Burner-5 trip valve opens. The HO burns with the ard of ignitors. After a
time delay Burner-7 atomising valve and burner trip valve open. Lamp 57PB4 burns
indicating Burner 5 & 7 are in service.

10) Changing over L.O. firing to H.O. firing in Elevation ‘AB’.

Press burner stop push button of the burner where L.O. is fired. Corresponding BTV
closes. Close LO and air atomizing manual valve. Discharge and remove oil gun.
Change the 15% MCR to 30% MCR HO tips. Reintroduce and engage the oil gun.
Open HO and steam atomizing manual valves. Select H.O. by pressing 13PB7/24PB7.
Press burner start push button. The BTV opens and the flame is established aided by
ignitor flame.

11) When all burners are in service and if there is an indication for elevation load greater
than 30% (L8), the ignitor may be removed from service.

12) AUTO SCAVENGING:

To stop oil burner, ignitor must be put in service if not in service. Now press burner
stop push button, BTV closes. Then burner atomizing valve and burner scavenge valve
open and admit steam/compressed air to clean the gun. The remnant oil in the gun is
burnt off by the ignitors. After preset time the ignitor is stopped, the flow of
steam/compressed air is continued through the gun and purge complete light/alarm
comes. Reset the alarm. Retract the gun manually. On retraction burner atomizing
valve and scavenge valve close.

Remote manual purging of the gun may be performed by pressing scavenge start PB as
under section V item 6.
 88

INTERLOCK SYSTEM

I. INDUCED DRAFT FANS (ID FAN)

A STARTING :- I.D. FAN can be started if the following conditions are satisfied.
a) Regulating vane in minimum position.
b) Start signal initiated.
c) Outlet & inlet dampers are in close position.

B TRIPPING :- I.D Fan can be tripped if any one of the following conditions exists
a) Winding temp. high temp. trip setting is 1050 C
b) Electrical protection operated :
i) Over load
ii) Instantaneous short circuit
iii) Instantaneous earth fault
iv) Instantaneous unbalance
v) Delayed under voltage

c) Trip signal initiated.

C LOCAL CONTROL :- I) I.D fan can be started from local if L.R. switch is selected
local by turning T-N-C switch to close position.
II) I D fan can be tripped from local by turning the T-N-C switch to
trip position.

II I.D. FAN INLET AND OUTLET DAMPERS

a) To close automatically when corresponding I D fan trips.

b) To open automatically when both I D fan trips.
c) To open or close by pressing open or close PB if manual position is selected.

III I. D. FAN REGULATING VANES

INTERLOCKS :-

a) To open wide automatically when both I.D fans are tripped.

b) To come to minimum position automatically when corresponding I D fan trips
and disconnect auto signal.
c) To connect auto signal when fan is running.
d) To become stay put under air failure.
 89

IV Dampers before/after electrostatics precipitators

No interlock is invisaged dampers can be open/close by push button.
F.D. FAN
INTERLOCKS

I STARTING

F.D. fan can be started if the following conditions are satisfied.

a) Direct or cross connections ID fan is running.
b) Inlet and outlet dampers of corresponding ID fan are open.
c) Any one set of the flue gas dampers before and after EP are open.
d) Regulation vanes are in minm position.
e) Start signal initiated
f) F.D. fan outlet damper in close position.
II TRIPPING

FD fan motor will be tripped if any one of the following condition exist.
a) Corresponding (selected) ID fan tripped
b) Motor winding temperature high setting 1050 c
c) Electrical protection operated.

III F.D FAN OUTLET DAMPERS

INTERLOCKS :-

a) To close automatically when corresponding fan tripped.

b) To open wide automatically when both FD fan tripped.
c) To open automatically when corresponding FD started after some time-
delay.
d) Remains as it is on air failure.
e) To open/close by pressing open/close PB if manual position is selected.

IV F.D. FAN REGULATION VANE

a) To minm position automatically when corresponding FD fan trips Φ dia
connected.
b) To open wide automatically when both FD fans tripped.
c) To connect auto control when fan is running.
d) Remains as it under air failures.
 90

IGNITOR FAN

STARTING :-

a) Fan can be started from UCB by pressing start push button.

b) Fan can be started from local by pressing start push button if load operation is
selected.

TRIPPING :-

Motor can be tripped if any of the following conditions exists.

a) Stop push button of UCB/local pressed.
b) Overload protection acts.
c) Both FD fan tripped.

SCANNER FAN

1. AUTO STARTING

Fan starts running automatically when any of the following conditions exists.
1) Furnace/scanner outlet DP (differential pressure) below 2.2” W.C.
2) Both FD tripped and emergency damper open.

2. MANUAL STARTING ;-
Fan starts when the following conditions are satisfied.

1) Any one of the F.D fan running and ignitor fan running.
OR
Fan not running and emergency dampers open.
2.) Start push button pressed.

TRIPPING :-
Fan trips if any one of the condition exists.
1) Stop P.B.at UCB /local pressed.
2) Scanner to furnace D.P. is above 4.5” W.C (High load)
3) Over load protection acted.
 91

SCANNER FAN EMERGENCY DAMPLR

A. control at U.C.B.
i) Automatic selector switch – 1 no.
ii) Open-close selection switch – 1 no.
iii) Open-close indication lamp – 2 no.

B. INTERLOCK
i) Damper can be open and close by pressing open/close PB if manual position
selected.
ii) Damper opens automatically if both F.D. trip.
iii) Auto closing in the event of one of the F.D. fan is running.

MFR SYSTEM

A. CONTROL AT U.C.B.
i) Purge start push button
ii) Reset push button.
iii) Emergency trip P.B.
iv) Lamps for (1) purge progress.
(2) Purge required
(3) Purge complete.
(4) M.F.R. On.
Purge interlock is O.K.

B INTERLOCK :-
Purge cycle can be started provided following conditions are satisfied.
i) At least one set of I.D & F.D. are running.
ii) Purge air flow more than 30% MCR quantity.
iii) All auxiliary dampers not closed (positioned to ½” furnace/wind box (D.P.)
iv) Ignitor oil trip V/V closed.
v) All burner trip V/V closed
vi) All mills proven off.
vii) Furnace draught normal, (-3 to 10 mm w.c.)
 92

Drum level normal

viii) M.F.R. de-energised
ix) Ignitor fan running
x) Light oil pressure O.K.
xi) Compressed oil pressure O.K.
xii) Heavy oil trip V/V closed
xiii) Light oil trip V/V closed
xiv) All hot air gate closed

When all the above conditions are satisfied “Ready for Purge” Lamp shall glow. Purge
shall be started by de-pressing “Purge start PB” and continued at least for 5 minutes.
(0-15minutes adjustable) once the purge is completed
Purge complete lamp shall glow and simultaneously M F R energized

C MFR de-energised to trip the boiler when any of the following conditions exists.
i) Both F.D. fan tripped or both I.D. fan tripped
ii) Drum level very low -200 M.M.W.C.
iii) Furnace draught very high
iv) All mills tripped/Heavy oil ignitor oil and light oil trip valves closed. If 3 out of 4
ignitors are proven in any elevation.
v) Emergency trip P.B. pressed.
vi) Air flow less than 30%
vii) Scanners show no flame (Both elevation scanner show min 2 out of 4 scanners. No
flame) and 3 out of 4 ignitors not in service

MILLS

D) STARTING
Mill can be started when followed conditions are satisfied.
i) M.F.R. energized
ii) Exhauster discharge V/V open
iii) Hot air control damper in minimum position
iv) Hot air shut of gate closed.
v) Tempering air control damper in minimum position.
 93

vi) At least 3 out of 4 burners, proven AB/AB or BC/BC

vii) Nozzles in horizontal position.
viii) Start signal available

E) TRIPPING
i) If F.D. fan one set gets tripped, all mills tripped except selected mills
ii) If Both I.D. and F.D. fans tripped, all mills tripped.
iii) If electrical protection operated

RAW COAL FEEDER (RCF)

STARTING
Feeder can be started if the following conditions are satisfied.
a) Corresponding mill is running
b) Corresponding R.C. bunker gate open
c) Heater in min position
d) Start signal initiated
e) Mill outlet temp. is 700 C
f) 3 out of 4 burners proven in service in EL AB or BB
g) Hot air gate in open position.

TRIPPING
Feeder will be tripped if the following conditions exist.
a) Corresponding mill tripped.
b) Electrical protection operated.
c) Stop PB pressed.
d) Coal flow through the feeder confirm no coal flow for more than 5 sec. and also
confirmed by low current relay of the pulveriser.

Feeder will be brought to minimum speed when the pulveriser ‘DP’ is high or
pulveriser high current relay[ 11% of FL Ct.] is picked up and will be released back on
drop off.
 94

LOCAL CONTROL ;-

a) Feeder can be started from local by pressing start PB. If switch selected in local
position.
b) Feeder can be tripped from local by pressing stop PB.

EXHAUSTER IN LET CONDITION DAMPER

INTERLOCK ;-
a) To connect auto control when mill is started.
b) To disconnect auto control when mill is stopped.
c) To become stay put under all failure.
 95

FUEL SPECIFICATION

COAL

1. Carbon 30 %
2. Volatile Matter 24.5 %
3. Moisture 6.5 %
4. Ash 39.0 %
5. Hydrogen 3.05 %
6. Grindobility 50 hard groove
7. High headers valve 4271 K cal
8. Low heating value 4100 K cal.
9. Coal size feeding to mill 20 mm

FUEL OIL

1. C/H ratio 8:5

2. Sp. Gravity (150 C/40 C) 0.85 to 0.95
3. Sulphur (s) wt. % 4.20 %
4. Nitrogen wt. 0.4
5. Oxygen wt. 0.44
6. Ash wt. ppm <500 ppm
7. Sodium (Na) wt. ppm 80
8. Vonadium (Va) wt. ppm 160
9. Silica wt. ppm as silica maxm 5
10. Calcium wt. ppm maxm 40
11. Magnecium wt. ppm maxm 2 ppm
12. Nickel maxm 50 ppm
13. Water volume % 10 % maxm
0 0
14. Viscosity (C.S.) 50 – at 95 C 150 contistocke
15. Viscosity (C.S.) 500 – at 950 C 30 contistocke

POLISH WATER

1. P.H. 6.5 TO 6.9

2. Turbidity <20 DEGREE
3. TDS <418 PPM
 96

4. Alkalinity (Methel orange) <180 Mol/L as caco3

5. Total hardness <209 mg/ L as caco3
6. Hardness other than calcium (Ca) <59 mg/ L as caco3
7. Ca-Hardness <150 mg/ L as caco3
8. Chloride <40 mg/ L as cl
9. Chloride injection level 0.3 ppm
10. Pressure inlet 5 kg cm2
11. Pressure return 3kg/cm2
12. Temperature 330 C

BOILER FEED WATER

---- General requirement Clean and colourless

---- Total hardness N.T.
---- PH value at 250 c 8.8 to 9.2
---- Conductivity < 0.02 Micro mho/cm
----- Oil Contains Nil
---- SIO2 CONTAINS ,0.02 ppm after daceration
----- Oxygen [ o2] Nil
---- Total co2 < 0.02 mg/kg as Fe
----- Fe contents < 0.003 mg/kg as cu
---- Pressure 125 kg/cm2
----- Temperature 1880 c

SPECIFICATION OF STEAM FROM S.G. PLANT

Sio2 < 0.015 PPM

TDS < 0.2 PPM
PO4 < 0.02PPM
Fe < 0.005 PPM
Al < 0.003 PPM